Service: Passat 2006 Passat 2011 Passat Variant 2011 Touran 2003

Service
Workshop Manual
Passat 2006 ➤
Passat 2011 ➤
Passat Variant 2011 ➤
Touran 2003 ➤
4-cylinder direct-injection engine (1.4 l, natural gas, EA
111, turbocharger, supercharger)
Engine ID
CDG
A
Edition 11.2015
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E801A6C32

Passat 2006 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ , Touran 2003 ➤
4-cylinder direct-injection engine (1.4 l, natural gas, EA 111, turbocharger, supercharger) - Edition
11.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 6
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Routing and securing lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Installing coolers, condensers and radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n .AG . .. V.o.lk.sw
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1.2 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . o. e.s.no. t. . . . . . . . . 20
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2 Assembly mountings . . . . . . . . . . . . . . . . .ris.e.d . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra. n.te. . . . 25
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2.1 Assembly overview - assembly mountings au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r .a .
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.2 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.4 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1.5 Removing and installing pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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4.2 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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4.3 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t. Cop py
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4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.3 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 Removing and installing valve timing housing (timing case) . . . . . . . . . . . . . . . . . . . . . . . . 74
Contents i
11.2015
3 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.1 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.2 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4 Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . . 106
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.g.en. A. G. ..V.o.lk.sw. a. g.e.n .A.G.d.o . . . . . . . . 124
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1.1 Assembly overview – sump/oil pump . . . . . . . . . . . b.y.V.ol.k . . . . . . . . . . . . . . . . . . . . .no. t.g.ua. . . 124
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1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.ri.se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a. n.tee126
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1.3 Removing and installing sump . . . . . . . . . .s a.u.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 or
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1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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2.1 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.1 Assembly overview - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

2.3 Removing and installing coolant pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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2.4 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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3 Radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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3.1 Assembly overview – radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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3.2 Removing and installing cowl together with radiator fan V7 and radiator fan 2 V177 . . . . 159
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3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.4 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.5 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.3 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.1 Assembly overview - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.2 Removing and installing supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.3 Removing and installing drive unit seal for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . 201
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
ii Contents
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4-cylinder direct-injection engine (1.4 l, natural gas, EAthor111, turbocharger, supercharger) - Edition eo
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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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1.1 General notes on injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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2.2 Releasing high pressure in fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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2.4 Renewing seal on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3 Checking natural gas supply system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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3.1 Different pressure sections of natural gas supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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3.2 Determining pressure in gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.3 Determining operating mode of natural gas vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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3.4 Activating/deactivating natural gas mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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3.5 Checking gas system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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Gas injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Removing and installing gas rail with gas injectors N366 , N367 , N368 , N369 . . . . . . . . 225
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5 Gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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5.1 Assembly overview - gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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5.2 Removing and installing gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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5.3 Removing and installing tank pressure sensor G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . opyri
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238
6 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
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6.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
6.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
7 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
7.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
7.2 Removing and installing upper part of intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
7.3 Removing and installing lower part of intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
7.4 Removing and installing regulating flap control unit J808 and throttle valve module J338
........................................................................ 258
7.5 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
8.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
9 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
9.1 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
10.1 Removing and installing engine control unit J623 (Passat ▶10.2010) . . . . . . . . . . . . . . . . 272
10.2 Removing and installing engine control unit J623 with protective housing (Passat ►
10.2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
10.3 Removing and installing engine control unit J623 (Passat 11.2010▶) . . . . . . . . . . . . . . . . 274
10.4 Removing and installing engine control unit J623 with protective housing (Passat
11.2010▶) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
10.5 Removing and installing engine control unit J623 (Touran) . . . . . . . . . . . . . . . . . . . . . . . . 278
10.6 Removing and installing engine control unit J623 with protective housing (Touran) . . . . . . 279
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

1 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
1.1 Assembly overview – emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Contents iii
11.2015
1.2 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1.3 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
1.4 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 289
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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iv Contents
AG. Volkswagen AG d
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Passat 2006 is➤ e , Passat 2011 ➤ , Passat Variant 2011
d b ara ➤ , Touran 2003 ➤
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4-cylinder direct-injection engineu(1.4
tho l, natural gas, EA 111, turbocharger, supercharger)
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00 – Technical data
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1 Identification
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(20; Edition 11.2015)
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⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data
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– Detach hose from activated charcoal filter at hose clip

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Engine code and engine number can be found on the sticker
-arrow- on the control housing.
Starting with the letter “C”, new four digit engine codes have been
introduced. The first 3 digits denote the mechanical design of the
engine and are stamped on the engine as before. The fourth digit
denotes the performance and torque rating of the engine and de‐
pends on the engine control unit - J623- . The four digit engine
code can be found on the identification plate, the vehicle data
sticker and on the engine control unit.
Note
Vehicles for some countries do not have an identification plate.

Fittings locations for vehicle data sticker and identification plate
⇒ Maintenance ; Booklet .
Engine code CDGA

Manufactured
Passat 01.09►
Touran 06.09►
Emission standards EU 5
Capacity cm3 1390
Output kW at rpm 110/5,500 (natural gas/petrol)
Torque Nm at rpm 220/1,500-4,500 (natural gas/petrol)
Bore Diameter, mm 76.5
Stroke mm 75.6
Compression ratio 10
RON Petrol 95 unleaded
Natural gas Up to 1401)
Injection, ignition Motronic MED 17
Firing order 1-3-4-2
Type of mixture formation Homogeneous
1. Identification 1
11.2015
Engine code CDGA

Turbocharging/supercharging Turbocharger and mechanical supercharger
• 1)In gas mode, the engine output and the torque depend on
the quality of the natural gas used. The methane content for L
gas (low calorific gas: methane content 79.8% - 87.0%) and H
gas (high calorific gas: methane content 87.1% - 98.0%) may
vary in different regions.
AG. Volkswagen AG d
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2 Rep. gr.00 - Technical data

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⇒ “2.1 Safety precautions when working on fuel
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⇒ “2.2 Safety precautions when working on natural gas system”,
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⇒ “2.4 Safety precautions when working on cooling system”, page
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7
⇒ “2.5 Safety precautions when working on ignition system”, page
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2.1 Safety precautions when working on

fuel supply system
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Please note the following when working on fuel supply system:

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Risk of injury due to highly pressurised fuel.

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♦ The fuel system is pressurised! The fuel pressure in the

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high-pressure section of the injection system must be re‐
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⇒ “2.2 Releasing high pressure in fuel system”, Prote AG.
page 207 .
♦ To release the residual pressure of approx. 7 bar, the con‐
nection must be separated »immediately« after releasing
the high pressure. To do this, wrap a clean cloth around
the connection.
♦ Wear protective gloves.
♦ Wear eye protection.
Risk of fire due to escaping fuel.
♦ The fuel pump will be activated by the driver door contact
switch when the driver door is opened. Therefore the pow‐
er supply to the fuel pump must be interrupted if the battery
power has NOT been disconnected yet.
♦ Pull off fuse for fuel pump control unit - J538- ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
Caution
Risk of damage to the electronic components when discon‐

necting the battery.
♦ Observe notes on procedure for disconnecting the battery.
Only disconnect battery with ignition switched off ⇒ Electrical

system; Rep. gr. 27 ; Battery; Disconnecting and reconnecting
battery .
2. Safety instructions 3
11.2015
Even small amounts of contamination/soiling can lead to defects.

For this reason, please observe the following rules for cleanliness
when working on the fuel supply system and injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Any open lines, pipes, hoses and connections must be sealed
immediately with a suitable cap or plug.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle unless absolutely necessary.
♦ Protect detached electrical connections against dirt and mois‐
ture and only connect when they are dry.

natural gas system
• Before renewing tank shut-off valve or natural gas tank:
• Instruct the customer to leave as little natural gas in the tank
as possible.
• This is to avoid unnecessary costs for the customer as well as
the pollution of the environment.
WARNING
Release pressure in the system before working on the natural

gas system. swa
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Connect ⇒ Vehicle diagnostic testerd b and perform Guided Func‐
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components have been removed ⇒ Maintenance ; Booklet

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35.1 ; Description of work; Performing visual inspection of gas

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tanks for corrosion and leakage test .

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11.2015
DANGER!
• The mechanic may be the source for electrostatic dis‐

charge. Therefore, it is mandatory to wear protective cloth‐
ing.
• Before performing any work on the natural gas system,
make sure to take the necessary measures to avoid elec‐
trostatic discharge/to ensure that any existing static
charge has been discharged.
• The vehicle or removed natural gas tanks will note be‐
come electrostatically charged.
Protective gloves containing cotton must be worn to avoid in‐
juries and static charging.
Volkswagen safety shoes must be worn to avoid static charg‐
ing.
Volkswagen workwear (of cotton blend fabric) must be worn,
this workwear contains a residual moisture which also prevents
static charging.
DANGER!
Before evacuating natural gas tanks, make sure to comply with

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♦ Natural gas tanks must not be evacuated in confined
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♦ Before evacuation, establish a safetysszone
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♦ Do not touch tank shut-off valves during the evacuation:
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• If evacuation of the natural gas tanks is not possible, close t to the co

the tank shut-off valves.
• Do not perform any further repair work.
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• Contact your importer for further procedure regarding the

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natural gas tanks that are still filled with fuel.

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WARNING
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• Observe the country-specific regulations as well as spec‐

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ifications provided by the importer regarding the safety

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11.2015
Caution
Prior to doing any repair work, especially in the engine com‐

partment, pay attention to the following due to the cramped
conditions:
♦ Route high-pressure lines in their original positions.
♦ Ensure lines have sufficient clearance to moving or hot
components.
♦ Never attempt to reshape high-pressure lines of natural
gas system.
AG. Volkswagen AG d
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♦ On no account a must the union nut be tightened further than r ac
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specified, otherwise
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♦ A leakage test of the system must always be performed after
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components have been removed ⇒ Maintenance ; Booklet
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♦ Disconnect battery earth strap before carrying out work on spec

es, in part or in w
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natural gas system.
♦ Only components of the same type and with the same type
approval may be exchanged on the high-pressure system.
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2.3 Safety precautions during road tests in

l purpos
which testing and measuring equipment

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Please note the following if the use of test and measuring equip‐
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AG.
♦ Always strap test and measuring equipment in place on

rear seat and have a 2nd person operate them.
♦ Operation of test and measuring instruments while driving
results in distraction
♦ Greater injury hazard as a result of unsecured test and
measuring equipment must be eliminated.

11.2015

cooling system
WARNING
Steam may escape when expansion tank is opened.

♦ Wear eye protection and protective clothing to avoid eye
injuries and scalding.
♦ Cover cap with cloth and open carefully.
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from AG. Volkswagen AG d
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♦ When the engine is warm, the cooling system is under pres‐
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sure. If necessary, release pressure before beginning repair
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♦ Secure all hose connections with hose clips, allocation ⇒
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Electronic Parts Catalogue “ETKA” .
es, in part or in w
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♦ Hose clip pliers - VAS 6499- are recommended to install
spring-type clips.
♦ Renew gaskets and seals.
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♦ When installing coolant hoses, route stress-free so that they
l purpos
do not come into contact with other components (observe

markings on coolant connection and hose). nf
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11.2015
2.5 Safety precautions when working on ig‐

nition system
WARNING
To prevent injuries to persons and/or damage to the injection

and ignition system, the following must be observed:
Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
AG. Volkswagen A gen G do
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Fuel pump is activated by switching
by
Vol
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on ignition and via driver
not
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door contact switch. If therisbattery
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nected, the connector uof
tho the fuel delivery unit must be discon‐ eo
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nected or the fuel spump
sa fuse must be removed for safety c
reasons before opening the fuel system.
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11.2015
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 9
⇒ “3.2 Foreign objects in engine”, page 9
⇒ “3.3 Contact corrosion”, page 9
⇒ “3.4 Routing and securing lines”, page 9
⇒ “3.5 Installing coolers, condensers and radiators”, page 10
3.1 Rules for cleanliness

When working on the fuel supply and injection system or the nat‐
ural gas supply system, always observe the following “5 rules” for
cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened componentswaor
geseal iforepairs
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be carried out immediately. y Volks ot g
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♦ Install clean componentshoonly.
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immediately before installing. Do not or
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use parts that have not
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♦ When the system is open: Do not work with compressed air.
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Do not move vehicle.
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To prevent the ingress of foreign bodies during work on the en‐
gine, seal open channels of the intake and exhaust sections with t to the co
suitable plugs, for example from the engine bung set - VAS 6122- .
3.3 Contact corrosion

rrectne
Contact corrosion can occur if unsuitable connecting elements

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

s o
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For this reason, only connecting elements with a special surface

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Moreover, certain rubber or plastic parts as well as adhesives

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made of electrically non-conductive materials.

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

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is to use new parts ⇒ Electronic Parts Catalogue .

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3.4 Routing and securing lines
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♦ In order to ensure that lines are all installed in their original cop Vo
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position, the lines for the fuel, hydraulic and vacuum systems cted agen
Prote AG.
and for the activated charcoal filter system as well as electrical
wires must be marked appropriately before they are removed.
If necessary, take a photo or make a sketch.
♦ Because of the lack of space in the engine compartment, make
sure that there is sufficient clearance between lines and all
moving or hot components. This is to avoid damage to lines.
♦ Any clips, cable ties or other fastening devices that have been
cut through or damaged when loosening must be renewed.
♦ Insulation mats and other insulating devices must always be
re-fitted in their original positions.
3. Repair instructions 9
11.2015
3.5 Installing coolers, condensers and radi‐

ators
Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does not
mean that these components have been damaged. It is not per‐
missible to renew radiators, condensers or charge air coolers only
because of such minor dents.
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Prote AG.

11.2015
10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ “1.1 Removing engine”, page 11 .
Installing engine ⇒ “1.2 Installing engine”, page 20 .
1.1 Removing engine
Note
♦ Crankcases were installed with different size threaded holes.

♦ Check these holes before dismantling/assembling and install
the respective engine support.
♦ The engine support - T40075- can continue to be used if con‐
verted as described in the respective work sequence.
♦ The fitting of engine support - T40075- and engine support -
T40075A- on the crankcase is described in the respective
work sequence.
Modifying engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a-: 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill a hole with a 13 mm bit. AG. Volkswagen AG d
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– Identify engine support with an -A- behind tool designation.
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1. Removing and installing engine 11

11.2015
Special tools and workshop

equipment required
♦ Engine support - T40075- n AG. Volkswagen AG do
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engine support - T40075A- d by V ua
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♦ Torque wrench - V.A.G
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♦ Engine and gearbox jack -
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V.A.G 1383 A-
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♦ Engine and gearbox sup‐
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port - VAS 6095-
spec
♦ Drip tray for workshop hoist
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- VAS 6208-
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12 Rep. gr.10 - Removing and installing engine

11.2015
♦ Hose clip pliers - VAS

6340-
1332-
♦ Guide rods - T10093-
♦ Commercially available
stepladder (not illustrated)
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Before working on the natural gas system, always observe
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⇒ “2.2 Safety precautions when working on natural gas sys‐ Prote AG.
tem”, page 4 !!!
WARNING
• Make sure that the tank shut-off valve on each of the nat‐
ural gas tanks is closed.
– Empty gas system ⇒ Fuel supply system – natural gas en‐

gines; Rep. gr. 20 ; Fuel tank; Releasing pressure in high-
pressure line .
Note
Before carrying out further work, disconnect battery earth strap.

Check whether a coded radio is fitted. Obtain anti-theft coding first
if necessary.

11.2015
– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
– Unbolt heat shield over turbocharger -arrows-.
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14
Prote AG.
Rep. gr.10 - Removing and installing engine
AG. Volkswagen
11.2015
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– Unscrew bolts -1- ed
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remove pressure pipe. ua
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Item -2- can beautdisregarded.
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– Remove air filter
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⇒ “6.2 Removing and installing air filter housing”, page 243 .
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Observe safety precautions
hole
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⇒ “2.4 Safety precautions when working on cooling system”,
es, in part or in w
page 7 .
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Note
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Pull coolant hoses off engine with hose clip pliers - VAS 6340- .
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– Open and close expansion tank cap to release pressure in
m
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cooling system.
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– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 137 .
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⇒ “2.1 Safety precautions when working on fuel supply sys‐ p by
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Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Before loosening
hose connections, wrap a cloth around the connection. Then
release pressure by carefully pulling hose off connection.
– Separate fuel supply line and line to activated charcoal filter.

Press release tabs to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Unscrew securing nuts/bolts -arrows- for gas pressure regu‐

lator bracket.
Caution
Ensure that high-pressure lines are not kinked.

11.2015
– Push gas pressure regulator -1- in direction of -arrow- and se‐

cure to side with wire.
– Remove securing bolts -arrows- of engine splash protection.

– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
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– Bring lock carrier into service position w⇒
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exterior; Rep. gr. 50 ; Body - front;
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The engine is removed downwards
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

un
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necting and reconnecting battery .

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– Remove battery and battery carrier ⇒ Electrical system; Rep.
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– All cable ties which are opened or cut through when engine is
hole
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removed must be replaced in the same position when engine
es, in part or in w
is installed. t to the co
– Disconnect all electrical wiring from gearbox, alternator and
starter, and lay it to one side.
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– Disconnect all other electrical wiring as necessary from en‐

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gine, and lay it to one side.

– Pull vacuum and breather hoses off engine.
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– Pull connectors off thermal switch and radiator fan.

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– Remove plenum chamber bulkhead ⇒ General body repairs;

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Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

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– Remove engine control unit - J623-

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⇒ “10 Engine control unit”, page 272 .

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– Open all line guide fasteners -arrows-. t. C rig
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– Remove wiring from engine control unit.
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– Secure lines/wiring to engine with a cable tie.
– Remove wiring for Lambda probe after catalytic converter -
G130- and for alternator from cable guides -arrows-.

11.2015
– Pull connector off Lambda probe after catalytic converter -

G130- and remove.
– Open hose clip -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from catalytic converter -arrows-.
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– Unbolt exhaust pipe together with decoupling element

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-arrows-.
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– Unhook rear exhaust system from mountings and pull system
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slightly to rear in direction of -arrow-.
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– Push exhaust pipe out of mounting -1-.
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– Remove exhaust pipe.
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– Disconnect pendulum support -arrows-.

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– Unbolt selector mechanism from gearbox ⇒ 6-speed manual

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gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .

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– Remove strut -1-.

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11.2015
– Remove slave cylinder -arrows- and lay to side.ADo not

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– Remove hydraulic clutch slave cylinder:
ris
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⇒ 6-speed manual tee
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gearbox 02S; Rep. gr. 30 ; Repairing
au
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♦ Clutch pedal must not be depressed.
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♦ To prevent damage to condenser or to refrigerant lines and
h re
ole,
hoses, ensure that lines and hoses are not stretched, kinked
spec
or bent.
t to the co
– Remove poly V-belt
⇒ “1.3 Removing and installing poly V-belt”, page 30 .
rrectnes
Note
s o
cial p
f inform
The air conditioning system lines must not be opened.
mer
atio
om
– Remove retaining clamp(s) for refrigerant lines.
n
c
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To facilitate removing and installing engine without opening re‐

t
sd
va
frigerant circuit:
i
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– Remove air conditioner compressor ⇒ Heating, air condition‐

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ing system; Rep. gr. 87 . t. Cop py
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• Secure air conditioner compressor to lock carrier. p by
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• Ensure that lines are not kinked. Prote AG.
– Remove right drive shaft, unscrew left drive shaft at gearbox

and tie up: ⇒ Running gear, axles, steering; Rep. gr. 40 ;
Repairing drive shafts; Removing and installing drive shafts.
Work sequence with engine support - T40075-
Engine support - T40075- with adapters -/4-, -/5- and -/6- is re‐
quired to lower engine with gearbox.
– Screw adapter T40075/4 into crankcase to stop.

– Position the engine support - T40075- with adapters -/5- and
-/6- on crankcase.

11.2015
– Secure engine support - T40075- hand-tight to crankcase us‐

ing bolt -1-.
– Tighten all bolts on engine support - T40075- to 20 Nm.

Work sequence with engine support
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Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐ t to the co
quired to lower engine with gearbox.
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– Screw adapter T40075 A /4 into crankcase to stop.

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– Secure engine support - T40075A- hand-tight to crankcase
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using bolt -1-.
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– Tighten all bolts on engine support - T40075A- to 20 Nm.
cial p
f inform
– Lift engine and gearbox lightly using engine and gearbox jack
mer
- V.A.G 1383 A- .
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– Unbolt engine side of assembly mounting from above

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

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

♦ When lifted out, the assembly must be carefully guided to pre‐
vent damage to the bodywork.
– Carefully lower engine and gearbox.
1.2 Installing engine

Installation is carried out in the reverse order. When installing,
note the following:

11.2015
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
agen
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– Check clutch uthrelease bearing for wear and renew if necessary.
o
or
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ss
– Lightly lubricate clutch release bearing, release bearing guide
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nl
sleeve and splines on input shaft with grease ⇒ Electronic
pt
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Parts Catalogue (ETKA) .
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– Check whether dowel sleeves for centring engine/gearbox
ility
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– Hook intermediate plate onto sealing flange and slide onto
hole
spec
dowel sleeves -arrows-.
es, in part or in w
t to the co
– When swinging engine in, ensure that there is clearance be‐
tween drive shafts.
rrectness of i
Align engine mountings as follows:
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11.2015
♦ There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ Ensure that edges of support arm -1- and gearbox bracket
-2- are parallel on gearbox side.
– Install pendulum support.
Note
Specified torques for assembly mountings

⇒ “2 Assembly mountings”, page 25
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

40 ; Repairing drive shafts; Removing and installing drive
shafts.
– Install air conditioner compressor ⇒ Heating, air conditioning
system; Rep. gr. 87 .
– Move lock carrier back from service position ⇒ Body, front;
Rep. gr. 50 ; Lock carrier; Moving to and back from service
position .
– Install poly V-belt ⇒ page 30 .
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
– Install hydraulic clutch slave cylinder: ⇒ 6-speed manual gear‐
box 02S; Rep. gr. 30 ; Repairing clutch mechanism .
AG. Volkswagen gen AG do
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– Attach selector mechanism: y V⇒ 6-speed manual gearbox 02S;
olk not
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Rep. gr. 34 ; Repairing edb
selector mechanism . ara
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– Tighten union nuts -arrow-
s to 5 Nm +70° additional specified
ce
le
angle.
un
pt
an
d
itte
– Counterhold on union with an open-end spanner

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11.2015
– Tighten securing bolts and nuts -arrows- on bracket for gas

pressure regulator to 8 Nm.
– Install engine splash guard ⇒ Exterior equipment; Rep. gr.
66 ; Noise insulation; Removing and installing noise installa‐
tion .
– Install front right and front left wheel housing liners ⇒ Exterior
equipment; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Fill with coolant wage
es n
s
⇒ “1.2 Draining and fillingycoolant”,
Volk page 137 . ot g
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ed nte
– Install air filter tho
ris e or
⇒ “6.2 Removings aand installing air filter housing”, page 243 .
u ac
s
ce
le
– Install battery and battery carrier ⇒ Electrical system; Rep. gr.

un
pt
27 ; Removing and installing battery .
an
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itte
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– Install plenum chamber cover ⇒ Body, front; Rep. gr. 50 ;
pe
ility
Plenum chamber bulkhead; Removing and installing plenum
ot
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chamber bulkhead .
h re
hole
spec
– Install engine control unit
es, in part or in w
⇒ “10 Engine control unit”, page 272 .
t to the co
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
rrectness of i
– Connect Vehicle diagnostic, testing and information system -
l purpos
VAS 5051B- .
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Note
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Natural gas system may not be operated until tested accordingly.
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WARNING
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• Operating the natural gas system without having tested it Cop py
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The necessary scope of the leakage test depends on the pres‐
AG.
sure section which has been worked on.

Note the following allocation!
Allocation:
⇒ “3.1 Different pressure sections of natural gas supply system”,
page 214
– Open fuel tank shut-off valves -N361/N362/N363/N429- (de‐
pending on vehicle model and equipment level) using hand
wheel - T50026- .
– Check gas system
⇒ “3 Checking natural gas supply system for leaks”,
page 214
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided Functions”.
– Carry out vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
ded fault finding”.
– End the vehicle system test so that any entries stored in the
event memory during assembly can be deleted automatically.

11.2015
– Push engine cover panel down at points -1- in direction of

-arrow- until it engages.
Observe applicable safety precautions during road test.
– Carry out a road test.
– Then carry out vehicle system test again and rectify any faults
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which may have occurred. d byV ua
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Specified torques: utho or
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ss
♦ Securing bolts for heat shield
ce
le
un
⇒ “1.1 Assembly overview – emission control”, page 283
pt
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♦ Securing bolts for pressure pipe
rm
ab
pe
⇒ “2.1 Assembly overview - charge air system”, page 180
ility
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♦ Securing bolts for air filter
h re
⇒ “6.1 Assembly overview - air filter housing”, page 242
hole
spec
es, in part or in w
♦ Securing bolts for gas pressure regulator
t to the co
⇒ “5.1 Assembly overview - gas pressure regulator”,
page 228
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♦ Specified torque for lambda probe
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♦ Securing nuts for exhaust pipe

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♦ Specified torques for assembly mountings

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Threaded connections Specified torque
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Bolts, nuts M6 10 Nm
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M8 20 Nm
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M10 45 Nm
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M12 60 Nm
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Prote AG.

11.2015
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 25
2.1 Assembly overview - assembly mount‐

ings
Specified torques
Engine assembly mountings
Bolt Specified torque Note
A 20 Nm + turn 90° Renew
further
B 40 Nm + turn 90° Renew
further
C 60 Nm + turn 90° Renew
further
Gearbox assembly mounting

Bolt Specified torque
en AG. V
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B au 60 Nm + turn 90° Renew ra
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Pendulum support
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Bolt Specified torque Note

A – property class 8.8 40 Nm + turn 90° Renew
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further
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A – property class 10.9 50 Nm + turn 90° Renew

further
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ercia
B 100 Nm + turn Renew

90° further
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2. Assembly mountings 25
11.2015
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 26
⇒ “1.2 Assembly overview - cylinder block (pulley end)”,
page 28
⇒ “1.3 Removing and installing poly V-belt”, page 30
⇒ “1.4 Removing and installing ancillary bracket”, page 33
⇒ “1.5 Removing and installing pulley”, page 34
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 36
1.1 Assembly overview - poly V-belt drive
1 - Bolt
❑ To loosen and tighten
securing bolt, counter‐
hold supercharger shaft
with 16 mm spanner.
❑ Renew.
❑ 40 Nm + turn 90° further
2 - Belt pulley
❑ For supercharger.
3 - Bolt
❑ 23 Nm
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❑ For supercharger poly d by ara
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V-belt hor eo
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❑ Relieve tension using ss c
16 mm spanner.
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❑ Lock with locking pin -

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T10060 A- .
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5 - Bolt
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❑ 8 Nm
hole
spec
6 - Coolant pump with magnet‐

es, in part or in w
t to the co
ic clutch for supercharger -

N421-
❑ Removing and installing
rrectness of i
⇒ “2.2 Removing and in‐

stalling coolant pump”,
l purpos
page 145 .
nform
ercia
coolant pump pulley

m
a
com
stalling coolant pump

ion in
pulley”, page 151 .

r
te o
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7 - Bolt
do
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rp
cum
❑ 23 Nm
fo
en
ng
t.
yi Co
8 - Tensioning element t. Cop py
rig
❑ For poly V-belt.
gh ht
pyri by
Vo
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by c
❑ Relieve tension using 16 mm open-end spanner - T10241- .
lksw
cted agen
Prote AG.
26 Rep. gr.13 - Crankshaft group

11.2015
❑ Lock with locking pin - T10060 A- .
Note
♦ Vehicles with a manual gearbox:

idler pulley installed instead of
tensioning element.
♦ Specified torque for securing
bolt: 40 Nm.
9 - Bolt
❑ 23 Nm
10 - Alternator
11 - Belt pulley
❑ With diamond coated washer
❑ Observe note on diamond coated washers ⇒ page 38 .
❑ Contact surfaces must be free of oil and grease.
12 - Securing bolt
❑ Always make sure to observe procedure ⇒ “1.5 Removing and installing pulley”, page 34 .
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.
❑ Secure pulley against turning with counterhold - 3415- .
❑ Turning further can be done in several stages.
❑ The turning further angle can be measured with a commercial protractor.
❑ Renew
13 - Bolt
❑ Removing and installing with vehicle raised
❑ Renew.
AG. Volkswagen AG d
14 - Air conditioner compressor agen oes
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15 - Bolt orise nte
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❑ 23 Nm aut ra
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16 - Tensioning element
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pt
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❑ For poly V-belt.

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❑ Relieve tension with spanner.

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❑ Lock with 4 mm Allen key.

wit
, is n
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hole
17 - Poly V-belt
spec
es, in part or in w
❑ Mark direction of rotation before removing.

t to the co
Caution
rrectness of i
When installing poly V-

belt, observe direction of
l purpos
rotation and make sure it

is properly seated on pul‐
nform
ercia
leys and tensioning ele‐

ments.
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❑ Removing and installing poly V-belt ⇒ “1.3 Removing and installing poly V-belt”, page 30 .
te o
thi
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18 - Poly V-belt
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fo
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t.
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Cop py
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27
copy Vo
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Prote AG.
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h eo
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sa c
11.2015 s
ce
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❑ Mark direction of rotation before removing.
an
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Caution
wit
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When installing poly V-
ole,
belt, observe direction of
spec
rotation and make sure it
t to the co
is properly seated on pul‐
leys and tensioning ele‐
ments.
rrectness o
cial p
f
1.2 Assembly overview - cylinder block (pulley end)
inform
mer
atio
om
1 - Cylinder head with cam‐
n
c
i
or
n
shaft housing
thi
te
sd
va

i
o
pr
cum
r

fo
en
ng
stalling cylinder head”,

t.
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op
page 59 . C py
t. rig
gh ht
❑ Sealing surface must yri
p by
co Vo
not be reworked.
by lksw
cted agen
Prote AG.
❑ With integrated cam‐
shaft bearings.
❑ Remove sealant resi‐
due.
❑ When installing, insert
vertically from above so
that dowel pins fit into
holes in cylinder head
2 - Cylinder block
❑ Dismantling and assem‐
bling cylinder block
⇒ “2.1 Assembly over‐
view - cylinder block,
gearbox end”,
page 40
❑ Dismantling and assem‐
bling pistons and con‐
rods
⇒ “4 Pistons and con‐
rods”, page 52 .
3 - Bracket for ancillaries
❑ For tensioning element
and air conditioner com‐
pressor.
stalling ancillary brack‐
et”, page 33 .
4 - Cover
5 - Chain sprocket
❑ For oil pump drive and timing chain.
6 - Bolt
❑ Renew

11.2015
7 - Chain sprocket
❑ Lock chain sprocket using counterhold - T10172- .
8 - Drive chain
❑ Before removing, mark direction of rotation (installation position).
9 - Bolt
❑ 25 Nm
10 - Bolt
❑ 15 Nm
11 - Chain tensioner with tensioning plate
❑ For oil pump drive.
12 - Tensioning spring
13 - Sump
❑ Removing and installing ⇒ “1.3 Removing and installing sump”, page 127 .
❑ Clean sealing surface before fitting.
❑ Install with sealant ⇒ Electronic Parts Catalogue (ETKA) .
14 - Bolt
❑ 13 Nm
15 - Piston
❑ For drive chain tensioner.
16 - Spring
17 - Chain tensioner
18 - Bolt
❑ 9 Nm
19 - Valve timing housing
AG. Volkswagen
Removing and installing valve timing housing wage
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olks
⇒ “2.1 Removing and installing valved btiming
y V housing (timing case)”, page
ot g
ua74
e ran
ris t
❑ Additionally apply sealantuthwhen
o installing ⇒ Electronic Parts Catalogue
ee
o(ETKA)
ra
.
a
❑ To facilitate guidance on
s installation, screw two “M6x80” studs into camshaft
s c
housing and cylinder block.
ce
le
un
❑ For better guidance of valve timing housing, secure sump in position with 2 bolts.
pt
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20 - Bolt
erm
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❑ 10 Nm
wit
is n
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21 - Belt pulley
ole,
spec
❑ With diamond coated washer

t to the co

❑ Observe tightening procedure ⇒ “1.5 Removing and installing pulley”, page 34 .
rrectne
❑ Secure pulley against turning with counterhold tool - 3415- .

s
❑ Removing and installing ⇒ “1.3 Removing and installing poly V-belt”, page 30 .
s o
cial p
f i
22 - Securing bolt
nform
mer
❑ Always make sure to observe procedure ⇒ “1.5 Removing and installing pulley”, page 34 .
atio
m
o
n
c
i
or

thi
te
sd
va
❑ Secure pulley against turning with counterhold tool - 3415- .

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cum
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fo

en
ng
t.
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❑ Renew ht. Cop py
rig
❑ 150 Nm + turn 180° further rig ht
py by
co Vo
by lksw
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Prote AG.
1. Cylinder block (pulley end) 29

11.2015 wage
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23 - Bearing bush ris
ed
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❑ Contact surfaces must
au be free of
t oil and grease. ra
c
ss
24 - O-ring
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nl
pt
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❑ Renew.
itte
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ab
25 - Bolt
ility
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wit
❑ 50 Nm
, is n
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hole
26 - Gasket
spec
es, in part or in w
27 - Bolt
t to the co
❑ Lock chain sprockets using counterhold - T10172- .
❑ Bolt with left-hand thread.
rrectness of i
❑ Renew.
l purpos

28 - Bolt
nf
ercia
o
❑ Renew
rm
m
atio
m

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29 - Tensioning plate
thi
te
sd
iva
o
30 - Camshaft adjuster
r
rp
cu
o
m
f
❑ Removing and installing ⇒ “3.2 Adjusting valve timing”, page 90 .
en
ng
t.
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op
❑ Must not be dismantled. C py
t. rig
gh ht
yri by
31 - Timing chain op Vo
by c lksw
cted agen
❑ Removing and installing Prote AG.
⇒ “3.4 Removing and installing timing chain and chain drive for oil pump”, page 106 .
32 - Sprocket
❑ Removing and installing ⇒ “3.2 Adjusting valve timing”, page 90 .
❑ For exhaust camshaft.
❑ Lock chain sprockets using counterhold -T10172- .
33 - Guide rail
❑ For timing chain.
34 - Guide pins
❑ Specified torque: 20 Nm
35 - Bearing bush
1.3 Removing and installing poly V-belt

⇒ “1.3.1 Belt routing in air conditioner compressor belt drive”,
page 32
Special tools and workshop equipment required

11.2015
♦ Locking pin - T10060 A-
AG. Volkswagen AG d
agen oes
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ris nte
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aut ra
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un
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an
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itte
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ab
ility
♦ 16 mm open-end spanner - T10447-
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
♦ 4 mm Allen key
i
or
n thi
te
sd
a
Removing
iv
o
pr
cum
r
fo
– Unscrew securing bolts -arrows- for engine splash guard ⇒

en
ng
t.
Exterior equipment; Rep. gr. 66 ; Noise insulation; Removing
op
yi Co
and installing noise installation .
C py
ht. rig
rig ht
py by
– Remove front right wheel housing liner ⇒ General body re‐
co Vo
by lksw
pairs; Rep. gr. 66 ; Wheel housing liner; Removing and
cted agen
Prote AG.
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt, swing tensioning element in direction

of -arrow- from below using 16 mm open-end spanner.
– Lock tensioning element with a 4 mm Allen key -1-.

11.2015
– To slacken poly V-belt, swivel tensioning element in direction

of -arrow- from above using 16 mm open-end spanner -
T10447- .
– Lock tensioning element using locking pin - T10060 A- .
AG. Volkswagen AG d
– Remove poly V-belt -2-. ksw
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Installing ised b ara
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Caution s
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nl
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Ensure, before installing poly V-belt, that all ancillaries (alter‐
itte
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erm
nator, air conditioner compressor) are secured tightly.
ab
ility
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When installing poly V-belt, observe direction of rotation and
wit
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make sure it is properly seated on pulleys and tensioning ele‐
h re
hole
ments.
spec
es, in part or in w
t to the co
– Fit poly V-belt over crankshaft pulley first. Finally, push belt
onto tensioning roller.
rrectness of i
Further assembly is basically the reverse of the dismantling se‐
l purpos
quence.
Check after completing repair:
nf
ercia
or
– Start engine and check that belt runs properly.
m
m
atio
om
n in
c
1.3.1 Belt routing in air conditioner compres‐

or
thi
te
sd
sor belt drive
iva
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f
Belt drive with air conditioner compressor
en
ng
t.
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op py
1 - Coolant pump pulley
. C rig
ht ht
rig by
py
2 - Crankshaft pulley
co Vo
by lksw
cted agen
Prote AG.
3 - Tensioning roller
4 - Tensioning roller or idler pulley
5 - Alternator pulley
6 - Air conditioner compressor pulley
7 - Poly V-belt
Belt drive for supercharger
Note
♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .
1 - Supercharger pulley
2 - Tensioning roller
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt

11.2015
1.4 Removing and installing ancillary brack‐

et
♦ Torque wrench - V.A.G 1331-
lkswage es n
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d ran
ir se tee
tho
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a ac
ss
ce
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un
pt
an
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itte
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rm
ab
pe
ility
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wit
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Removing
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
l purpos
– Remove air conditioner compressor ⇒ Heating, air condition‐

ing system; Rep. gr. 87
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
The air conditioning system lines must not be opened.
iva
do
r
rp
cum
fo
en
g
– Secure air conditioner compressor to lock carrier.

n
t.
yi Co
Cop py
– Ensure that lines are not kinked.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
– Unscrew securing bolts -1- and remove bracket.
agen
Prote AG.
Installing
– Fit ancillary bracket to cylinder block.

11.2015
– Tighten securing bolts -1- to specified torque ⇒ page 34 .

quence.
Specified torques:
♦ Specified torque for tensioning element
⇒ “1.1 Assembly overview - poly V-belt drive”, page 26
Component Specified torque
Securing bolts for ancillary bracket 25 Nm
1.5 Removing and installing pulley

equipment required
1601-
♦ Counterhold - 3415-
♦ Pin - 3415/1- (not illustra‐
ted) AG. Volkswagen AG d
agen oes
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♦ Locking pin - T10340- by Vol
gu
ara
d
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♦ Torque wrench - V.A.G thor eo
1331- ss au ra
c
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.2015
♦ Dial gauge - VAS 6079-

♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170
A-
Note
If the dial gauge adapter - T10170 A- is used, the ball head does
not need to be unscrewed from the dial gauge - VAS 6079- . Theswagen AG. Volkswagen AG does
ball head is fitted onto the flat side of the rod. by
Vol
k not
gu
ara
ed nte
ris
ho e
Removing au
t or
ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
– Loosen pulley securing bolt. Hold pulley with counterholds -
pe
ility
ot
3415- and -3415/1- .
wit
, is n
h re
Installing
hole
spec
es, in part or in w
– Tighten pulley hand-tight using a new securing bolt.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
– Turn crankshaft in direction of engine rotation to TDC for No.
on in
1 cylinder.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11.2015
– Unscrew plug from crankcase.

– Screw locking pin - T10340- to stop into crankcase.
– Tighten locking pin - T10340- to 30 Nm.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Locking pin - T10340- locks crankshaft in direction of engine
auth ro‐ or
ac
tation. ss
ce
e
nl
pt
du
an
itte
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Note
erm
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ility
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♦ Observe notes on diamond coated washers ⇒ page 38 .
wit
, is n
h re
hole
♦ Always use a new bolt.
spec
es, in part or in w
♦ Oil threads before inserting.
t to the co
♦ Contact surfaces must be free of oil and grease.
rrectness of i
Hold pulley with counterhold - 3415- and -3415/1- .
l purpos
Specified torque: 150 Nm + turn 180° further

⇒ “1.2 Assembly overview - cylinder block (pulley end)”,
nform
ercia
page 28
m
at
om
– Unscrew locking pin - T10340- from crankcase.
ion
c
in t
or
– Screw plug into crankcase.
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Specified torque: 30 Nm
– Install poly V-belt
quence.
1.6 Renewing crankshaft oil seal - belt pulley end

11.2015

equipment required
♦ Oil seal extractor - 3203-
1332-
♦ Assembly sleeve -
T10117/2-
♦ Assembly tool - T10053-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
Removing by c lksw
cted agen
Prote AG.
pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
Continuation for all vehicles
– Removing and installing crankshaft pulley
⇒ “1.5 Removing and installing pulley”, page 34 .

11.2015
– Now remove pulley securing bolt. Hold pulley with counterhold

-3415- and -3415/1- .
– Remove centre bolt and remove crankshaft pulley.
– Unscrew inner part of oil seal extractor - 3203- 3 turns (approx.
5 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out. G. Volkswagen nA AG do
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– Remove bearing bush from crankshaft Vol
ks journal and clean con‐
s no
t gu
by
tact surfaces of crankshaftrisechain sprocket and bearing bush.
d ara
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tho or
Installing s au ac
s
ce
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nl
pt
du
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Note
itte
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erm
ab
ility
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♦ From model year 2009, a diamond-coated washer is installed.
wit
, is n
The washer prevent the crankshaft from being turned when

h re
the securing bolt is tightened.
hole
spec
es, in part or in w
♦ Install a diamond-coated washer -7- if a washer was not fitted t to the co

as original equipment ⇒ Electronic Parts Catalogue “ETKA”.
♦ The washer is fitted -7- between the bearing bush -5- and the
crankshaft chain sprocket.
rrectness of i
♦ Note that all contact surfaces from the securing bolt to the
l purpos
crankshaft chain sprocket must be free of oil and grease.

nf
ercia
orm
– Clean sealing surfaces carefully. They must be free of oil and

m
atio
m
grease.
o
n in
or c
1 - Securing bolt
thi
te
sd
iva
o
r
2 - Crankshaft belt pulley

rp
cu
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f
en
ng
3 - Diamond coated washer (clipped onto crankshaft belt pulley)

t.
yi Co
Cop py
t.
4 - Crankshaft oil seal
rig
gh ht
pyri by
Vo
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5 - Bearing bush
lksw
cted agen
Prote AG.
6 - O-ring
7 - Diamond coated washer
– Push bearing bush onto crankshaft journal.

11.2015
. Volkswagen AG
a gen AG d
– Fit sleeve -T10117/2-
Volonto bush and slide oil seal oonto
ksw
oes
n t
g
bush.
y ua
db ran
– Remove sleeve
or -T10117/2- from bush.
ise tee
th or
au ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
– Using assembly tool - T10053- , drive in oil seal into valve tim‐
rrectness of i
ing housing as far as it will go with even blows of hammer.
l purpos

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

11.2015
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 40
⇒ “2.2 Renewing crankshaft sealing flange - flywheel end”,
page 41
2.1 Assembly overview - cylinder block,

gearbox end
Note
Repairing clutch ⇒ Repairing clutch; Rep. gr. 30 ; Removing and

installing clutch .
1 - Securing bolt
❑ Always make sure to ob‐
serve procedure
stalling pulley”,
page 34 .
❑ Contact surface for se‐
curing bolt must be free
of oil and grease.
AG. Volkswagen AG d
❑ Oil threads before in‐ lksw
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not
serting. byV
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ed
❑ Secure pulley against horis nte
eo
turning with counterhold aut ra
s c
tool - 3415- . s
ce
e
nl
pt
❑ The turning further an‐
du
an
itte
gle can be measured
y li
erm
ab
with a commercial pro‐
ility
ot p
tractor.
wit
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❑ Renew
h re
hole
spec
❑ 150 Nm + turn 180° fur‐
es, in part or in w
ther
2 - Belt pulley t to the co
❑ With diamond coated
rrectness of i
washer
l purpos
❑ Observe note on dia‐

mond coated washers
⇒ page 38 .
nform
ercia
❑ Contact surfaces must

m
be free of oil and grease.

at
om
ion
c
❑ Secure against turning

in t
or
with counterhold - 3415-

his
ate
when removing and in‐

do
priv
stalling
um
for
en
ng
❑ Remove poly V-belt

t.
yi Co
op
C py
ht. rig
stalling poly V-belt”, rig ht
py by
Vo
page 30 .
co lksw
by
cted agen
Prote AG.
3 - Seal
❑ Renew.
4 - Bearing bush

11.2015
5 - O-ring
❑ Renew.
6 - Cylinder block
❑ Removing and installing ⇒ “1 Removing and installing engine”, page 11 .
7 - Bolt
❑ Renew
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold - T10044- .
9 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
10 - Bolt
❑ Renew
❑ 12 Nm n AG. Volkswagen AG do
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11 - Sealing flange with sender wheel and oil seal byV
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ed ran
❑ Removing and installing engine speed sender hor - G28- (not shown)
is tee
⇒ “1.5 Removing and installing engine speed
aut sender G28 ”, page 291 . or
ac
ss
❑ Specified torque for engine speed sender - G28- : 5 Nm.
ce
le
un
pt
❑ Renew sealing flange complete with oil seal and sender wheel only.
an
d
itte
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❑ Renewing crankshaft sealing flange - flywheel end
erm
ab
ility
⇒ “2.2 Renewing crankshaft sealing flange - flywheel end”, page 41 .
ot p
wit
is n
h re
ole,
spec
2.2 Renewing crankshaft sealing flange -
t to the co
flywheel end
rrectne
♦ 24 mm tool insert - V.A.G 1332/11-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
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pyri by
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co lksw
by
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Prote AG.
♦ Depth gauge - VAS 6082-
2. Cylinder block, gearbox end 41

11.2015
AG. Volkswagen AG d
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hole
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es, in part or in w
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♦ Bolt M6x35 (qty. 3)
♦ Hexagon key
rrectness of i
Pressing sealing flange with sender wheel off crankshaft
l purpos
Note
nf
ercia
orm
m
atio
♦ For the sake of clarity, the work is performed with the engine
om
removed.
n in
or c
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e
♦ The procedure is identical whether the engine is installed or

t
sd
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removed.
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Procedure t. Cop py
rig
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– Remove flywheel or drive plate ⇒ Item 8 (page 41) . yri
p by
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by c lksw
cted
– Set engine to TDC No. 1 cylinder
agen
Prote AG.
⇒ “3.1 Checking valve timing”, page 88
– Remove sump
⇒ “1.3 Removing and installing sump”, page 127 .
– Remove engine speed sender - G28- -arrow-.

11.2015
– Unscrew securing bolts -arrows- of sealing flange -1-.
– To press off, screw 3 M6x35 bolts -arrows- into the sealing

flange -1-.
Note
The sealing flange -1- is pressed off the crankshaft -3- together
with sender wheel -2-.
– Alternately turn the bolts a maximum of a 1/2 turn into the

sealing flange.
– Remove the sealing flange -1- together with the sender wheel
-2-.
Pressing sealing flange with sender wheel onto crankshaft
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

agen
AG. Volkswagen AG d
lip support ring -2-. This support ring serves as a fitting
olksleeve
sw o es n
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and must not be removed prior to installation. sed b ua
ran
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or
♦ Sealing flange and sender wheel -1- must not
au be separated
th or
ac
after removal from packaging. ss
ce
e
nl
pt
♦ The sender wheel -1- is held in its installation position on the

du
an
itte
assembly device - T10134- by a locating pin ⇒ page 44 .

y li
erm
ab
ility
♦ Sealing flange and oil seal form one unit and must only be
ot p
wit
renewed together with the sender wheel.

, is n
h re
hole
♦ The assembly device - T10134- is held in its position relative

spec
to the crankshaft by a guide pin ⇒ page 44 inserted into a

es, in part or in w
t to the co
hole in the crankshaft.

rrectness of i
l purpos
nf
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orm
m
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n in
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Cop py
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by
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Prote AG.

11.2015
Components of assembly tool - T10134- :

A - Clamping surface
B - Hexagon nut
C - Assembly housing
D- wage
es n
Locating pin yV
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b
ed ran
E - Hexagon socket head bolthoris tee
ut or
a ac
F- ss
Guide pin for petrol engines (red knob)
ce
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nl
pt
du
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itte
G - Guide pin for diesel engines (black knob)
y li
erm
ab
ility
H - Knurled screws (qty. 3)
ot p
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I - Inner part
h re
hole
spec
es, in part or in w
Mounting seal with sender wheel on assembly tool - T10134-
t to the co
– Screw on nut -B- until just before it touches the clamping sur‐
face -A- of the threaded spindle.
rrectness of i
l purpos
nf
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m
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– Clamp assembly device - T10134- in a vice -1- on clamping

f
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t.
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surface -A- of threaded spindle.
Co
Cop py
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– Press assembly housing -C- downwards until it lies on hexa‐
ht
pyri by
gon nut -B-.
co Vo
by lksw
cted agen
Prote AG.
• Inner part of assembly tool and assembly housing must be at
same height.
– If fitted, remove securing clip -arrow- from new sealing flange.
Note
Do not take the sender wheel out of the sealing flange or rotate it
out of position.

11.2015
– Place sealing flange -1- with front side facing down on a clean
level surface.
– Push sealing lip support ring -2- downwards in
-direction of arrow- until it lies on flat surface.
lkswage es n
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d ran
ir se tee
tho
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un
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an
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• The upper edge of the sealing lip support ring -1- and front
y li
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ab
edge of the sealing flange -2- must align -arrows-.
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Place sealing flange -1- with front side onto the assembly tool
- T10134- so that locating pin -D- sits in the sender wheel -2- atio
om
hole -3-.
n
c
i
or
n thi
e
• The sealing flange must rest flat against the assembly tool.
t
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Cop py
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cted agen
Prote AG.
– Screw knurled screws -H- onto sealing flange -1-.

– Push sealing flange -1- and sealing lip support ring -2- onto
the surface of the assembly tool - T10134- while tightening.
– This prevents the locating pin from slipping out of the sender
wheel hole.
– When installing sealing flange, ensure that sender wheel re‐
mains fixed in assembly device.
Mounting assembly tool - T10134- with sealing flange on crank‐
shaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.
– Screw on nut -B- until it reaches end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in
-direction of arrow-, until nut -B- lies against assembly housing
-C-.
– Align flat side of assembly housing to sealing surface of cyl‐
inder block on sump side.

11.2015
– Secure assembly tool - T10134- on the crankshaft -2- together

with the sealing flange -1-.
– To do this, screw hexagon socket head bolts -E- into crank‐
shaft flange (approx. 5 full turns) using a hexagon key.
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
– Screw 2 M6x35 -3- bolts into the cylinder block -2- to guide the
sealing flange -1-.
Bolting assembly tool - T10134- onto crankshaft flange:

olkswagen AG
en AG. V
– Push assembly housing -C- by hand oinlks-direction
wag of arrow- untildoes not
sealing lip support ring -1- touches
ed
b crankshaft flange -2-.
y V gu
ara
is nte
or
– Check that the guide pin for au
thpetrol engines (red knob) -F- sits eo
ra
correctly in the hole in crankshaft.
ss This ensures that the sender c
wheel reaches its final installation position.
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
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The guide pin for diesel engines (black knob) must not be inserted
hole
in threaded hole of crankshaft.

spec
es, in part or in w
t to the co
– Tighten the two hexagon socket head bolts of the assembly

tool hand-tight.
rrectness of i
– Screw nut -B- onto threaded spindle by hand until it lies against
assembly housing -C-.
l purpos
Pressing sender wheel onto crankshaft flange using assembly

nform
ercia
tool - T10134- :
m
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.

com
tion in
• After nut has been tightened to 35 Nm, a small air gap must
r
te o
thi
still be present between cylinder block -2- and sealing flange

s
iva
do
-1-.
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Cop py
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Prote AG.

11.2015
Checking sender wheel installation position on crankshaft

– Screw on nut -B- until it reaches end of threaded spindle.
– Unscrew both bolts -2- from cylinder block.
– Pull guide pin for petrol engines (red knob) -F- out of crank‐
shaft flange.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange. To do
this, unscrew the hexagon socket head bolts -E- from crank‐
shaft flange.
– Remove sealing lip support ring.
– Position depth gauge - VAS 6082- on crankcase flange -2-.

– Measure distance between crankshaft flange -2- and sender
wheel -1-.
AG. Volkswagen AG d
agen oes
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un
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ility
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– Measured distance -a- between crankshaft flange -2- and
is n
h re
sender wheel -1-.
ole,
spec
• Specification: dimension -a- = 0.5 mm
t to the co
– If specification is not achieved, press sender wheel further in
⇒ page 47 .
rrectne
– If specification is achieved, proceed with subsequent work
steps.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
Re-pressing sender wheel

thi
te
sd
va
– Secure assembly tool - T10134- on crankshaft flange -2-.

i
o
pr
cum
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fo
en
ng
– Ensure the locating pin of the assembly tool - T10134- is seat‐

t.
yi Co
ed in the hole of the sender wheel. Cop py
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rig ht
– Tighten hexagon socket head bolts -E- finger-tight. py by
co Vo
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– Push assembly tool - T10134- against sealing flange -1- by Prote AG.
hand.
– Screw nut -B- onto threaded spindle by hand until it lies against
the assembly tool - T10134- .
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
– Screw knurled screws -H- into sealing flange -1-.
– To guide sealing flange, screw 2 M6×35 mm bolts -2- into cyl‐
inder block.

11.2015
– Tighten nut -B- of assembly tool - T10134- to 40 Nm.

– Check sender wheel installation position on the crankshaft
again ⇒ page 47
– If the specification is not achieved, tighten nut of assembly tool
- T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 47 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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au ra
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nl
pt
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itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
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nf
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Prote AG.

11.2015
3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 49
⇒ “3.2 Crankshaft dimensions”, page 50
⇒ “3.3 Renewing needle bearing in crankshaft”, page 50 lkswage es n
o ot g
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3.1 Assembly overview - crankshaft ho
ir se
d ran
tee
ut or
a ac
ss
ce
le
1 - Bolt
un
pt
an
d
❑ Only tighten to 50 Nm
itte
y li
erm
when measuring crank‐
ab
ility
shaft radial clearance.
ot p
wit
Do not turn further.
is n
h re
ole,
❑ Renew
spec
t to the co
2 - Bearing cap
❑ Do not interchange
rrectne
bearing caps (mark po‐
sitions).
s
❑ Bearing cap 3 with re‐
s o
cesses for thrust wash‐
cial p
f in
ers.
form
mer
❑ Bearing shell retaining
atio
m
lugs in cylinder block

o
n
c
i
and bearing caps must
or
n thi
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align.
t
sd
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pr
c
3 - Crankshaft
um
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fo
en
ng
t.
❑ Axial clearance (new):
yi Co
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0.07 ... 0.24 mm
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❑ Wear limit: 0.26 mm
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co Vo
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Check radial clearance with
Prote AG.
Plastigage.
❑ New: 0.03 … 0.05 mm
❑ Wear limit: 0.13 mm
❑ Do not rotate crankshaft
when checking radial
clearance.
❑ Pulling needle bearing
out of and driving into
crankshaft
⇒ “3.3 Renewing needle
bearing in crankshaft”,
page 50 .
❑ Crankshaft dimensions ⇒ “3.2 Crankshaft dimensions”, page 50 .
4 - Sealing flange with sender wheel and oil seal
❑ With engine speed sender - G28- (not illustrated).
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end
⇒ “2.2 Renewing crankshaft sealing flange - flywheel end”, page 41 .
5 - Bolt
❑ Renew
❑ 12 Nm
3. Crankshaft 49
11.2015
6 - Thrust washers
❑ For bearing cap 3.
❑ Note fixing arrangement.
7 - Bearing shell
❑ In cylinder block.
8 - Chain sprocket
❑ For oil pump drive and timing chain.
9 - Bearing shell
❑ In bearing cap.
❑ Do not interchange used bearing shells (mark).
3.2 Crankshaft dimensions

Honing Crankshaft bearing Conrod
dimension in mm journal diameter journal diameter
Basic dimension -0.022 -0.022
54.00 47.80 AG. Volkswagen AG d
agen oes
ksw
-0.037 -0.037 byV
ol not
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Stage I -0.022 -0.022 horis nte
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53.75 47.55 aut ra
s c
-0.037 -0.037 s
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nl
pt
Stage II --- -0.022
du
an
itte
47.30
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erm
ab
-0.037
ility
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3.3 Renewing needle bearing in crankshaft
h re
hole
spec
Only vehicles with a dual clutch gearbox
es, in part or in w
t to the co
♦ Adapter - 22/1- from Kukko
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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f
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11.2015
♦ Puller - Kukko 21/2-
♦ Drift - VW 207 C-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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un
pt
an
d
itte
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erm
ab
ility
ot p
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is n
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ole,
spec
Removing
t to the co
– Pull out needle bearing using commercially available puller,
e.g. Kukko - 21/2- and Adapter Kukko - 22/1- .
Installing
rrectne
– Drive in flush with drift - VW 207 C- or centring mandrel -

3176- .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
3. Crankshaft 51
11.2015
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 52. Volkswage
n AG n AG d
wage oes
⇒ “4.2 Checking piston and cylinder bore”, page
yV
olk53
s not
gu
b ara
ed
⇒ “4.3 Removing and installing oil sprayhorjets”,
is page 55 nte
eo
t
au ra
⇒ “4.4 Separating new conrod”, page
ss 56 c
ce
e
nl
pt
4.1 Assembly overview - pistons and con‐
du
an
itte
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rods
erm
ab
ility
ot p
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, is n
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Note
hole
spec
es, in part or in w
t to the co
All bearing points and running surfaces must be oiled before as‐
sembly.
rrectness of i
1 - Circlip
l purpos
2 - Piston pin
nf
ercia
❑ If difficult to remove,
or
heat piston to 60°C.
m
m
atio
m
❑ Remove and install with

o
n in
c
drift - 10 - 14- .
or
thi
te
sd
iva
3 - Piston
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❑ Checking
f
en
ng
t.
⇒ “4.2 Checking piston
yi Co
op
and cylinder bore”, page
C py
t. rig
gh
53 .
ht
pyri by
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by
❑ Mark installation posi‐ Prote
cted AG.
agen
tion and cylinder num‐
ber.
❑ Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring
clamp.
4 - Compression rings
❑ Offset gaps by 120°.
❑ Remove and install
compression rings with
piston ring pliers.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
53 .
❑ Checking ring-to-groove
clearance
53 .
5 - Oil scraper rings
❑ Carefully remove and install 3-part oil scraper rings by hand.
❑ Checking ring gap ⇒ “4.2 Checking piston and cylinder bore”, page 53 .
❑ Ring-to-groove clearance not measurable.

11.2015
6 - Conrod bolt
❑ Oil threads and contact surface.
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
❑ Renew
❑ M 7 × 0.75: 20 Nm + 90° further
❑ M 8 × 1: 30 Nm + 90° further
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod.
❑ Marking -A-: mark with cylinder number
❑ Marking -B-: mark paired conrods and conrod bearing caps
8 - Bearing shell
❑ Do not interchange used bearing shells.
AG. Volkswagen
❑ Insert bearingswshells
agen centrally. AG does
k not
y Vol gu
Checking radial
se
d b clearance with Plastigage: ara
nte
ri
ho eo
❑ New:
au
t 0.020 … 0.060 mm ra
c
ss
❑ Wear limit: 0.090 mm ce
e
nl
pt
du
❑ Do not rotate crankshaft when checking radial clearance. an

itte
y li
erm
ab
9 - Pressure relief valve ility
ot p
❑ Opening pressure of pressure relief valve: 1.8 … 2.2 bar

wit
, is n
h re
❑ 27 Nm
hole
spec
10 - Oil spray jet

es, in part or in w
t to the co
❑ For piston cooling.

11 - Conrod
rrectness of i
❑ Renew as set only.

l purpos
❑ Marking -A-: mark with cylinder number

❑ Marking -B-: mark paired conrods and conrod bearing caps
nform
ercia
❑ Guided axially by piston.

m
at
om
ion
c
in t
or
4.2 Checking piston and cylinder bore

his
ate
do
priv
⇒ “4.2.1 Checking piston”, page 53

um
for
en
ng
t.
yi
⇒ “4.2.2 Checking cylinder bores”, page 54
Co
Cop py
t. rig
⇒ “4.2.3 Piston and cylinder dimensions”, page 54
gh ht
pyri by
Vo
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by c lksw
4.2.1 Checking piston
cted agen
Prote AG.

♦ External micrometer 75…100 mm
Checking piston
– Measure approx. 12 mm from lower edge of skirt, at 90° angle
to piston pin axis. Difference between actual and nominal di‐
ameter: not more than 0.04 mm. Nominal dimension
4. Pistons and conrods 53

11.2015
Checking piston ring gap

– Push ring squarely from above down into cylinder bore to ap‐
prox. 15 mm from bottom end of cylinder. n AG. Volkswagen A G do
wage es n
olks ot g
Piston ring New Wear by Vlimit ua
dimensions in mm ed ran
ris tee
tho or
u
1st compression ring 0.20 … 0.40 ss a 1.0 ac
ce
le
2nd compression ring 0.40 … 0.60 1.0
un
pt
an
d
itte
Oil scraper ring 0.20 … 0.80 ---1)
y li
erm
ab
ility
1) No wear limit details available ot p
wit
is n
h re
ole,
Checking ring-to-groove clearance
spec
Clean annular groove before check.
t to the co
Piston ring New Wear limit
dimensions in mm
rrectne
1st compression ring 0.04 … 0.08 0.15
ss
2nd compression ring 0.02 … 0.06 0.15
o
cial p
f i
Oil scraper ring Not measurable
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
4.2.2 Checking cylinder bores

p
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh
♦ Cylinder gauge 50…100 mm
ht
pyri by
Vo
co lksw
by
Checking cylinder bores
cted agen
Prote AG.
– Take measurements at 3 positions in both lateral direction

-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.08 mm.
– Nominal dimension
Note
Cylinder bores must not be measured when cylinder block is

mounted on engine and gearbox support - VAS 6095- , as meas‐
urements may be incorrect.
4.2.3 Piston and cylinder dimensions

Honing dimen‐ Piston diame‐ Cylinder bore diame‐
sion ter 2) ter
Basic dimen‐ mm 76.460 76.51
sion
Stage I mm 76.710 76.76
Stage II mm 76.960 77.01
2) Measure pistons approx. 12 mm from lower edge.

11.2015
4.3 Removing and installing oil spray jets

♦ Socket - T10545-
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove sump
– Remove oil pump
⇒ “1.4 Removing and installing oil pump”, page 130 .
Note
♦ The crank web of the respective cylinder must be positioned

so that the socket - T10545- can be inserted in the pressure
relief valve as close to vertical as possible.
♦ Furthermore, the corners of the socket - T10545- and of the
pressure relief valve must engage well.
– Turn the crankshaft using the securing bolt of the vibration

damper until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using socket - T10545- .
– Remove oil spray jets -2-.
Installing
lkswage es n
o ot g
yV ua
Caution ir se
d b ran
o tee
th or
u
Risk of damage to soil
s spray jets.
a ac
ce
le
un
♦ Do not bend oil spray jets.

pt
an
d
itte
y li
♦ Check that oil spray jets can operate freely after reinstal‐
rm
ab
pe
lation of pistons.
ility
ot
wit
, is n
♦ Bent oil spray jets must be renewed.

h re
hole
spec
es, in part or in w
t to the co
1- Pressure relief valve, 27 Nm

rrectness of i
2- Oil spray jet

l purpos
• Installation position: align leading edge of oil spray jet arrow

with machined surface of cylinder block.
nform
ercia
– Install oil pump

⇒ “1.4 Removing and installing oil pump”, page 130 .
m
a
com
tio
– Install sump
n in
r

te o
thi
s
iva
do
– Install noise insulation ⇒ General body repairs, exterior; Rep.

r
rp
cum
gr. 66 ; Noise insulation; Assembly overview - noise insula‐

fo
en
g
tion .
n
t.
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Cop py
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Prote AG.
4. Pistons and conrods 55

AG. Volkswagen
Passat 2006 ➤ , Passat 2011 ks➤
wag,ePassat Variant 2011
n AG do
es➤
not , Touran 2003 ➤
Vol
4-cylinder direct-injection d b engine (1.4 l, natural gas, EA 111,
y gu turbocharger, supercharger) - Edition
ara
se nte
11.2015 thori
eo
au ra
c
ss
4.4 Separating new conrod
ce
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nl
pt
du
an
itte
On a new conrod, it is possible that the breaking point has not
y li
erm
ab
fully separated. Proceed as follows, when the conrod bearing cap
ility
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cannot be removed by hand:
wit
, is n
h re
– Mark cylinder allocation of conrod ⇒ Item 11 (page 53)
hole
spec
– Gently clamp conrod, as shown in illustration, in a vice with
es, in part or in w
t to the co
soft aluminium jaws.
rrectness of i
Note
l purpos
♦ To prevent damage to the conrod, only clamp conrod in lightly.

♦ Conrod is clamped below the dashed line.
nform
mercia
at
– Unscrew the two bolts -arrows- approx. 5 turns.
om
ion
c
in t
or
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ate
do
priv
cum
or
– Using a plastic hammer, carefully knock against conrod bear‐

f
en
ng
ing cap in -direction of arrow- until it is loose.

t.
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Cop py
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by c lksw
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Prote AG.

11.2015
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 57
⇒ “1.2 Removing and installing cylinder head”, page 59
⇒ “1.3 Removing and installing camshaft housing”, page 64
⇒ “1.4 Checking compression”, page 72
1.1 Assembly overview - cylinder head
1 - Bolt
❑ 20 Nm
2 - High-pressure pump
❑ For fuel supply.
❑ With fuel pressure regu‐
lating valve - N276- .
stalling high-pressure
pump”, page 263 .
3 - Cable guide
❑ Bolt to camshaft hous‐
AG. Volkswagen AG d
ing with 8 Nm torque. ksw
agen oes
not
Vol
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4 - Bleeder hose to air filter ise
d b ara
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or
❑ Check for damage, and auth eo
ra
renew if necessary ss c
ce
e
nl
pt
5 - Bolt
du
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❑ 10 Nm
erm
ab
ility
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6 - Hall sender - G40-
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❑ With O-ring.
h re
hole
spec
❑ Renew O-ring if dam‐
es, in part or in w
aged.
t to the co
7 - Stud
❑ 6 Nm
rrectness of i
8 - Bolt
l purpos
❑ Tighten from inside out‐

wards.
nf
ercia
❑ Renew
rm
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atio

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n in
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9 - Camshaft housing
thi
te
sd
iva
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Note
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The strainer for oil circuit must be Cop py
installed in cylinder head.
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by
❑ Removing and installing ⇒ “1.3 Removing and installing camshaft housing”, page 64 . Prote
cted AG.
agen
❑ Remove sealant residue.

❑ Carefully clean sealing surfaces. They must be oil and grease free.
❑ Before fitting, coat with sealant ⇒ Electronic Parts Catalogue (ETKA)
1. Cylinder head 57
11.2015
10 - Bolt
❑ 20 Nm
11 - Lifting eye
12 - Turbocharger
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 166 .
13 - Oil pressure switch - F1-
❑ Checking ⇒ “2.1 Checking oil pressure and oil pressure switch”, page 133 .
❑ If seal is leaking, nip open and renew.
❑ 20 Nm
14 - Cylinder head gasket
❑ Metal gasket.
❑ After renewing, renew entire coolant.
❑ Renew
15 - Cylinder head
Note
The strainer for oil circuit must be

installed in cylinder head.
❑ Removing and installing ⇒ “1.2 Removing and installing cylinder head”, page 59 .
❑ Check for distortion ⇒ page 59 .
❑ Sealing surfaces to camshaft housing must be oil and grease free.
❑ After renewing, renew entire coolant.
16 - Guide pins
❑ 20 Nm
17 - Dowel pin
18 - Oil strainer
AG. Volkswagen AG d
❑ Inserted into cylinder head. agen oes
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❑ Renew. rise
d b ara
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19 - Support element s au ra
c
s
❑ Do not interchange.
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le
un
pt
an
❑ With hydraulic valve clearance compensation.

d
itte
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erm
ab
❑ Oil contact surface.

ility
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20 - Roller rocker finger

wit
is n
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❑ Check roller bearing for ease of movement.

ole,
spec

t to the co
❑ When installing, secure to supporting element using securing clip.

21 - Seal
rrectne
Note
ss o
Note the different sealing types

cial p
f in
when removing and installing the

form
mer
camshaft housing ⇒ page 64 .

atio
om
❑ Renew.
n
c
i
or
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e
❑ Qty. 4.
t
sd
iva
o
r
❑ Inserted into cylinder head.

p
cum
r
fo
en
ng
22 - Cylinder head bolt

t.
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op py
❑ Renew. t. C rig
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Vo
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by
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58
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
11.2015
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 63 .
23 - Roller tappet
❑ Lightly coat contact surface with engine oil.
24 - O-ring
❑ Renew.
❑ Moisten with oil before inserting.
lkswage es n
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d ran
ir se
Checking cylinder head for distortion tho tee
or
au ac
Use straightedge 500 mm - VAS 6075- and feeler gauge for
ss
ce
e
checking.
nl
pt
du
an
itte
y li
Max. permissible distortion: 0.05 mm
erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
1.2 Removing and installing cylinder head
l purpos
nf
ercia
or
equipment required
m
m
atio
om
♦ Support bracket - 10 - 222
n in
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A-
thi
te
sd
iva
♦ Adapter - 10 - 222 A /8-
o
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cu
(Passat)
o
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f
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t.
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♦ Adapter - 10 - 222 A /26- Cop py
. rig
(Touran)
t
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co
♦ Adapter - 10-222 A/30-
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Prote
(Touran)
AG.
♦ Hook - 10 - 222 A /10-

(Touran, not illustrated)
♦ Shackle - 10 - 222 A /12-
(Touran, not illustrated)
♦ Bracket - T10358-
1332-
1. Cylinder head 59
11.2015
1331-
DANGER!

⇒ “2.2 Safety precautions when working on natural gas sys‐
tem”, page 4 !!!
WARNING
Note
♦ When installing an exchange cylinder head, all the contact

surfaces between the support elements, roller rocker arms
and the cams must be oiled before installing the camshaft
housing.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
♦ All bearing points and running surfaces must be oiled before
assembly.

gines; Rep. gr. 20 ; Fuel tank; Releasing pressure
olkswagein high- es n
ot g
pressure line . d byV ua
ra e nte
ris
Removing utho eo
ra
a c
ss
– Loosen union nut at threaded connection of low-pressure line
ce
le
un
-arrow-, while at the same time counterholding at gas rail with

pt
an
d
a spanner.
itte
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rm
ab
pe
– Allow residual gas to escape.

ility
ot
wit
, is n
– Remove regulating flap control unit - J808- and throttle valve

h re
module - J338-
hole
spec
⇒ “7.4 Removing and installing regulating flap control unit J808

es, in part or in w
and throttle valve module J338 ”, page 258 .

t to the co
– Removing intake manifold

⇒ “7.1 Assembly overview - intake manifold”, page 244 .
rrectness of i
– Remove turbocharger
l purpos
⇒ “1.2 Removing and installing turbocharger”, page 166 .

– Remove thermostat housing from cylinder head
nform
ercia
⇒ “2.1 Assembly overview - thermostat”, page 144 .

m
– Removing and installing valve timing housing

com
tion in
⇒ “2.1 Removing and installing valve timing housing (timing

r
te o
thi
case)”, page 74
s
iva
do
r
– Remove timing chain and drive chain for oil pump

rp
cum
fo
⇒ “3.4 Removing and installing timing chain and chain drive

en
ng
t.
yi
for oil pump”, page 106 .
Co
Cop py
t. rig
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Touran
ht
pyri by
Vo
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by
cted agen
Prote AG.
60 Rep. gr.15 - Cylinder head, valve gear

11.2015
– Unscrew securing bolt for gearbox and attach bracket -

T10358- as shown.
– Attach hooks of support bracket - 10 - 222 A- to bracket -
T10358- as shown.
– Turn spindle until the hooks are lightly tensioned.
– Unhook hook -1- from left lifting eye and push spindle onto left
side of support bracket - 10 - 222 A- .
Passat
– Removing and installing camshaft housing
⇒ “1.3 Removing and installing camshaft housing”,
page 64 .
Note agen
AG. Volkswagen AG d
oes
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b ara
Ensure that roller rocker
orise fingers and support elements are not
d
nte
interchanged. aut h eo
ra
ss c
ce
e
nl
– Remove roller rocker fingers together with support elements

pt
du
an
and lay aside on a clean surface.

itte
y li
erm
ab
– Loosen and unscrew cylinder head bolts in the given se‐

ility
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quence.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 61
11.2015
Specified sequence for loosening cylinder head bolts

– Carefully remove cylinder head.
Installing
• The pistons must not be positioned at TDC.
Note
AG. Volkswagen AG d
agen oes
ksw
♦ Do not remove new cylinder
by Vol
head gasket from its packing
not
gu until
immediately beforerise installing.
d ara
nte
tho eo
♦ Handle new sgasket
sa
u
with extreme care. Damage will cause ra
c
leakage.
ce
e
nl
pt
du
♦ The strainer for oil circuit must be installed in cylinder head.
an
itte
y li
erm
ab
ility
ot p
– Place clean cloths in cylinders so that no dirt or emery cloth
wit
particles can get in between cylinder wall and piston.
, is n
h re
hole
– Now carefully clean sealing surfaces of cylinder head and cyl‐
spec
inder block. When doing this, ensure that surfaces are not
es, in part or in w
t to the co
scored or scratched (if abrasive paper is used, grade must not
be less than 100).
– Carefully remove metal particles, emery residue and cloths.
rrectness of i
– Set No. 1 cylinder piston to top dead centre, then turn crank‐
l purpos
shaft approx. 45° in direction of engine rotation.

– Fit new cylinder head gasket. The part number must be read‐
nf
ercia
able.
rm
m
atio
m
– Fit cylinder head. When doing this, observe centring pins in

o
n in
c
cylinder block.
or
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

wage
e
11.2015
ks s no
Vol t gu
by ara
Specified tightening sequence for cylinder head bolts ris
ed
nte
tho eo
– Tighten cylinder head bolts observing given tightening
ss
au se‐ ra
c
quence and specified stages ⇒ page 63 .
ce
e
nl
pt
du
an
– Install supporting elements in cylinder head and fit respective
itte
y li
roller rocker finger onto respective valve stem end or support‐
erm
ab
ing element.
ility
ot p
wit
, is n
– Install camshaft housing
h re
⇒ “1.3 Removing and installing camshaft housing”,
hole
spec
page 64 .
es, in part or in w
t to the co
– Adjust valve timing ⇒ “3.2 Adjusting valve timing”, page 90 .
rrectness of i
quence.
l purpos
Note
nf
ercia
or
m
m
atio
om
n in
or c
thi
e
WARNING
t
sd
iva
o
r
rp
cu
o
m
• Operating the natural gas system without having tested it
f
en
ng
t.
for leaks according to specifications may result in severe
yi Co
op
injuries or death.
C py
t. rig
gh ht
yri by
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by c lksw
cted
agen
Prote AG.
Allocation:
page 214
wheel - T50026- .
page 214
Specified torques:
Cylinder head bolts
Stage Bolts (renew) Specified torque/ addi‐
tional specified angle
1. 1 ... 10 Pre-tighten by hand
2. 1 ... 10 30 Nm
3. 1 ... 10 90°
4. 1 ... 10 90°
5. 1 ... 10 90°
♦ Gearbox securing bolt ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Specified torque for gearbox
♦ Securing bolts for intake manifold
⇒ “7.1 Assembly overview - intake manifold”, page 244
♦ Securing bolts for regulating flap control unit - J808- and throt‐
tle valve module - J338-
1. Cylinder head 63
11.2015
♦ Securing bolts for turbocharger

⇒ “1.1 Assembly overview - turbocharger”, page 162
♦ Securing bolts for thermostat housing
⇒ “2.1 Assembly overview - thermostat”, page 144
♦ Securing bolts for valve timing housing cover
⇒ “1.2 Assembly overview - cylinder block (pulley end)”, page
28
1.3 Removing and installing camshaft housing

equipment required AG. Volkswagen AG d
agen oes
ksw
♦ Dial gauge - VAS 6079- byV
ol not
gu
ara
ed
is nte
♦ Puller - T10094 A- hor eo
aut ra
c
♦ Dial gauge adapter - ss
ce
e
T10170- or dial gauge

nl
pt
du
an
adapter - T10170 A-
itte
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erm
ab
♦ Camshaft clamp - T10171
ility
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A-
wit
, is n
h re
♦ Counterhold - T10172-
hole
spec
♦ Locking pin - T40011-
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
iva
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11.2015
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 65
11.2015
♦ Spark plug socket and extension - 3122 B-

♦ Sealant ⇒ Electronic Parts Catalogue (ETKA)
Removing
DANGER!

tem”, page 4 !!!
WARNING
AG. Volkswagen AG d
agen oes
lksw not
– Empty gas system ⇒ Fuel supply system d–bnatural
yV
o
gas en‐ gu
ara
gines; Rep. gr. 20 ; Fuel tank; Releasing orisepressure in high- nte
eo
pressure line . auth
ra
ss c
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
♦ The camshafts are mounted in the camshaft housing on this
ot p
wit
engine. Before removing camshaft housing, first remove valve
, is n
h re
timing housing.
hole
spec
♦ Removing and installing valve timing housing
es, in part or in w
t to the co
case)”, page 74
♦ The camshaft housing sealing surface must not be reworked.
rrectness of i
l purpos
– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
nform
ercia
– With ignition switched off, disconnect battery earth strap.

m
at

om
ion

c
in t
or
his
te

a
do
priv
cum
or
– Remove coolant hoses and line/wiring guides.

f
en
ng
t.
yi Co
– Unscrew securing bolts and remove camshaft sealing covers Cop py
-1-.
t. rig
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pyri by
Vo
co
– Remove turbocharger
by lksw
cted agen
Prote
AG.
– Removing and installing valve timing housing

case)”, page 74
– Turn crankshaft to TDC for No. 1 cylinder. Then turn crank‐
shaft 2 full turns in direction of engine rotation and remove
camshaft timing chain sprockets with timing chain
⇒ “3.2 Adjusting valve timing”, page 90 .
– Unbolt camshaft sealing covers.
– Pull connectors off fuel pressure sender for low-pressure -
G410- and off high-pressure pump.
– Unscrew earth cable from camshaft housing.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
ise Passat 2006 ➤ , Passat 2011 ➤ , Passat nte Variant 2011 ➤ , Touran 2003 ➤
d b ara
r
4-cylinder direct-injection
autho
engine (1.4 l, natural gas, EA 111, turbocharger,
eo
ra supercharger) - Edition
ss c
11.2015
ce
e
nl
pt
du
an
– Remove ignition coils. Use puller -T10094 A- for this purpose
itte
y li
⇒ “1.4 Removing and installing ignition coils with output stage”,
erm
ab
page 289 .
ility
ot p
wit
, is n
– Remove cable guide with wiring harness from camshaft hous‐
h re
hole
ing.
spec
es, in part or in w
t to the co
WARNING
Fuel supply lines are under pressure! Wear eye protection and
rrectness of i
gloves to avoid injuries and skin contact. Before loosening
l purpos
hose connections, wrap a cloth around the connection. Then

release pressure by carefully pulling hose off connection.
nf
ercia
orm
m
atio
m
– Pull connector and fuel supply line -arrows- off high-pressure

o
n in
c
pump.
or
thi
te
sd
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 67
11.2015
– Remove wiring guide -2- and remove connector -4- from Hall
sender - G40- .
Note
Use a spanner to counterhold threaded connections on high pres‐

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

– Pull out oil dipstick.
– Remove lower part of intake manifold
⇒ “7.3 Removing and installing lower part of intake manifold”,
page 256 .
– Unbolt left lifting eye.
– Loosen camshaft housing bolts from outside to inside, alter‐
nately and diagonally and remove.
– Carefully lift camshaft housing off.
Installing
• The pistons must not be positioned at TDC.
AG. Volkswagen AG d
agen oes
olksw not
Note d by V gu
ara
rise nte
tho eo
The strainer for oil circuit must be installeds ain cylinder head.
u ra
c
s
ce
le
un
pt
– Remove sealant residues from cylinder head and camshaft
an
d
itte
housing with a rotating brush, e.g. a hand drill with a plastic
y li
rm
ab
brush (wear eye protection).
pe
ility
ot
wit
– Clean sealing surfaces carefully. They must be free of oil and
, is n
h re
grease.
hole
– Also prevent dirt and residual sealant from entering cylinder spec
es, in part or in w
head. t to the co
Caution
rrectness of i
l purpos
Before using camshaft clamp - T10171 A- you must check that

the pins on the tool project by at least 7 mm.
nform
ercia
If this is not the case, the camshaft clamp is defective and must
be renewed.
m
a
com
tio
The camshaft clamp must not be positioned using any kind of

n in
r
te o
hammer.
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.2015
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be inserted into holes in camshaft to stop.
– Screw in an M6 bolt hand-tight to secure camshaft clamp -
T10171 A- , but do not tighten.
Note
Camshaft housings with different sealing variants in area of spark

plug recess have been fitted.
Sealing on cylinder head with no sealing ring in area of spark plug

recess
Caution
No sealant is applied in area of the oil strainer -1-.
– Apply thin, even coat of sealant on clean camshaft housing

sealing surface. See hatched area in illustration.
Note
Sealant must not be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
Sealing on cylinder head with sealing ring in area of spark plug

recess
– Place new seals into grooves in cylinder head.
Caution
AG. Volkswagen AG d
agen oes
ksw
No sealant is applied inbyarea
Vol
of the oil strainer -1-. not
gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Apply thin, even coat of sealant on clean camshaft housing
ce
e
nl
pt
sealing surface. See hatched area in illustration.

du
an
itte
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erm
– Do not apply sealant in area of -arrows-.

ab
ility
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Sealing on cylinder head with machined chamfer in area of spark

wit
, is n
plug recess
h re
hole
spec
es, in part or in w
Caution
t to the co
No sealant is applied in area of the oil strainer -1-.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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f
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted
69
agen
Prote AG.
1. Cylinder head
11.2015
– Apply thin, even coat of sealant - D 154 103 A1- on clean

camshaft housing sealing surface. See hatched area in illus‐
tration.
– Apply sealant -D 176 600 A1- to the chamfer -arrows- of cyl‐
inder head.
The sealant bead must be 2 mm thick.
Note
Sealant must not be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
Caution agen
AG. Volkswagen AG d
oes
olksw not
byV gu
Ensure that all roller rocker fingers contact valve rised stem ends ara
nte
-1- correctly and that they are clipped into their
ut respective sup‐
ho eo
ra
port elements -2-. s s a c
ce
le
Proceed with extreme caution when fitting the camshaft hous‐

un
pt
an
d
ing onto the cylinder head in order to prevent the roller rocker
itte
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11.2015
– Then, carefully lower camshaft housing in

-direction of arrow- towards cylinder head.
Note
Ensure that no oil residue can drip onto sealing surfaces.
Note
Ensure that no oil residue can drip onto sealing surfaces.
– Tighten new camshaft housing securing bolts to specified tor‐

que ⇒ page 71 .
Observe given procedure ⇒ page 71 .
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page 214
Specified torques:
Component Specified torque Procedure
Securing bolts for cam‐ 10 Nm + turn 90° Tighten mount‐
shaft housing/renew further ings from centre
outwards
1. Cylinder head 71
11.2015

case)”, page 74
♦ Install turbocharger
♦ Install crankshaft belt pulley
♦ Connect fuel lines
⇒ “8.2 Removing and installing high-pressure pump”,
page 263 . n AG. Volkswagen AG do
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Test prerequisite
• Engine oil temperature must be at least 30°C.
Procedure
– Remove ignition coils. Use puller - T10094 A- for this purpose.

11.2015
– Unscrew spark plugs with spark plug socket and extension -

3122 B-
page 289 .
– Remove fuse for fuel pump control unit voltage supply from
fuse holder under left side of dash panel. Fuse assignment:
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
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Connect ⇒ Vehicle y Vdiagnostic tester and perform guided
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“Releasing pressure
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– Checks aucompression using compression tester - V.A.G 1763- ra
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adapter
s - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .
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Using compression tester: ⇒ Operating instructions .
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Compression pressures:
rrectne
New bar pressure Wear limit bar pres‐ Difference between

sure cylinders bar pres‐
s
sure
s o
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10.0 … 15.0 7.0 max. 3.0

nform
mer
– Insert spark plugs using spark plug socket and extension -

atio
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3122 B- and tighten to 25 Nm.

o
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memory: ⇒ Vehicle diagnostic tester “Guided Fault Finding”. . Cop py
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1. Cylinder head 73
11.2015
2 Cover for timing chain

case)”, page 74
2.1 Removing and installing valve timing

housing (timing case)
⇒ “2.1.1 Removing and installing valve timing housing (Passat)”,
page 74
⇒ “2.1.2 Removing and installing control housing (Touran)”, page
80
2.1.1 Removing and installing valve timing housing (Passat)

equipment required
♦ Support bracket - 10-222A-
♦ Adapter - 10 - 222 A /8-
♦ Pins - 3415/1-
1331-
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11.2015

♦ Silicone adhesive sealant ⇒ Electronic Parts Catalogue (ET‐
KA)
Removing
DANGER!

tem”, page 4 !!!
WARNING

pressure line .
– Mark the direction of rotation of the poly V-belt and remove
belt ⇒ “1.3 Removing and installing poly V-belt”, page 30 .
– Turn crankshaft in direction of engine rotation to TDC for no.
1 cylinder ⇒ “3.1 Checking valve timing”, page 88 .
– Remove coolant pump
⇒ “2.2 Removing and installing coolant pump”, page 145 .
– Carefully loosen union nut -arrow- and allow residual gas to

escape.
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2. Cover for timing chain 75

11.2015
– Push gas pressure regulator -1- in direction of -arrow- and se‐

cure to side with wire.
– Remove banjo bolt from oil supply pipe to turbocharger.
– Remove air conditioner compressor from bracket with refrig‐
erant lines still connected ⇒ Heating, air conditioning; Rep.
gr. 87 .
– Remove bracket for tensioning element and air conditioner
compressor.
– Remove alternator.
– Position support bracket - 10 - 222 A- with adapter - 10 - 222

A /8- and hook - 10 - 222 A /10- as shown in illustration.
– Fit adapter - 10 - 222 A /8- behind bolts -arrow 1- and
-arrow 2-.
WARNING
Not not fit adapter - 10 - 222 A /8- on edges of wing.

The wing will otherwise be damaged.
AG. Volkswagen AG d
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– Take up weight of engine and remove securing
ised b bolts ara
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- 3415- and -3415/1- .
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nform
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11.2015
– Remove Allen bolts for valve timing housing andgehexagon

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bolts indicated by -arrows-. yV
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– Remove valve timing housing. thoris e or
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Note that crankshaft bearing bush remains in sealing flange.
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Note
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rrectness of i
installed. The diamond coated washer prevents the crankshaft
from being turned when the securing bolt is tightened.
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♦ Install a diamond-coated washer -7- if a washer was not fitted

as original equipment ⇒ Electronic Parts Catalogue “ETKA”.
nform
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crankshaft chain sprocket must be free of oil and grease.
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5 - Bearing bush
6 - O-ring
Note
♦ The valve timing housing is still sealed to engine with a gasket

and, additionally, with silicone adhesive sealant ⇒ Electronic
Parts Catalogue .
♦ The silicone adhesive sealant ⇒ Electronic Parts Catalogue
is intended to prevent leaks between the valve timing housing
and the joints -1- and -2-.
♦ Sealant spots must have a diameter of 10 mm and a thickness
of approx. 1 mm.
♦ Do not apply sealant until directly before the valve timing
housing is fitted.

11.2015
– Apply silicone adhesive sealant to joints camshaft housing/

cylinder head -1- and cylinder head/cylinder block -2-.
– Fit new gasket onto dowel pins.
– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
AG. Volkswagen AG d
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fied tightening procedure ⇒ page 79 .
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Install crankshaft belt pulley
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mercia
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– Tighten union nut -arrow- to 5 Nm +70° additional specified

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11.2015

pressure regulator to 8 Nm.
Note
♦ On no account must the union nut be tightened further than

specified, otherwise the special connection will be damaged
♦ Natural gas system may not be operated until tested accord‐
ingly.

quence.
WARNING

injuries or death.
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Allocation: s au ra
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⇒ “3.1 Different pressure sections of natural gas supply system”, s ce
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page 214
pt
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– Open fuel tank shut-off valves -N361/N362/N363- using hand
erm
ab
wheel - T50026- .
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page 214
es, in part or in w
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Specified torques:
Component: Specified torque Procedure
rrectness of i
securing bolts for valve

timing housing cover
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Stage 1 (all bolts) hand-tight Pre-tighten in di‐

agonal sequence
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♦ Securing bolts for coolant pump
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⇒ “2.2 Removing and installing coolant pump”, page 145
Prote AG.
♦ Securing bolt for crankshaft pulley

28
♦ Securing bolts for sump
⇒ “1.3 Removing and installing sump”, page 127

AG. Volkswagen AG d
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Passat 2006 ➤ , Passat 2011 ➤ , Passat Variant
rised
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4-cylinder direct-injection engine (1.4 l,anatural
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gas, EA 111, turbocharger, supercharger) ra - Edition
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11.2015 s
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2.1.2 Removing and installing control housing (Touran)
itte
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♦ Support bracket - 10-222A-
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♦ Adapter - 10 - 222 A /26-
♦ Adapter - 10-222 A/30-
rrectness of i
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♦ Pins - 3415/1-
nf
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Prote AG.

11.2015

♦ Silicone adhesive sealant
Removing
DANGER!

tem”, page 4 !!!
WARNING

pressure line .
– Mark the direction of rotation of the poly V-belt and remove
belt ⇒ “1.3 Removing and installing poly V-belt”, page 30 .
– Turn crankshaft in direction of engine rotation to TDC of
No. 1 cylinder ⇒ “3.1 Checking valve timing”, page 88
agen
AG. . Volkswagen AG d
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olks ot g
– Remove coolant pump db
yV ua
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⇒ “2.2 Removing and installing coolant
orisepump”, page 145 . tee
th or
s au ac
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– Carefully loosen union nut -arrow- and allow residual gas to
ce
e
nl
escape.
pt
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nform
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mercia
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Caution
on
c
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11.2015 gen AG
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d
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– Push gas pressure regulator
ed b -1- in direction of -arrow- and se‐
ara
nte
ris
cure to side withuwire.
tho eo
ra
sa c
– Remove banjo bolt from oil supply pipe to turbocharger.
s
ce
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nl
pt
du
– Remove air conditioner compressor from bracket with refrig‐
an
itte
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erant lines still connected ⇒ Heating, air conditioning; Rep.
erm
ab
gr. 87 .
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ot p
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– Remove bracket for tensioning element and air conditioner
h re
compressor.
hole
spec
es, in part or in w
– Remove alternator.
t to the co
Note
rrectness of i
♦ The Touran has different versions of the front end.
l purpos
♦ The shape of the headlights is a distinguishing characteristic.
nf
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o
♦ Determine which version of the front end is at hand and use
rm
the correct adapters accordingly.
m
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or c
Vehicles ► 11.06
thi
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Small headlights -arrow 1-: adapter - 10-222A/22- .
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Vehicles from 12.06 ► 05.10 t. Cop py
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Large headlights with curve -arrows 2-: adapter - 10-222A/26- . yri
p by
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Vehicles 06.10 ►
agen
Prote AG.
Large headlights without curve -arrow 3-: adapter - 10-222A/30- .

11.2015
– Fit engine support bracket - 10-222A- with adapter and take

up weight of engine in installation position.
– Take up weight of engine and remove securing bolts

-arrows-.
– Remove sump
AG. Volkswagen AG d
agen oes
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au ra
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pt
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- 3415- and -3415/1- .
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t to the co
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l purpos
nform
mercia
at
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ion
c
in t
or
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ate
do
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cum
for
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ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.

11.2015
– Remove Allen bolts for valve timing housing and hexagon

bolts indicated by -arrows-.
– Remove valve timing housing.
Note
Note that crankshaft bearing bush remains in sealing flange.
Installing
Note
♦ From model year 2009, a diamond-coated washer is installed.

The washer prevent the crankshaft from being turned when
the securing bolt is tightened.
♦ Install a diamond-coated washer -7- if none was already fitted
⇒ Electronic Parts Catalogue “ETKA”.
crankshaft chain sprocket must be free of oil and grease. n AG. Volkswagen AG do
lkswage es n
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– Clean sealing surfaces carefully. They must be freethoof
r oil and
is tee
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ac
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1 - Securing bolt
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6 - O-ring
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♦ The valve timing housing is still sealed to engine with a gasket

form
mer
and, additionally, with silicone adhesive sealant ⇒ Electronic

atio
Parts Catalogue .
om
n
c
i
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♦ The silicone adhesive sealant ⇒ Electronic Parts Catalogue

thi
e
is intended to prevent leaks between the valve timing housing

t
sd
iva
and the joints -1- and -2-.

pr
cum
r
fo
en
ng
♦ Sealant spots must have a diameter of 10 mm and a thickness

t.
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op
of approx. 1 mm. C py
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p by
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housing is fitted. Prote
cted AG.
agen

11.2015
– Apply silicone adhesive sealant to joints camshaft housing/

cylinder head -1- and cylinder head/cylinder block -2-.
– Fit new gasket onto dowel pins.
– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
Note
Ensure that timing housing is not canted.
– Tighten valve timing housing securing bolts observing speci‐

fied tightening procedure ⇒ page 86 .

Install crankshaft belt pulley
AG. Volkswagen AG d
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– Tighten union nut -arrow-
utho to 5 Nm +70° additional specified eo
ra
angle. ss a c
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tion in
r
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s
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11.2015

pressure regulator to 8 Nm. gen AG
. Volkswagen AG
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WARNING
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injuries or death.
nform
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tion in
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thi
s
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do
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Allocation:
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t.
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Co
op py
page 214 t. C rig
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5-seater
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– Open fuel tank shut-off valves -N361/N362/N363- using hand
wheel - T50026- .
7-seater
– Open fuel tank shut-off valves -N361/N362/N363/N429- using
hand wheel - T50026- .
All vehicles
page 214
Specified torques:
Component: Specified torque Procedure
securing bolts for valve
timing housing cover
Stage 1 (all bolts) hand-tight Pre-tighten in di‐
agonal sequence
quence
quence
♦ Securing bolts for gas pressure regulator
⇒ “5.1 Assembly overview - gas pressure regulator”,
page 228
♦ Securing bolts for coolant pump

11.2015
♦ Securing bolt for crankshaft pulley n AG. Volkswagen AG do

wage
⇒ “1.2 Assembly overview - cylinder block Volks(pulley end)”, page es n
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28 d by ua
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♦ Securing bolts for sump au
t or
ac
⇒ “1.3 Removing and installing
ss sump”, page 127
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pt
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Prote AG.

11.2015
3 Chain drive
⇒ “3.1 Checking valve timing”, page 88
⇒ “3.2 Adjusting valve timing”, page 90
⇒ “3.3 Checking timing chain”, page 99
⇒ “3.4 Removing and installing timing chain and chain drive for
oil pump”, page 106
3.1 Checking valve timing

equipment required
tension - 3122 B-
1331-
AG. Volkswagen AG d
♦ Puller - T10094 A- agen oes
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♦ Dial gauge adapter - orise nte
T10170- or dial gauge auth eo
ra
adapter - T10170 A- (ob‐ ss c
serve note ⇒ page 89 ).
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nl
pt
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ion
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Prote AG.
Note
The mounting points for securing the camshaft clamp were modi‐
fied. A new special tool designated camshaft clamp - T10171 A-
has been introduced. Previous camshaft clamp - T10171- can
continue to be used if modified as described below.

11.2015
– Place template -1- onto camshaft clamp - T10171- as shown.

– Mark camshaft clamp - T10171- at mark -2- using a centre
punch.
– Drill through camshaft clamp - T10171 - using a 7 mm bit.
– Deburr hole on both sides.
– Additionally mark tool designation -T10171- with an »A«.
Test procedure
– Remove lower part of front right wheel housing liner ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
. Volkswagen AG
a gen AG d
– Remove spark plug from No. 1 Vocylinder.
lksw To do this, use puller
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not
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- T10094 A- and spark plug ed bsocket
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nte
thoris ignition coils with output stage”, eo
page 289 . sa
u ra
c s
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nl
pt
– Release and pull off connector -2-.
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– Remove oil pressure switch - F1- -1-.
ab
ility
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– Then remove bolts for both camshaft covers -3-.
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unclip engine pre-wiring harness -1-.

m
at
– Pull coolant pipe -2- and engine pre-wiring harness -1- away
om
io
from cylinder head.

n
c
in t
or
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e
– Remove both bolts -3- from cylinder head.

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Note
yi Co
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If the dial gauge adapter - T10170 A- is used, the ball head does p by
co Vo
not need to be unscrewed from the dial gauge - VAS 6079- . The
by lksw
cted agen
Prote
ball head is fitted onto the flat side of the rod.
AG.
– Screw dial gauge adapter - T10170- into spark plug hole to

stop.
– Insert dial gauge - VAS 6079- with extension from dial gauge
adapter - T10170- to stop and lock using lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC for No.
1 cylinder. Note position of small needle on dial gauge.
3. Chain drive 89
11.2015
The holes -arrows- in the camshaft must align as shown. Other‐

wise turn crankshaft one rotation (360°) further.
Note
olkswagen AG
en AG. V
♦ If crankshaft is turned 0.01
olkmm
swa passed TDC, turn dcrankshaft
g oes
no
two full turns in engine d bdirection of rotation to set crankshaft
yV t gu
arat
an
TDC for No. 1 cylinder.
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♦ Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.
ac
ss
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pt
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Caution
erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
be renewed.
hammer.
rrectness of i
l purpos
– Insert camshaft clamp - T10171 A- to stop in camshaft open‐
nf
ercia
ings.
orm
m
atio
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
om
tion “TOP” -arrow 3- must be readable from above.

n in
or c
thi
e
If camshaft clamp - T10171 A- cannot be inserted into camshaft

t
sd
iva
openings to stop, then timing is incorrect and must be readjusted

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rp
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⇒ “3.2 Adjusting valve timing”, page 90 .

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op
Timing is OK if camshaft clamp - T10171 A- can be fitted into C py
t. rig
camshaft openings to stop. gh ht
pyri by
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by c lksw
Further assembly is basically the reverse of the dismantling se‐ Prote
cted AG.
agen
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
3.2 Adjusting valve timing

11.2015

equipment required
♦ Dial gauge adapter -
adapter - T10170 A- (ob‐
A-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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nl
pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Chain drive 91
11.2015

1601-
1331-
AG. Volkswagen AG d
agen oes
olksw not
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pe
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nform
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Procedure
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DANGER!
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te o
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um
fo
tem”, page 4 !!!

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Cop py
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by
WARNING
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Prote AG.

pressure line .
– Remove valve timing housing
case)”, page 74 .

11.2015
– To turn crankshaft, reinstall bearing bush, crankshaft pulley

-2- and crankshaft bolt -3- and securely tighten crankshaft bolt
(use counterhold - 3415- ).
– Remove spark plug from No. 1 cylinder. To do this, use puller
- T10094 A- and spark plug socket and extension - 3122 B-
page 289 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
– Release and pull off connector -2-. aut ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
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from cylinder head.
orm
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atio
om
n in
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te
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Note
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not need to be unscrewed from the dial gauge - VAS 6079- . The Cop py
t. rig
ball head is fitted onto the flat side of the rod. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.
– Then turn crankshaft 2 revolutions in engine direction of rota‐
tion.
3. Chain drive 93
11.2015
– Press tensioning plate -1- in direction of -arrow- and lock pis‐

ton with locking pin - T40011- .
– Mark direction of rotation of timing chain -3- using coloured felt

tip marker pen.
Note
♦ Camshaft adjuster centre bolt -2- has a left-hand thread.

♦ Counterhold using counterhold - T10172- .
AG. Volkswagen AG d
agen oes
olksw not
V
– Remove bolts -2- and -4-, and remove camshaft adjuster
d by -1- gu
ara
with timing chain -3-. rise nte
tho eo
au ra
– Install camshaft adjuster -1- again. ss c
ce
e
nl
pt
– Renew bolts -2- and -4-, and tighten bolts -2- and -4- to speci‐
du
an
itte
fied torque, stage 1 ⇒ page 99 .
y li
erm
ab
ility
ot p
Caution
wit
, is n
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hole
spec
es, in part or in w
t to the co
be renewed.
rrectness of i
l purpos
hammer.
nform
ercia
– Turn inlet and exhaust camshafts until camshaft clamp -

m
at
om
T10171 A- can be inserted into holes in camshaft to stop.

ion
c
in t
or
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐

his
ate

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Note t. Cop py
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Camshafts must not be pushed axially whilst turning.
cop Vo
by lksw
cted agen
Prote AG.

11.2015
– Screw M6 bolt hand-tight into corresponding bore -arrows- (do

not tighten) to secure camshaft clamp - T10171 A- .
Note
Note that there are different securing points for the camshaft
clamp - T10171 A- .
– Remove camshaft sprocket bolts. It is absolutely necessary to

use counterhold - T10172- for this.
AG. Volkswagen AG d
agen oes
olksw not
Note ed byV gu
ara
ris nte
ho eo
ut
The camshaft clamp - T10171 A- must not sbe
s used as a counter‐
a ra
c
hold.
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nl
pt
du
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itte
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– Remove one camshaft sprocket.
erm
ab
ility
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Caution
, is n
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hole
spec
If the camshaft adjuster has been removed, the guide sleeve
es, in part or in w
must seat in the camshaft when installing!
t to the co
– Place timing chain over camshaft sprockets, observing chain
rrectness of i
direction of rotation, and install camshaft sprocket again.
l purpos
– Tighten camshaft bolts until camshaft sprockets can still just

be turned on camshafts.
nform
ercia
– Tension timing chain by removing locking pin - T40011- .

m
at
om
ion
c
– Turn crankshaft in engine direction of rotation to TDC for No.
in t
or
1 cylinder. Permissible deviation from TDC for No. 1 cylinder:
his
ate
do
± 0.01 mm.
priv
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for
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op
Note C py
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rig ht
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If crankshaft is turned 0.01 mm passed TDC, turn crankshaft two by c lksw
cted agen
full turns in engine direction of rotation to set crankshaft at TDC Prote AG.
for No. 1 cylinder.
– Unscrew plug -arrow- from crankcase.

3. Chain drive 95
11.2015
Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
– Using counterhold tool - T10172- , hold camshaft sprockets
-1- and -5- in this position.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Tighten bolts -2- and -4-aut to specified torque, stage 1 ra
c
⇒ page 99 . ss
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
Crankshaft must not move and timing chain -3- must remain ten‐
, is n
h re
sioned on both sides when tightening camshaft bolts.
hole
spec
es, in part or in w
– Remove camshaft clamp - T10171 A- .
t to the co
rrectness of i
l purpos
– Unscrew locking pin - T10340- from crankcase.

– Turn crankshaft 2 turns in direction of engine rotation to TDC
nf
ercia
of No. 1 cylinder. Permissible deviation from TDC of No. 1 cyl‐

inder: ± 0.01 mm. orm
m
atio
om
n in
or c
Caution
thi
te
sd
iva
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cu

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f

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t.
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op py
If this is not the case, the camshaft clamp is defective and must t. C rig
gh ht
be renewed. yri
p by
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by c lksw
cted
agen
Prote AG.
hammer.

ings.
If camshaft clamp - T10171 A- cannot be fitted:
– Repeat adjustment.
If camshaft clamp - T10171 A- can be inserted:

11.2015

AG. Volkswagen AG d
agen oes
– Remove camshaft clamp - T10171 A- ; counterhold Vol at cam‐
ksw not
gu
shaft sprockets with counterhold tool - T10172-
d by . ara
se ri nte
ho eo
aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Chain drive 97
11.2015
– Tighten bolts -2- (left-hand thread) and -4- to specified torque,

stage 2 ⇒ page 99 .
Note
♦ Camshaft adjuster centre bolt -2- has a left-hand thread.

♦ Camshaft sprockets must not move on camshaft whilst tight‐
ening.
Further assembly is basically the reverse of the dismantling

nAG. Volkswagense‐
AG do
quence. In the process, note the following: wage es n
olks o t gu
yV
db ara
rise nte
tho eo
Note au ra
c
ss
ce
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nl
The locking pin - T10340- remains in the crankcase until the
pt
du
an
crankshaft pulley is installed.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

injuries or death.
nf
ercia
orm
m
atio
m

o
n in
or c

thi
te
sd
iva
o
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rp
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f
en
ng
Allocation:
t.
yi Co
op
⇒ “3.1 Different pressure sections of natural gas supply system”, C py
ht. rig
page 214 rig ht
py by
co Vo
by lksw
– Open fuel tank shut-off valves -N361/N362/N363/N429- (de‐ Prote
cted AG.
agen
wheel - T50026- .
page 214
case)”, page 74
♦ Install crankshaft belt pulley
♦ Install poly V-belt
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.

11.2015
Specified torques:
Component: Specified Specified Note
camshaft adjuster/ torque, torque, stage
camshaft sprocket stage 1 2
Securing bolt for 40 Nm (left- Turn 90° fur‐ Renew
camshaft adjuster hand thread) ther
-2-
Securing bolt for 50 Nm Turn 90° fur‐ Renew
camshaft sprocket ther
-4-
♦ Spark plug ⇒ “1.3 Test data, spark plugs”, page 289
⇒ “1.2 Assembly overview - cylinder gblockAG.(pulley
Volkswagend)”,
en AG page
a en does
28 Vo lksw not
y gu
db ara
♦ Securing bolts for valveotiming
ris
e housing cover nte
eo
⇒ “1.2 Assembly overview
auth
- cylinder block (pulley end)”, page ra
28 ss c
ce
e
nl
pt
du
an
3.3 Checking timing chain
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Torque wrench - VAS 6583-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
♦ Test tool - T10550-

iv
o
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
♦ Camshaft clamp - T10550/1-

♦ Indicator - T10550/2-
♦ Scale sleeve - T10550/3-
• The engine oil temperature must be at least 40°C ⇒ Vehicle
diagnostic tester.
• The engine must not necessarily be at »TDC« position.
– Carry out function Timing chain elongation ⇒ Vehicle di‐
agnostic tester.
3. Chain drive 99
11.2015
– Remove right front wheel ⇒ Running gear, axles, steering;

Rep. gr. 44 ; Wheels, tyres .
– Remove noise insulation ⇒ Body, front; Rep. gr. 50 ; Noise
insulation; Assembly overview - noise insulation .
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
Vehicles with condensate trap on charge air pipe
– Clamp off coolant hoses -1- with hose clips up to 40 mm -
3093- .
– Open clips -arrows-.
– Pull off coolant hoses -1- on charge air pipe -2-.
Vehicles with engine preheater heater element - Z97-

– Unclip wire -1- to engine preheater heater element - Z97- on
charge air pipe -2- -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
Vehicles with auxiliary heater:

e
nl
pt
du
an
itte
– Open clamps, and pull coolant hoses off coolant pipes -1-.
y li
erm
ab
ility
– Remove auxiliary heater with exhaust pipe and coolant hoses

ot p
wit
still connected ⇒ Auxiliary heater, supplementary heater; Rep.

, is n
h re
gr. 82 ; Auxiliary heater, supplementary heater; Removing and

hole
spec
installing auxiliary/supplementary heater .

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

11.2015
Continuation for all vehicles:

– Pull off securing clip on charge
olks
wageair cooler in es n
ot g
-direction of arrow-. d by V ua
ran
e
ris tee
– Pull charge air uhose
tho -arrow- off charge air cooler. or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
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is n
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ole,
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t to the co
– Remove securing bolt -arrow- for charge air pipe -1-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
– Release and pull off connector -1- on oil level and oil temper‐
yi Co
op py
ature sender - G266- . t. C rig
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pyri by
– Unclip bracket -2- on subframe for electric wire to oil level and
co Vo
by lksw
cted
oil temperature sender - G266- .
agen
Prote AG.
– Unscrew securing bolt -arrow- for charge air pipe -1-.
3. Chain drive 101

11.2015
– Lift off engine cover panel at points -1- and pull it forwards in
direction of -arrow-.
– Remove air filter housing
– Pull off fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing release tabs.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
– Pull off hose -1- from pressure pipe.

itte
y li
rm
ab
pe
– Unscrew securing bolts -2- from pressure pipe and remove
ility
ot
pressure pipe.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unscrew hose clip -1- on charge air pipe.

m
a
com
– Open hose retainer -2- and pull out hose. tion in

r
te o
thi
– Unscrew securing bolt for charge air pipe -3- and pull off con‐
s
iva
do
nector from charge air pressure sender - G31- with intake air
r
rp
cum
temperature sender 2 - G299- .

fo
en
ng
t.
yi
– Remove holder -4-.
Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

11.2015
– To do this, unscrew bolts -arrows-.

– Remove bracket -1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Unscrew bolts -arrows- and remove charge pressure sender - s
ce
le
G31- -1-.
un
pt
an
d
itte
y li
– Remove charge air pipe downwards.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Disregard item -1-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

– Unclip wiring harness -1-.
– Pull coolant pipe -2- and wiring harness -1- away from cylinder
head.
– Lever both camshaft covers -3- out of cylinder head.
3. Chain drive 103

11.2015
– The hole in the exhaust camshaft -left arrow- must be posi‐

tioned as shown in the illustration.
– If necessary, turn crankshaft in direction of engine rotation.
– Insert camshaft clamp - T10550/1- to stop in camshaft open‐

ings.
– The locking pin -arrow A- must engage in hole -arrow B- in
exhaust camshaft.
– Inscription “TOP” must be readable from above.
– Bolt on camshaft clamp - T10550/1- hand-tight.

. Volkswagen AG
gen AG does
– Use one bolt of the camshaft covers for this purpose -arrow-.
Vol
ksw
a
not
by gu
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ed nte
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th
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ss
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le
un
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ility
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t to the co
– Screw indicator - T10550/2- into hole in sump.
– Align centring point vertically so that the tip faces upwards.
rrectne
– Tighten centring point with knurled nut.

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

11.2015
– Position scale sleeve - T10550/3- on belt pulley.
Caution
There is a risk of injury caused by trapping fingers.

The scale sleeve - T10550/3- is equipped with magnets.
Proceed with great care when joining the components.
Note that the components are joined quickly by the magnetic
force.
– Align scale sleeve - T10550/3- with indicator - T10550/2- as

shown in illustration.
– Fit torque wrench - VAS 6583- with a suitable socket to crank‐

shaft bolt.
– Push torque wrench - VAS 6583- clockwise and keep it pushed
with a torque of 40 Nm.
– Set scale sleeve - T10550/3- and indicator - T10550/2- to »0«.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
ce
le
un
pt
an
d
itte
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ab
ility
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is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
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fo
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Cop py
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3. Chain drive 105

11.2015
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– Switch setting of torque wrench - VAS 6583- , and push
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– Read value on the scale.
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– If the chain skips during the test, renew timing chain
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rrectness of i
Conclusions after the test
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– If a chain elongation of up to 28° has been determined during

the test, the timing chain is OK.
nf
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– If a chain elongation of 29° and more has been determined,
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♦ The scale sleeve - T10550/3- is equipped with magnets.
♦ Do not use any levers for removing the scale sleeve -
T10550/3- from the belt pulley!
– Turn scale sleeve - T10550/3- towards right by approx. 45° so

that the indicator - T10550/2- is not positioned within the range
of the scale anymore.
– Grasp behind scale sleeve - T10550/3- with both hands.
– Push your thumbs onto the bolt of the belt pulley, and pull off
scale sleeve - T10550/3- .
– Renew oil seals for camshaft sealing cover and oil them before
fitting.
– Replenish coolant
⇒ “1.2 Draining and filling coolant”, page 137 .
Specified torque
♦ ⇒ “4.1 Assembly overview - valve gear”, page 117
♦ ⇒ “2.1 Assembly overview - charge air system”, page 180
♦ ⇒ “7.1 Assembly overview - intake manifold”, page 244
♦ ⇒ “2.2 Assembly overview - charge-air hose connections”,
page 181
♦ ⇒ Body, front; Rep. gr. 50 ; Noise insulation, Assembly over‐
view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
3.4 Removing and installing timing chain and chain drive for oil pump

11.2015

equipment required
♦ Dial gauge adapter -
adapter - T10170 A- (ob‐
A-
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3. Chain drive 107

11.2015

Removing
DANGER!

tem”, page 4 !!!
WARNING
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– Empty gas system ⇒ aFuel
uth
supply system – natural gas en‐ or
ac
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pressure line .
nl
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rection of -arrow-.
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⇒ “6.2 Removing and installing air filter housing”, page 243

spec
es, in part or in w
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 137 . t to the co
rrectness of i
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– Remove coolant hoses and line/wiring guides -arrows-.

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– Unscrew securing bolts of camshaft cover -1-.

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– Remove spark plug from No. 1 cylinder. To do this, use puller

p
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- T10094 A- and spark plug socket and extension - 3122 B-

for
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page 289 . Cop py
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Prote AG.

11.2015

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Note
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not need to be unscrewed from the dial gauge - VAS 6079- . The
ball head is fitted onto the flat side of the rod.
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stop.
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– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
i
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stop and lock in position with lock nut -arrow-.
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3. Chain drive 109

11.2015
The holes -arrows- in the camshaft must align as shown. Other‐

wise turn crankshaft one rotation (360°) further.
Note
♦ If crankshaft is turned 0.01 mm past TDC, turn crankshaft two

full turns in direction of engine rotation to set crankshaft in di‐
rection of engine rotation at TDC for No. 1 cylinder.
♦ Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.
Caution

the pins on the tool project by at leasto7lksmm.
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Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐ spec
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– Screw an M6 bolt hand-tight into corresponding bore

o
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c
-arrows- (but do not tighten) to secure camshaft clamp -

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T10171 A- .
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– Remove valve timing housing

case)”, page 74 .

11.2015
– Pull cover -1- off chain sprocket for oil pump.
– Press tensioning rail in -direction of arrow- by hand and lock

piston of chain tensioner with locking pin - T40011- .
AG. Volkswagen AG d
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– Mark direction of rotation of timing chain -3- usingsecoloured
db
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felt ara
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tip marker pen. thori
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pt
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Camshaft adjuster securing bolt -2- has a left-hand thread.
ility
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– Unscrew bolts -2- and -4-, and remove camshaft adjuster -1-
h re
hole
together with timing chain -3-. Counterhold using counterhold
spec
- T10172- .
es, in part or in w
t to the co
rrectness of i
– Hold oil pump chain sprocket with counterhold - T10172- and
loosen securing bolt -1-.
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Prote AG.
3. Chain drive 111

11.2015
– Use a screwdriver on bolt -2- to release tensioning spring -1-

then remove tensioning spring -1-.
– Unscrew securing bolt -3- and remove chain tensioner.
– Mark direction of rotation of oil pump drive chain -2- using felt-
tip marker.
– Unscrew securing bolt for chain sprocket -1- and remove chain
sprockets -1- and -3- together with drive chain for oil pump
-2-.
Installing
• The crankshaft must be positioned at TDC for No. 1 cylinder.
AG. Volkswagen AG d
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– Push chain sprocket -1- in -direction of arrow- onto crankshaft

ility
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Cast lug -2- on chain sprocket -1- must seat in groove -3- on
crankshaft journal.
rrectness of i
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– Mark position of chain sprocket and crankshaft to cylinder

o
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block using a felt-tip marker.

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Prote AG.

11.2015
– Place oil pump drive chain -3- onto drive chain sprocket -1-
and position drive chain sprocket -2- onto oil pump drive shaft
at same time.
Note
♦ Note running direction mark on oil pump drive chain.

♦ Oil pump drive sprocket only fits on oil pump drive shaft in one
position -arrow-.
– Hold oil pump drive sprocket with counterhold - T10172- .

– Tighten securing bolt -1- to 20 Nm + 90° further.
AG. Volkswagen AG d
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– Position chain tensioner on oil pump drive chain and tighten ss c
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securing bolt -3- to 15 Nm.

nl
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– Lever tensioning spring -1- onto bolt -2- using a screwdriver.

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Note
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♦ Note marks -arrows-.

es, in part or in w
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♦ The crankshaft must not rotate.

rrectness of i
– Tighten chain sprocket -3- hand-tight with new securing bolt.

l purpos
– Place timing chain -1- on crankshaft chain sprocket -4-, ex‐

haust camshaft chain sprocket -3-, and tighten camshaft ad‐
nform
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juster -2- hand-tight using a new securing bolt.

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♦ Note running direction mark on timing chain -1-.

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♦ Camshaft adjuster securing bolt -2- has a left-hand thread.
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Prote AG.
3. Chain drive 113

11.2015
Timing chain must lie on guide rail -1- and crankshaft chain
sprocket -arrow-.
– Install chain tensioner -1- and tighten securing bolts -2- to

9 Nm.
– Tension timing chain by pulling locking pin - T40011- from
chain tensioner.
– Check marks on crankshaft chain sprocket and cylinder block;
they must align.
Note
Use counterhold tool -T10172- .
– Tighten securing bolt -2- and bolt -4- to specified torque,

stage 1 ⇒ page 116 .
– Check valve timing ⇒ “3.1 Checking valve timing”, page 88
If timing is not OK:
Note
♦ The camshaft adjuster securing bolt -2- has a left-hand thread.agen AG. Volkswagen AG do
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♦ Camshaft sprockets must not move on camshaft whilst
d b tight‐
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♦ Tighten securing bolts -2- and -4- to specifiedsstorque, stage 2 ac
⇒ page 116 .
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– Unscrew bolt -arrow- and remove camshaft clamp - T10171

ility
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A- from camshaft housing.

wit
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cial p
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Rep. gr.15 - Cylinder head, valve gear cted agen
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11.2015
– Install oil pump wheel cover -1-.

– Install valve timing housing
case)”, page 74 . wage
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– Install crankshaft pulleyed by ara
nte
⇒ “1.5 Removing and tho
rinstalling
is pulley”, page 34 . eo
au ra
– Install poly V-beltss c
ce
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un
pt
an
d
itte
– Renew oil seals for camshaft sealing cover and oil them before
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hole
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Note
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WARNING
nform
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m
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com
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injuries or death.
n in
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te o
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⇒ “3.1 Different pressure sections of natural gas supply system”, Prote AG.
page 214
wheel - T50026- .
page 214
3. Chain drive 115

11.2015
Specified torques:
Component: Specified Specified Note
camshaft adjuster/ torque, torque, stage
camshaft sprocket stage 1 2
Securing bolt for 40 Nm (left- Turn 90° fur‐ Renew
camshaft adjuster hand thread) ther
-2-
Securing bolt for 50 Nm Turn 90° fur‐ Renew
camshaft sprocket ther agen
AG. Volkswagen AG d
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-4- Vol
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♦ Spark plug ⇒ “1.3 Test data, sparkthoplugs”,
ris page 289 tee
or
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ss
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nl
pt
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28
an
itte
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♦ Securing bolts for valve timing housing cover
ility
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28
h re
hole
spec
♦ Securing bolt for oil pump sprocket
es, in part or in w
⇒ “1.1 Assembly overview – sump/oil pump”, page 124
t to the co
rrectness of i
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nf
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Prote AG.

11.2015
4 Valve gear
⇒ “4.1 Assembly overview - valve gear”, page 117
⇒ “4.2 Measuring axial play of camshaft”, page 119
⇒ “4.3 Removing and installing valve stem seals”, page 119
4.1 Assembly overview - valve gear
1 - Bolt
❑ Left-hand thread.
❑ Renew
2 - Camshaft adjuster
❑ Must not be dismantled.
⇒ “3.2 Adjusting valve
timing”, page 90 .
3 - Camshaft chain sprocket
❑ Note position when in‐
stalling timing chain.
4 - O-ring
❑ Renew if damaged.
❑ Before installing, coat AG. Volkswagen AG d
agen
lightly with engine oil. Volksw
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not
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5 - Inlet camshaft control valve orise nte
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1 - N205- aut
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6 - Bolt
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❑ 10 Nm
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7 - Bolt
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❑ Tighten from inside out‐

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8 - Camshaft housing
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stalling camshaft hous‐
ss
ing”, page 64 .
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❑ Remove sealant resi‐

form
mer
due.
atio
m
❑ Before fitting, coat with sealant ⇒ Electronic Parts Catalogue

o
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9 - Bolt
thi
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sd
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❑ 10 Nm
i
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10 - Cap yi
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❑ For inlet camshaft.
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11 - Roller rocker finger Prote AG.
❑ Check roller bearing.

❑ When installing, secure to supporting element using securing clip.
4. Valve gear 117

11.2015
12 - Valve cotters
13 - Valve stem seal
❑ Renew.
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14 - Support element Vol
not
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❑ Check oil spray holes. orise nte
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th
❑ With hydraulic valve clearance compensation.ss au ra
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❑ Do not interchange.
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❑ Before installing, check camshaft axial clearance ⇒ “4.2 Measuring axial play of camshaft”, page 119 .
itte
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15 - Valve guide
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❑ Checking ⇒ “5.1 Checking valve guides”, page 122 .
hole
spec
es, in part or in w
16 - Valve spring
t to the co
❑ To remove and install with cylinder head removed, use valve spring tool - 3362- .
❑ With cylinder head installed ⇒ “4.3 Removing and installing valve stem seals”, page 119 .
rrectness of i
17 - Cylinder head
l purpos
❑ Removing and installing ⇒ “1.2 Removing and installing cylinder head”, page 59 .
❑ Rework valve seat ⇒ “5.2 Reworking valve seats”, page 122
nform
ercia
❑ Reworking sealing surface ⇒ page 118

m
at
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18 - Valves
ion
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❑ Do not rework, only lapping-in is permitted.

o
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ate
❑ Valve dimensions ⇒ page 119
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19 - Exhaust camshaft
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❑ Checking axial clearance ⇒ “4.2 Measuring axial play of camshaft”, page 119 .
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❑ Coat with oil before inserting (also axial bearing shoulder).
by
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20 - Guide sleeve
21 - Inlet camshaft
❑ With cam for high-pressure pump
❑ Before removing, remove and renew bucket tappet for high-pressure pump.
❑ Do not interchange with exhaust camshaft.
❑ Checking axial clearance ⇒ “4.2 Measuring axial play of camshaft”, page 119 .
❑ Coat with oil before inserting (also axial bearing shoulder).
22 - Bolt
❑ Renew
Reworking cylinder head sealing surface

Cylinder head reworking dimension: a = at least 108.25 mm
Note
When the sealing surface has been reworked, the valves must be
set deeper by the same amount (valve seat inserts reworked) or
valves will contact pistons. When doing this, ensure that the per‐
missible minimum dimension is maintained ⇒ page 119 .

11.2015
4.2 Measuring axial play of camshaft

♦ Universal dial gauge bracket - VW 387-
lkswage es n
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♦ Dial gauge
hole
spec
es, in part or in w
Perform measurements with camshaft housing removed and cap
t to the co
fitted.
Checking camshaft axial clearance
rrectness of i
Wear limit: max. 0.40 mm
l purpos
nform
mercia
at
om
ion
c
in t
or
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Valve dimensions
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Cop py
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Note p by
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Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

Diameter a mm 29.5 26.0
Diameter b mm 5.973 5.953
c mm 100.9 100.5
α ∠° 45 45
4.3 Removing and installing valve stem seals
4. Valve gear 119

11.2015

equipment required
tension - 3122B-
♦ Valve spring tool - 3362-
with thrust piece - 3362/1-
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Pressure hose - VW 653/3-
AG. Volkswagen AG d
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ility
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spec
es, in part or in w
t to the co
rrectness of i
Removing
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• (With cylinder head installed)

nform
ercia
– Remove camshaft housing

⇒ “1.3 Removing and installing camshaft housing”, page 64 .
m
at
om
io
– Remove roller rocker fingers and place onto a clean surface.

n
c
in t
or
When doing this, ensure that the roller rocker fingers are not
his
ate
interchanged.
do
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– Remove spark plugs using spark plug socket and extension -

f
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t.
3122 B- .
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Cop py
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– Set piston of respective cylinder to “bottom dead centre”. gh ht
pyri by
Vo
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by
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Prote AG.

11.2015
– Attach valve spring tool - 3362- with thrust piece - 3362/1- .

– Screw pressure hose - VW 653/3- into spark plug thread.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing
AG. Volkswagen AG d
agen oes
– Place plastic sleeve supplied on respective valve stem. VoThis
lksw not
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will prevent damage to new valve stem seal. d by ara
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– Place new valve stem seal in valve stem sealaufitting
t
tool - ra
c
3365- . ss
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pt
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– Oil valve stem seal sealing lip and press carefully onto the
an
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valve guide.
erm
ab
ility
ot p
– Install camshaft housing
wit
⇒ “1.3 Removing and installing camshaft housing”, page 64 .
, is n
h re
hole
– Adjust valve timing ⇒ “3.2 Adjusting valve timing”, page 90 .
spec
es, in part or in w
t to the co
Specified torques:
rrectness of i
♦ Camshaft housing
l purpos
⇒ “1.1 Assembly overview - cylinder head”, page 57

nform
ercia

case)”, page 74
m
at
om
ion
c
♦ Fuel lines
in t
or
⇒ “8.2 Removing and installing high-pressure pump”,

his
ate
page 263
do
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or
♦ Spark plugs
f
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ng
t.
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⇒ “1.2 Assembly overview - ignition system”, page 287
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Prote AG.
4. Valve gear 121

11.2015
5 Inlet and exhaust valves

⇒ “5.1 Checking valve guides”, page 122
⇒ “5.2 Reworking valve seats”, page 122
5.1 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock by moving valve in direction of -arrow-.
Wear limit: 0.8 mm AG. Volkswagen AG d
agen oes
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If rock tolerance is exceeded: d by V gu
ara
rise nte
– Renew cylinder head. utho eo
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5.2 Reworking valve seats

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♦ Depth gauge
es, in part or in w
t to the co
♦ Valve seat refacing tool

rrectness of i
Note
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♦ When repairing engines with leaking valves, it is not sufficient

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

wear ⇒ “5.1 Checking valve guides”, page 122 .
m
a
com
tio
♦ Valve seats are only to be reworked to the extent required to

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

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

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

rp
cum
fo
draulic valve clearance compensation can no longer be

en
ng
t.
yi
guaranteed and the cylinder head must be renewed.
Co
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11.2015
The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.
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Note
ir se
d ran
tee
tho
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If the valve is to be renewed as part of a repair, use a new
ss valve
ce
e
for the calculation.

nl
pt
du
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itte
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erm
– Measure distance between end of valve stem and upper edge
ab
ility
of cylinder head.
ot p
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– Calculate maximum permissible reworking dimension from
h re
hole
measured distance and minimum dimension.
spec
es, in part or in w
Minimum dimensions: inlet valve 7.6 mm, exhaust valve 7.6 mm
t to the co
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
rrectness of i
Example:
l purpos
-Measured distance 8.0 mm

Minimum dimension 7.6 mm
nform
ercia
=max. perm. rework dimension 3) 0.4 mm

m
at
om
ion
3) The max. permissible reworking dimension is shown as dimension “b” in the
c
in t
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illustrations for reworking valve seats.

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Reworking inlet valve seat

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a = 28.7 mm in diameter
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b = max. permissible reworking dimension1
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c = 1.5…1.8 mm
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Z
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= cylinder head lower edge
Prote
cted agen
α
AG.
= 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
4) Calculating max. permissible reworking dimension ⇒ page 122 .
Reworking exhaust valve seat.
a = 25.0 mm in diameter
b = max. permissible reworking dimension1
c = approx.1.8 mm
Z = Cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
5) Calculating max. permissible reworking dimension ⇒ page 122 .
5. Inlet and exhaust valves 123

11.2015
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview – sump/oil pump”, page 124
⇒ “1.2 Engine oil”, page 126
⇒ “1.3 Removing and installing sump”, page 127
⇒ “1.4 Removing and installing oil pump”, page 130
1.1 Assembly overview – sump/oil pump
1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 126 .
2 - Engine oil cooler
3 - O-ring
❑ Renew
4 - Coolant pipe
❑ For engine oil cooler
❑ Specified torque, brack‐ AG. Volkswagen AG d
et to crankcase: 20 Nm. lksw
agen oes
not
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5 - Bolt rised b ara
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❑ 8 Nm aut
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6 - Cap
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❑ Renew seal if damaged.
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7 - Seal
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8 - Oil filter
spec
❑ Loosen with oil filter tool
t to the co
- 3417- .
❑ Observe installation in‐
structions on oil filter. rrectne
❑ With non-return valve.
s
❑ 20 Nm
s o
cial p
9 - Valve timing housing

inform
mer
❑ Additionally apply sili‐

atio
cone adhesive sealant

om
⇒ Electronic Parts
c
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or
Catalogue when instal‐

thi
te
sd
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ling
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Removing and installing valve timing housing

en
ng
t.
yi
⇒ “2.1 Removing and installing valve timing housing (timing case)”, page 74
Co
Cop py
ht. rig
❑ When installing, install two -M6x80- studs in cylinder block and camshaft housing as a guide. rig ht
py by
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❑ To guide valve timing housing, secure sump in position with two bolts.
by lksw
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10 - Bolt
❑ 10 Nm
11 - Securing bolt
❑ Removing and installing crankshaft pulley ⇒ “1.5 Removing and installing pulley”, page 34
124 Rep. gr.17 - Lubrication

11.2015
❑ Secure pulley against turning with counterhold tool - 3415-
❑ Renew AG. Volkswagen AG d
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12 - Belt pulley ris nte
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❑ With diamond ss acoated washer c
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❑ Contact surfaces of pulley must be free of oil and grease.

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❑ Removing and installing poly V-belt ⇒ “1.3 Removing and installing poly V-belt”, page 30 .
ility
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❑ Secure pulley against turning with counterhold - 3415- .
wit
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13 - Seal
spec
❑ Renew.
t to the co
14 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
rrectne
15 - Gasket
s
s o
cial p
f
16 - Chain sprocket
inform
mer
atio
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n
c
❑ For oil pump drive.
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17 - Bolt
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❑ Renew
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18 - Sprocket
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❑ Removing and installing Prote
cted AG.
agen
❑ For oil pump.
❑ Lock with counterhold - T10172- .
19 - Drive chain
❑ For oil pump.
❑ Before removing, mark direction of rotation (installation position).
20 - Bolt
❑ 10 Nm
21 - Oil level and oil temperature sender - G266-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
22 - Oil drain plug
❑ With attached seal.
❑ Renew.
❑ 30 Nm
23 - Bolt
❑ Loosen and tighten flywheel end bolts only with long-reach Allen key - T10058- .
❑ 13 Nm
1. Sump, oil pump 125

11.2015 en AG. V
olkswagen AG
ag does
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24 - Bolt ed
by ara
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ris
❑ 40 Nm tho eo
au ra
c
ss
25 - Sump
ce
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un
pt
❑ Removing and installing ⇒ “1.3 Removing and installing sump”, page 127 .
an
d
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❑ Clean sealing surface before fitting.
erm
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❑ Apply silicone adhesive sealant ⇒ Electronic Parts Catalogue when installing
wit
is n
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26 - Bolt
ole,
spec
❑ Renew
t to the co
27 - Oil pump
rrectne
Caution
ss
The oil supply line must
o
cial p
f
be renewed on the tur‐
inform
bocharger if a new oil
mer
pump or oil suction pipe
atio
m
is fitted.
o
n
c
i
or
n thi
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sd
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❑ with oil suction pipe

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❑ Specified torque oil suction pipe: 9 Nm

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28 - Bolt Cop py
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❑ 5 Nm
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29 - Oil separator
agen
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Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: do not top up with
engine oil!
b - Oil level within hatched zone: can be topped up with engine
oil.
c - Area from min. mark up to hatched field: top up with max. 0.5
l of engine oil!
1.2 Engine oil

Oil capacities
With oil filter, 3.6 l
Note
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 126 .
♦ Finding metal shavings or a large quantity of small metal par‐
ticles during engine repair could indicate that the conrod bear‐
ings are damaged. To prevent this from causing further
damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renew oil filter.

11.2015
Engine oil specifications

⇒ Maintenance ; Booklet ; Service tables
Changing engine oil: “Engine oil: drain or extract”.
⇒ Maintenance ; Booklet ; Service tables
1.3 Removing and installing sump

♦ Allen key, long reach 5 mm - T10058-
AG. Volkswagen AG d
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nl
pt
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ility
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spec
es, in part or in w
t to the co
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orm
m
atio
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♦ Wedge - T10383/2-
o
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or c
thi
te
sd
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Prote AG.

11.2015
♦ Cutting tool - T10561-
♦ Hand drill with plastic brush

♦ Flat scraper
♦ Eye protection
♦ Silicone sealant ⇒ Electronic Parts Catalogue
Removing
Rep. gr. 50 ; Removing and installing noise insulation .
– Drain engine oil ⇒ Maintenance ; Booklet 36.1 .
– Disconnect front exhaust pipe from catalytic converter
⇒ “1.1 Assembly overview – emission control”, page 283 .
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - front wheel housing liner . n AG. Volkswagen AG age does
ksw not
– Pull 3-pin connector off oil level and oil temperature
by
Vol sender - gu
ara
G266- -1-. ris
ed
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tho eo
– Remove bolts from sump. ss au ra
c
ce
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un
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Note
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ab
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♦ The sump is sealed with liquid sealant ⇒ Electronic Parts

ot
wit
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Catalogue .
h re
hole
spec
♦ When hardened, the sealant has a high adhesive strength.

es, in part or in w
t to the co
♦ Two bolts must be loosened but not removed to secure the

sump from falling after seal has been cut.
rrectness of i
– Cut through seal between oil sump -4- and engine -1-.
l purpos
– Use cutting tool - T10561- to do this.

nform
ercia
• Centre the cut between bolts -3- only.

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

com
tio
ing.
n in
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te o
thi
s
iva
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Cop py
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rig ht
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by lksw
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Prote AG.

11.2015
– Drive in cutting tool - T10561- -3- using a hammer as far as it

will go -arrow-.
– Do not cant cutting tool - T10561- when doing this.
– Do not cutting tool - T10561- sideways.
AG. Volkswagen AG d
– Do not lever with cutting tool - T10561- . agen oes
olksw not
byV gu
ara
– Perform procedure at other points as described untilris oil sump
ed
nte
is detached. aut
ho eo
ra
ss c
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nl
pt
du
Note
an
itte
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erm
ab
A sucking noise will be audible when the strength of the seal has
ility
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been overcome.
wit
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h re
hole
spec
– Use wedge - T10383/2- to further loosen detached positions.
es, in part or in w
t to the co
– Using a plastic hammer, carefully drive in wedge.
– Drive in wedge - T10383/2- only to same depth as sealing
surface.
rrectness of i
– Release sump carefully from adhesive.
l purpos
– Remove bolts which are still holding the sump.
nform
ercia
– Remove sump.
m
at
om
– Remove sealant residue from cylinder block with a flat scraper.
ion
c
in t
or
his
e
– Remove sealant residues on sump with a rotating brush, e.g.

at
do
riv
an electric drill with plastic brush attachment (wear eye pro‐

p
cum
or
tection).
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ng
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op
– Clean sealing surfaces. They must be free of oil and grease. C py
ht. rig
rig ht
Installing
py by
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by lksw
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Prote AG.
Note
♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted into the cylinder block flange at two
positions as guides.

11.2015
– Cut off tube nozzle at forward marking (diameter of nozzle ap‐

prox. 3 mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
wage
The sealing compound bead must not be thicker, otherwiseyex‐ Volks es n
ot g
cessive sealing compound will enter the sump and may block
ir se
d b the ua
ran
oil suction pipe strainer. tho tee
or
au ac
ss
– Install sump immediately and tighten all sump bolts lightly.
ce
e
nl
pt
du
an
itte
– Tighten oil sump bolts to specified torque ⇒ page 130 .
y li
erm
ab
ility
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Note
h re
hole
spec
Let sealing compound dry for approx. 30 minutes after installing
es, in part or in w
sump. Only then fill with engine oil.
t to the co
Specified torques:
rrectness of i
Component Specified Note
l purpos
torque
Securing bolt 13 Nm Loosen and tighten fly‐
nf
ercia
sump/crankcase wheel-end bolts with Allen
orm
key, long reach 5 mm -
m
atio
m
T10058-
o
n in
or c
Bolt for securing 40 Nm
thi
te
sump to gearbox
sd
iva
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rp
cu
Oil drain plug 30 Nm Renew (with captive seal)
o
m
f
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t.
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♦ Securing bolts, front exhaust pipe/catalytic converter Cop py
. rig
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pyri by
Vo
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cted agen
1.4 Removing and installing oil pump
Prote AG.
Caution
The oil supply line must be renewed on the turbocharger if a

new oil pump or oil suction pipe is fitted.

11.2015
Removing
– Remove sump
– Hold oil pump chain sprocket with counterhold - T10172- .
– Loosen chain sprocket securing bolt.
Note
Do not remove bolt completely.
– Press chain tensioner in direction of -arrow- with a screwdriv‐

er.
. Volkswagen AG
gen AG d
– Remove chain
Vol
sprocket
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a
securing bolt.oes not
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– Takeorchain
ise sprocket off oil pump and out of chain.
an
tee
th or
au ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
– Loosen oil pump securing bolts -arrows- and remove them.

t to the co
– Remove oil pump from cylinder block.

Installing
rrectness of i
l purpos
Caution
nf
ercia
The oil supply line must be renewed on the turbocharger if a

orm
new oil pump or oil suction pipe is fitted.

m
atio
om
n in
or c
thi
e
– Install oil pump and tighten securing bolts to 14 Nm + 90° fur‐

t
sd
iva
ther.
o
r
rp
cu
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f
en
ng
Specified torque oil suction pipe: 9 Nm yi

t.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
131
Prote AG.
1. Sump, oil pump
11.2015
– Press chain tensioner in direction of -arrow- with a screwdriv‐

er.
– Seat chain sprocket in chain and fit chain sprocket onto oil
pump shaft.
– Observe installation position of chain sprocket on oil pump

shaft -arrows-.
– Screw in chain sprocket securing bolt.
– Hold chain sprocket with counterhold - T10172- .
– Position torque wrench - V.A.G 1331- as shown.

G. Volkswagen
– Tighten securing bolt toag20
lksw
en ANm + 90° further.
AG do
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– Install sump i⇒ edpage 127 . ran
rs tee
ho
aut or
ac
ss
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
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thi
s
iva
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11.2015
2 Oil filter, oil pressure switch

⇒ “2.1 Checking oil pressure and oil pressure switch”,
page 133
2.1 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Voltage tester - V.A.G
1527B-
♦ Auxiliary measuring set -
V.A.G 1594C-
♦ 24 mm jointed spanner -
T40175-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
nform
ercia
Fitting locations
m
at
om
io
Test procedure
n
c
in t
or
his
e
The oil pressure switch is located on the gearbox side beneath

at
do
riv
the two camshaft covers.

p
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
2. Oil filter, oil pressure switch 133

11.2015
– Pull connector off oil pressure switch - F1- -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
ris nte
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aut ra
ss c
ce
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– Remove oil pressure switch - F1- using 24 mm jointed spanner

nl
pt
du
- T40175- and screw switch into oil pressure tester - V.A.G
an
itte
y li
1342- .
erm
ab
ility
ot p
– Screw tester into cylinder head in place of oil pressure switch.
wit
, is n
h re
– Connect brown wire of tester to earth (-).
hole
spec
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
es, in part or in w
t to the co
and oil pressure switch using cable from auxiliary measuring
set - V.A.G 1594C- .
– If LED lights up, replace pressure switch - F1- .
rrectness of i
If LED does not light up:
l purpos
– Start engine and increase speed slowly. At 0.3…0.7 bar the

LED must light up, otherwise renew oil pressure switch.
nform
ercia
– Increase engine speed further. At 2,000 rpm and an oil tem‐

m
at
om
perature of 80°C the oil pressure should be at least 2.0 bar.
ion
c
in t
or
At higher engine speeds, the oil pressure must not exceed 7.0
his
ate
bar. do
priv
cum
or
Oil pressure values at oil temperature of 80°C:

f
en
ng
t.
yi Co
op
At idling speed: at least 1.3 bar. C py
ht. rig
rig ht
by
At 2,000 rpm: at least 2.0 bar. copy Vo
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cted agen
Prote
Specified torque:
AG.
♦ Oil pressure switch: 20 Nm

Passat 2006 n A➤
G. V, oPassat
lkswagen2011
AG do ➤ , Passat Variant 2011 ➤ , Touran 2003 ➤
wage
4-cylinder direct-injection Vengine
olks (1.4 l, natural gas, EA es n
111,
ot g turbocharger, supercharger) - Edition
by ua
rised ran
t
11.2015
ee
tho or
s au ac
s
19 – Cooling
ce
e
nl
pt
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itte
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ab
1 Cooling system, coolant
ility
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⇒ “1.1 Coolant hose schematic diagram”, page 135
hole
spec
⇒ “1.2 Draining and filling coolant”, page 137
es, in part or in w
t to the co
⇒ “1.3 Checking cooling system for leaks”, page 141
rrectness of i
WARNING
l purpos
• Always observe
⇒ “2.4 Safety precautions when working on cooling sys‐
nform
ercia
tem”, page 7 before working on the cooling system.

m
at
om
ion
c
in t
or
Caution
his
ate
do
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cum
or
♦ When doing any repair work, especially in the engine com‐

f
en
g
partment, pay attention to the following due to the cram‐

n
t.
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op
ped conditions: C py
t. rig
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ cop Vo
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vated charcoal filter system, coolant and refrigerant, brake cted agen
Prote AG.
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
Note
♦ Hoses are secured with spring-type clips. In case of repair,

only use spring-type clips.
♦ Hose clip pliers - VAS 6340- or spring-type clip pliers - VAS
5024A- are recommended for use in installing spring-type
clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Test for leaks in cooling system using cooling system tester -

V.A.G 1274 B- and adapter for cooling system tester - V.A.G
1274/8- and adapter for cooling system tester - V.A.G 1274/9- .
1.1 Coolant hose schematic diagram
1. Cooling system, coolant 135

11.2015
1 - Expansion tank
wage
2 - Coolant pump olks es n
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3 - Gas regulator with high- ir se tee
ho
pressure valve for gas mode - aut or
ac
N372- ss
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un
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4 - Intake manifold
an
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5 - Cylinder head/cylinder
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block
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❑ If renewed, refill system
h re
ole,
with fresh coolant.
spec
6 - Heat exchanger for heater
t to the co
unit
7 - Thermostat housing
rrectne
8 - Radiator/cooler
s
9 - Engine oil cooler
s o
cial p
f i
10 - Coolant circulation pump -
nform
V50-
mer
atio
m

o
n
c
i
or
n thi
stalling coolant circula‐
te
sd
va
tion pump V50 ”,

i
o
pr
c
page 155 .
um
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fo
en
ng
t.
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11 - Turbocharger
Co
Cop py
t. rig
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yri by
⇒ “1.2 Removing and in‐ cop Vo
by lksw
cted
stalling turbocharger”,
agen
Prote AG.
page 166 .
12 - Circulation pump - V55-
❑ Optional equipment.
13 - Auxiliary heater
❑ Optional equipment.
136 Rep. gr.19 - Cooling

11.2015
1.2 Draining and filling coolant

equipment required
♦ Refractometer - T10007 A-
6340-
♦ Cooling system charge unit
- VAS 6096-
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
an
itte
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ility
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Draining
hole
spec
es, in part or in w
t to the co
WARNING
Steam may escape when expansion tank is opened. Wear eye

rrectness of i
protection and protective clothing to avoid eye injuries and

scalding. Cover cap with cloth and open carefully.
l purpos
nform
ercia
– Open filler cap on coolant expansion tank.

m
at
– Remove engine splash protection.

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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Cop py
t. rig
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pyri by
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by
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Prote AG.

lkswage es n
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Passat 2006 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤ d , Touran 2003 ➤
by ua
ran
ir se
4-cylinder direct-injection engine (1.4 l, natural gas, EAth 111, turbocharger, supercharger) - Editione o
o te
u ra
11.2015 ss
a c
ce
e
nl
pt
du
– Pull off retaining clip -arrow- and remove coolant hose from
an
itte
y li
radiator.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Detach spring-type clip and pull off coolant hose -2-.
orm
m
atio
Disregard item -1-.
om
n in
or c
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a
Note
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Observe environmental regulations for disposal.
t.
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Cop py
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Filling yri
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Prote AG.
Caution
Only distilled water may be used for mixing with coolant addi‐
tives. The use of distilled water ensures optimum protection
against corrosion.

11.2015
Note
♦ The amount of water used in the coolant mixture has a great

influence on its effectiveness. Because the water quality dif‐
fers from country to country and even region to region, the
quality of the water to be used has been defined. Distilled AG. Vwa‐
olkswagen AG
agen
ter fulfils all requirements. For this reason, we olrecommend
ksw
does
not
using distilled water when mixing coolantefor d b topping up or re‐
y V gu
ara
placing coolant. thoris nte
e or
au ac
♦ Use only coolant additives which conform
ss with the ⇒ Elec‐
tronic Parts Catalogue (ETKA) . Other coolant additives may
ce
e
nl
pt
du
reduce corrosion protection substantially. The resulting dam‐
an
itte
y li
age could lead to loss of coolant and subsequent severe
erm
ab
damage to the engine.
ility
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♦ The correct coolant solution ratio helps prevent damage due
h re
to freezing and corrosion as well as scaling. Moreover, the
hole
spec
boiling temperature is raised. Therefore, the cooling system
es, in part or in w
must be filled all year round with coolant additive.
t to the co
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
rrectness of i
tropical climates.
l purpos
♦ ONLY refractometer - T10007A- may be used for determining

current anti-freeze value.
nf
ercia
♦ The normal frost protection must be at least -25 °C, in coun‐
or
tries with arctic conditions to -36 °C. When climatic conditions
m
m
atio
require a stronger frost protection, only then may the frost pro‐
om
n in
tection be increased. But it may only be increased to -48°C.
or c
thi
Otherwise, the cooling effect of the coolant will be impaired.
te
sd
iva
o
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♦ The coolant concentration must not be reduced by adding wa‐

rp
cu
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m
ter even in warmer seasons and in warmer countries. Frost
f
en
ng
t.
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protection must be guaranteed down to at least -25°C.
Co
Cop py
t. rig
gh
♦ Read off anti-freeze figures for respective replenished anti-
ht
pyri by
freeze.
o Vo
by c lksw
cted agen
Prote AG.
♦ The temperature read off the refractometer - T10007A- equa‐
tes to the »ice flocculation point«. Flakes of ice can start
forming in the coolant below this temperature.
♦ Do not reuse old coolant.
♦ Use only a water/anti-freeze mixture as a slip agent for coolant
hoses.
Recommended mixing ratios (use only distilled water for mixing):

Frost protection Amount of anti- Coolant ad‐ Distilled wa‐
to freeze ditive 6) ter 6)
-25°C 40 % 2.25 l 3.35 l
-36°C 50 % 2.8 l 2.8 l
6) The quantity of coolant can vary depending upon vehicle equipment.

AG. Volkswagen AG d
11.2015 ksw
agen oes
n
ol ot g
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db ran
– Press connection againstor
is radiator
e
and slide retaining clip tee
-arrow- into groove.auth or
ac
ss
– Install engine splash protection.
ce
e
nl
pt
du
an
With cooling system charge unit - VAS 6096-
itte
y li
erm
ab
– Fill coolant circuit using cooling system charge unit -
ility
ot p
VAS 6096- ⇒ Operating instructions for cooling system charge
wit
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unit VAS 6096 .
h re
hole
spec
Without cooling system charge unit - VAS 6096-
es, in part or in w
t to the co
rrectness of i
– Fill with coolant up to max. marking on expansion tank.
l purpos
With or without cooling system charge unit - VAS 6096-

– Fit expansion tank cap.
nf
ercia
orm
– Turn off heater controls.
m
atio
om
n in
Vehicles with no auxiliary heater
or c
thi
te
sd
– Start engine and maintain an engine speed of about 2,000 rpm
iva
o
r
for about 3 minutes.

rp
cu
o
m
f
en
ng
– Run engine until radiator fan - V7- cuts in.

t.
yi Co
Cop py
. rig
Vehicles with auxiliary heater
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
Caution
AG.
Do not switch auxiliary heater on until the cooling circuit has

been filled as subsequently described.

11.2015
– Connect vehicle diagnostic, testing and information system -

VAS 5051B- as follows:
– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary heater” and “03 - Final control diagnosis” one after
the other.
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- .
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed at approx.
2,000 rpm for about 1 minute.
– Run engine until radiator fan - V7- cuts in.
WARNING
Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
– Check coolant level and top up if necessary. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark; when the engine is cold, between the min.
and max. marks.
olkswagen AG
en AG. V
1.3 Checking cooling system
Vol
ksw
ag
for leaks does
not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11.2015

equipment required
♦ Cooling system tester -
V.A.G 1274 B-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
AG. Volkswagen AG d
♦ Adapter for cooling system agen oes
olksw not
V
tester - V.A.G 1274/9- ed by gu
ara
ris nte
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aut ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Test prerequisite
• Engine at operating temperature.
Test procedure
WARNING
Steam may escape when expansion tank is opened. Cover cap

with cloth and open carefully.
– Open cap on coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Use hand pump on tester to create a pressure of about 1.0 bar.

11.2015
WARNING
Risk of scalding! Before disconnecting cooling system tester -

V.A.G 1274 B- from connecting hose or connector - V.A.G
1274 B/1- , always relieve existing pressure. To do this, press
pressure relief valve on cooling system tester - V.A.G 1274 B-
until pressure gauge displays value of »0«.
If pressure drops:
– Find leaks and rectify.
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Use hand pump on cooling system tester to create a pressure
of max. 1.6 bar. G. Volkswagen nA AG do
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The pressure relief valve must
y V not open.
olks ot g
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If the pressure relief tvalve
ho
ris opens prematurely: tee
or
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– Renew sealingsscap.
ce
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nl
pt
– Increase pressure to over 1.6 bar.

du
an
itte
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erm
The pressure relief valve must open.

ab
ility
ot p
If the pressure relief valve does not open:

wit
, is n
h re
– Renew sealing cap.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.2015
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - thermostat”, page 144
⇒ “2.3 Removing and installing coolant pump pulley”, page 151
⇒ “2.4 Removing and installing coolant circulation pump V50 ”,
page 155
2.1 Assembly overview - thermostat

Thermostat side
1 - Connection
2 - O-ring
❑ Renew.
3 - Spring
4 - Plunger
❑ Do not cant when instal‐
ling.
5 - Thermostat 2 AG. Volkswagen AG d
agen
❑ Opening starts at 96°C olksw
oes
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6 - Coolant temperature send‐ orise nte
eo
er - G62- aut
h
ra
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❑ Before removing, re‐
ce
e
nl
lease pressure in cool‐

pt
du
an
ing system if necessary.

itte
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erm
ab
7 - Retaining clip
ility
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wit
❑ Check for secure seat‐

, is n
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ing.
hole
spec
8 - Thermostat housing
es, in part or in w
t to the co
❑ Securing bolts, 10 Nm
9 - Seal
rrectness of i
❑ Renew.
l purpos
10 - Thermostat 1
❑ Opening starts at 80°C
nform
ercia
11 - To expansion tank.
m
at
om
❑ Coolant hose schematic

ion
c
diagram
in t
or
his
e
⇒ “1.1 Coolant hose

at
do
riv
schematic diagram”,
p
cum
page 135 .
for
en
ng
t.
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12 - Connection . Cop py
rig
ht ht
rig
13 - Coolant pipe py by
co Vo
by lksw
❑ Coolant hose schematic diagram ⇒ “1.1 Coolant hose schematic diagram”, page 135 . cted agen
Prote AG.
14 - Coolant pipe
❑ Coolant hose schematic diagram ⇒ “1.1 Coolant hose schematic diagram”, page 135 .
15 - Bolt
❑ 5 Nm

11.2015
16 - From bottom of radiator.

17 - To top of radiator
2.2 Removing and installing coolant pump

equipment required
6340-
1331-
♦ 16 mm open-end spanner -
T10241- (not shown) n AG. Volkswagen AG do
swage es n
♦ Bit - T10451- (not shown) byV
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♦ Locking pin - T10060A- tho tee
or
au ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system 145

11.2015
Removing
Rep. gr. 50 ; Removing and installing noise insulation or skid
plate .
– Pull retaining clip in direction of -arrow- and pull out charge air
hose -1- from charge air pipe.
Note
Charge air hoses with screw-type clips are also installed.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
– Unscrew securing bolt for charge air pipe -arrow-.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove securing bolt -arrow- for charge air pipe -1-.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– Unclip bracket -2- for electric wire to oil level and oil tempera‐
ture sender - G266- .
Vehicles with condensate trap on charge air pipe

11.2015
– Open clips -arrows-.

– Pull off coolant hoses -1- on charge air pipe -2-.
Vehicles with auxiliary heater
– Pull off coolant hoses for auxiliary heater - Z- from coolant

pipes -1-.
– Remove auxiliary/supplementary heater ⇒ Rep. gr. 82 ; Aux‐
iliary heater, supplementary heater; Removing and installing
auxiliary/supplementary heater .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Carefully press locking
ss tabs on noise insulation housing for
supercharger -arrows- outwards.
ce
le
un
pt
an
d
itte
– Pull off housing with noise insulation and place to one side.
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
Housing with noise insulation remains in vehicle.

t to the co
rrectnes
– Lift off engine cover panel at points -1- and pull it forwards in
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.2015
– Pull off fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing release tabs.
– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.
AG. Volkswagen AG d
– Unscrew hose clip -1- on charge
lksw
agenair pipe. oes
not
o
byV gu
– Open hose retainerri-2-
sed and pull out hose. ara
nte
tho eo
– Unscrew securing
s au bolt for charge air pipe -3- and pull off con‐ r ac
nector from charge air pressure sender - G31- with intake air
s
ce
le
temperature sender 2 - G299- .

un
pt
an
d
itte
y li
– Remove holder -4-.

rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– To do this, unscrew bolts -arrows-.

rrectness of i

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

11.2015
– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
– Remove charge air pipe downwards.
– Release tension from supercharger poly V-belt by swinging

tensioning element using open-end spanner, 16 mm -
T10241- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
– Unscrew securing bolts -arrows- for tensioning element and
ce
le
un
pt
remove tensioning element.

an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Hold supercharger shaft with AF 16 spanner -1-.

nform
ercia
– Remove securing bolt -2- for belt pulley and remove belt pulley
m
and supercharger poly V-belt -3-.

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

11.2015
– Loosen bolts -arrows- of coolant pump using socket -

T10451- .
– Remove coolant pump with magnetic clutch for supercharger
- N421- from cylinder block.
Installing
note the following: olkswage es n
o
yV t gu
db ara
ir se nte
ho eo
Note aut ra
c
ss
ce
le
Coolant pump seal is bonded in position. If the seal is damaged,

un
pt
an
d
the coolant pump must be renewed.

itte
y li
rm
ab
pe
ility
– Insert coolant pump with magnetic clutch for supercharger -
ot
wit
, is n
N421- into cylinder block.
h re
hole
spec
– Tighten securing bolts to specified torque ⇒ page 151 .
es, in part or in w
t to the co
– Place poly v-belt on the magnetic clutch for supercharger -
N421- .
– Bolt on supercharger pulley with poly-v-belt and new securing
rrectness of i
bolt.
l purpos
Vehicles with screw-type hose clips on charge air hoses
nform
ercia
Caution
m
a
com
tion in
The screw-type clips on the charge air pipes must be tightened
r
te o
to 5.5 Nm. If the torque is too low or too high, the charge air
thi
s
iva
hose may slip off the charge air pipe during vehicle operation.
do
r
rp
cum
fo
en
ng
t.
yi Co
Vehicles with push-fit charge air hoses Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
Note installation of charge air hoses.

11.2015
– If oil seal is renewed, place seal in groove of charge air hose.

Ensure that seal is correctly seated around groove and is not
twisted. . Volkswage n AG n AG d
wage oes
– Coat sealing surface and oil sealy with
Vol oil.
ks not
gu
b ara
ed
– Bring retaining clip to release
ho position -1-.
ris nte
eo
t
au ra
– Push charge air hose into
ss coupling as far as stop. c
ce
e
nl
pt
– Bring retaining clip to locking position -2- and then press
du
an
itte
charge air hose again.
y li
erm
ab
ility
– Pull on hose to ensure that plug-in connector is properly seat‐
ot p
wit
ed and engaged.
, is n
h re
hole
– Replenish coolant
spec
es, in part or in w
t to the co
Specified torques:
rrectness of i
Securing bolts for coolant pump 8 Nm
l purpos
Belt pulley to coolant pump 24 Nm

Belt pulley for supercharger 40 Nm + 90°
nf
ercia
or
Securing bolts for charge air 5 Nm
m
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atio
pipe
om
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or c
Screw-type hose clips on 5.5 Nm
thi
e
charge pressure pipes

t
sd
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Securing bolts for bracket 20 Nm
o
m
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en
ng
t.
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♦ Assembly overview – belt drive Cop py
⇒ “1.1 Assembly overview - poly V-belt drive”, page 26 ht. rig
rig ht
py by
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♦ Assembly overview - supercharger by c lksw
cted agen
⇒ “3.1 Assembly overview - supercharger”, page 192
Prote AG.
♦ Assembly overview - charge air system

♦ Install poly V-belt
2.3 Removing and installing coolant pump pulley

11.2015

equipment required
♦ Bit XZN 10 - T10154-
6340-
1331- AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove securing bolts -arrows- and remove engine splash
protection.

11.2015
– Pull retaining clip in direction of -arrow- and pull charge air

hose -1- out of charge air pipe.
– Unscrew securing bolt for charge air pipe -arrow-.
– Lift engine cover panel at points -1- and pull it forwards in di‐ en AG. Volkswagen AG
rection of -arrow-. olks
wag does
not
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db ara
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au ra
c
ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11.2015
swage es n
– Pull hose -1- from pressure pipe. byV
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– Unscrew securing bolts -2- from pressure pipe th and remove
o tee
or
pressure pipe. ss
au ac
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– Unscrew hose clip -1- at charge air pipe.
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– Open hose clip -2- and pull hose out.
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– Unscrew securing bolt for charge air pipe -3- and pull connec‐
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tor off charge air pressure sender - G31- with intake air tem‐
perature sender 2 - G299- .
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– Loosen securing bolts -1- for coolant pump pulley. cop Vo
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WARNING
As the poly V-belt is still tensioned, the pulley securing bolts

must not yet be removed.

– Unscrew securing bolts -1- and pull pulley from coolant pump.
Installing

11.2015
– Position pulley on coolant pump and tighten securing bolts

-1- hand-tight.
– Install poly V-belt
– Tighten securing bolts -1- to 24 Nm.
Further installation is carried out in reverse order of removal.
When installing, note the following:

Specified torques:
♦ Assembly overview - charge air system
♦ Assembly overview - intake manifold
2.4 Removing and installing coolant circulation pump - V50-

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11.2015

equipment required
6340- AG. Volkswagen AG d
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♦ Torque wrench - V.A.G byV
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Cop py
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Prote AG.
Removing
– Remove securing bolts -arrows- and remove engine splash
protection.

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– Remove spring-type clips -arrows- and pull coolant hoses off.
itte
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– Pull connector -1- off and remove securing bolt -2-.
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– Remove coolant circulation pump - V50- .
, is n
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hole
Installing
spec
es, in part or in w
t to the co
note the following:
Specified torque
rrectness of i
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Securing bolt for continued coolant 10 Nm

circulation pump - V50- .
nform
mercia
at
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ion
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ate
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Cop py
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Prote AG.

11.2015
3 Radiator/radiator fan
⇒ “3.1 Assembly overview – radiator/radiator fan”, page 158
⇒ “3.2 Removing and installing cowl together with radiator fan V7
and radiator fan 2 V177 ”, page 159
⇒ “3.3 Removing and installing radiator”, page 160
3.1 Assembly overview – radiator/radiator fan
1 - Radiator/cooler
⇒ “3.3 Removing and in‐ en AG. Volkswagen AG
stalling radiator”, olkswag does
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page 160 . d by V gu
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❑ After renewing,uthor
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entire coolant.
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2 - O-ring
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3 - Upper coolant hose
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❑ To connection on cylin‐
h re
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hole
spec
❑ Coolant hose schematic
es, in part or in w
diagram t to the co
⇒ “1.1 Coolant hose
schematic diagram”,
rrectness of i
page 135 .
l purpos
4 - Expansion tank
❑ Test cooling system for
leaks using cooling sys‐
nf
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tem tester - V.A.G 1274

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B- and adapter for cool‐

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ing system tester -

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cooling system tester -
agen
Prote AG.
V.A.G 1274/9- .
❑ Pressure relief valve
must open at a pressure
of between 1.4 and
1.6 bar
7 - Bolt
❑ 5 Nm
8 - Plastic inserts
❑ For securing bolts.
9 - Bracket
10 - Cowling
11 - Bolt
❑ 5 Nm

11.2015
12 - Radiator fan 2 - V177-

13 - Connector
14 - Radiator fan - V7-
❑ With radiator fan control unit - J293- .
15 - Bracket
❑ For connector.
16 - Lower coolant hose
❑ To connection for thermostat.
17 - Retaining clip
18 - Radiator outlet coolant temperature sender - G83-
19 - Nut
❑ 5 Nm
3.2 Removing and installing cowl together . Volkswagen AG

gen AG
with radiator fan - V7- and radiator fan k2
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Removing radiator fan ss ac
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– Remove engine cover panel.
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– Remove upper securing bolts of cowling -arrows-.
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Rep. gr. 50 ; Body - front; Noise insulation .
h re
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spec
es, in part or in w
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– Separate connector -1- and unscrew lower cowling securing

m
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bolts -arrows-.
ion in
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– Remove cowling downwards.

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Prote AG.
3. Radiator/radiator fan 159

11.2015
– Separate electrical connector -1- and free wiring.

– Unscrew nuts -arrows- and remove fan.
Installing radiator fan
Installation is carried out in the reverse order. When installing, en AG. Volkswagen AG
note the following: olks
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Specified torques: rise nte
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Component ss Nm c
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Radiator fan to cowling 10
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Cowling to radiator rm 5
ab
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3.3 Removing and installing radiator
, is n
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spec
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equipment required
rrectness of i
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6340-
nform
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1331-
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Cop py
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rig ht
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by lksw
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Prote AG.
Removing
– Pull coolant hoses off radiator.

11.2015
– Remove cowling together with radiator fans

⇒ “3.2 Removing and installing cowl together with radiator fan
V7 and radiator fan 2 V177 ”, page 159
– Remove radiator securing bolts and take out radiator forwards.
Note
wage es n
To prevent damage to condenser yV
olks
or to refrigerant lines and ot gho‐
ua
ses, ensure that lines and ir se hoses are not stretched, kinked or bent.
d b ran
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un
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– Unbolt condenser from radiator and secure to lock carrier.
an
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note the following:
h re
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spec
Filling with new coolant
es, in part or in w
t to the co
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
rrectness of i
Specified torques:
l purpos
Component Nm
nform
ercia
Radiator fan to cowling 10

m
Cowling to radiator 5
a
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tion in
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♦ Securing bolts for radiator

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⇒ “3.1 Assembly overview – radiator/radiator fan”, page 158

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3. Radiator/radiator fan 161

11.2015
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 162
⇒ “1.2 Removing and installing turbocharger”, page 166
⇒ “1.3 Checking vacuum unit for turbocharger”, page 170
⇒ “1.4 Adjusting vacuum unit for turbocharger”, page 172
⇒ “1.5 Renewing vacuum unit for turbocharger”, page 177
Note
♦ Secure all hose connections with hose clips which conform to

production standard.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. The oil seal and seal‐
ing surface must only be oiled lightly for plug-in connectors.
⇒ “2.2 Assembly overview - charge-air hose connections”,
page 181
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts. AG. Volkswagen AG d
agen oes
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Spring-type clip pliers - VAS 5024A- y V or hose clip pliers - VAS
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of spring-type clips. nte
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♦ Fill turbocharger with engine
ss a oil at oil supply line connection. ra
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♦ After installing turbocharger, run engine for about 1 minute at

nl
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an
idle and do not rev up immediately. This ensures that the tur‐
itte
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bocharger is fully primed with oil.

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1.1 Assembly overview - turbocharger

hole
spec
es, in part or in w
Parts l and ll
t to the co
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at
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ion
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or
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Cop py
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rig ht
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by lksw
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Prote AG.
162 Rep. gr.21 - Turbocharging/supercharging

11.2015
AG. Volkswagen AG d
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Part 1
1. Turbocharger 163
11.2015
1 - Charge pressure control

solenoid valve - N75-
2 - Bolt
❑ 10 Nm
3 - Bolt
❑ 7 Nm
4 - Turbocharger air recircula‐
tion valve - N249-
❑ To remove, pressure
pipe must be removed
⇒ page 168 .
5 - O-ring
6 - Turbocharger
page 166 .
❑ Checking turbocharger
vacuum unit
⇒ “1.3 Checking vac‐
uum unit for turbocharg‐ agen
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❑ Removing and installing orise nte
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charger ss c
⇒ “1.5 Renewing vac‐
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uum unit for turbocharg‐
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❑ Adjusting vacuum unit
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for turbocharger
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⇒ “1.4 Adjusting vac‐
hole

spec
es, in part or in w
er”, page 172 .

t to the co
7 - Connecting hose
8 - Connecting hose
rrectness of i
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Part II
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Cop py
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Prote AG.

11.2015
1 - Bolt
❑ 8 Nm
2 - Coolant pipe
3 - O-ring
❑ Renew
4 - Stud
❑ 20 Nm
5 - Turbocharger
page 166 .
❑ Checking turbocharger
vacuum unit
⇒ “1.3 Checking vac‐
er”, page 170 .
vacuum unit for turbo‐
charger
⇒ “1.5 Renewing vac‐
er”, page 177 .
❑ Adjusting vacuum unit
for turbocharger
⇒ “1.4 Adjusting vac‐
er”, page 172 .
6 - Gasket n AG. Volkswagen AG do
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❑ Renew byV
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7 - Nut utho tee
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❑ Renew studs and fas‐ ss
tening nuts.
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❑ Screw studs into cylinder head until they project only by 25 mm.
itte
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❑ Coat studs with high-temperature paste.

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❑ Observe tightening sequence and specified torques: items -A- to -I-.

wit
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❑ 25 Nm
ole,
spec
8 - Coolant pipe
t to the co
9 - Gasket
❑ Renew
rrectne
10 - Bolt
❑ 8 Nm
ss o
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11 - Oil return pipe

inform
mer
❑ To remove, catalytic converter needs to be removed

atio
m
12 - Banjo bolt
o
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c
i
or
❑ Secured to valve timing housing.

thi
te
sd
va
❑ 20 Nm
i
o
pr
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fo
en
ng
13 - Seal yi
t.
Co
op
❑ Renew.
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Prote AG.
1. Turbocharger 165
11.2015
14 - Oil supply pipe
Caution
Oil supply line must be
renewed when installing
a new turbocharger.
15 - Banjo bolt
❑ 30 Nm
1.2 Removing and installing turbocharger

♦ Hose clip pliers - VAS 6340-

AG. Volkswagen AG d
agen oes
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Removing
Caution
rrectness of i
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When a mechanical fault is found on the turbocharger, e.g. a

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
nform
ercia
perform the following repairs:

m
♦ Check air filter housing, air filter element and intake hoses
com
tion in
for soiling.
r
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♦ Check complete charged air routing and charge air cooler

s
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for foreign objects.

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If foreign objects are found in the charge air system, the charg‐
n
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ed air routing must be cleaned and the charge air cooler must C py
ht. rig
be renewed, if necessary. rig ht
py by
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by lksw
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Prote AG.

11.2015
Note
Before carrying out further work, disconnect battery earth strap.

Check whether a coded radio is fitted. Obtain anti-theft coding first
if necessary.
AG. Volkswagen AG d
agen oes
olksw not
– Disconnect battery ⇒ Electrical system; Rep. gr. d27 by ; Discon‐
V gu
ara
necting and reconnecting battery . orise nte
eo
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– Lift engine cover panel at points -1- and pull
ss a
it forwards in di‐ c
rection of -arrow-.
ce
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nl
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spec
es, in part or in w
t to the co
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nform
ercia
cooling system.
m
at
om
i
– Now, drain coolant
on
c
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or
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ate
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or
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op py
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– Observe rules for cleanliness
agen
Prote AG.
⇒ “3.1 Rules for cleanliness”, page 9 .
– Pull off connecting hoses -1- and coolant hoses -3-.

– Unscrew bracket -2- and securing nuts -4- from turbocharger.
1. Turbocharger 167
11.2015
– Unscrew securing bolt -2- and remove upper coolant pipe.
Note lkswage es n
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ir se
The lower coolant pipe can only be removed following th the removal
o tee
or
of the catalytic converter. ss
au ac
ce
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nl
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– Unscrew bolts -1-, and remove
an
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pressure pipe
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.
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G130- and remove.

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AG. Volkswagen A 11.2015
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– Unbolt exhaust pipe ed
by to rear silencer -arrows-. ua
ran
oris tee
th or
au ac
ss
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itte
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es, in part or in w
t to the co
rrectness of i
– Loosen securing bolts of double clamp -arrows- and pull ex‐
haust pipe to rear.
l purpos
– Also pull out exhaust pipe together with flexible joint.
nf
ercia
– Remove catalytic converter together with charge air pipe
or
downwards.
m
m
atio
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– Unscrew securing bolt -arrow- for oil return pipe -2- from tur‐
o
n in
or c
bocharger.
thi
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Cop py
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rig ht
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– Pull oil return pipe downwards. by c lksw
cted agen
Prote AG.
– Unbolt charge air hose -1- from turbocharger.
– Unscrew banjo bolts of oil supply pipe -arrows- from turbo‐
charger and valve timing housing.
– Remove oil supply pipe.

– Unscrew all securing nuts from exhaust manifold -1-.
– Pull exhaust manifold out upwards with turbocharger.
Note
The turbocharger can only be renewed together with the exhaust

manifold.
Installing
Caution
Oil supply line must be renewed when installing a new turbo‐

charger.

note the following:
1. Turbocharger 169
11.2015
♦ Observe tightening sequence and specified torques: items

-A- to -I-
⇒ “1.1 Assembly overview - turbocharger”, page 162 .
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a gen AG does
♦ Renew seals, gaskets and self-locking
Vol
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♦ Fill turbocharger with engine orisoil
e
at oil supply line connection. nte
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th
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♦ After installing turbocharger,
ss a
run engine for about 1 minute at c
idling speed to ensure that oil is supplied to turbocharger.
ce
le
un
pt
an
d

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erm
free of oil and grease before assembly.
ab
ility
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spec
♦ Install exhaust system and align it free of stress.
t to the co
♦ When installing air pipes with plug-in connector, ensure that
securing clip -arrow- audibly engages into retaining lug -A-.
rrectne
Fitting hose connections with plug-in connector
page 181
ss o
cial p
f
Specified torques:
inform
mer
atio
m
Note
o
n
c
i
or
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te
Observe tightening sequence for exhaust manifold.
sd
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♦ Assembly overview - turbocharger

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⇒ “1.1 Assembly overview - turbocharger”, page 162 t. Cop py
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Prote AG.
♦ Assembly overview – catalytic converter and add-on parts

1.3 Checking vacuum unit for turbocharger


11.2015
♦ Hand vacuum pump
olks
w-aVAS
ge 6213- es n
ot g
yV ua
db ran
rise tee
tho or
au ac
ss
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nl
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Check retaining clip -1- is seated correctly on vacuum unit
rrectness of i
linkage.
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Securing nut -2- must be locked with sealing paint.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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rig ht
– Pull hose -arrow- off vacuum unit. py by
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by lksw
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Prote AG.
– Fit hose -2- onto vacuum unit connection.

– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
stop in direction of -arrow-.
1. Turbocharger 171
11.2015
– Operate hand vacuum pump - VAS 6213- until a pressure of

700 mbar is displayed on pressure gauge.
Linkage of vacuum unit -1- must move in direction of -arrow-.
If pressure of 700 mbar is displayed:
Vacuum unit is OK.
If pressure drops abruptly:
– Renew vacuum unit
⇒ “1.5 Renewing vacuum unit for turbocharger”, page 177 .
1.4 Adjusting vacuum unit kfor

swa
turbocharger
gen AG. Volkswagen AG do
es n
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Note utho or
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The vacuum unit must only be adjusted when the linkage has
nl
pt
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an
been loosened.
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ab
ility
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equipment required
hole
spec
es, in part or in w
♦ Pressure regulating valve -
t to the co
VAS 6342-
♦ Dial gauge set, 4-part - VAS
rrectness of i
6341-
l purpos
♦ Hand vacuum pump - VAS

6213-
nf
ercia
♦ Turbocharger tester -
or
V.A.G 1397A-
m
m
atio
m
♦ Universal dial gauge brack‐

o
n in
or c
et - VW 387-
thi
te
sd
iva
♦ Dial gauge extension, 30

o
r
rp
cu
mm - VAS 6341/3- (not

o
m
f
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ng
shown)
t.
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Cop py
.
♦ Flat pickup - VAS 6341/4-
t rig
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(not shown) cop Vo
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Prote AG.

lkswage es n
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d Passat 2006 ➤ , Passat 2011 ran ➤ , Passat Variant 2011 ➤ , Touran 2003 ➤
tee
o
4-cylinder
auth direct-injection engine (1.4 l, natural gas, EA or 111, turbocharger, supercharger) - Edition
ac
ss 11.2015
ce
le
un
pt
an
d
Procedure
itte
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pe
ility
ot
rection of -arrow-.
wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
on in
r
te o
thi
s
iva
cooling system.
do
r
rp
cum
fo
– Now drain coolant.
en
ng
t.
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Cop py
t. rig
gh ht
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Note
p by
co Vo
by lksw
cted agen
Prote AG.
– Pull off connecting hoses -1- and coolant hoses -3-.

– Unscrew securing nuts -4- from turbocharger.
– Unscrew securing bolt -2- and remove upper coolant pipe.
Note
The lower coolant pipe can only be removed following the removal
of the catalytic converter.
– Unscrew bolts -1- and remove pressure pipe.
1. Turbocharger 173
11.2015


G130- and remove.
– Remove catalytic converter downwards.
– Pull hose -arrow- from vacuum unit on turbocharger.
Checking vacuum unit adjustment ⇒ page 170 . agen
AG. Volkswagen AG d
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Continuation if the vacuum unit has been renewed ed by or the linkage ara
nte
is
loosened. hor eo
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– Remove sealing paint from lock nuts -2-.
s c
ce
le
un
pt
an
d
itte
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rm
ab
– Pull off retaining clip -1- and loosen lock nut -2- on vacuum
pe
ility
unit linkage.
ot
wit
, is n
h re
– Pre-adjust bypass flap -2- on vacuum unit linkage -1- via

hole
spec
knurled screw, so that bypass flap can just be turned by hand.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
do
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

11.2015
– Turn knurled nut 2 turns further.

– Tighten lock nut hand-tight.
– Connect up hand vacuum pump . V-oVAS

lkswag6213-
en AG , turbocharger
tester - V.A.G 1397A- gen AG
kto
swaconnection -II- and pressure control
does
o l not
valve - VAS 6342-d byas
V shown in illustration. gu
ar e an
ris tee
– Close pressure
ut
ho control valve - VAS 6342- at lever -2-. or
sa ac
– Push sliding
s
ring -1- on hand vacuum pump - VAS 6213- to
ce
e
nl
pressure gauge in direction of -arrow-.
pt
du
an
itte
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– Switch on turbocharger tester - V.A.G 1397A- and set sliding
erm
ab
switch to position -II-.
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Turbocharger 175
11.2015
– Secure universal dial gauge bracket - VW 387- to turbocharg‐

er.
Note
The dial gauge linkage and the vacuum unit linkage must align.
– Secure dial gauge - VAS 6341/1- with dial gauge extension,

30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to uni‐ AG. Volkswagen
versal dial gauge bracket - VW 387- . lksw
agen AG do
es n
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– With pressure at 0 bar, set dial gauge - VAS 6341/1-
ris
ed to 1 mm ran
tee
preload. utho or
sa ac
– Operate hand vacuum pump - VAS 6213- s
until a pressure of
ce
le
800 mbar is displayed on turbocharger tester - V.A.G 1397A- .

un
pt
an
d
itte
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– Vent system via pressure control valve - VAS 6342- so that
rm
ab
pressure reading drops to 0 mbar.
pe
ility
ot
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– Repeat this procedure approx. 3-5 times.
h re
hole
spec
es, in part or in w
Note
t to the co
This procedure is intended to prevent the vacuum unit bypass flap
rrectness of i
or linkage from jamming.
l purpos
Note
nform
mercia
The values in mm refer to the read value (includes 1 mm preten‐
a
com
tio
sion).
n in
r
te o
thi
s
iva
do
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rp
c
pressure reading drops to 0 mbar.
um
fo
en
ng
t.
yi
– Set dial gauge - VAS 6341/1- to 0.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
♦ The following measurements must be performed in continuous

sequence. Do not allow the pressure to drop to 0 between
measurements.
♦ Do not knock against linkage throughout the entire measure‐
ment procedure.
– Operate hand vacuum pump - VAS 6213- until turbocharger

tester - V.A.G 1397A- indicates 500 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Operate vacuum pump - VAS 6213- until turbocharger tester
- V.A.G 1397A- indicates 800 +/- 5 mbar.
pressure reading drops to 500 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5.5 +/- 0.25 mm.

11.2015
– Correct setting if the result (average) is not 5.5 +/- 0.25 mm,
tighten lock nut hand-tight and repeat measurement.
– If the result (mean value) is 5.5 +/- 0.25 mm, tighten the lock
nut to 9 Nm and secure with sealing paint.
– Secure retaining clip to vacuum unit linkage.
note the following:
♦ Renew seals, gaskets and self-locking nuts.

♦ If renewed, place oil seal in groove of charge air hose. Ensure
seal is correctly seated in groove.
♦ Lightly moisten seal with engine oil. AG. Volkswagen AG d
agen oes
lksw not
♦ Bring retaining clip to release positiond by -arrow-.
Vo gu
ara
ise nte
r
♦ When installing air pipes with ut plug-in connector, ensure that
ho eo
ra
securing clip -arrow- audibly
ss a engages into retaining lug -A-. c
ce
e
nl
Specified torques:
pt
du
an
itte
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♦ Assembly overview - turbocharger
erm
ab
⇒ “1.1 Assembly overview - turbocharger”, page 162 .
ility
ot p
wit
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♦ Assembly overview – charge air system
h re
hole
spec
es, in part or in w
♦ Removing and installing parts of exhaust system
t to the co
1.5 Renewing vacuum unit for turbocharger

rrectness of i
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Removing
– Release vacuum hose on vacuum reservoir -arrow- and pull it
off.
1. Turbocharger 177
11.2015
swage es n
– Lift engine cover panel at points b-1- y V and pull it forwards in di‐
olk ot g
ua
rection of -arrow-. ir se
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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o
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f
en
ng
t.
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Cop py
t. rig
gh ht
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– Pull hose -1- from pressure pipe and unscrew securing bolts cop Vo
by lksw
-2- for pressure pipe. cted agen
Prote AG.
– Remove pressure pipe.
– Pull hose -arrow- from vacuum unit.

– Remove sealing paint from securing nut -2-.

11.2015
– Pull off retaining clip -1- and loosen securing nut -2- on vacuum
unit linkage.
– Unscrew knurled nut from vacuum unit stud.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
– Unscrew securing bolts -arrows- for vacuum unit and remove
hole
spec
vacuum unit from turbocharger.
es, in part or in w
t to the co
Installing
note the following:
rrectness of i
♦ Linkage must be adjusted after installing vacuum unit
l purpos
⇒ “1.4 Adjusting vacuum unit for turbocharger”, page 172 .

♦ Specified torque for vacuum unit to turbocharger: 10 Nm
nform
ercia

m
at
om
ion
c
in t
or
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ate
do
riv

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for
en
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t.
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op
Specified torques:
C py
ht. rig
rig ht
py by
♦ Securing bolts for heat shield co Vo
by lksw
cted agen
Prote AG.

1. Turbocharger 179
11.2015
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 180 agen
AG. Volkswagen AG d
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⇒ “2.2 Assembly overview - charge-air hose connections”, d by ara
page 181 rise nte
tho eo
au ra
⇒ “2.3 Checking charge air system for leaks”, page 182 ss c
ce
le
un
pt
⇒ “2.4 Removing and installing charge air cooler”, page 186
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - VAS
spec
6340- are recommended for installation of spring-type clips. es, in part or in w
t to the co
rrectness of i
free of oil and grease before assembly. The oil seal and seal‐
l purpos
ing surface must only be oiled lightly for plug-in connectors

⇒ page 181 .
nform
ercia
♦ Charge air system must be free of leaks.

m
a
com
tion in
2.1 Assembly overview - charge air system
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.

11.2015
1 - Charge air cooler

stalling charge air cool‐
er”, page 186 .
2 - Bolt
❑ 5 Nm
AG. Volkswagen AG d
3 - Mounting wage
n oes
Volks not
gu
❑ For echarge
db
y air cooler. ara
nte
is
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4 - Seal
au
th ra
ss c
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nl
pt
du
an
5 - Charge air hose
itte
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erm
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6 - Intake manifold connection
ility
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❑ With seals.
wit
, is n
h re
hole
7 - Throttle valve control mod‐
spec
ule - J338-
es, in part or in w
t to the co
❑ Clean
⇒ “7.5 Cleaning throttle
valve module J338 ”,
rrectness of i
page 260 .
❑ If renewed, erase learnt
l purpos
values and adapt en‐

gine control unit - J623-
nf
ercia
⇒ Vehicle diagnostic
or
tester “Guided func‐

m
m
atio
tions”.
om
n in
or c
8 - Bolt
thi
te
sd
iva
❑ 7 Nm
o
r
rp
cu
o
m
f
9 - Hose clip
en
ng
t.
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op
10 - Charge air hose
C py
t. rig
gh ht
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11 - Bolt cop Vo
by lksw
cted agen
❑ 10 Nm
Prote AG.
12 - Charge air pipe

13 - Charge air pressure sender - G31- with intake air temperature sender 2 - G299-
14 - Bolt
❑ 5 Nm
❑ To turbocharger.
16 - Charge air pipe
2.2 Assembly overview - charge-air hose

connections
Caution
The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
This can cause leakage. Observe installation instructions.
2. Charge air system 181

11.2015
Removing:
– Release plug-in connector by pulling out retaining clip
-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place oil seal in groove of charge air hose. Make
sure that the seal is correctly seated in the groove all round
the complete circumference and that it is not twisted.
– Lubricate sealing surface and seal with oil.
– Bring retaining clip to release position -1-.

– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if plug-in connector seats correctly and is properly en‐
gaged by pulling hose.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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2.3 Checking charge air system for leaks

h re
hole
spec
es, in part or in w

t to the co
♦ Charge air system tester - V.A.G 1687-

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

11.2015
♦ Engine bung set - VAS 6122- (not shown)

rection of -arrow-.
– Press hose locking mechanism and pull hose for crankcase
breather -1- off intake connecting pipe.
– Also pull crankcase breather hose off valve timing housing.
Caution
Crankcase breather hose must be pulled off during leak test to

prevent damage to engine.
AG. Volkswagen AG d
agen oes
olksw not
– Seal intake connecting pipe with a bung from d by V engine bung set gu
ara
- VAS 6122- . orise nte
eo
th
u ra
– Remove spring-type clips -2- fromss intake
a
hose and remove c
intake hose.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Renew spring-type clips -arrows- with screw-type clips from

rrectne
charge air system tester - V.A.G 1687- .

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

11.2015
– Slide adapter - V.A.G 1687/6- into intake hose -2- and secure
hose to intake connecting pipe with screw-type clips -1- from
charge air system tester - V.A.G 1687- .
Prepare charge air system tester - V.A.G 1687- as follows:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
– Unscrew pressure regulating valve -2- and close valves -3-
pt
an
d
itte
and -4-.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Connect charge air system tester - V.A.G 1687- as shown.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
Passat 2006 ➤ , Passat 2011 ➤ rise, Passat Variant 2011 ➤ , Touran 2003
d b ara ➤
nte
4-cylinder direct-injection engine (1.4 l, natural gas,autEA 111, turbocharger, supercharger) - Editione or
ho
a
ss 11.2015 c
ce
le
un
pt
an
d
– Connect pressure hose -1- (compressed air supply) to charge
itte
y li
air system tester - V.A.G 1687- .
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
If there is water in the sight glass, drain at water drain screw -6-.
t to the co
– Open valve -3-.
rrectness of i
– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
l purpos
Caution
nform
ercia
The pressure must not exceed 0.5 bar! If the pressure is too
m
a
high this can cause damage to the engine.
com
tion in
r
te o
thi
s
iva
do
– Open valve -4- and wait until the test circuit is filled. If neces‐
r
rp
cum
sary readjust pressure to 0.5 bar.
fo
en
ng
t.
yi Co
– Check the charge air system for leaks by hearing, touching, Cop py
with commercially available leak detector spray or using ultra‐
t. rig
gh ht
yri
sonic tester - V.A.G 1842- .
p by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Slight leaks in the area of the intake connecting pipe

-arrows- are permissible, as the intake hoses are not designed
for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/6- before removing adapter.
♦ Hose connections and hoses must be free of oil and grease
before assembly.
♦ After testing compression, secure intake hoses again with
spring-type clips.


11.2015
2.4 Removing and installing charge air cool‐

er
⇒ “2.4.1 Removing and installing charge air cooler (Passat)”,
page 186
⇒ “2.4.2 Removing and installing charge air cooler (Touran)”,
page 189 agen
AG. Volkswagen AG d
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olksw not
V
2.4.1 Removing and installing charge air cooler (Passat) by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
equipment required
du
an
itte
y li
♦ Refractometer - T10007-
erm
ab
ility
ot p
wit
, is n
6340-
h re
hole
spec
♦ Torque wrench
es, in part or in w
(5 … 50 Nm) - V.A.G 1331-
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Remove noise insulation or skit plate ⇒ General body repairs,
exterior; Rep. gr. 50 ; Removing and installing noise insulation
or skid plate .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper .

11.2015
Vehicles with push-fit charge air hoses

– Release securing clip on right of charge air cooler in direction
of -arrow- and pull off hose -arrow-.
– Release and pull off charge air hose in same way on left-hand
side.

– Loosen hose clip -arrow-.
– Pull off charge air hose -1- on left of charge air cooler -2-.
– Also loosen hose clip on right-hand side and pull off charge air
AG. Volkswagen AG d
hose. lksw
agen oes
n o ot g
yV ua
Continuation for allrisvehicles
ed
b ran
tee
tho o
– Drain coolant
s a ⇒ “1.2 Draining and filling coolant”,
u page 137 .r ac
s ce
e

nl
pt
du

an
itte
y li
erm
ab
ility
ot p
– Release retaining clip -arrow-.

wit
, is n
h re
– Pull off coolant hose -1- from radiator.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Undo and remove bolts -arrows- of cowling.

in t
or
his
te
– Release connector -1- and pull off.

a
do
priv
cum
or
– Remove cowling downwards.

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

11.2015
AG. Volkswagen AG d
– Unscrew bolts -arrows-. ksw
agen oes
not
Vol
y gu
– Remove radiator -1- downwards. ise
d b ara
nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Undo and remove coolant pump bolts -arrows- of the radiator
support.
rrectness of i
– Pull out bottom of radiator from mounting.
l purpos
– Tilt radiator backwards.
nform
ercia
Vehicles with air conditioner

m
at
om
ion
c
Note
in t
or
his
ate
do
riv
Make sure that the coolant lines/hoses are not excessively

p
cum
or
stretched, kinked or bent.

f
en
ng
t.
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Cop py
t. rig
gh ht
– Undo and remove condenser bolts -arrows-. pyri by
Vo
co lksw
by
cted agen
– Secure condenser to lock carrier. Prote AG.

– Remove radiator downwards.
Installing
Install in reverse order. In the process, note the following:
Caution
The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.
Vehicles with push-fit charge air hoses
Note
Note installation of charge air hoses.

. Volkswage
11.2015
AG n AG d
agen oes
olksw not
– If renewed, place oil seal in groove of d bycharge
V air hose. Ensure gu
ara
that seal is correctly seated aroundorise groove and is not twisted. nte
eo
th
u ra
– Coat sealing surface and oilssseal
a
with oil. c
ce
le
un
– Bring retaining clip to release position -1-.
pt
an
d
itte
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– Push charge air hose into coupling as far as stop.
rm
ab
pe
ility
– Bring retaining clip to locking position -2- and then press
ot
wit
, is n
charge air hose again.
h re
hole
spec
– By pulling on hose, check whether plug-in connector seats
es, in part or in w
correctly and is properly engaged.
t to the co
Fill with new coolant
rrectness of i
l purpos
– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.
nform
mercia
a
com
tion in
Specified torque
r
te o
thi
s
iva
do
r
rp
cum
fo
Radiator to charge air cooler 5 Nm
en
ng
t.
yi Co
Cowling to radiator 5 Nm
Cop py
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2.4.2 Removing and installing charge air cooler (Touran)

11.2015
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Removing
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Removing and installing bumper cover
– Remove radiator
⇒ “3.3 Removing and installing radiator”, page 160 .
Note
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.

4-cylinder direct-injection engine (1.4 l, .natural
AG Volkswaggas,
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– Unscrew securing bolt -arrow-.
– Unscrew securing bolts -arrows-.

– Remove charge air cooler downwards.
Installing
note the following:
Specified torques:
Component Nm
Cowling to radiator 5
Radiator to charge air cooler 5
Charge air cooler to condenser 5

11.2015
3 Supercharger
⇒ “3.2 Removing and installing supercharger”, page 194
⇒ “3.3 Removing and installing drive unit seal for supercharger”,
page 201
3.1 Assembly overview - supercharger
1 - Housing with noise insula‐

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❑ For silencer.
2 - Silencer
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8 - Pressure pipe
9 - Noise insulation
10 - Housing
❑ For noise insulation.
11 - Silencer
❑ For charge air.
❑ With seal.
❑ Renew seal between supercharger and intake silencer.
12 - Belt pulley

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11.2015
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3. Supercharger 193
11.2015
3.2 Removing and installing supercharger

equipment required
♦ Spring-type clip pliers -
VAS 5024A-
1331-
♦ Guide pins - T10341-
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11.2015
– Detach spring-type clip from intake hose -arrow-.
– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
– Unscrew hose clip -1- at charge air pipe.

– Remove securing bolt for charge air pipe -2-.
n AG. Volkswagen AG
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pairs; Rep. gr. 66 ;ssWheel housing liner; Removing and
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– Remove Lambda probe after catalytic converter - G130- -1-.

t to the co

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3. Supercharger 195
11.2015
– Unbolt exhaust pipe to front silencer -arrows-.

– Prise front exhaust pipe out of mounting using a lever.
– Pull exhaust pipe out forwards, together with flexible joint.
– Push securing clip at charge air cooler in direction of -arrow-

and pull hose -arrow- off.
– Unscrew securing bolt forswcharge

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– Opens clips for hose guides -2- and push hoses to one side.
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– Carefully press locking lugs on noise insulation housing

-arrows- outwards.
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11.2015
– Pull off front housing with noise insulation.
– Slacken supercharger poly V-belt by swinging tensioning ele‐

ment in direction of -arrow- with 16 mm spanner.
– Unscrew securing bolts -arrows- for tensioning element and

remove tensioning element.
– Hold supercharger shaft with 16 mm spanner -1-.
AG. Volkswagen AG d
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3. Supercharger 197
11.2015
– Unscrew securing bolts -1- for supercharger and remove su‐

percharger together with intake silencer.
Removing intake silencer for charge air:
lkswage es n
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t to the co
intake silencer for charge air (note locating element).
rrectness of i
– Push intake silencer for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
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allow both dowel sleeves -3- to sit in holes.
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groove.
– Push supercharger together with intake silencer onto guide
pins - T10341- and tighten upper securing bolts hand-tight.
– Remove guide pins - T10341- .
– Tighten lower securing bolts hand-tight.

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– Tighten securing bolts -arrows- to specified torque

⇒ page 200 .
– Hold tensioner using a 16 mm spanner and pull out pin -

T10060 A- .
– Position housing with noise insulation onto supercharger.
Note
Ensure correct position of noise insulation in housing.
3. Supercharger 199
11.2015
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charger until locking lugs -arrows- click into place. agen oes
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♦ Install exhaust system and align it free of stress.
mer
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♦ When installing air pipes with plug-in connector, ensure that

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Specified torques:
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Securing bolts for super‐ 25 Nm Tighten in diago‐
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Securing bolt for super‐ 40 Nm + turn 90° Renew
charger pulley further
Securing bolts for ten‐ 23 Nm
sioning element
♦ Assembly overview – charge air system
♦ Assembly overview – catalytic converter and add-on parts
♦ Intake manifold and add-on parts

– Fit vacuum hose onto connection -arrow-.

11.2015
3.3 Removing and installing drive unit seal

for supercharger
♦ Gearbox bracket - T10108-
♦ Puller hooks - T20143-
♦ Repair kit for supercharger ⇒ Electronic Parts Catalogue (ET‐
KA)
Note
All components in the repair kit must be used!

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– Remove supercharger hor eo
⇒ “3.2 Removing and installing aut
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– Pull out the seal -1- with the puller hooks - T20143/1- .
Installing
3. Supercharger 201
Passat 2006 ➤ , Passat 2011 ➤ , ePassat
ag n AG. VolVariant
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– Pull down the assembly cone - T10208/5- from the assembly

sleeve in the -arrow direction- -T10208/4- .
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– Slide the assembly sleeve - T10208/4- onto the compressor

shaft.
– Using the thrust piece - T10208/2- , press in the seal via the
assembly sleeve - T10208/4- up to the stop.

11.2015
– Press in the new circlip -1- up to the stop also using the as‐
sembly tool - T10208/2- .
Changing the compressor fluid
– Undo the securing bolts for the drive unit according to the
specified sequence -A- to -H-.
– Turn the gearbox support - T10108- until the shaft points to
the floor.
– Unscrew the securing bolts and remove the drive unit -1-.
– Drain compressor oil completely from drive unit.
– Collect the escaping fluid in a suitable container.
– Turn the gearbox support - T10108- until the pair of gears point
upwards.
AG. Volkswagen AG d
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– Remove sealant olksresidues from compressor
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Add only the oil specified in repair set ⇒ Electronic Parts Cata‐
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– Fill the space -arrow- with new oil (44 ml) from the repair set.
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Sealant must not be applied too thickly, otherwise excess sealant

on
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Do not apply sealant until directly before the drive unit is fitted.
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– Apply sealant to the sealing surface on the compressor.
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3. Supercharger 203
11.2015
Bead of sealant must be 2 … 3 mm thick and must run closer to

inside edge in area of bolt holes.
– Tighten new securing bolts for drive unit in given sequence to
specified torque ⇒ page 204 .
– Install supercharger
⇒ “3.2 Removing and installing supercharger”, page 194
Specified torques:
Component Specified torque Tightening se‐
quence
Securing bolts for drive 12 Nm -A- through -H-
unit
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11.2015
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 General notes on injection.”, page 205
1.1 General notes on injection.

♦ The engine control unit - J623- is equipped with self-diagnosis.
Before carrying outgrepairs
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age the Lambda probe.
spec
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♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched off
via the fuel pump relay. The system also improves the starting
characteristics of the engine. When door is opened, the fuel rrectness of i
pump is activated for 2 seconds to build up pressure in the fuel
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1. Injection system 205

11.2015
2 Injectors
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 206
⇒ “2.2 Releasing high pressure in fuel system”, page 207
⇒ “2.3 Removing and installing injectors”, page 208
⇒ “2.4 Renewing seal on injector”, page 211
2.1 Assembly overview - fuel rail with injectors
1 - Seal
❑ Renew all, if lower part
of intake manifold has
been removed
⇒ “2.4 Renewing seal on
injector”, page 211
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
2 - Spring element
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❑ Injector, cylinder 1 -
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⇒ “7.3 Removing and installing lower part of intake manifold”, page 256 cted agen
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206 Rep. gr.24 - Mixture preparation - injection

11.2015
Caution
If only lower part of in‐
take manifold is to be re‐
moved, ensure injectors
remain in cylinder head.
To remove, use hold-
down device - T10510- .
Reason: if injectors have
been removed, they
must be renewed.
2.2 Releasing high pressure in fuel system
WARNING
AG. Volkswagen AG d
Risk of injury caused by high fuel pressure. agen oes
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♦ The injection system consists of a high-pressure
rised section nte
(maximum approx. 120 bar) and a low-pressure
ut
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section eo
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(approx. 7 bar). ss a c
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♦ Prior to opening the high-pressure section, e.g. when re‐
pt
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moving the high-pressure pump, fuel rail, injectors, a fuel
itte
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line, or the fuel pressure sender - G247- , the fuel pressure
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in the high-pressure section must be reduced to a residual
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pressure of approx. 7 bar. The appropriate procedure is
, is n
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described as follows.
hole
spec
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♦ Vehicle diagnostic tester
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Releasing high pressure in fuel system:
l purpos
– Connect vehicle diagnostic tester and then carry out the func‐
tion “Reducing high fuel pressure” in “Guided functions”.
nf
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• The fuel pressure will drop to the specified value.
m
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– Switch off ignition.

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The fuel rail is still filled with fuel, but the fuel is not under high
t
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pressure anymore.
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♦ Always wear eye protection and protective clothing when
AG.
opening the fuel system.

♦ Wrap a clean cloth around the connection before opening
the high-pressure section in order to catch escaping fuel.
– After the high pressure has been released, the high-pressure

system must be opened »immediately«. To do this, wrap a
clean cloth around the connection before opening it. Catch the
escaping fuel.
2. Injectors 207
11.2015
Note
♦ If the high-pressure system is not opened immediately, the

pressure will rise again due to reheating effects.
♦ Now the ignition must not be switched on anymore, because
switching the ignition on would cause the pressure to rise
again.
Concluding measures
– Clear event memory and generate the readiness code in en‐
gine control unit using “Guided functions” mode.
2.3 Removing and installing injectors
DANGER!

tem”, page 4 !!!
WARNING

gines; Rep. gr. 20 ; Fuel tank; Releasing pressure in high- AG. Volkswagen AG d
pressure line . agen oes
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If injectors are removed, they must be renewed.
du
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Special tools and workshop equipment required ab

ility
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♦ Torque wrench - V.A.G 1331- h re

hole
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11.2015
♦ Tool set - T10133-
lkswage es n
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Removing ir se
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Remove air filter au ac
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nl
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Remove regulating flap control unit - J808- and throttle valve
an
itte
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module - J338-
erm
ab
ility
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– Remove intake manifold and lower part of intake manifold
hole
spec
es, in part or in w
page 256 .
t to the co
– Press O-ring upwards by hand as shown, and remove it from
injector.
rrectness of i
– Screw slide hammer - T10133/3- to puller - T10133/15- .
l purpos
nform
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at
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ion
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or
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ate
do
priv
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t.
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– Then insert puller - T10133/15- into groove -arrow- on injector.
t. C rig
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2. Injectors 209
11.2015
– Pull injector out by tapping carefully.

Installing
AG. Volkswagen AG d
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cial p
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.

11.2015
– Thoroughly clean injector holes in cylinder head using nylon

brush - T10133/4- .
– Renew O-rings between injector and lower part of intake mani‐
fold and moisten slightly with clean engine oil.
Note
The Teflon seal on the injector must not be oiled or greased.
– Push new injector into hole in cylinder head to stop by hand.
Note
The injector must insert easily. If necessary wait until the seal has
contracted sufficiently.
– Ensure correct position of injectors in cylinder head. n AG. Volkswagen AG do

swage es n
– Place lower part of intake manifold carefully on injectors bandyV
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tighten securing bolts to 20 Nm ir se
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⇒ “7.3 Removing and installing lower part of intakeutmanifold”,
ho
or
page 256 . ss
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– Install intake manifold
pt
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itte
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ab
pe
– Install regulating flap control unit - J808- and throttle valve
ility
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module - J338-
wit
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hole
spec
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Note
rrectness of i
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WARNING
nform
mercia
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com
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injuries or death.
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Allocation:
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page 214
wheel - T50026- .
page 214
– Install air filter
2.4 Renewing seal on injector
2. Injectors 211
11.2015

equipment required
♦ Hold-down device -
T10510-
AG. Volkswagen AG d
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DANGER! h re
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tem”, page 4 !!!

rrectness of i
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WARNING
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Note
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♦ Renew the seals, if the lower part of intake manifold has been
Co
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♦ The support washer and spring elements cannot be renewed
co Vo
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individually.
agen
Prote AG.
♦ If the support washer or spring element are damaged, the in‐

jector must be renewed.
Procedure
• The injectors remain installed while the seals are renewed.
• Use hold-down tool - T10510- for removing and installing.

11.2015
– Remove O-ring -3-.

– Check support washer -2- and spring element -1- for damage.
– Moisten new O-ring with oil, and fit new O-ring -3- in front of
support washer -2-.
• If the spring element -1- is not damaged, it can be reused.
Further installation is carried out in the reverse sequence of re‐
moval. G. Volkswagen nA AG do
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– Place lower part of intake manifold Vol carefully on injectors and ot gu
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tighten securing bolts to 20 ris
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ra
page 256 . ss a c
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– Install intake manifold

un
pt
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itte
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– Install regulating flap control unit - J808- and throttle valve
ility
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wit
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Note t to the co
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WARNING
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injuries or death.
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t.
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Co
Cop py
t. rig
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Vo
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Allocation: cted agen
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page 214
wheel - T50026- .
page 214
– Install air filter
2. Injectors 213
11.2015
3 Checking natural gas supply system

for leaks
page 214 AG. Volkswagen AG d
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⇒ “3.2 Determining pressure in gas system”, page 217 d by V gu
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⇒ “3.3 Determining operating mode of natural gas vehicles”,
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217 ss a c
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⇒ “3.4 Activating/deactivating natural gas mode”, page 218
pt
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⇒ “3.5 Checking gas system for leaks”, page 219
erm
ab
ility
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DANGER!
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spec
♦ Risk of explosion and danger to life due to escaping nat‐
es, in part or in w
t to the co
ural gas.
♦ Leaks in natural gas system may lead to uncontrolled es‐
cape of natural gas.
rrectness of i
Risk of explosion leading to serious injuries or death.
l purpos
• Check natural gas system for leaks.
nform
mercia
at
Depending on the respective section of the natural gas supply
om
io
system, different procedures are described in this chapter.
n
c
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• These depend on the pressure section

at
do
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⇒ “3.1 Different pressure sections of natural gas supply sys‐

p
cum
or
tem”, page 214 that has been worked on, as well as on the
f
en
ng
actual pressure of the natural gas system

t.
yi Co
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⇒ “3.2 Determining pressure in gas system”, page 217 .
C py
t. rig
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– After working on high-pressure section, perform leakage test
op Vo
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according to manufacturer specifications ⇒ Maintenance ; cted agen
Prote AG.
Booklet 35.1 ; Description of work; Performing visual inspec‐
tion of natural gas tanks for corrosion and leakage test .
– After working on low pressure section, perform leakage test.
3.1 Different pressure sections of natural

gas supply system
⇒ “3.1.1 High-pressure section”, page 215
⇒ “3.1.2 low-pressure section”, page 216
• The pressure sections are defined via the respective compo‐
nents of the natural gas system.
• The pressure system comprises the high-pressure section and
the low-pressure section.
• The scope of the necessary leakage test
⇒ “3.5 Checking gas system for leaks”, page 219 upon com‐
pletion of repair work will be different depending on the pres‐
sure section that has been worked on.
• The allocation does not depend on the actual pressure in the
respective section.
• Example: if the actual pressure in the high-pressure section is
below 5 bar, proceed according to instructions described here
⇒ “3.1.1 High-pressure section”, page 215 .

11.2015
3.1.1 High-pressure section

The high-pressure section comprises the following:
♦ all gas-conducting components from filler neck to (and includ‐
ing) pressure regulator.
♦ All components that belong to high-pressure section are
marked »blue« in illustration.
1 - Natural gas tank

❑ Different types/versions
possible: made of steel
or fibre-reinforced com‐
posite
2 - Tank shut-off valve with sol‐
enoid valve
❑ Different amount de‐
pending on type and ve‐
hicle model
3 - High-pressure line
4 - Natural gas tank
❑ Different types/versions
possible: made of steel
or fibre-reinforced com‐
posite wage
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5 - Tank shut-off valve with sol‐ byV ua
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enoid valve ir se tee
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❑ Different amount de‐ ss
a ac
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7 - Connecting piece
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Note
spec
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Different designs possible depend‐
ing on vehicle type
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❑ Connecting piece with

2 connections
l purpos
❑ T-piece design
❑ Cross-piece design
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8 - Filling connection with filler

m
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line
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10 - Pressure regulator
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❑ Pressure regulator serves as transition between yi

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♦ high-pressure section and t. C rig
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♦ low-pressure section
co lksw
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Prote AG.
3. Checking natural gas supply system for leaks 215

11.2015
Necessary leakage test
DANGER!

ural gas.
– After working on high-pressure section, perform leakage test

according to manufacturer specifications ⇒ Maintenance ;
tion of natural gas tanks for corrosion and leakage test .
3.1.2 low-pressure section

The low-pressure section comprises all gas-conducting compo‐
nents from the pressure regulator and up to the gas injection
valves »green«
– After working on high-
pressure section, per‐
form leakage test ac‐
cording to manufacturer
specifications ⇒ Mainte‐
nance ; Booklet 35.1 ;
Description of work;
Performing visual in‐
spection of natural gas
tanks for corrosion and
leakage test . agen
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❑ (High-pressure section) byV gu
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10 - Pressure regulator aut
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– After working on high-
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form leakage test ac‐

y li
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ab
cording to manufacturer
pe
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specifications ⇒ Mainte‐
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nance ; Booklet 35.1 ;

h re
Description of work;
hole
spec
Performing visual in‐

es, in part or in w
spection of natural gas

t to the co
tanks for corrosion and

leakage test .
❑ Pressure regulator
rrectness of i
serves as transition be‐

tween
l purpos
♦ high-pressure section and

nform
ercia
♦ low-pressure section
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Cop py
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216
cted agen
Prote AG.
Rep. gr.24 - Mixture preparation - injection
11.2015
11 - Low-pressure line
Note
If the low-pressure line is detached

or renewed, an additional leakage
test will be necessary at the union
nut of the high-pressure line -9- on
the pressure regulator -10-.
12 - Gas rail with gas injection valves and pressure and temperature sender
13 - Intake manifold
Necessary leakage test
DANGER!

ural gas.
– After working on low pressure section, perform leakage test.

⇒ “3.5.2 Checking gas system for leaks after working on the
low-pressure section”, page 222
3.2 Determining pressure in gas system

Read system pressure using respective function ⇒ Vehicle diag‐
nostic tester gen AG
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d a oes
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Special tools and workshop equipment
db
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♦ Diagnosis system VCI, Win7
ut - VAS 6150C-
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– Switch ignition on.
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– Connect vehicle diagnostic tester , and start self-diagnosis.

an
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Basic characteristics of vehi-

y li
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cle
ab
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– Select engine code BSX , and confirm.

wit
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–
hole
⇒ 01 Engine electronics
spec
Measured val-
ues
es, in part or in w
t to the co
– MWB 187.2
• Further procedure depends on the determined system pres‐

rrectness of i
sure; allocation
l purpos
3.3 Determining operating mode of natural

nform
ercia
gas vehicles
m
at
om
Natural gas operating mode indicator in dash panel insert

ion
c
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or
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ate
do
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Note
p
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The type of indicator may vary depending on the vehicle type and
yi Co
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model year.
C py
t. rig
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217
Prote AG.
3. Checking natural gas supply system for leaks
11.2015
– Start vehicle, and ensure that natural gas mode is indicated in

dash panel insert.
The vehicle is in natural gas mode if:
• The natural gas mode is indicated by the symbol -1- in the left
fuel gauge.
• »CNG consumption« and »kg/h« is displayed in the multi-
function display in area -2-.
3.4 Activating/deactivating natural gas

mode
♦ Hand wheel - T50026-
AG. Volkswagen AG d
agen oes
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♦ Vehicle diagnosis, testing and information system - VAS

nl
pt
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5051B-
an
itte
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ab
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spec
es, in part or in w
t to the co
rrectness of i
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nf
• The fuel tank must be run empty, provided that the vehicle is
ercia
fully functional and fit for the road.

rm
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218
AG.
AG. Volkswagen AG d
agen oes
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Passat
d byV 2006 ➤ , Passat 2011 ➤ , tPassat
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e
4-cylinder direct-injection
oris engine (1.4 l, natural gas, EA 111, turbocharger,
nte
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th or
s au ac 11.2015
s
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Deactivating natural gas mode
an
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Note
wit
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When the gauge for natural gas shows “Tank empty”
spec
⇒ page 217 , and the engine control unit has switched to petrol
t to the co
mode, there is still a pressure of about 12 bar in the high-pressure
section of the natural gas system.
rrectne
– Activate »Petrol mode« using function Release pressure in
natural gas high-pressure line ⇒ Vehicle diagnostic
s
tester.
s o
cial p
f inform
DANGER!
mer
atio
om
n
c
i
or
n
ural gas.
thi
te
sd
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pr
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fo
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t.
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Risk of explosion leading to serious injuries or death. C py
ht. rig
rig ht
by
• Check natural gas system for leaks. copy Vo
by lksw
cted agen
Prote AG.
– Close fuel tank shut-off valve -N361- , -N362- , -N363- and -

N429- using handwheel - T50026- or suitable wrench (SW 5)
(depending on valve version).
– Pull relay for gas shut-off valves - J908- out of relay carrier.
Activating natural gas mode
– Insert relay for gas shut-off valves - J908- into relay carrier.
– Open fuel tank shut-off valve -N361- , -N362- , -N363- and -
N429- using handwheel - T50026- or suitable wrench (SW 5)
(depending on valve version).
– Resume function Release pressure in natural gas
high-pressure line ⇒ Vehicle diagnostic tester to activate
natural gas system.
DANGER!

ural gas.
• Scope of the leakage test depends on the pressure section

⇒ “3.1 Different pressure sections of natural gas supply sys‐
tem”, page 214 which has been worked on.
3.5 Checking gas system for leaks

– Determine pressure in natural gas system.
⇒ “3.2 Determining pressure in gas system”, page 217

11.2015
Test prerequisites
• If the actual pressure does not equal the required minimum
pressure (of approx. 5 bar), refuel the vehicle.
• The natural gas tanks must be filled up to maximum pressure.
• However, the fill level after filling must be ≥ 160 bar (80%).
• In order to avoid uncontrolled escape of natural gas after re‐
fuelling and before leakage test, pull relay for gas shut-off
valves - J908- out of relay carrier.
Note
♦ The gas shut-off valves are closed electrically upon pulling out
the relay for gas shut-off valves - J908- . The gas system can
still be filled.
♦ This will deactivate the gas system and it prevents the leakage
of larger amounts of gas through any possible leaks after the
gas system has been filled. en AG. V
olkswagen AG
ag does
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– Drive to the petrol station in petrol ed mode.
b ara
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After refuelling au ra
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ss
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– Drive back to the workshop in petrol mode.
e
nl
pt
du
an
itte
– Before driving the vehicle into the workshop, reactivate natural
y li
erm
ab
gas mode by inserting the relay for gas shut-off valves - J908-
ility
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into the relay carrier.
wit
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spec
Note
es, in part or in w
t to the co
♦ The fuel tank shut-off valves will be activated for only two sec‐
onds after the ignition has been switched on.
rrectness of i
♦ During the activation, a mechanical »clicking« noise can be

heard.
l purpos
♦ During activation of the fuel tank shut-off valves , pay particular

attention to noises coming from leaking gas in the section be‐
nform
ercia
ing repaired.
m
at
om
♦ If the injectors are not activated, perform an adaption drive to

on
c
in t
activate the gas system.

or
his
ate
♦ To ensure successful results from the adaption drive, the en‐

do
priv
gine must repeatedly be operated with partial load during the

um
for
en
g
drive.
n
t.
yi Co
op py
♦ To check whether the natural gas system has been activated
t. C rig
gh ht
yri
successfully, consult the fuel gauge of the natural gas system p by
co Vo
⇒ page 217
by lksw
cted agen
Prote AG.
• Before driving the vehicle into the workshop, check if any noise
from leaking gas can be heard.

11.2015
If noise can be heard:
DANGER!

ural gas.
G. Volkswagen AG d
• Do not perform any kind of work on the natural gaslksystem
swa
gen A oes
not
if noises from leaking gas can be heard. db
y Vo gu
ara
ise nte
• If such noises can be heard, do not drive
ut
hothe vehicle into
r eo
the workshop. a ra
ss c
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e
• Park the vehicle outside, and set up a safety area.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Set up a safety area, and observe safety precautions
wit
, is n
h re
tem”, page 4 .
hole
spec
– Set the petrol mode using the function Release pressure in
es, in part or in w
t to the co
natural gas high-pressure line ⇒ Vehicle diagnostic
tester.
rrectness of i
– Wait until no noise from escaping gas can be heard.
l purpos
If no noise from escaping gas can be heard:

– Drive the vehicle into the workshop.
nf
ercia
o
– Loosen all threaded connections already loosened during re‐
rm
m
pair work, and tighten them according to specifications.
atio
om
n in
c
– Drive vehicle out of workshop.

or
thi
te
sd
a
– Deactivate petrol mode using function Release pressure in

iv
o
r
rp
natural gas high-pressure line ⇒ Vehicle diagnostic cu

o
m
f
en
ng
tester.
t.
yi Co
Cop py
– Check if noise from escaping gas can be heard.
t. rig
gh ht
pyri by
Vo
o
If no noise can be heard: by c lksw
cted agen
Prote AG.
– Drive the vehicle into the workshop.
– Perform leakage test necessary after working on the high-
pressure section ⇒ page 222 , or the leakage test necessary
after working on the low-pressure section
⇒ “3.5.2 Checking gas system for leaks after working on the
low-pressure section”, page 222 .

11.2015 . Volkswage AG n AG d
agen oes
olksw not
3.5.1 Checking gas system for leaks after ise
db
yV gu
ara
nte
working on the high-pressure section
r
tho eo
s au ra
c
s
ce
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nl
pt
DANGER!
du
an
itte
y li
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ural gas.
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Test pressure: 160 - 200 bar
• A leakage test according to manufacturer specifications
nform
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⇒ Maintenance ; Booklet 35.1 ; Description of work; Perform‐

ing visual inspection of gas tanks for corrosion and leakage
m
at
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i
test must be performed at max. system pressure of 200 bar.
on
c
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or
• Not all filling systems are capable of pressurising the gas sys‐
his
ate
tem up to the maximum pressure.
do
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The vehicle must not be delivered to the customer without a leak‐
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3.5.2 Checking gas system for leaks after
cted agen
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working on the low-pressure section

♦ Gas leak tester for natural gas vehicles - VAS 6227-
♦ Leak detector spray (commercially available)
Note
♦ The test »Checking gas system for leaks after working on the
low-pressure section« does not replace the »Leakage test ac‐
cording to manufacturer specifications« which must be per‐
formed according to the maintenance schedule.
♦ Any work including leakage tests on the natural gas system
must be performed only by specially trained personnel.
♦ Check the gas system for leaks if gas-conducting components
in the low-pressure section have been loosened or renewed
⇒ “3.1.2 low-pressure section”, page 216 .

AG. Volkswagen
11.2015
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Test prerequisites: ed by V ua
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• Test pressure:au5 bar in low-pressure section, 160 - 200 bar ate or a
tho
transition between
ss low-pressure section and high-pressure c
section ⇒ “3.1.2 low-pressure section”, page 216
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• Activating the system guarantees that the required minimum
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pressure of 5 bar is attained.
ility
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wit
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hole
spec
• All screwed connections tightened to specifications.
es, in part or in w
t to the co
If shut-off valves have been closed electrically or mechanically
beforehand:
rrectness of i
– Reinsert relay for gas shut-off valves - J908- .
l purpos
– Open shut-off valves -N361- , -N362- , -N363- or -N429- , de‐

pending on type and version.
nf
ercia
– Reactivate natural gas system
or
⇒ “3.4 Activating/deactivating natural gas mode”, page 218 .
m
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n in
or c
DANGER!
thi
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Risk of explosion and danger to life due to sources of ignition
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♦ Escaping natural gas may ignite and cause an explosion. t. C rig
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♦ Risk of explosion leading to serious injuries or death.
co Vo
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Prote AG.
• Always make sure there are no possible sources of igni‐
tion close to the natural gas system.
• Observe safety instructions

tem”, page 4
Note
♦ The gas leak detector can only be used to find out whether
there is any gas in the surrounding air.
♦ Any other result than a green LED for »O. K.« is not permitted
on the gas leak detector. If a yellow or red LED lights up, a
leak detection spray must be used to obtain clear proof of
whether gas is really escaping from the vehicle's natural gas
system or not. When leak detection spray is being used, it must
be ensured that no bubbles come out of the sprayed area
within a testing time of 3 minutes. Any leaks that occur must
be repaired, and the test must then be repeated.
Procedure
– Read system pressure using ⇒ Vehicle diagnostic tester
⇒ “3.2 Determining pressure in gas system”, page 217 .
– All connections and components which have been opened or
exchanged, must be checked with gas leak tester for natural
gas vehicles - VAS 6227- and leak detector spray.
– Guide the gas leak tester around the point to be tested (»repair
area«), and take measurements every 90° for at least 5 sec‐
onds.

11.2015
. Volkswagen AG
a gen AG does
– Spray the respective connection or component Vol with leak de‐
ksw not
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tector spray, and observe approx. 3 minutes.
ed Ensure that there
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are no bubbles. tho
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• If the leakage test does not detectssa concentration of natural c
ce
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gas and consequently no gas leak, the vehicle can be taken
nl
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into operation.
an
itte
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• If the leakage test detects a gas leak, the cause of fault must
ility
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carried out again.
h re
hole
spec
• The vehicle must not be delivered to the customer without a
es, in part or in w
leakage test performed successfully.
t to the co
rrectness of i
l purpos
nform
mercia
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ion
c
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or
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ate
do
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Cop py
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by
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n AG. Volkswagen AG
lkswage Passat 2006 ➤ d,oPassat
es n 2011 ➤ , Passat Variant 2011 ➤ , Touran 2003 ➤
4-cylinder ddirect-injection
by
Vo engine (1.4 l, natural
ot g
uagas, EA 111, turbocharger, supercharger) - Edition
ran
ho
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tee 11.2015
ut or
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4 Gas injectors
un
pt
an
d
itte
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⇒ “4.1 Removing and installing gas rail with gas injectors N366 ,
erm
ab
ility
N367 , N368 , N369 ”, page 225
ot p
wit
is n
4.1 Removing and installing gas rail with
h re
ole,
spec
gas injectors -N366- , -N367- , -N368- ,
t to the co
-N369-
rrectne
DANGER!
ss o
cial p
f i
tem”, page 4 !!!
nform
mer
atio
om
n
c
i
or
n thi
WARNING
te
sd
iva
o
pr
cum
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fo
en
ng

t.
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Cop py
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pyri by
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c by lksw
cted agen
Prote AG.
Removing
pressure line .
rection of -arrow-.
– Remove securing bolts -1-.
4. Gas injectors 225

11.2015
– Carefully loosen union nut -2- and allow residual gas to es‐
cape.
– Detach spring-type clips and pull off hose -4- on activated
charcoal filter system solenoid valve 1 - N80- and pressure
pipe -5-.
– Unscrew securing bolt for pressure pipe -5- on turbocharger
and pull pressure pipe off.
– Pull off all connectors and hose connections on intake con‐
necting pipe -3- and regulating flap control unit - J808- .
– Unscrew intake connecting pipe securing bolts -arrows- and

pull intake connecting pipe upwards with regulating flap con‐
trol unit - J808- .
AG. Volkswagen AG d
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Prote AG.

11.2015
– Pull connector -2- off gas rail sensor - G401- .

– Pull connector -3- off gas injector and remove securing bolts
-1-.
– Remove gas rail together with gas injectors.
Installing
note the following:
– Ensure that retaining clips are seated properly.
– Position fuel rail with gas injectors on intake manifold and
press it in evenly.
Note

ingly.
WARNING

injuries or death.
sure section which has been worked
gen AG
. Volkswaon.
gen AG
a does
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Note the following
db
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Allocation:
ss
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un
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page 214
d
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ab

pe
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ot
wit
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wheel - T50026- .
h re
hole
spec

es, in part or in w

t to the co
page 214
Specified torques:
rrectness of i
Component Specified tor‐

l purpos
que
Securing bolts to bracket 8 Nm
nform
ercia
Low-pressure line to gas rail union (counterhold 5 Nm + turn

m
on union with a spanner) 70° further

a
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tion in
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4. Gas injectors 227

11.2015
5 Gas pressure regulator

⇒ “5.1 Assembly overview - gas pressure regulator”, page 228
⇒ “5.2 Removing and installing gas pressure regulator”,
page 233
⇒ “5.3 Removing and installing tank pressure sensor G400 ”, page
238
5.1 Assembly overview - gas pressure reg‐

ulator
⇒ “5.1.1 Assembly overview - gas pressure regulator, Passat”,
page 228
⇒ “5.1.2 Assembly overview - gas pressure regulator, Touran”,
page 231
5.1.1 Assembly overview - gas pressure regulator, Passat
1 - Connector
2 - Tank pressure sensor -
G400-
❑ 20 Nm AG. Volkswagen AG d
agen
❑ Removing and installing Volksw
oes
not
gu
⇒ page 238 d by ara
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3 - Coolant hoses auth
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4 - Spring-type clips
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hose clip pliers - VAS
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ab
6340- .
ility
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❑ Specified torque for un‐
spec
ion nut: first tighten
t to the co
hand-tight and then turn
90° further.
WARNING rrectness o
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Observe screw fixture

inform
regulations for newly in‐

mer
stalled fuel lines (initial

atio
m
installation) ⇒ page 230

o
n
c
i
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The screw fixture regula‐

t
sd
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tions only apply to fuel

i
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lines that were not al‐

fo
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❑ Specified torque for un‐ cop Vo
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90° further.
7 - Securing bolt
❑ 8 Nm
8 - Securing nut
❑ 8 Nm

11.2015
9 - Bracket
10 - Bonded rubber mounting
❑ Screw on hand-tight
11 - Gas regulator with high-pressure valve for gas mode - N372-
❑ Removing and installing ⇒ page 233
12 - Pipe connection
❑ Counterhold on pipe connection when loosening fuel line.
❑ 20 Nm
❑ 20 Nm
AG. Volkswagen AG d
agen oes
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spec
t to the co
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f inform
mer
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c
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5. Gas pressure regulator 229

11.2015
Note
The screw fixture regulations only apply to fuel lines that were not
already installed.
Screw fixture regulations for newly installed fuel lines (initial in‐
stallation)
The production date for fuel lines is engraved as a code -arrow-
on the lines.
♦ Up to and including production date »10E« -arrow- union nuts
on fuel lines are first tightened hand-tight, then tightened by
turning 90° further.
♦ From production date »10F« -arrow- union nuts on fuel lines
are first tightened hand-tight, then tightened by turning 180°
further.
♦ As of production month July 2010, the identification has been
changed; refer to the list below ⇒ page 230
AG. Volkswagen AG d
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or
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Cop py
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11.2015
Identification of production date

M Year
on
th
2010 2011 2012 2013 2014 2015
Ja 10A BA CA DA EA l wage
ksFA es n
Vo ot
nu (AA) ed
by gu
ara
ar thoris nte
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y au ra
c
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Fe 10B BB CB DB EB FB
ce
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nl
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br (AB)
du
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ry
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M 10C BC CC DC EC FC
wit
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ar (AC)
hole
ch
spec
es, in part or in w
Ap 10D BD CD DD ED FD
t to the co
ril (AD)
M 10E BE CE DE EE FE
rrectness of i
ay (AE)
Ju 10F BF CF DF EF FF
l purpos
ne (AF)
Ju AG BG CG DG EG FG
nf
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ly (10G)
rm
m
atio
Au AH BH CH DH EH FH
om
n in
gu (10H)
or c
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thi
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Se AJ (10J) BJ CJ DJ EJ FJ
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O AK BK CK DK EK FK
AG.
ct (10K)
ob
er
N AL (10L) BL CL DL EL FL
ov
e
m
be
r
D AM BM CM DM EM FM
ec (10M)
e
m
be
r
5.1.2 Assembly overview - gas pressure regulator, Touran

11.2015
1 - Connector
2 - Tank pressure sensor -
G400-
⇒ page 240
3 - Coolant hoses
4 - Spring-type clips
hose clip pliers - VAS
6340- .
90° further.
WARNING
On fuel lines that are
newly installed (initial in‐
stallation), union nuts
should first be tightened
hand-tight, then turned
180° further. AG. Volkswagen AG d
agen oes
lksw not
In case of repair, union by
Vo gu
ara
nuts are also first tight‐ rised
nte
ened hand-tight, then ho eo
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turned 90° further. ss c
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ility
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90° further.
is n
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ole,
7 - Securing bolt
spec
❑ 8 Nm
t to the co
8 - Securing nut
❑ 8 Nm
rrectne
9 - Bracket
ss
10 - Bonded rubber mounting

o
cial p
f in
❑ Screw on hand-tight
form
mer
11 - Bracket
atio
om
n
c
12 - Gas regulator with high-pressure valve for gas mode - N372-

i
or
n thi
te
❑ Removing and installing ⇒ page 235

sd
iva
o
pr
cum
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fo
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t.
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Co
Cop py
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❑ 20 Nm opyri
gh by
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by c lksw
14 - Pipe connection Prote
cted AG.
agen

❑ 20 Nm

11.2015
5.2 Removing and installing gas pressure

regulator
⇒ “5.2.1 Removing and installing gas pressure regulator, Passat”,
page 233
⇒ “5.2.2 Removing and installing gas pressure regulator, Touran”,
page 235
5.2.1 Removing and installing gas pressure

regulator, Passat
♦ Hose clamps up to 25 mm - 3094-

AG. Volkswagen AG d
agen oes
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es, in part or in w
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♦ Engine bung set - VAS 6122-
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
thi
te
sd
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op py
Removing t. C rig
gh ht
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– Observe safety precautions ⇒ page 3 .
op Vo
by c lksw
cted agen
Prote AG.
– Observe rules for cleanliness ⇒ page 9 .
– Observe safety precautions when working on natural gas sys‐
tem ⇒ page 4 .

11.2015
WARNING

gas system.
– Release pressure in high-pressure line ⇒ Fuel supply system

– natural gas engines; Rep. gr. 20 ; Fuel tanks; Releasing
pressure in high-pressure line .
– Detach exhaust hanger -1-, and loosen clamp -2-.
– Remove protective covers on underbody ⇒ Fuel supply agsys‐
en AG. V
olkswagen AG
does
tem – natural gas engines; Rep. gr. 20 ; Fuel tank; olksw
Assembly not
y V gu
overview - protective covers . isedb ara
n r tee
ho
aut or
ac
ss
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le
un
pt
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itte
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ab
ility
ot p
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ole,
– Close mechanical shut-off valves -1- and -2- using handwheel
spec
- T50026- .
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Close mechanical shut-off valve -1- using handwheel -

i
o
pr
cum
r
T50026- .
fo
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ng
t.
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– Release and unplug connectors -1-. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

11.2015
– Open clamps, and pull off coolant hoses.

– Clamp off coolant hoses -2- with hose clips up to 25 mm -
3094- .
WARNING
Risk of scalding! Allow engine to cool before pulling off coolant

hoses.
– Unbolt low-pressure line -4- and high-pressure line -3- from

gas pressure regulator (counterhold on union with an open-
end wrench).
– Immediately seal open connections with suitable plugs from
engine bung set - VAS 6122- .
– Unscrew securing bolts and nuts -arrows- from bracket.

Installing
WARNING
Observe screw fixture regulations for newly installed fuel lines

(initial installation) ⇒ page 230
The screw fixture regulations only apply to fuel lines that were
not already installed!
– Observe test prerequisites ⇒ Rep. gr. 00 ; Gas system test;

Test prerequisites for gas systems
wage
n AG..Volkswagen AG do
e ks s no
Vol t
– Perform gas system d test
by ⇒ Maintenance ; Booklet 35.1gu;aDe‐ran
scription of work; ise
rPerforming visual inspection of natural gas tee
tho
or
tanks for corrosion
s au and leakage test . ac
s
ce
le
Specified torque
un
pt
an
d
itte
♦ ⇒ “5.1.1 Assembly overview - gas pressure regulator, Passat”,

y li
rm
ab
page 228
pe
ility
ot
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♦ ⇒ Fuel supply system – natural gas engines; Rep. gr. 20 ;

, is n
h re
Fuel tank; Assembly overview - protective covers

hole
spec
es, in part or in w
5.2.2 Removing and installing gas pressure

t to the co
regulator, Touran
rrectness of i

l purpos

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

11.2015
♦ Hose clamps up to 25 mm - 3094-
AG. Volkswagen AG d
agen oes
olksw not
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♦ Handwheel - T50026-
aut
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ra
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♦ Engine bung set - VAS 6122- nform

mercia
a
com
tion in
r
te o
thi
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iva
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
tem ⇒ page 4 .

11.2015

– Remove protective covers on underbody ⇒ Fuel supply sys‐
tem – natural gas engines; Rep. gr. 20 ; Fuel tank; Assembly
overview - fuel tank .
– Release and unplug connectors -1-.

– Close mechanical shut-off valves -2- on all natural gas tanks
using hand wheel - T50026- .
WARNING

gas system.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
– Release and unplug connectors -1-. AG. Volkswagen AG d

agen oes
olksw not
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– Clamp off coolant hoses -2- with hose clips ise
dup
b to 25 mm - ara
nte
3094- . thor eo
au ra
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WARNING
un
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an
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itte
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erm
Risk of scalding! Allow engine to cool before pulling off coolant

ab
ility
hoses.
ot p
wit
is n
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ole,
spec
– Open clamps, and pull off coolant hoses.

t to the co
– Unbolt low-pressure line -4- and high-pressure line -3- from

gas pressure regulator.
– Counterhold on union with open-end wrench while doing so.
rrectne

s

s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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11.2015 gen AG
. Volkswagen AG
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– Unscrew securing bolts and nuts -arrows-isefrom
d b bracket. ara
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Installing au
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Installation is performed in the reverse order of removal.
ce
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un
pt
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itte
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ab
WARNING
pe
ility
ot
wit
On fuel lines that are newly installed (initial installation), union , is n
h re
nuts should first be tightened hand-tight, then turned 180° fur‐
hole
spec
ther.
es, in part or in w
t to the co
In case of repair, union nuts are also first tightened hand-tight,
then turned 90° further.
rrectness of i
– Observe test prerequisites ⇒ Rep. gr. 00 ; Gas system test;
l purpos
Test prerequisites for gas systems .
nform
ercia
– Perform gas system test ⇒ Maintenance ; Booklet 35.1 ; De‐

scription of work; Performing visual inspection of natural gas
m
a
com
tion in
r
Specified torques
te o
thi
s
iva
do
♦ ⇒ page 228
r
rp
cum
fo
en
ng
t.
yi Co
Fuel tank; Assembly overview - fuel tank t. Cop py
rig
gh ht
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview yri
p by
o Vo
- silencers
c by lksw
cted agen
Prote AG.
5.3 Removing and installing tank pressure

sensor - G400-
⇒ “5.3.1 Removing and installing tank pressure sensor G400 ,
Passat”, page 238
⇒ “5.3.2 Removing and installing tank pressure sensor G400 ,
Touran”, page 240
5.3.1 Removing and installing tank pressure

sensor - G400- , Passat

11.2015
♦ Engine bung set - VAS 6122-
Removing
tem ⇒ page 4 . wage
e
olks s no
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gas system.
pt
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– natural gas engines; Rep. gr. 20 ; Fuel tanks; Releasing h re

hole
spec
es, in part or in w

t to the co

– Remove protective covers on underbody ⇒ Fuel supply sys‐
rrectness of i
tem – natural gas engines; Rep. gr. 20 ; Fuel tank; Assembly

l purpos
overview - protective covers .

nform
mercia
at
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– Close mechanical shut-off valves -1- and -2- using handwheel

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Prote AG.

11.2015
– Close mechanical shut-off valve -1- using handwheel -

T50026- .
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spec
Unscrew sensor -2-.
es, in part or in w
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l purpos

Specified torque
nform
ercia
♦ ⇒ “5.1.1 Assembly overview - gas pressure regulator, Passat”,

m
a
page 228
com
tion in
r

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Fuel tank; Assembly overview - protective covers
s
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en
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sensor - G400- , Touran
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♦ Handwheel - T50026-

11.2015

Removing
tem ⇒ page 4 .
AG . Volkswagen AG
– Remove protective covers on underbody ⇒ Fuel ksw
supply
agen sys‐ does
not
l
tem – natural gas engines; Rep. gr. 20 ; Fuel
by tank; Assembly
Vo gu
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overview - fuel tank . ris
ed
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es, in part or in w
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– Close mechanical shut-off valves -2- on all natural gas tanks
using hand wheel - T50026- .
rrectness of i
WARNING
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gas system.
nf
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
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Disconnecting and reconnecting battery .

t.
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– Release and disconnect connector -1- from tank pressure pyri by
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sensor - G400- .
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Unscrew sensor -2- from gas pressure regulator.
Installing
Specified torques
♦ ⇒ page 228
Fuel tank; Assembly overview - fuel tank

11.2015
6 Air filter
⇒ “6.1 Assembly overview - air filter housing”, page 242
⇒ “6.2 Removing and installing air filter housing”, page 243
6.1 Assembly overview - air filter housing

Removing and installing air filter
1 - Bolt
❑ 1.6 Nm
2 - Air filter upper part
3 - Vacuum hose
Caution
To prevent damage to AG. Volkswagen AG d
the connection and to the lksw
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vacuum hose, do not use d by Vo gu
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❑ From camshaft housing.
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4 - Spring-type clip
wit
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ole,
ing spring-type clip pli‐

spec
ers - VAS 5024A- .

t to the co
5 - Intake hose
6 - Cover
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7 - Intake air duct

s
8 - Air filter lower part

s o
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❑ With captive securing

inform
bolt.
mer
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❑ With intake connection.

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❑ Specified torque setting:

or
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8 Nm
t
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9 - Water drain connection

um
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❑ When installing, arrows

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on lower part of air filter
C py
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and water drain union
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must align.
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10 - O-ring
❑ Renew.
11 - Filter element

11.2015
6.2 Removing and installing air filter hous‐

ing
Removing
– Pull coolant hose upwards out of brackets -arrows-.
– Press fastener -1- and pull intake air duct cover out upwards.
– Press fastener -arrows- and pull intake air duct upwards.
AG. Volkswagen AG d
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– Release spring-type clip -1- and pull intake hose and vacuum
wit
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hose off air filter.

h re
ole,
spec
– Loosen securing bolt -2- and pull air filter housing upwards
from locating pins -arrows-.

t to the co
Installing
rrectne

– Push air filter housing onto locating pins -arrows- from above.
ss o
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mer
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– Tighten new securing bolt -2- to 8 Nm and slide spring-type

or
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clip -1- with intake hose onto air filter connection.

t
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6. Air filter 243

11.2015
7 Intake manifold
⇒ “7.2 Removing and installing upper part of intake manifold”,
page 251
page 256
and throttle valve module J338 ”, page 258
⇒ “7.5 Cleaning throttle valve module J338 ”, Vpage 260
olkswa . gen AG
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7.1 Assembly overview
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t.
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Cop py
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Prote AG.

11.2015
Part I
Note
♦ If hoses have been removed during repair, ensure that all ho‐
ses are firmly connected after reinstallation.
♦ Tug on hoses having catches to make sure they are securely
seated.
1 - Intake air temperature

sender 3 - G520- with intake
manifold pressure sender 3 -
G583-
2 - Bolt
❑ 3 Nm
3 - Bolt
❑ 7 Nm
4 - Intake connecting pipe agen
AG. Volkswagen AG d
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5 - Seal ed byV gu
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WARNING ss c
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nl
Operating
• the natural gas
pt
du
an
system without having
itte
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tested it for leaks accord‐
erm
ab
ility
ing to specifications may
ot p
wit
result in severe injuries or
, is n
h re
death.
hole
spec
The necessary scope of
es, in part or in w
t to the co
the leakage test de‐
pends on the pressure
section which has been
worked on.
rrectness of i
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Note the following allo‐

cation!
nf
ercia
orm
Allocation:
m
atio
m
⇒ “3.1 Different pressure sec‐

o
n in
c
tions of natural gas supply sys‐

or
thi
e
tem”, page 214

t
sd
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cu
❑ Renew.
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❑ Before installing, lightly coat seal with clean engine oil. Cop
yi Co
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ht. rig
6 - Regulating flap control unit - J808- rig ht
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❑ Removing and installing by c lksw
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⇒ “7.4 Removing and installing regulating flap control unit J808 and throttle valve module J338 ”,
Prote AG.
page 258 .
Note
Regulating flap control units with

plastic housing need not be adapted
to the engine control unit - J623- .
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
functions”.
7. Intake manifold 245

11.2015
7 - Bolt
❑ 7 Nm
8 - Intake connecting pipe
9 - Intake manifold connection
10 - Bolt
❑ 7 Nm
11 - Bolt
❑ 7 Nm
12 - Gas rail sensor - G401-
❑ 20 Nm
13 - Gas rail with gas injectors
WARNING
Operating
• the natural gas
death.
worked on. swage
es n
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Note the following allo‐ ir se
d ran
tee
cation! utho
or
a ac
ss
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nl
pt
Allocation: ⇒ “3.1 Different pressure sections of natural gas supply system”, page 214
du
an
itte
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erm
ab
ility
⇒ “4.1 Removing and installing gas rail with gas injectors N366 , N367 , N368 , N369 ”, page 225 .
ot p
wit
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❑ Ensure securing clips are properly seated when installing.

h re
hole
❑ Gas injector 1 - N366-

spec
es, in part or in w

t to the co

rrectness of i
l purpos
nf
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orm
m
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or c
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t.
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Cop py
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Prote AG.

11.2015
WARNING
Operating
• the natural gas
death.
worked on.
cation!
❑ Specified torque for union nut: 5 Nm + turn 70° further
15 - Bolt
❑ 3 Nm
16 - Intake manifold pressure sender - G71-
17 - O-ring
❑ Renew.
AG. Volkswagen AG d
agen
18 - Upper part of intake manifold Volksw
oes
not
gu
d by ara
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or eo
WARNING aut
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Operating
• the natural gas
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un
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d
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ot
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death.
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The necessary scope of spec

es, in part or in w
t to the co

worked on.
rrectness of i

l purpos
cation!
nform
ercia
m
a
com
❑ Removing and installing ⇒ “7.2 Removing and installing upper part of intake manifold”, page 251 .
ion in
r
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Note
s
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fo
♦ If the intake manifold was re‐

en
ng
t.
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moved, you must check that all
Co
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hoses are securely connected t. C rig
gh ht
on the intake manifold after in‐ pyri by
Vo
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stallation.
by c lksw
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♦ Tug on hoses having catches to
make sure they are securely
seated.

11.2015
❑ To remove: Removing and installing regulating flap control unit - J808- and throttle valve module - J338-
page 258
19 - Bolt
❑ 20 Nm
20 - Fuel pressure sender - G247-
❑ Checking fuel pressure in high-pressure section
⇒ “9.1 Checking fuel pressure sender G247 ”, page 268 .
❑ 22 Nm
21 - Screw-in part
❑ 80 Nm
22 - Gasket
WARNING
Operating
• the natural gas
death.
worked on.
cation!
❑ Renew.
❑ Note installation position.wagen AG. Volkswagen AG doe
ks s no
Vol t gu
23 - Lower part of intake
ed manifold
by ara
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WARNING
ss c
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un
Operating
• the natural gas
pt
an
d

itte
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rm

ab
pe
ility

ot
wit

, is n
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death.
hole
spec

es, in part or in w
t to the co

rrectness of i
worked on.
l purpos

cation!
nform
mercia
a
com
tion in
❑ Removing and installing ⇒ “7.3 Removing and installing lower part of intake manifold”, page 256 .
r
te o
thi
s
iva
24 - Bolt
do
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cum
❑ 20 Nm
fo
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t.
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Cop py
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rig ht
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248
by lksw
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Prote
AG.
11.2015
25 - Throttle valve control module - J338-

page 258 .
❑ Clean ⇒ “7.5 Cleaning throttle valve module J338 ”, page 260 .
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
functions”.
26 - Bolt
❑ 7 Nm
27 - Pressure pipe
❑ From turbocharger
28 - Retaining clip
29 - Bolt
❑ 7 Nm
Part II AG. Volkswagen AG d

agen oes
olksw not
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Note horis nte
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aut ra
ss c
♦ If hoses have been removed during repair, ensure that all ho‐
ce
e
nl
ses are firmly connected after reinstallation.
pt
du
an
itte
y li
♦ Tug on hoses having catches to make sure they are securely
erm
ab
seated.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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n in
or c
thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

11.2015
1 - Connection
2 - Activated charcoal filter sol‐
enoid valve 1 - N80-
3 - Connecting hose
4 - Connecting pipe
5 - Connecting hose
❑ To intake manifold con‐
nection.
6 - Connecting hose
7 - Connecting hose
❑ To pressure pipe.
8 - Bolt
❑ 8 Nm
9 - Fuel pipe
❑ High-pressure.
❑ Specified torque for un‐ n AG. Volkswagen AG do
ion nuts: 18 Nm. lkswage es n
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10 - Connection ir se
d ran
tee
ho
❑ To intake connecting s aut or
ac
pipe. s
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nl
pt
du
11 - Non-return valve an
itte
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❑ For crankcase ventila‐
erm
ab
ility
tion.
ot p
wit
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12 - Connecting hose
h re
hole
spec
13 - Charge pressure control

es, in part or in w
solenoid valve - N75-

t to the co
14 - Bolt
❑ 5 Nm
rrectness of i
l purpos
❑ To turbocharger.
nf
ercia
orm
❑ To vacuum unit.
m
atio
om
n in
17 - Connection
or c
thi
e
❑ For crankcase ventilation.

t
sd
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cu
❑ Connected to valve timing housing.

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t.
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Cop py
❑ For crankcase ventilation.
t. rig
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pyri by
Vo
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19 - Fuel hose
c by lksw
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Prote AG.
❑ Low-pressure.
❑ To high-pressure pump.

11.2015
7.2 Removing and installing upper part of

AG. Volkswagen AG d
agen
intake manifold by Vol
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not
gu
ara
ed nte
oris e
th or
au ac
ss
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
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nform
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m
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com
tion in
♦ Torque wrench VAS 6854
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Removing
s
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do
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fo
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DANGER!
n
t.
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Cop py
t. rig
gh ht
Removing the intake manifold opens the low-pressure section yri
p by
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of natural gas system. For this reason, a leakage test must
c by lksw
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always be performed after completion of work ⇒ Maintenance ;
Prote AG.

tion of gas tanks for corrosion and leakage test .
• Before working on the natural gas system, always observe
⇒ “2.2 Safety precautions when working on natural gas
system”, page 4 !!!
WARNING

pressure line .
– Lift engine cover panel at points -1-, and remove it in direction
of -arrow-.

11.2015
– Open connection -1- at gas rail whilst counterholding at rail

-2- with open-end spanner, »AF 16 mm«.
Note
Warning: residual gas may escape when opening! The quantity

of the escaping gas is small, and the pressure is low.
– Disconnect hoses from intake manifold.
– Loosen bolts -arrows-, and remove intake manifold.
– Open hose clamps -1- and -2-, and pull off intake hose.
AG. Volkswagen AG d
agen oes
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an
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– Pull off connectors -a- and -b-.

itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote
252
AG.
11.2015
– Loosen hose clamps -arrows-, and pull off hoses.
– Loosen bolts -1- and -2-.
AG. Volkswagen AG d
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ility
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– Pull off hoses »item 5« and »item 10«.

wit
is n
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– Also pull off hose of crankcase breather valve »item 11«.

ole,
spec
– Remove hose set, and place it to right side.

t to the co
Note
rrectne
♦ Ensure correct position of the clamp on noise insulation.

ss o
♦ The clamp must be positioned so that it is still easily accessible

cial p
f i
after installation of the intake manifolds.

nform
mer
atio
om
n
c
i
or
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te
sd
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– Open clamp -a-, and slide it in direction of -arrow-.
p by
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Prote AG.

11.2015
– Unscrew clamp »item 9«, and push charge air hose »item 10«
off throttle valve module - J338- -7-.
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t to the co
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mer
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c
i
or
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254
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Rep. gr.24 - Mixture preparation - injection cted agen
Prote AG.
11.2015
swage es n
– Unscrew 5 securing bolts -arrows- of bintake yV
olk
connecting pipe. ot g
ua
d ran
ir se
– Pull pressure sender connector toff h gas rail. Disconnect all re‐
o tee
or
maining hoses still connectedss ato
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intake connecting pipe. ac
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un
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an
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itte
Note
y li
rm
ab
pe
ility
The intake connecting pipe can now be removed upwards.
ot
wit
, is n
h re
hole
– Disconnect connector of intake manifold pressure sender -
spec
G71- .
es, in part or in w
t to the co
– Loosen and unscrew 6 securing bolts for upper part of intake
manifold ⇒ Item 24 (page 248) .
rrectness of i
Installing
l purpos

note the following:
nform
ercia
♦ The charge air hose should not be reinstalled to the throttle

valve module before the intake connecting pipe has been se‐
m
a
com
ti
cured at its 5 securing points.
on in
r
te o
thi
♦ Seals and O-rings must be renewed and coated lightly with
s
iva
clean engine oil before installing.
do
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cum
fo
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t.
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Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
Note
WARNING

injuries or death.
Allocation:
page 214
wheel - T50026- .
page 214
Specified torque:
♦ Securing bolts

11.2015
7.3 Removing and installing lower part of in‐

take manifold
DANGER!

tem”, page 4 !!!
WARNING

pressure line .
Caution
If only lower part of intake manifold is to be removed, ensure

injectors remain in cylinder head.
To remove, use hold-down device - T10510- .
Reason: if injectors have been removed, they must be re‐
newed.
– Remove regulating flap control unit - J808- with throttle valve

module - J338-
and throttle valve module J338 ”, page 258 . Volkswag AG. en AG
agen does
– Remove intake manifold yV
olks
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⇒ “7.1 Assembly overview - intakeisemanifold”, page 244 .
d b ara
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r
ho eo
To remove and install securing bolt
sa
ut -arrow-, use holder for bits ra
c
with 5/16'' drive - V.A.G 1766/2-s and special wrench, long reach
ce
le
- 3320/2- .
un
pt
an
d
itte
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Removing
rm
ab
pe
ility
– Insert hold-down device - T10510- in the two holes on cylinder

ot
wit
head.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
t. rig
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256
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Prote
AG.
11.2015
– Push pin -1- in direction of -arrow- until hold-down device is

securely seated on injectors.
– Tighten knurled nuts -1- and -2- hand-tight.
– Pull lower part of intake manifold evenly off injectors.
Installing
– Fit new gasket on cylinder head.
Note
Renew the injector seals before installing the lower part of intake
manifold ⇒ “2.4 Renewing seal on injector”, page 211 !
– Press lower part of intake manifold evenly onto injectors.

– Remove hold-down device - T10510- .
lkswage Note es n
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byV ua
d ran
ir se
On renewal,th erase learnt values and adapt intake manifold
o tee flap
or
potentiometer
ss
au
- G336- to engine control unit - J623- ⇒ Vehicleac
diagnostic tester “Guided functions”.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
Note
ot p
wit
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hole
spec
es, in part or in w
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WARNING
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Allocation:
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page 214
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page 214
Specified torque:
♦ Securing bolts

11.2015
7.4 Removing and installing regulating flap

control unit - J808- and throttle valve
wage
module - J338- by
Volks es n
ot g
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ris
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Note ss
ac
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To remove throttle valve module - J338- , regulating flap control
an
itte
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unit - J808- must first be removed.
erm
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ility
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hole
spec
es, in part or in w
t to the co
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nform
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at
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ion
c
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or
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ate
do
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cum
for
en
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t.
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t. rig
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pyri by
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by
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Removing regulating flap control unit - J808-

rection of -arrow-.

AG. Volkswagen AG d
4-cylinder direct-injection engine (1.4 l, natural gas, EA 111, ksw
turbocharger,
agen supercharger)
oes
not
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ol
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d ar an
e
ris tee
ho
– Remove securing bolts -1-. au
t or
ac
ss
– Detach spring-type clips and pull off hose -2- on activated
ce
le
un
pt
charcoal filter system solenoid valve 1 - N80- and pressure
an
d
itte
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pipe -3-.
erm
ab
ility
ot p
– Unscrew securing bolt for pressure pipe -3- on turbocharger
wit
is n
and pull pressure pipe -3- off.
h re
ole,
– Pull off all connectors and hose connections on intake con‐
spec
necting pipe -4- and regulating flap control unit - J808- .
t to the co
rrectne
– Unscrew intake connecting pipe securing bolts -arrows- and
ss
pull intake connecting pipe upwards with regulating flap con‐
o
cial p
f
trol unit - J808- .
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew securing bolts -arrows-.
Removing throttle valve module - J338-
– Detach coolant hose -1- from hose clips.
– Pull connector -2- off intake air temperature sender 3 - G520-

with intake manifold pressure sender 3 - G583- .
– Remove charge air hose -3- from throttle valve module - J338-
and charge air pipe.

11.2015
– Unscrew securing bolts -arrows- and pull throttle valve module

- J338- from intake manifold connection.
Installing
note the following:
♦ Seals and O-rings must be renewed and coated lightly with
clean engine oil before installing.

If a new regulating flap control unit or throttle valve module has
been installed:
– Erase learnt values and adapt engine control unit - J623- to
regulating flap control unit and throttle valve module ⇒ Vehicle
diagnostic tester “Guided functions”.
Note
Regulating flap control units with plastic housing need not be

adapted to the engine control unit - J623- .
Specified torques:
♦ Assembly overview - part I, intake manifold
⇒ “7.1 Assembly overview - intake manifold”, page 244 . n AG. Volkswagen AG do
lkswage es n
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7.5 Cleaning throttle valve module - J338- d b ran
ir se tee
tho
u or
a ac
ss
ce
le
Note
un
pt
an
d
itte
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erm
♦ If a new engine control unit - J623- is installed the throttle valve ab

ility
module must be adjusted. Adaptation must be performed only
ot p
wit
with a new or cleaned throttle valve module, because soiling
is n
h re
or coking at the end stop of the throttle valve can lead to in‐
ole,
spec
correct adaptation values.

t to the co
♦ When cleaning the throttle valve housing it must not be

scratched.
rrectne

ss
– Remove throttle valve module

o
cial p

inform

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

11.2015
– Open throttle valve by hand and lock in open position using a

suitable object (e.g. wood or plastic wedge) -arrow-.
WARNING
Acetone is highly inflammable. Please observe the accidental

regulations and safety notes when handling with highly inflam‐
mable fluids. Do not use compressed air when cleaning the
throttle valve. Wear eye protection and protective clothing to
avoid possible injury and skin contact.
– Thoroughly clean throttle valve housing, especially around the

closed throttle valve -arrows- using commercially available
acetone according to DIN 53247 and a brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely, and reinstall throttle
valve module after cleaning
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
tions”.
AG. Volkswagen AG d
agen oes
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ara
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ris nte
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un
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an
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ab
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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c
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11.2015
8 High-pressure pump
⇒ “8.1 Assembly overview - high-pressure pump”, page 262
⇒ “8.2 Removing and installing high-pressure pump”, page 263
8.1 Assembly overview - high-pressure yV
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pump d b ua
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WARNING
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The injection system consists of a high-pressure section (max‐
erm
ab
imum approx. 120 bar) and a low-pressure section (approx. 6
ility
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bar).
wit
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Prior to opening the high-pressure area, e.g. when removing
hole
spec
the high-pressure pump, fuel rail, injectors, a fuel line, or the
es, in part or in w
fuel pressure sender - G247- , the fuel pressure in the high-
t to the co
pressure area must be reduced to a residual pressure of
approx. 6 bar. The appropriate procedure is described in chap‐
ter ⇒ “2.2 Releasing high pressure in fuel system”, page 207 .
rrectness of i
l purpos
1 - Roller tappet
nform
ercia
❑ Lightly coat with engine

m
at
oil when installing.
om
ion
c
in t
2 - O-ring
or
his
ate
❑ Renew.
do
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❑ Lightly coat with engine
for
en
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oil when installing.

n
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3 - High-pressure pump with
t. rig
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fuel pressure regulating valve -
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cted AG.
agen
Caution
Only grasp high-pres‐
sure pump on housing
when removing and in‐
stalling!
When the high-pressure
piston spring package
loosens the high-pres‐
sure pump will leak and
must be replaced.
4 - Bolt
❑ Tighten bolts evenly.
❑ 20 Nm
5 - Connection
❑ High-pressure.
6 - Union nut
❑ Observe safety precau‐
tions
⇒ “2.1 Safety precau‐
tions when working on
fuel supply system”,
page 3 .

11.2015
❑ Counterhold when loosening connection to high-pressure pump.
AG. Volkswagen AG d
❑ 18 Nm swagen oes
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7 - Fuel hose rise nte
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❑ Low-pressure. s au ra
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❑ With spring-type clip.
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8 - Connection
itte
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❑ Low-pressure. pe
ility
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8.2 Removing and installing high-pressure
es, in part or in w
pump
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
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Cop py
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by
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♦ Hose clip pliers - VAS 6340- Prote AG.
Removing
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3 .
Observe rules for cleanliness
⇒ “3.1 Rules for cleanliness”, page 9 .
8. High-pressure pump 263

11.2015
rection of -arrow-.
WARNING

bar).
the high-pressure pump, fuel rail, injectors, a fueleline, orolkthe
AG. V swagen AG
fuel pressure sender - G247- , the fuel pressure ag n
ksw in the high-
does
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pressure area must be reduced to a dresidualby
V pressure of gu
ara
approx. 6 bar. The appropriate procedure
oris is described in chap‐
e nte
eo
ter ⇒ “2.2 Releasing high pressureauin
th fuel system”, page 207 . ra
css
ce
e
nl
pt
du
an
itte
y li
– Separate fuel supply line -arrow-.
erm
ab
ility
ot p
– Remove intake connecting pipe ⇒ Item 8 (page 246) .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Pull connector and fuel supply line -arrows- off high-pressure
m
atio
m
pump.
o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
yi
Catch escaping fuel in a cloth.
Co
Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

11.2015
– Remove wiring guide -2- and take clip -4- off high-pressure
line.
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must beoreplaced.
lkswa
AG. V gen AG
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– Loosen union nuts -3-oris and -1- of high-pressure line.
e nte
h eo
aut ra
s c
– Evenly unscrews securing bolts -arrows-.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Pull high-pressure pump -3- and roller tappet -1- out of cam‐
o
cial p
f i
shaft housing.
nform
mer
Installing
atio
om

c
i
or
n thi
note the following:

te
sd
iva
o
pr
cum
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fo
en
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Note
t.
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♦ Moisten high-pressure pump roller tappet with clean engine
gh ht
pyri by
oil.
o Vo
by c lksw
cted agen
Prote AG.
♦ The high-pressure pump O-ring must be renewed.
– Slide roller tappet -1- into camshaft housing.

11.2015
– Insert new, lubricated O-ring -2- in groove of high-pressure

pump -3-.
– Place high-pressure pump -3- onto camshaft housing.
– Screw in securing bolts -arrows- by hand until bolt heads are

seated on flange.
– Tighten securing bolts -arrows- evenly until flange is seated
on camshaft housing.
– Tighten securing bolts to specified torque ⇒ page 267 .
AG. Volkswagen AG d
agen oes
ksw
– Tighten union nuts by V of high-pressure line -1- and -3-
ol not
guhand-tight.
ara
d
ise nte
– Install wiring
thor guide -2- and fit clip -4- on high-pressure line.
eo
au ra
s c
Tighten securing
s bolt for cable guide to specified torque
ce
le
⇒ page 267 .
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
Use a spanner to counterhold threaded connections on high-

hole
spec
pressure pump and on lower part of intake manifold when tight‐

es, in part or in w
ening union nuts.

t to the co
– Tighten union nuts -1- and -3- of high-pressure line to specified

rrectness of i
torque ⇒ page 267 .

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

11.2015
– Secure fuel supply line and connector -arrows- on high-pres‐

sure pump.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
– Reconnect fuel supply line -arrow-.
ot
wit
, is n
h re
– Install intake connecting pipe and air filter
hole
spec
es, in part or in w
t to the co
Specified torques:
rrectness of i
Securing bolts for high-pressure 20 Nm
pump
l purpos
Securing bolt for cable guide 8 Nm
nform
ercia
Union nuts for high-pressure lines 18 Nm

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

11.2015
9 Senders and sensors

⇒ “9.1 Checking fuel pressure sender G247 ”, page 268
9.1 Checking fuel pressure sender - G247-

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
♦ Double hexagon
ss
au
socket, 1/2", 27 mm - VAS 5301/7- ac ce
le
♦ Digital pressure gauge - VAS 6394/1-

un
pt
an
d
itte
y li
♦ Test adapter - VAS 5570-

erm
ab
ility
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wit
is n
WARNING
h re
ole,
spec


t to the co
bar).
rrectne
the high-pressure pump, fuel rail, injectors, a fuel line, or the

fuel pressure sender - G247- , the fuel pressure in the high-
pressure area must be reduced to a residual pressure of
ss o
approx. 6 bar. The appropriate procedure is described in chap‐

cial p
f in
ter ⇒ “2.2 Releasing high pressure in fuel system”, page 207 .

form
mer
atio
om
n
c
Procedure
i
or
n thi
te
sd
a
iv
o
r
rection of -arrow-.
p
cum
r
fo
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.2015
– Remove fuel pressure sender - G247- -1-.
– Instead of fuel pressure sender - G247- , screw in adapter -

6394/2- and tighten to 22 Nm.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
– Open cover -2- of risedigital pressure gauge - VAS 6394/1- and
d
nte
tighten fuel pressure
utho
sender - G247- to digital pressure gauge eo
ra
to 22 Nm. ss a c
ce
le
un
– Screw pressure line -1- of digital pressure gauge - VAS

pt
an
d
6394/1- hand-tight to adapter - 6394/2- .

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Connect test adapter - VAS 5570- between fuel pressure

sender - G247- -1- and connector.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Senders and sensors 269

11.2015
– Connect vehicle diagnosis, testing and information system -

VAS 5051B- -1- as follows:
– Push diagnostic cable connector -2- onto diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
– Press following keys on display in succession:
Vehicle self-diagnosis
Vehicle self-diagnosis
01 - Engine electronics
011 - Measured values
– There, enter 141 and acknowledge with Q .

Display field 3 shows the actual value reported to the vehicle by
the fuel pressure sender - G247- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

11.2015
– Switch on digital pressure gauge - VAS 6394/1- by pressing

key -A- briefly once.
Note
When button -A- is pressed for 2 seconds, the illumination will be

switched on for 20 seconds.
Digital pressure gauge - VAS 6394/1- should display 0 bar; if this

is not the case, press key -C-sw briefly
agen once for zero
AG. Volkswagen AGpoint
does compen‐
sation. by
Volk not
gu
ara
ed n
– Start engine. thoris tee
or
au a
– Compare pressure
ss displayed by digital pressure gauge - VAS c
ce
le
6394/1- with actual value of vehicle diagnosis, testing and in‐

un
pt
formation system - VAS 5051B- .
an
d
itte
y li
erm
ab
The pressures may deviate by up to 5 bar.
ility
ot p
wit
If pressures do not correspond, fuel pressure sender - G247-
is n
h re
must be renewed.
ole,
spec
t to the co
WARNING
Digital pressure gauge - VAS 6394/1- is subject to high fuel
rrectne
pressure! With engine running, pull connector off fuel pressure
regulating valve - N276- . This reduces fuel pressure to approx.
6 bar. Switch off ignition. Place a cleaning cloth around fuel
ss
pressure sender - G247- , then reduce residual pressure by
o
cial p
f i
carefully loosening fuel pressure sender - G247- .
nform
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
♦ When the engine is idling and the electrical connector is pulled

en
ng
t.
off the fuel pressure regulating valve - N276- the pressure in
yi Co
op py
the high-pressure area will drop to approx. 6 bar. . C rig
ht ht
rig by
py
♦ Once the high-pressure in the high-pressure area is reduced,
co Vo
by lksw
cted
open the system immediately as the pressure will rise again
agen
Prote AG.
due to warming.
– Renew fuel pressure sender - G247- and again compare both

measured values.
If measured values again fail to correspond:
– Check wiring ⇒ Vehicle diagnostic tester.
If measured values correspond:
– Further testing is carried out with “Guided Fault Finding” ⇒ Ve‐
hicle diagnostic tester.
9. Senders and sensors 271

11.2015
10 Engine control unit

⇒ “10.1 Removing and installing engine control unit J623 (Passat
▶10.2010)”, page 272
⇒ “10.2 Removing and installing engine control unit J623 with
protective housing (Passat ► 10.2010)”, page 273
⇒ “10.3 Removing and installing engine control unit J623 (Passat
11.2010▶)”, page 274
protective housing (Passat 11.2010▶)”, page 276
⇒ “10.5 Removing and installing engine control unit J623 (Tour‐
an)”, page 278
protective housing (Touran)”, page 279
10.1 Removing and installing engine control

unit - J623- (Passat ▶10.2010)
If you wish to replace the engine control unit, connect the vehicle
diagnosis, testing and information system - VAS 5051B- and carry
out the guided function “Renew control unit”.
Removing
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Removing and installing plenum chamber
cover n AG. Volkswagen A ge G do
swa es
– Pull connector -1-byoff
Vol heated windscreen control unit
k not
gu - J505- .
a d ran
se
– Slide connector
tho
ri locking devices -2- on engine control unit
teeout‐
or
wards and
ss
au
pull off both connectors. ac
ce
e
– Remove securing bolts -3-.

nl
pt
du
an
itte
y li
– Remove retainer frame with engine control unit from plenum

erm
ab
chamber.
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press locking device -1- outwards and slide engine control unit
l purpos
-2- in -direction of arrow-.

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

11.2015
– Slide engine control unit -1- into retaining frame in

-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.
– Tighten securing bolts -3- to 7 Nm.

– Fit connectors to engine control unit and slide locking devices
-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
. Volkswagen AG
cover . kswagen AG does
n ol ot g
yV
– Install wiper arms
ed ⇒ Electrical system; Rep. gr. 92 ;raWind‐
b ua
nte
ris
screen wiper
th system; Removing and installing wiper arms
o eo .
au ra
c
ss
ce
le
un
pt
an
d
itte

y li
erm
ab
unit - J623- with protective housing

ility
ot p
wit
is n
(Passat ► 10.2010)
h re
ole,
spec
If you wish to replace the engine control unit, connect the vehicle
diagnosis, testing and information system - VAS 5051B- and carry

t to the co
out the guided function “Renew control unit”.

rrectne
♦ Grip pliers
ss
Removing
o
cial p
f in

form
mer
atio

om

n
c
i
or
n thi
e
– Remove plenum chamber cover: ⇒ General body repairs, ex‐

t
sd
va
terior; Rep. gr. 64 ; Removing and installing plenum chamber

i
o
pr
cum
r
cover
fo
en
ng
t.
yi Co
– Remove bolts -1-. Cop py
t. rig
gh ht
yri
– Cover the plenum chamber with a clean cloth so that it is not
p by
co Vo
scratched.
by lksw
cted agen
Prote AG.
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly.
10. Engine control unit 273

11.2015
– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.
AG. Volkswagen AG d
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olksw not
y V gu
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rise nte
tho eo
au ra
ss c
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
– Slide connector locking devices -1- on engine control unit out‐
h re
wards and pull off both connectors.
ole,
spec
– Remove engine control unit.
t to the co
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– Slide engine control unit -1- in direction of -arrow- in retaining
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-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off.

unit - J623- (Passat 11.2010▶)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.

11.2015
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gr. 50 ; Front body, plenum chamber cover .
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is n
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to stop in direction of -arrow-.
– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-.
– Fit plenum chamber cover ⇒ General body repairs; Rep. gr.
50 ; Front body, plenum chamber cover .
– Fit wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing wiper arms

11.2015

(Passat 11.2010▶)
unit”.
Removing
– Remove plenum chamber cover ⇒ General body repairs; Rep.
gr. 50 ; Front body, plenum chamber cover .
– Press retaining frame down in -direction of arrow- and remove
engine control unit.
– Unscrew shear-head bolts -arrows- using pliers.
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– Carefully press screwdriver in direction of -arrow- and bend

locking bar -1- upwards at the same time.
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11.2015
– Bend locking bar -1- in direction of -arrow- until it can be pulled

off connectors.
– Push connector locking devices in -direction of arrow- and pull

off connector.
Installing
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– Fit connectors to engine control unit and slideulocking
tho
devices eo
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to stop in direction of -arrow-. ss a c
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– Fit locking bar -1- onto connectors and press it in direction of
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-arrow-.
– Guide pin -2- to stop into hole on engine control unit.
nf
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11.2015
– Secure locking bar with new shear-head bolts to engine con‐

trol unit -arrows-.
– Tighten shear-head bolts evenly until heads shear-head off
-arrows-.
– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-.
– Fit plenum chamber cover ⇒ General body repairs; Rep. gr.
50 ; Front body, plenum chamber cover .
– Fit wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing wiper arms

unit - J623- (Touran)
unit”.
Removing AG. Volkswagen AG d
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– Remove wiper arms and plenum chamber cover thor ⇒ Electrical eo
system; Rep. gr. 92 ; Windscreen wiper system;
s au Removing ra
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and installing windscreen wiper system .
s
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– Then remove securing nuts for control unit bracket -arrows-.

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11.2015
– Release connectors on engine control unit and pull off con‐

nector.
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ility
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– Push engine control unit onto control unit bracket until it en‐
es, in part or in w
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t to the co
– Fit connectors to engine control unit and lock in position.
rrectness of i
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at
– Tighten securing bolts -arrows- to 10 Nm.
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– Install plenum chamber bulkhead ⇒ General body repairs;
– Install wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing

(Touran)

11.2015
♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

unit”.
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The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
rrectness
Caution
o
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Cover lines, connections and control units in the vicinity of the

mer
engine control unit to prevent damage through heat.

atio
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Perform settings on hot air blower -4- as shown:

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11.2015
– Turn temperature setting potentiometer -2- to maximum heat

output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Then remove securing nuts for control unit bracket -arrows-.
AG. Volkswagen AG d
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– Press catches -1- and -2- outwards. Then pull engine control
rrectness of i
unit off control unit bracket in -direction of arrow-.

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Installing
– Push engine control unit onto control unit bracket until it en‐
nform
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gages in catches.
m
at
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– Fit connectors to engine control unit and lock in position.

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– Install cover of protective housing.
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agen EA 111, turbocharger,
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– Tighten new shear-head bolts -arrows-s aevenly
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11.2015
26 – Exhaust system
1 Emission control
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamp and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
wage
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⇒ “1.1 Assemblyris
e overview – emission control”, pagera283
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utho eo
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1.1 Assembly overview – emission control
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1 - Heat shield
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2 - Bolt
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❑ 10 Nm h re
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spec
3 - Bolt
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❑ 10 Nm
4 - Gasket
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❑ Renew.
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5 - Exhaust pipe
❑ With decoupling ele‐
ment.
nform
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❑ Do not bend decoupling

m
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com
element more than 10° -

ion in
otherwise it can be dam‐

r
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aged.
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6 - Lambda probe after catalyt‐

um
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probe body.
❑ If seal is leaking, nip
open and renew.
7 - Catalytic converter with ex‐
haust pipe
8 - Nut
❑ Renew.
❑ Coat studs of turbo‐
charger with high-tem‐
perature paste.
❑ 23 Nm
9 - Gasket
❑ Renew
1. Emission control 283

11.2015
10 - Nut
❑ Renew
❑ 25 Nm
11 - Bolt
❑ 25 Nm
12 - Mounting
13 - Nut
❑ Renew.
❑ Coat studs with high-temperature paste.
❑ 23 Nm
14 - Gasket
❑ Renew
15 - Bolt
❑ 25 Nm
16 - Bolt AG. Volkswagen AG d
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17 - Bracket horis nte
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18 - Lambda probe - G39-
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❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe
un
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❑ Remove and install with Lambda probe open ring spanner set - 3337- .
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19 - Nut
hole
spec
❑ Observe tightening sequence and specified torques: items -A- to -I- ⇒ Item 7 (page 165) .
es, in part or in w
t to the co
❑ 25 Nm
20 - Turbocharger
rrectness of i
❑ The turbocharger and the exhaust manifold can only be renewed together.
l purpos
21 - Gasket
❑ Renew.
nform
mercia
a
com
tion in
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284 Rep. gr.26 - Exhaust system

11.2015
2 Exhaust pipes, silencers

⇒ “2.1 Assembly overview - silencers”, page 285
⇒ “2.2 Removing and installing front exhaust pipe”, page 286
2.1 Assembly overview - silencers
1 - Centre silencer with rear si‐

lencer
❑ Aligning exhaust sys‐
tem free of stress
2 - Mounting olkswage es n
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3 - Clamp ir se
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❑ 23 Nm aut or
ac
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4 - Exhaust tailpipe
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5 - Mounting
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6 - Bolt
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❑ 20 Nm
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7 - Nut
spec
❑ Renew
t to the co
❑ 25 Nm
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mer
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2. Exhaust pipes, silencers 285

11.2015
2.2 Removing and installing front exhaust

pipe
Removing
– Remove Lambda probe after catalytic converter - G130- -1-.
– Unbolt exhaust pipe together with decoupling element

-arrows-.
– Unhook rear exhaust system from mountings and pull system
slightly to rear in direction of -arrow-.
– Push exhaust pipe out of mounting -1-.
Installing
Installation is performed in the reverse order of removal.
Specified torques:
♦ Lambda probe after catalytic converter - G130-
. Volkswagen AG
⇒ “1.1 Assembly overview
swagen–AG
emission control”,
does page 283
k not
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♦ Securing nutssefor
d b front exhaust pipe
y ua
ran
⇒ “1.1 Assembly
thori overview – emission control”, page 283
tee
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c
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286 Rep. gr.26 - Exhaust system

11.2015
28 – Ignition system
AG. Volkswagen AG d
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1 Ignition system ol not
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⇒ “1.1 General notes”, page 287 . auth
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⇒ “1.2 Assembly overview - ignition system”, page 287
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nl
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⇒ “1.3 Test data, spark plugs”, page 289
itte
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page 289
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⇒ “1.5 Removing and installing engine speed sender G28 ”, page
hole
spec
291
es, in part or in w
t to the co
1.1 General notes
• Observe safety precautions
rrectness of i
⇒ “2.5 Safety precautions when working on ignition system”,
page 8 .
l purpos
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
nform
mercia
♦ Do not touch or disconnect ignition cables when the engine is
at
om
i
running or being turned at starter speed.
on
c
in t
or
♦ Switch off ignition before connecting or disconnecting injection
his
ate
do
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and ignition system wiring as well as test instrument cables.

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Note the following if testers and measuring instruments have to
en
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be used during a road test:
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♦ Test and measuring instruments must always be secured to
ht
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rear seat and operated by a second person from this location.
c by lksw
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Prote AG.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull all 4-pin connectors -arrows- off ignition coils with final
output stage.
page 289
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er. Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
♦ The engine control unit - J623- is equipped with self-diagnosis.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Certain tests may lead to a fault being detected and stored by
the engine control unit - J623- . Therefore, after completing all
the checks and repairs, read the event memory and clear it if
necessary.
1.2 Assembly overview - ignition system
1. Ignition system 287

11.2015
1 - Connector
❑ Black, 4-pin.
❑ With assembly tool -
T10118- .
2 - Ignition coils
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N292-
stage - N291- AG. Volkswagen AG d
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❑ Removing and installing ed by V gu
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⇒ “1.4 Removing and in‐ horis nte
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stalling ignition coils aut ra
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with output stage”, pagess
ce
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289 .
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3 - Connector
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❑ Black, 2-pin.
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❑ For knock sensor 1 -
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G61- .
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spec
❑ Connector contacts are
t to the co
gold-plated.
4 - Knock sensor 1 - G61-
rrectne
❑ Connector contacts are
gold-plated.
s
❑ To remove, remove su‐
s o
percharger
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⇒ “3.2 Removing and in‐ f inform

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stalling supercharger”,
atio
page 194 .
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5 - Bolt
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❑ The specified torque influences the function of the knock sensor.

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❑ 20 Nm
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6 - Connector t. Cop py
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7 - Hall sender - G40-
8 - O-ring
9 - Bolt
❑ 10 Nm
10 - Spark plugs
❑ If a spark plug is replaced, regrease ignition coil with final output stage
⇒ “1.4 Removing and installing ignition coils with output stage”, page 289
❑ Remove and install with spark plug socket and extension - 3122 B- .
❑ Type and electrode gap ⇒ “1.3 Test data, spark plugs”, page 289 .
❑ 25 Nm
11 - Cable guide
❑ Bolt to camshaft housing with 5 Nm torque.
288 Rep. gr.28 - Ignition system

11.2015
12 - Earth wire
❑ Loosen or tighten only with ignition switched off.
13 - Pins
❑ Loosen or tighten only with ignition switched off.
❑ 10 Nm
1.3 Test data, spark plugs

Engine codes CDGA
Firing order 1-3-4-2
Spark plugs
VW part number 101 905 626 A
Electrode gap 0.5 … 0.6 mm
Specified torque 25 Nm
Change interval ⇒ Maintenance ; Booklet ; Time or distance de‐
pendent additional work
1.4 Removing and installing ignition coils

with output stage
♦ Assembly tool - T10118- lkswage es n
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11.2015
Note
The housings for ignition coils with output stages have been
modified. As a result, these ignition coils can only be installed or
removed using puller - T10094 A- . The previous puller - T10094- gen AG
. Volkswagen AG
does
can continue to be used if modified as described below. Volkswa not
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– Remove marked area -2- using suitable workshop
tho equipment or
au
to attain the new nominal dimension -B- ofss18 mm. ac
ce
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nl
– Additionally identify the tool designation with the letter A -1-.
pt
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Removing
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es, in part or in w
t to the co
rrectness of i
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rection of -arrow-.
– Remove securing bolts -1- from crankcase breather connec‐
nf
ercia
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tion and from non-return valve.
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Prote AG.
– Pull off connectors -2- and hose connection -3-.
– Pull off hose -4- from intake manifold connection.
Note
To remove ignition coil cylinder 1, press non-return valve and ho‐

ses to side.
– Fit puller - T10094 A- on ignition coil with final output stage

-arrow-.
– Pull ignition coil with final output stage out slightly.
– Fit assembly tool - T10118- as shown.
– Carefully release connector locking mechanism and pull off
connector.
Installing
– Fit puller - T10094 A- on ignition coil with final output stage.
– Push connector onto ignition coil with final output stage until it
audibly engages.

AG. Volkswagen AG d
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olksw not
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Passat 2006 ➤s,edPassat 2011 ➤ , Passat Variant 2011
b ara➤ , Touran 2003 ➤
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4-cylinder direct-injection engine (1.4
ut
h l, natural gas, EA 111, turbocharger, supercharger)
o eo
ra
- Edition
a
ss c 11.2015
ce
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un
pt
– Press ignition coil with final output stage into cylinder head in
an
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es, in part or in w
t to the co
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nform
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– Push rubber sleeve -1- into hose -2-.

m
a
– Push hose -2- onto intake manifold connection -3-.
com
tion in
r
Further installation is carried out in the reverse sequence of re‐

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Specified torques of securing bolts for crankcase breather con‐
fo
en
ng
nection and for non-return valve: 10 Nm

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1.5 Removing and installing engine speed

sender - G28-
The engine speed sender - G28- is located on the sealing flange
on the flywheel end of the crankcase.

11.2015

equipment required
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en AG. V
♦ Hose clip pliers - VAS olkswag does
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ara
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♦ Torque wrench
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ra
1331- ss c
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♦ Guide pins - T10341-
pt
an
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itte
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rm
ab
pe
ility
♦ Allen key, long reach 4 mm
ot
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, is n
- T10370-
h re
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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Removing
– Remove compressor
⇒ “3.2 Removing and installing supercharger”, page 194 .
– Pull off connector -1- from engine speed sender - G28- .
– Remove gasket -2- from cylinder block and remove engine
speed sender - G28- with socket - T10370- .
Installing
– Install engine speed sender - G28- , and tighten securing bolt
to specified torque ⇒ page 292 .
quence.
Specified torques:
Securing bolt for engine speed send‐ 5 Nm
er - G28-
♦ Components for securing supercharger

Service: Passat 2006 Passat 2011 Passat Variant 2011 Touran 2003

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E801A6C32

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.2 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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

3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1.2 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1.1 Engine number, engine data

– Detach hose from activated charcoal filter at hose clip

Vehicles for some countries do not have an identification plate.

Engine code CDGA

Engine code CDGA

2 Rep. gr.00 - Technical data

2.1 Safety precautions when working on

Please note the following when working on fuel supply system:

Risk of injury due to highly pressurised fuel.

♦ The fuel system is pressurised! The fuel pressure in the

Risk of damage to the electronic components when discon‐

Only disconnect battery with ignition switched off ⇒ Electrical

Even small amounts of contamination/soiling can lead to defects.

2.2 Safety precautions when working on

Release pressure in the system before working on the natural

A leakage test of the system must always be performed after

components have been removed ⇒ Maintenance ; Booklet

35.1 ; Description of work; Performing visual inspection of gas

tanks for corrosion and leakage test .

4 Rep. gr.00 - Technical data

• The mechanic may be the source for electrostatic dis‐

Before evacuating natural gas tanks, make sure to comply with

♦ The safety zone must be permanently supervised during

• If evacuation of the natural gas tanks is not possible, close t to the co

• Contact your importer for further procedure regarding the

natural gas tanks that are still filled with fuel.

• Observe the country-specific regulations as well as spec‐

ifications provided by the importer regarding the safety

measures described in this manual.

Prior to doing any repair work, especially in the engine com‐

and the pressure line must be renewed.

♦ A leakage test of the system must always be performed after

35.1 ; Description of work; Performing visual inspection of gas

tanks for corrosion and leakage test .

♦ Disconnect battery earth strap before carrying out work on spec

2.3 Safety precautions during road tests in

which testing and measuring equipment

ment is required during a road test:

♦ Always strap test and measuring equipment in place on

6 Rep. gr.00 - Technical data

2.4 Safety precautions when working on

Steam may escape when expansion tank is opened.

When doing any repair work, especially in the engine compart‐