GTI D4B802E46CA-4-Cyl Direct Injection Engine (1 8 L and 2 0 L 4 V EA 888 Gen III Turbocharger Chain Drive)

Service
Workshop Manual
Arteon 2018 ➤, Arteon 2021 ➤,
Arteon Shooting Brake 2021 ➤,
Golf 2013 ➤, Golf 2017 ➤, Golf 2020 ➤,
Golf Variant 2014 ➤, Golf Variant 2017 ➤,
Passat 2015 ➤, Passat 2019 ➤,
Passat Variant 2015 ➤,
Passat Variant 2019 ➤, Sharan 2016 ➤,
Tiguan 2016 ➤, Tiguan 2021 ➤,
Tiguan RUS 2017 ➤, Tiguan RUS 2021 ➤,
Touran 2016 ➤
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA
888 gen III, turbocharger, chain drive)
Engine ID
CHH CHH CNT CJSA CJSC CJSB CJXA DED CJXE
A B A A
CXD CXD DLBA DJH DHG CNT DLR CJXH DKT
A B C A C B A
DKT DNU DNU
B A C
Edition 04.2021
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2021 Volkswagen AG, Wolfsburg D4B802E46CA

Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2 ...
4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive) - Edition
04.2021
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.6 Checking adjustment of assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.7 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.7 Renewing seal for vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Contents i
04.2021
3.4 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.7 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.1 Assembly overview - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.3 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Assembly overview - cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.1 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.2 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.3 Assembly overview - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.4 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.5 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.4 Removing and installing exhaust camshaft control valve 1 N318 . . . . . . . . . . . . . . . . . . . . 218
4.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 235
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
1.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.6 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
ii Contents
04.2021
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.2 Assembly overview - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . 256
4.3 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 258
4.4 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 259
4.5 Removing and installing oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
4.6 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.4 Flushing cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
2.4 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
2.6 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
2.7 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
2.8 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 337
2.9 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 340
2.10 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . . . 341
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.3 Removing and installing upper coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.1 Assembly overview – radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.2 Assembly overview - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
4.3 Assembly overview – radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4.6 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4.7 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 392
1.4 Adjusting charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
2.6 Removing and installing air intake pipe between turbocharger and charge air cooler . . . . 410
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Contents iii
04.2021
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
2.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
2.4 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
2.5 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
4.1 Assembly overview – intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
4.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
4.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
5.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne
sound, Golf, Passat, Touran, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
5.2 Assembly overview - actuator for structure-borne sound and control unit for structure-borne
sound, Arteon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
5.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
5.4 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
5.5 Removing and installing fuel pressure sender for low-pressure G410 . . . . . . . . . . . . . . . . 469
5.6 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
5.7 Removing and installing pressure differential sender for particulate filter G1037 . . . . . . . . 471
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
6.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
6.2 Removing and installing engine (motor) control unit J623 with protective housing . . . . . . 477
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
7.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
8.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1.1 Assembly overview – silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1.2 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
1.3 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
2.1 Assembly overview – emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
2.2 Assembly overview - bracket and pipes for pressure differential sender for particulate filter
G1037 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
2.3 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
2.4 Removing and installing holder of pressure differential sender for particulate filter G1037 . . 567
2.5 Removing and installing exhaust flap control unit J883/J945, Passat CJXA, Arteon . . . . . . 568
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
3.1 Assembly overview – exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . 569
3.2 Removing and installing parts of exhaust gas temperature regulation . . . . . . . . . . . . . . . . 570
iv Contents
04.2021
4 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575

4.1 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
4.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . . . 576
4.3 Renewing stop buffer for secondary air pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
4.4 Removing and installing secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . 577
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 581
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
Contents v
04.2021
vi Contents
04.2021
00 – Technical data
1 Safety information
(VRL015532; Edition 04.2021)
⇒ r1.1 egulations for working on fuel supply”, page 1
⇒ m1.2 easures when working on vehicles with a start/stop
system”, page 1
⇒ p1.3 recautions when using testers and measuring instru‐
ments during a road test”, page 2
⇒ p1.4 recautions when working on ignition system”, page 2
⇒ p1.5 recautions when working on the cooling system”, page
2
⇒ p1.6 recautions when working on exhaust system”, page 3
1.1 Safety regulations for working on fuel supply

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

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

Risk of injury due to unexpected motor start
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indi‐
cates whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
04.2021
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring in‐
struments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
Or
– Have a second person operate the test and measuring
equipment on the rear seat.
1.4 Safety precautions when working on ignition system

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

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

Danger of scalding by hot coolant
When the motor is hot, the cooling system is under high pres‐
sure. Danger of scalding by steam and hot coolant.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
2 Rep. gr.00 - Technical data

04.2021
1.6 Safety precautions when working on exhaust system

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

Do not allow the flexible joint to kink by more than 10°.
Install flexible joint so that it is not under tension.
Do not damage wire mesh on decoupling element.
1. Safety information 3
04.2021
2 Identification
⇒ n2.1 umber/engine data”, page 4
2.1 Engine number/engine data

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

the oil filter.
In addition, there is a sticker on the right of the timing chain
cover with “engine code” and “serial number”.
The first 3 digits denote the mechanical design of the engine
and are stamped on the engine. The fourth digit shows the
engine output and torque and varies according to engine control
unit. The four-digit engine code can be found on the identifica‐
tion plate. It can also be read from the engine control unit.
Engine data
Codes CHHA CHHB CNTA CNTC CJSA CJSB CJSC CJXA
Manu‐ Golf 04.2013 04.2013 11.2013 05.2017 --- --- --- ---
factured ► ► ► ►
from
Golf Estate --- --- --- --- --- 04.2015 --- ---
Passat --- 02.2015 --- --- 02.2015 -- 02.2015 05.2015
► ► ► ►
Sharan --- 05.2015 --- --- --- --- --- ---
►
Touran --- --- --- --- 11.2015 --- --- ---
►
Tiguan --- 05.2016 --- --- --- --- --- ---
►
Arteon --- --- --- --- --- --- --- 03.2017
►
Exhaust emission EU 6 EU 6 SULEV SULEV EU 6 EU 6 EU 6 EU 6
standard

04.2021
Codes CHHA CHHB CNTA CNTC CJSA CJSB CJSC CJXA

Dis‐ l 2.0 2.0 2.0 2.0 1.8 1.8 1.8 2.0
place‐
ment
Power kW at rpm 169 at 162 at 155 at 162 at 132 at 132 at 132 at 206 at
4700 to 4500 to 4300 to 4500 to 5100 to 4500 to 4200 to 5600 to
6200 6200 6200 6200 6200 6200 6200 6500
Torque Nm at rpm 350 at 350 at 350 at 350 at 250 at 280 at 320 at 350 at
4600 4400 4200 4400 5000 4500 3500 5600
Bore Diame‐ 82.5 82.5 82.5 82.5 82.5 82.5 82.5 82.5
ter, mm
Stroke mm 92.8 92.8 92.8 92.8 84.2 84.2 84.2 92.8
Compression ratio 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1 9.3:1
RON 95 95 95 95 95 95 95 98
Injection system Direct Direct Direct Direct Direct Direct Direct Direct
injection injection injection injection injection injection injection injection
and in‐ and in‐ and in‐ and in‐ and in‐ and in‐
take take take take take take
manifold manifold manifold manifold manifold manifold
injection injection injection injection injection injection
Firing 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
order
Charging Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐
charger charger charger charger charger charger charger charger
Camshaft timing ad‐ yes yes yes yes yes yes yes yes
justment
Valve lift switching yes yes yes yes yes yes yes yes
Secondary air injec‐ No No yes yes No No No No
tion
Valves per cylinder 4 4 4 4 4 4 4 4
Oil pressure control yes yes yes yes yes yes yes yes
Codes CJXE DEDA CXDA CXDB DLBA DHGA DJHC DLRB

Manu‐ Golf 01.2016 --- 12.2015 12.2015 03.2017 03.2017 --- ---
factured ► ► ► ► ►
from
Passat --- --- 12.2015 --- --- --- --- ---
►
Sharan --- 05.2015 --- --- --- --- --- ---
►
Arteon --- --- --- --- --- --- 03.2017 04.2018
► ►
Exhaust emission EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 EU 6 LEV 3
standard
Dis‐ l 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
place‐
ment
Power kW at rpm 195 at 162 at 162 at 169 at 180 at 180 at 206 at 200 at
6600 6200 6200 6200 6200 6200 6500 6500
Torque Nm at rpm 350 at 350 at 350 at 350 at 370 at 370 at 350 at 350 at
5800 4400 4200 4600 4300 4300 5600 5400
Bore Diame‐ 82.5 82.5 82.5 82.5 82.5 82.5 82.5 82.5
ter, mm
Stroke mm 92.8 92.8 92.8 92.8 92.8 92.8 92.8 92.8
2. Identification 5
04.2021
Codes CJXE DEDA CXDA CXDB DLBA DHGA DJHC DLRB

Compression ratio 9.3:1 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1 9.3:1 9.3:1
RON 98 95 95 95 95 95 98 98
Injection system Direct Direct Direct Direct Direct Direct Direct Direct
injection injection injection injection injection injection injection injection
and in‐ and in‐ and in‐ and in‐ and in‐ and in‐ and in‐
take take take take take take take
manifold manifold manifold manifold manifold manifold manifold
injection injection injection injection injection injection injection
Firing 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
order
Charging Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐
charger charger charger charger charger charger charger charger
Camshaft timing ad‐ yes yes yes yes yes yes yes yes
justment
Valve lift switching yes yes yes yes yes yes yes yes
Secondary air injec‐ No No No No No No No No
tion
Valves per cylinder 4 4 4 4 4 4 4 4
Oil pressure control yes yes yes yes yes yes yes yes
Codes DKTA DKTB DNUA DNUC CJXH

Manufac‐ Golf --- 06.2018 ► --- 11.2018 ► 11.2018 ►
tured from
Passat --- --- 09.2018 ► --- ---
Arteon --- --- 09.2018 ► --- ---
Tiguan 09.2018 ► --- --- --- ---
Exhaust emission standard EU 6 EU 6 EU 6 EU 6 EU 6
Displace‐ l 2.0 2.0 2.0 2.0 2.0
ment
Power kW at rpm 169 at 5000 180 at 5000 200 at 5500 213 at 5400 213 at 5900
to 6200 to 6200 to 6500 to 6500 to 6400
Torque Nm at rpm 350 at 1500 370 at 1600 350 at 2000 380 at 1950 350 at 1700
to 4300 to 4300 to 5400 to 5300 to 5800
Bore Diameter, mm 82.5 82.5 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8 92.8 92.8
Compression ratio 9.6:1 9.6:1 9.3:1 9.3:1 9.3:1
RON 95 95 98 98 98
Injection system Direct injec‐ Direct injec‐ Direct injec‐ Direct injec‐ Direct injec‐
tion tion tion tion tion and in‐
take mani‐
fold injection
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Charging Turbocharg‐ Turbocharg‐ Turbocharg‐ Turbocharg‐ Turbocharg‐
er er er er er
Camshaft timing adjustment yes yes yes yes yes
Valve lift switching yes yes yes yes yes
Secondary air injection No No No No No
Particulate filter yes yes yes yes No
Valves per cylinder 4 4 4 4 4
Oil pressure control yes yes yes yes yes

04.2021
3 Repair instructions
⇒ f3.1 or cleanliness”, page 7
⇒ o3.2 bjects in engine”, page 7
⇒ c3.3 orrosion”, page 7
⇒ a3.4 nd attachment of lines”, page 7
⇒ r3.5 adiator and condensers”, page 8
⇒ v3.6 acuum system”, page 8
3.1 Rules for cleanliness

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

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

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

♦ To prevent interchanging and to maintain the original instal‐
lation position, mark fuel lines, vacuum lines, pipes/hoses
for activated charcoal filter system and electrical wiring etc.
3. Repair instructions 7
04.2021
before removal. Make sketches or take photographs if nec‐

essary.
♦ To avoid damage to lines, ensure adequate clearance from
all moving or hot components in the engine compartment on
account of the confined space.
3.5 Fitting radiator and condensers

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

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

04.2021
10 – Removing and installing engine

1 Removing and installing engine
⇒ e1.1 ngine”, page 9
⇒ e1.2 ngine and gearbox”, page 30
⇒ e1.3 ngine on engine and gearbox support”, page 40
⇒ e1.4 ngine”, page 43
1.1 Removing engine

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

04.2021
♦ Release lever -80 - 200-
♦ Safety glasses
♦ Safety gloves
♦ Stepladder
Note
The engine is removed downwards with gearbox. To do this, the

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

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

04.2021
– Place drip tray for workshop hoist -VAS 6208- underneath.

– Lift retaining clip -3-, disconnect coolant hose (bottom right)
from radiator and drain off coolant.
– Remove engine cover panel ⇒ page 81 .
– Remove air filter housing ⇒ page 443 .
– Unscrew bolt -arrow- on left and right.
– Unclip lower part of air duct -1- and remove it.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27; Battery;
Disconnecting and connecting battery.
– Battery in engine compartment: Remove battery tray -1-

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

04.2021
– Press release tabs on vacuum hose -1-, and remove hose

from vacuum pump.
Vehicles without seat heating:
– Lift retaining clips -arrows- and disconnect coolant hoses

from heat exchanger for heater.
– Hold coolant hoses downwards to allow coolant to drain.
Vehicles with auxiliary heater:
– Release hose clip -1-, lift retaining clips -arrows-, and dis‐
connect coolant hoses.

04.2021
Continued for all vehicles:
– Detach electrical connectors -1, 2- from bracket, unplug con‐

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

04.2021
– Release hose clips -1, 2-, and remove coolant hoses.
– Lift retaining clip -arrow- and disconnect coolant hose (top

left) from radiator.

04.2021
Note
For the work steps below, use removal lever -80 - 200- to unclip
the binding clips.
Golf, Passat, Arteon:
– Separate connector -1- on engine control unit -J623- ⇒ page

473 .
– Remove connectors -2, 3- from retainer and disconnect
them.
– Move electrical lines free.
– Release catches -arrows- and detach cover -1- for electron‐
ics box in engine compartment.
– Release catch using a screwdriver -arrow- and detach cover

-1- for electronics box in engine compartment upwards.

04.2021
– Remove nut -arrow-, detach electrical wiring and move clear.
Sharan:
– Release and pull off connector on engine control unit -J623-

⇒ page 473 .
– Open cable duct latches on longitudinal member -arrows-.
– Release and disconnect connectors -1- and -2-.

04.2021
– Open locking elements -arrows- of cable guide, and place

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

04.2021
Vehicles with manual gearbox:

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

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

2- For reversing light switch -F4-
– Disconnect gear selector cable and gate selector cable from
gearbox. Then, unbolt cable support bracket, and lay it to
one side together with cables ⇒ Rep. gr. 34; Selector mech‐
anism; Removing and installing selector mechanism.
– Clamp off pipe/hose line -A- leading to slave cylinder using
hose clamp -3094-.

04.2021
– Pull out clip -arrow- for pipe/hose line to stop.

– Pull pipe/hose line out of slave cylinder breather.
Vehicles with dual clutch gearbox:

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

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

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

04.2021
Vehicles with automatic gearbox:
– Using e. g. open-end spanner, lever selector lever cable -1-

off gearbox selector lever -2-.
– Pull connector -6- off multifunction switch -F125- and lay
electrical wiring on bracket aside.
– Unscrew bolts -5- from cable support bracket -4-. Do not
detach securing clip -3-.
– Unhook selector lever cable -1- from securing clip -arrow-.
Note
♦ Do not bend or kink selector lever cable.

♦ To ensure that the cable is not a hindrance when removing
and installing the gearbox, raise the cable to a suitable posi‐
tion on the body and tie using e.g. cable ties.
– Detach electrical connector from gearbox as follows. Push

locking mechanism -1- in direction of arrow, fold out bar -2-,
and pull connector -3- off gearbox.

04.2021
– Separate electrical connectors from starter ⇒ Electrical sys‐

tem; Rep. gr. 27; Starter; Removing and installing starter.
Continued for all:
– Loosen bolts -arrows- for gearbox mounting approx. 2 turns.

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

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

04.2021
– Simultaneously press locking tabs -B- on left and right of ra‐

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

04.2021
– Unscrew bolts -arrows-.

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

felt pen to mark the running direction.

04.2021
– To relieve tension on poly V-belt, swivel tensioning device in

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

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

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

04.2021
Vehicles with front differential lock
– Disconnect electrical connector -arrow- of axle differential

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

Propshaft; Removing and installing propshaft.

04.2021
– If necessary, counterhold at rear final drive when loosening

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

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

– Place cloth -A- on support and lay propshaft on that.

04.2021
– Unscrew nuts -2-.

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

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

shown in illustration.

04.2021
– Use locking element -A- from gearbox support -3282- to se‐

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

04.2021
– Remove bolts -arrows- securing gearbox mounting.
– Carefully lower engine/gearbox assembly. Check that all

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

04.2021
1.2 Separating engine and gearbox

⇒ e1.2.1 ngine and gearbox, vehicles with manual gearbox”,
page 30
⇒ e1.2.2 ngine and gearbox, vehicles with 7-speed dual clutch
gearbox”, page 33
⇒ e1.2.3 ngine and gearbox, vehicles with 6-speed dual clutch
gearbox”, page 35
⇒ e1.2.4 ngine and gearbox, vehicles with automatic gearbox”,
page 38
1.2.1 Separating engine and gearbox, vehi‐

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

04.2021
• Engine/gearbox assembly removed and attached to engine

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

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

04.2021
– Attach lifting tackle -T40013- to gearbox and close lock.
– Attach workshop hoist -VAS 6100- with hooks -10 - 222 A /2-
to lifting tackle.
– Remove bolts -1, 2, 3, 6, 7, 8, 9- securing gearbox to engine.
Note
Disregard -items 4, 5- and -A-.
– Pull gearbox off engine.

04.2021

cles with 7-speed dual clutch gearbox
♦ Engine bung set -VAS 6122-
NOTICE
Secondary damage due to damaged needle bearing.
– If engine and gearbox are separated, needle bearing in
crankshaft must be renewed ⇒ page 115 .
bracket -T10497-.
– Remove starter ⇒ Electrical system; Rep. gr. 27; Starter;
Removing and installing starter.
– Unscrew coolant pipe from gearbox.
– Unscrew nuts -arrows-, and remove bracket at front of sump.
Note
The studs are welded to the front of the sump.

04.2021
– Unscrew bolts -1, 2-, and remove bracket for bevel box.
Note
Use a cloth to catch the escaping coolant.
– Loosen hose clips -arrows- and remove coolant hoses from

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

04.2021

– Before assembling, renew needle bearing in crankshaft ⇒
page 115 .

cles with 6-speed dual clutch gearbox
♦ Adapter -10 - 222 A /20-
♦ Hook of -2024 A /1- lifting tackle -2024 A-

04.2021
NOTICE
Secondary damage due to damaged needle bearing.
– If engine and gearbox are separated, needle bearing in
crankshaft must be renewed ⇒ page 115 .

bracket -T10497-.
– Unscrew nuts -arrows-, and remove bracket at front of sump.

04.2021
Note
The studs are welded to the front of the sump.
– Unscrew bolts -1, 2-, and remove bracket for bevel box.
Note
♦ Use a cloth to catch the escaping coolant.

♦ Disregard -3094-.
– Loosen hose clips -arrows- and remove coolant hoses from

gear oil cooler.
– Unscrew bolts -1- and lay coolant valve for gearbox -N488-
to one side.
– Attach hook of lifting tackle -2024 A- to gearbox lifting eye
and secure with pin -arrow-.

04.2021
– Attach hook -2024 A /1- to workshop hoist -VAS 6100- with

adapter -10 - 222 A /20-.
– Unscrew bolts -1 to 8- securing gearbox to engine.
Note
Disregard -item A-.

– Before assembling, renew needle bearing in crankshaft ⇒
page 115 .

cles with automatic gearbox
Vehicles with all-wheel drive
– Remove bevel box ⇒ Rep. gr. 37; Bevel box; Removing
bevel box.
All vehicles
– Unscrew six converter nuts -arrow-.

04.2021
– To do this, turn engine with counterhold -T10172A- 60° for

each nut in engine direction of rotation.
Note
If all 6 nuts are not removed from the torque converter, the tor‐
que converter will be pulled out when the gearbox is removed
from the engine!
– Unscrew bolts securing sump to gearbox -arrows-.
– Unscrew upper connecting bolts -arrows- securing gearbox

to engine using e.g. double hexagon flex head socket.

04.2021
– Press gearbox off engine -3- while pressing torque converter

-1- against gearbox in -direction of arrow- using, for exam‐
ple, a screwdriver -2-.
– After gearbox has been removed, secure torque converter to

prevent it from falling out.
1.3 Securing engine on engine and gearbox support

04.2021
Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-

♦ Engine and gearbox support -VAS 6095-
• Gearbox detached from engine ⇒ page 30 .
– Release catch -arrow-, and pull off left mounting -1- for en‐
gine cover panel.

04.2021
– Unclip right mounting -1- for engine cover panel.
– Attach lifting tackle -2024 A- to engine on workshop hoist

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

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

04.2021
1.4 Installing engine

Specified torques
Note
♦ The specified torques are only valid for nuts and bolts
which have been slightly greased, oiled, phosphate-treated
or black-oxided.
♦ Additional lubricant such as engine oil or gear oil may be
used, but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for specified torques ± 15%.
Component Nm
Bolts and nuts M6 10
M7 15
M8 20
M10 40
M12 65
♦ Assembly mountings ⇒ o2.1 verview - assembly mountings”,
page 47 .
♦ Securing gearbox to engine ⇒ Rep. gr. 34; Removing and
installing gearbox; Specified torques for gearbox.
Note
♦ Renew bolts that are tightened with turning further angle.

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

if damaged.

04.2021
– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
– If clutch release bearing is worn, renew it ⇒ Rep. gr. 30;
Clutch mechanism; Repairing clutch release mechanism.
– Lightly grease input shaft splines using grease as per
⇒ Electronic parts catalogue (ETKA).
– Check centring of clutch plate.
– Bolt gearbox to engine.
– If engine and gearbox were separated, renew needle bear‐
ing in crankshaft ⇒ page 115 .

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

hand.

04.2021
– Adjust assembly mountings and tighten bolts ⇒ page 78 .

– Remove engine bracket -T10359- from engine.
– Install drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40; Drive shaft; Assembly overview - drive shaft.
– Install clutch slave cylinder ⇒ Rep. gr. 30; Clutch mecha‐
nism; Removing and installing clutch slave cylinder.
– Install cables with cable support bracket ⇒ Rep. gr. 34; Se‐
lector mechanism; Assembly overview - selector cables.
– Install and adjust selector lever cable ⇒ Rep. gr. 34; Selector
mechanism; Removing and installing selector lever cable.
– Install air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor.
– Install poly V-belt ⇒ page 85 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27; Battery;
Assembly overview - battery.
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, elec‐
tronics boxes and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
– Install air filter housing ⇒ page 443 .
– Fit engine cover panel ⇒ page 81 .
– Check oil level.
– Connect coolant hoses with plug-in connector to heat ex‐
changer for heater ⇒ page 349 .
– Install subframe ⇒ Running gear, axles, steering; Rep.
gr. 40; Subframe; Removing and installing subframe without
steering rack.
– Install front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66; Wheel housing liner; Removing and
installing front wheel housing liner.
– Add coolant ⇒ page 282 .
If a new base engine or short engine was installed, additional
adaptations must be carried out in the engine control unit. Pro‐
ceed as follows to do this:

04.2021
– Connect ⇒ Vehicle diagnostic tester, and select following

functions.
♦ 0001 - Engine electronics functions
♦ 0001 - Basic setting
♦ Timing chain length compensator, reset after re-
newing chain

04.2021
2 Assembly mountings
⇒ o2.1 verview - assembly mountings”, page 47
⇒ e2.2 ngine in installation position”, page 51
⇒ a2.3 nd installing engine mounting”, page 72
⇒ a2.4 nd installing gearbox mounting”, page 74
⇒ a2.5 nd installing pendulum support”, page 76
⇒ a2.6 djustment of assembly mountings”, page 77
⇒ a2.7 ssembly mountings”, page 78
2.1 Assembly overview - assembly mount‐

ings
⇒ o2.1.1 verview - assembly mountings, Golf, Passat, Touran,
Tiguan, Arteon”, page 47
⇒ o2.1.2 verview – assembly mountings, Sharan”, page 49
2.1.1 Assembly overview - assembly mountings, Golf, Passat, Touran, Tiguan,

Arteon
2. Assembly mountings 47
04.2021
1 - Bolt
❑ Renew
❑ Specified torque and
tightening sequence ⇒
page 99
2 - Engine support
❑ Removing and instal‐
ling ⇒ page 98
3 - Engine mounting
❑ With support arm
ling ⇒ page 72
4 - Bolt
❑ Renew
❑ 40 Nm +90°
5 - Bolt
❑ Renew
❑ 23 Nm +90°
6 - Bolt
❑ Renew
❑ 40 Nm +90°
7 - Bolt
❑ Renew
❑ 60 Nm +90°
8 - Pendulum support
ling ⇒ page 76
9 - Bolt
❑ Renew
❑ Specified torque and tightening sequence ⇒ page 76
10 - Bolt
❑ Renew
11 - Bolt
❑ Renew
12 - Bolt
❑ Renew
❑ 60 Nm +90°
13 - Bolt
❑ Renew
❑ 60 Nm +90°
14 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ page 74
15 - Bolt
❑ Renew

04.2021
❑ 50 Nm +90°
2.1.2 Assembly overview – assembly mountings, Sharan
04.2021
1 - Bolt
❑ Renew
❑ 23 Nm + 90° (1/4 turn)
further
2 - Bolt
❑ Engine mounting to
body
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further)
3 - Engine mounting
ling ⇒ page 72
4 - Bolt
❑ Engine mounting to
body
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further)
5 - Bolts
❑ Engine mounting to en‐
gine support
❑ Renew
❑ 60 Nm + 90° (1/4 turn
further)
6 - Pendulum support
ling ⇒ page 77
7 - Bolt
❑ Pendulum support to
subframe
❑ Renew
8 - Bolt
❑ Pendulum support to gearbox
❑ Renew
9 - Bolt
❑ Pendulum support to gearbox
❑ Renew
10 - Bolts
❑ Gearbox mounting to gearbox
❑ Renew
❑ 60 Nm + 90° (1/4 turn) further
11 - Bolts
❑ Gearbox mounting to body
❑ Renew

04.2021
❑ 40 Nm + 90° (1/4 turn) further
12 - Gearbox mounting
13 - Engine support
14 - Bolts
❑ Engine support to engine
❑ Renew
❑ 40 Nm + 180° (1/2 turn further)
2.2 Supporting engine in installation posi‐

tion
⇒ e2.2.1 ngine in installation position, Arteon”, page 51
⇒ e2.2.2 ngine in installation position, Golf, Touran”, page 55
⇒ e2.2.3 ngine in installation position, Passat”, page 60
⇒ e2.2.4 ngine in installation position, Sharan”, page 65
⇒ e2.2.5 ngine in installation position, Tiguan”, page 68
2.2.1 Supporting engine in installation posi‐

tion, Arteon
♦ Support bracket -10 - 222 A-
♦ Adapter -10 - 222 A /8-
04.2021
♦ Shackle -10 - 222 A /12- qty. 2
♦ Square tube -T40091/1-
♦ Joints -T40091/3-
♦ Spindle -T40093/3-
♦ Adapter -T40093/3-6A-

04.2021
Supporting engine

– Unclip right mounting -1- for engine cover panel from retain‐
er -2-.
– Remove foam elements -arrows- for plenum chamber seal
on left and right.
Assemble engine support bracket -10-222 A- as shown:
A - Adapter -10 - 222 A /8-

B - Support bracket -10-222 A-
C - Square tube -T40091/1-
D - Connector -T40091/3-
04.2021
E - Shackle -10 - 222 A /12-

F - Spindle -T40093/3- with adapter -T40093/3-6A-
– Place adapters -10 - 222 A /8- -A- on longitudinal member
behind bolt -arrow- on both sides of vehicle, as shown in
illustration.
– Place adapter -T40093/3-6A- on right longitudinal member.
• The adapter -T40093/3-6A- is locked with the pin -A- behind

the flange of the longitudinal member -arrow-.
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system
⇒ Heating, air conditioning; Rep. gr. 87; Refrigerant circuit;
System overview - refrigerant circuit.
– Take up weight of engine/gearbox assembly using spindles.

04.2021
WARNING
Risk of injury due to improper handling of the support bracket.
Improper handling can lead to damage of the tool and subse‐
quent injuries.
– Never loosen and dismantle the engine and gearbox
mountings at the same time to avoid overloading of the
support bracket.

tion, Golf, Touran
♦ 2 x adapter -10 - 222 A /29-
♦ Adapter -10 - 222 A /18-
04.2021
♦ Hook -10 - 222 A /20-
♦ Shackle -10 - 222 A /12-, qty. 2
♦ Square tube -T40091/1-
♦ Joints -T40091/3-
♦ Spindle -T40093/3-

04.2021
♦ Adapter -T40093/3-6A-
Supporting engine

gine cover panel.
er -2-.
– On both sides of vehicle, insert adapters -10 - 222 A /29-

between wing mounting flange and sheet metal for mounting
wing underneath it.
04.2021
♦ Installation position:
“L” = -1- adapter is to be used on “right” side of vehicle (adapter
engages in recess of wing).
“R” (not shown in illustration), adapter is to be inserted on “left”

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

29-.
– If present, pull off wires in front area of flange on both
longitudinal members -arrow-. Do not disconnect pipe/hose
system.

04.2021
– Fit adapter -T40093/3-6A- to right longitudinal member as

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

hind flange of longitudinal member -arrow-.
– Bolt on spindles -T40093 /3-.
04.2021
– Connect spindles -T40093 /3- to support bracket -T40091/1-

using square tubes -10-222 A-, and tighten.
– Then, hook spindles into lifting eyes of engine. Use hook -10
- 222 A /20- and, if necessary shackle -10 - 222 A /12- for
this purpose.
WARNING
quent injuries.
support bracket.

tion, Passat

04.2021
♦ Square tube -T40091/1-, qty. 2
♦ Connecting piece -T40091/3-, qty. 2

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

♦ 2 x adapter -T40093/3-6A-
♦ Hook -10 - 222 A /20-
04.2021
♦ Shackle -10 - 222 A /12-
At a later point, support bracket -10-222 A- will be fitted onto

longitudinal members with adapters -T40093/3-6A-.
• To prevent damage to the longitudinal members, wrap the
front section of the adapters -T40093/3-6A- with textile-rein‐
forced adhesive tape ⇒ Electronic parts catalogue (ETKA
chemical substances).
Supporting engine

gine cover panel.
er -2-.

on left and right.

04.2021
– Slide two connecting pieces -T40091/3- -(D)- onto support

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

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

tudinal members -arrow-.
– Fit adapter -T40093/3-6A- to right longitudinal member as
04.2021
– Fit adapter -T40093/3-6A- to left longitudinal member. If

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

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

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

04.2021
WARNING
quent injuries.
support bracket.

tion, Sharan
♦ Adapters -10 - 222 A /8-
♦ Adapter -10 - 222 A/3-
04.2021
♦ Square section tube -T40091/1-, qty. 2

♦ Support -T40093/3-, qty. 2

♦ Foot -T40093/3-5-
Setting up support bracket:

– Remove plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Bulkhead; Removing and installing ple‐
num chamber cover.
– Remove radiator grille ⇒ General body repairs, exterior;
Rep. gr. 66; Radiator grille/front panel; Removing and instal‐
ling radiator grille.
– Push articulated joint -T40091/3- as well as adapter -10 -
222 A /3- onto square tube of support bracket -10 - 222 A-.

04.2021
– Fit adapter -10 - 222 A /8- as shown, and bolt it to square

tube.
• Rubber blocks -A- are pointing outwards.
• Set up support bracket -10-222 A- behind bonnet support.

– Screw foot -T40093/3-5- into support -T40093/3-.
– Push mounting -T40093/3- as well as one spindle onto

square tube -T40091/1-.
04.2021
– Place support -T40093/3- together with foot -T40093/3-5- on

bumper carrier and push square section tube -T40091/1-
into swivel joint -T40091/3-.
– Align support bracket and tighten all bolts hand-tight.
– Insert hooks of spindles into engine lifting eyes with shackle
and brace engine in installation position.
WARNING
quent injuries.
support bracket.

tion, Tiguan

04.2021
♦ Hook -10-222A/10-
♦ Adapter -10-222A/28-
♦ Adapter -10-222A/28-2-
♦ 2 x adapter -10 - 222 A /29-
♦ -T40091/1- and -T40091/3- from engine support basic set

-T40091-, qty. 2
04.2021
♦ Shackle -10 - 222 A /12-
Supporting engine
on left and right.
– On both sides of vehicle, insert adapters -10 - 222 A /29- be‐

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

04.2021
– Unscrew bolts -arrows- for lock carrier bracket on left and

right.
– Unscrew lower supports from adapters -10 - 222 A /28- and

replace them with adapters -10-222 A /28-2-.
– Unscrew bolts -arrows- for securing support bracket to lock

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

shown.
04.2021
– Engage spindles in support eyes of engine. Use shackle -10

- 222 A /12- if necessary.
WARNING
quent injuries.
support bracket.
2.3 Removing and installing engine mount‐

ing
Golf, Passat, Touran, Tiguan, Arteon:

04.2021
– Free hoses -2- from fittings and lay them to one side.
– Using a screwdriver, release fasteners -arrow- and move
coolant expansion tank to one side.
All vehicles:
– Support engine in its installation position ⇒ page 51 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew bolts -arrows- and remove engine mounting -1-.
Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings ⇒ page 77 .
Specified torques
♦ ⇒ o2.1 verview - assembly mountings”, page 47
04.2021
2.4 Removing and installing gearbox

mounting
Removing

filter housing.
Golf, Passat, Touran, Tiguan, Arteon:
– Remove engine control unit -J623- from bracket ⇒ page

473 .
– Unscrew nuts -arrows- and remove bracket -1-.
Note
Different types of brackets are fitted depending on version.

04.2021
All vehicles:
– If present, unclip cable guide -1- upwards -arrows- and push

slightly to one side.
– Unscrew bolts -2-. Then unscrew bolts -arrows-, and remove
gearbox mounting -1-.
Installing
Note
♦ Renew bolts that are tightened with specified tightening an‐

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

– Lift gearbox with spindle of support bracket until gearbox
support makes contact with support arm of gearbox mount‐
ing.
– Start bolts by hand. Ensure to not screw in the bolts at an
angle while doing so.
04.2021
– Checking adjustment of assembly mountings ⇒ page 77 .

– When the bolts are tightened to specified torque, remove
support bracket -10 - 222 A- from engine.
Specified torques
♦ Battery; Assembly overview - battery ⇒ Electrical system;
Rep. gr. 27; Battery; Assembly overview - battery
2.5 Removing and installing pendulum

support
⇒ a2.5.1 nd installing pendulum support, Golf, Passat, Touran,
⇒ a2.5.2 nd installing pendulum support, Sharan”, page 77
2.5.1 Removing and installing pendulum

support, Golf, Passat, Touran, Tiguan,
Arteon
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Unscrew bolts -1, 2, 3-, and remove pendulum support.
Installing
Specified torques
Stage Bolts Specified torque/turning further angle
1 -2, 3- 50 Nm
2 -1- 130 Nm
3 -1 to 3- Turn 90° further
♦ Noise insulation; Assembly overview - noise insulation
⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

04.2021
2.5.2 Removing and installing pendulum

support, Sharan
Removing
insulation.
– First unscrew bolt -1-.
– Then remove bolts -2- and -3-.

– Remove pendulum support -4-.
Installation
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Specified torques
1 -2, 3- 50 Nm
2 -1- 100 Nm
2.6 Checking adjustment of assembly

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

support -2- and engine mounting -1-.
• Side surface of engine support casting should be located
parallel to support arm of engine mounting.
04.2021
• Distance -b- = distance -b-.
Note
Distance -a- = 10 mm can be checked with a metal rod of

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

mountings ⇒ page 78 .
2.7 Adjusting assembly mountings


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

– Using assembly lever, adjust engine/gearbox assembly until
specifications listed below are attained:

04.2021
• There must be a distance of -a- = 10 mm between engine

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

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

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

– On gearbox side, ensure that support arm and gearbox
mounting are parallel.
04.2021
• Distance -x- = distance -x-.

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

04.2021
3 Engine cover panel

⇒ a3.1 nd installing engine cover”, page 81
3.1 Removing and installing engine cover

Removing
– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not pull off engine cover panel abrupt‐
ly or only on one side.
Installing
– To prevent damage, do not strike engine cover panel with
your fist or a tool.
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
– Press engine cover panel into rubber grommets first on left
side and then on right side.
3. Engine cover panel 81

04.2021
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ o1.1 verview - cylinder block (pulley end)”, page 82
⇒ a1.2 nd installing poly-V belt”, page 85
⇒ a1.3 nd installing tensioner for poly V-belt”, page 87
⇒ a1.4 nd installing vibration damper”, page 88
⇒ a1.5 nd installing bracket for ancillaries”, page 95
⇒ a1.6 nd installing engine support”, page 98
⇒ s1.7 eal for vibration damper”, page 100
1.1 Assembly overview - cylinder block (pulley end)
82 Rep. gr.13 - Crankshaft group

04.2021
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Poly V-belt routing ⇒
page 84
ling ⇒ page 85
❑ When installing, make
sure it is properly seat‐
ed on pulleys.
2 - Tensioning device for poly
V-belt
❑ Swing with open-end
spanner to slacken poly
V-belt.
❑ Lock with locking pin -
T10060 A-.
ling ⇒ page 87
❑ Specified torque for
tensioning roller to ten‐
sioner: 60 Nm
3 - Bolt
❑ Renew
❑ 8 Nm +45°
4 - Bolt
❑ Renew
❑ Moisten O-ring with oil.
❑ Use counter-hold tool -
T10355- to loosen and
tighten
❑ See ⇒ Electronic parts
catalogue (ETKA) for
allocation
Property class 8.8: 150 Nm +90
Property class 10.9: 100 Nm +180

5 - O-ring
❑ Not a replacement part. Included in items supplied with bolt.
6 - Vibration damper
❑ With poly V-belt pulley
❑ Renew seal for vibration damper ⇒ page 100
7 - Ancillary bracket
❑ With oil filter and engine oil cooler
❑ Removing and installing ancillary bracket ⇒ page 95 .
❑ Removing and installing engine oil cooler ⇒ page 251
8 - Seal
❑ Renew
9 - Bolt
❑ Renew
1. Cylinder block (pulley end) 83

04.2021
10 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview - alternator
11 - Alternator
❑ Assembly overview ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview - alternator
12 - Dowel sleeves
❑ For air conditioner compressor
13 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ Assembly overview ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Assembly
overview - drive unit of air conditioner compressor.
14 - Bolt
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Assembly over‐
Ancillary bracket - specified torques and tightening sequence
– Fit bracket for ancillaries (first tighten bolt -4- by hand).
Note
If a further tightening angle is specified for certain bolts, these

must be renewed.
– Tighten bolts in sequence -1 … 5- in 3 stages as follows:

1. Tighten bolts by hand.
2. Tighten bolts to 20 Nm.
3. Turn bolts 90° further.

Poly V-belt routing

04.2021
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
1.2 Removing and installing poly-V belt

♦ Locking pin -T10060 A-
Removing, vehicles with washer fluid reservoir on left side
– If fitted, unscrew bolt -arrow-, and place aside breather line

-2-.

04.2021
– If poly V-belt is to be reinstalled, mark direction of rotation on

belt using chalk or felt tip pen before removing.
– To slacken poly V-belt turn tensioning device in direction of

-arrow-. To do so, fit tool from “above”.
– Lock tensioning device in place with locking pin -T10060 A-.
– Remove poly V-belt.
Removing, vehicles with washer fluid reservoir on right side

insulation.
– Remove washer fluid reservoir ⇒ Electrical system; Rep.
gr. 92; Windscreen washer system; Removing and installing
washer fluid reservoir.
– If poly V-belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen before removing.
– To slacken poly V-belt turn tensioning device in direction of
-arrow-.
– Lock tensioning device in place with locking pin -T10060 A-.
– Remove poly V-belt.

04.2021
Installing

– When installing used poly V-belts, observe the direction of
rotation marked on removal.
– Fit poly V-belt as shown in figure.
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
– Turn tensioning device in -direction of arrow-, and pull out
locking pin -T10060 A-.
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
1.3 Removing and installing tensioner for

poly V-belt
Removing
– Remove poly V-belt from tensioner ⇒ a1.2 nd installing poly-
V belt”, page 85 .

04.2021
– Unscrew bolts -arrows- and pull tensioning device -1- for

poly V-belt off ancillary bracket.
Installing
Specified torques
♦ ⇒ o1.1 verview - cylinder block (pulley end)”, page 82
1.4 Removing and installing vibration

damper
♦ Counter-hold tool -T10355-
♦ Assembly tool -T10531-
Components of assembly tool -T10531-:

♦ Support -T10531/1-
♦ Clamping pin -T10531/2-
♦ Turning over tool -T10531/3-

04.2021
♦ Flange nut -T10531/4-

The vibration damper securing bolt -A- is used to secure the
vibration damper -1- and the timing chain sprocket -2- on crank‐
shaft -3-. Before removing the vibration damper, lock the timing
chain sprocket in position relative to crankshaft as described
below.
Removing vibration damper
– Remove front part of right wheel housing liner, or remove

right wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66; Wheel housing liner; Removing and installing
front wheel housing liner.
– Remove poly V-belt ⇒ page 85 .
– Pull locking pin -T10060 A- out of tensioning device for poly
V-belt.
– Turn vibration damper to TDC position -arrow- using coun‐
ter-hold tool -T10355-.
• Notch on vibration damper must align with arrow marking on
cover for timing chains (bottom).
• The marking on the cover is located at »4 o'clock position«.
– Loosen vibration damper bolt by 1/2 turn using counter hold
tool -T10355-.

04.2021
– If vibration damper was turned while loosening bolt, reset

TDC position.
– Unscrew securing bolts -arrows- for timing chain cover. Bolts
must be renewed.
– Fit support -T10531/1- to vibration damper, as shown in illus‐

tration, and tighten knurled screws -arrows- by hand.
– Unscrew vibration damper bolt completely.

– Check if turning over tool -A- slides easily over clamping
pieces -B-. If necessary, turn tensioning bolt -arrow-.

04.2021
Note
Do not turn the tensioning bolt any more, otherwise the clamp‐
ing pin -T10531/2- will be jammed when it is screwed into the
crankshaft.
– Screw clamping pin -T10531/2- into crankshaft, and tighten it

hand-tight with a 12 mm open-end spanner -A-.
– Tighten tensioning bolt -A- by hand in order to lock the chain

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

T10531/1- and vibration damper -A-.

04.2021
Turning crankshaft without vibration damper
– Fit turning over tool -A- on clamping pin. Pay attention to

toothed contours of chain sprocket while doing so. In TDC
position the flat section of the tool faces upwards.
– Tighten turning over tool with flange nut -B-.
– Crankshaft can now be turned on hexagon -arrow-.

04.2021
Installing vibration damper
– If necessary, remove flange nut -B- and turning over tool -A-
from clamping pin.
– Fit vibration damper in TDC position. Pay attention to teeth
of chain sprocket -arrow- while doing so.
– Fit turning over tool -A- on clamping pin. The hexagon faces
towards vibration damper while doing so.
– Screw on flange nut -B-. Move vibration damper slightly back

and forth while doing so, in order to ensure that vibration
damper is properly seated on teeth. Tighten flange nut, until
vibration damper cannot be turned any more.
– Fit support -T10531/1- to vibration damper, as shown in illus‐
tration, and tighten knurled screws -arrows- by hand.

04.2021
– Unscrew flange nut -A-, and loosen clamping pin -B-.
– Unscrew clamping pin, and remove it together with turning

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

T10531/1-.

04.2021
Note
Observe the property class of the bolt. The property class is

indicated on the bolt head.
– Tighten vibration damper bolt using counter hold tool -

T10355-.
– Screw in new securing bolts -arrows-.
Further assembly is basically a reverse of the dismantling se‐

quence.
Specified torques
1.5 Removing and installing bracket for an‐

cillaries
♦ Drip tray for workshop hoist -VAS 6208-

04.2021
Removing
– Drain coolant ⇒ page 278 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27; Alterna‐
tor; Removing and installing alternator.
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.
– Separate connector -1- on air conditioning compressor regu‐

– Detach air conditioner compressor from bracket (refrigerant
hoses remain connected) and tie up to right side. Do NOT
stretch, kink or bend refrigerant lines and hoses.
– Disconnect connectors:
1 - For oil pressure switch -F1- -item 2-.

3 - For oil pressure switch for reduced oil pressure -F378-
-item 4-.
5 - For piston cooling jet control valve -N522- -item 7-
– Remove oil filter element ⇒ Maintenance; Booklet ; Engine
oil: Draining; Renewing oil filter and replenishing engine oil.
– Remove bolt -1- for dipstick guide tube.

04.2021
– Unclip guide tube from timing chain cover (top) in direction of

-arrow-.
Note
Disregard -item 2-.
– Move wiring harness clear.
– Place drip tray -VAS 6208- beneath engine.

– Unscrew bolts -1 to 5- and pull ancillary bracket with engine
oil cooler off coolant pump housing.
– “Guide out” ancillary bracket between intake manifold and
engine support.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ If a further tightening angle is specified for certain bolts,

these must be renewed.
♦ Renew O-rings and gaskets.
– Moisten new O-rings -4- with coolant.

04.2021
– Insert connecting piece -2- in engine oil cooler -1-.

– Push ancillary bracket with engine oil cooler -1- onto con‐
necting piece, start bolts, and tighten them ⇒ page 84 .
– Install air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Assembly over‐
– Install alternator ⇒ Electrical system; Rep. gr. 27; Alternator;
Removing and installing alternator.
– Install oil filter and check oil level ⇒ Maintenance; Booklet ;
Engine oil: Draining; Renewing oil filter and replenishing en‐
gine oil.
Specified torques
♦ ⇒ o2.1 verview - cover for timing chain”, page 157
♦ Alternator; Assembly overview - alternator ⇒ Electrical sys‐
tem; Rep. gr. 27; Alternator; Assembly overview - alternator.
1.6 Removing and installing engine sup‐

port
♦ Bits -T10099-

04.2021
Removing
– Unclip lambda probe wire from retainers -arrows-.

insulation.
– Removing engine mounting ⇒ page 72 .
– Slightly lower engine, and unscrew bolts -1- and -2- from
below using bit -T10099-.
– Lift engine again, and unscrew bolt -3- from above.

Installing
Engine support - specified torque and installation sequence

04.2021
Note
Renew bolts.
– Tighten bolts in stages in the sequence shown.

1 -1 to 3- 7 Nm
2 -1 to 3- 40 Nm
– Install engine mounting ⇒ page 72 .
1.7 Renewing seal for vibration damper

♦ Thrust piece -T10354-
♦ Thrust pad -T10375-
♦ Flange nut -10531/4- from assembly tool -T10531-

04.2021
♦ Extractor hook -T40274-
Removing
– Remove vibration damper ⇒ page 88 .

• Clamping pin -T10531/2- is inserted.
– Using extractor hook -T40274-, pull out seal -arrow-.
Installing
– Clean contact surface and sealing surface.

– Slide seal -arrow- onto thrust piece -T10354-.
• Closed side of oil seal faces towards thrust piece -T10354-.
– Slide seal -arrow- with thrust piece -T10354- onto clamping
pin -T10531/2-, and fit it to lower timing chain cover.

04.2021
– In addition, fit thrust pad -T10375-, and screw on flange nut

-10531/4-.
– Using open-end spanner, AF 21, tighten flange nut until seal

has been pressed in as far as stop.
Note
♦ Renew bolt for vibration damper.

♦ Renew O-ring.

quence. During this procedure, observe the following:
– Install vibration damper ⇒ page 88 .

04.2021
2 Cylinder block, gearbox end

⇒ o2.1 verview - cylinder block, gearbox end”, page 103
⇒ a2.2 nd installing flywheel”, page 104
⇒ a2.3 nd installing sealing flange on gearbox side”, page 106
2.1 Assembly overview - cylinder block, gearbox end
1 - Flywheel
ling ⇒ page 104
❑ Can only be installed in
one position, holes are
offset.
2 - Dowel sleeve
3 - Sealing flange, gearbox
side
❑ With seal
❑ Renew
ling ⇒ page 106
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Do not remove guide
sleeve until sealing
flange has been slid
onto crankshaft journal.
4 - Cylinder block
5 - Bolt
page 106
6 - Intermediate plate
❑ Illustration does not
show version installed
in vehicle.
❑ Must seat on dowel
sleeves.
❑ Do not damage or bend
when assembling.
❑ Is fitted onto sealing flange ⇒ page 103
7 - Dowel sleeve
8 - Bolt
❑ For dual-mass flywheel
❑ Renew
❑ 60 Nm +90°
Installing intermediate plate
2. Cylinder block, gearbox end 103

04.2021
– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
2.2 Removing and installing flywheel

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

-item B-, loosen bolts for flywheel.
– Unscrew bolts -2-, and detach flywheel -1-.

04.2021
Installing
NOTICE
Oil may start to escape if threaded holes in crankshaft are not
cleaned or not cleaned properly.
– Clean threaded holes in crankshaft of adhesive residue
and locking fluid.
– Make sure not to damage oil seal when cleaning.
– Clean crankshaft flange until adhesive and locking fluid resi‐

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

vacuum cleaner at the threaded connection in order to col‐
lect the locking fluid residue that comes out.
– Repeat cleaning process for all threaded holes of crankshaft.
– Remove oil residue using commercially available oil dissolv‐
ing agent.
– Use a cloth to clean the flange of the crankshaft. Crankshaft
threads must be free of oil and grease.

04.2021
NOTICE
Risk of damaging flywheel.
– Mount flywheel in such a way that bolts align centrally with
holes.
– Screw in bolts by hand. Do not use pneumatic wrenches or
other power impact wrenches.
– Screw in bolts for flywheel as far as stop in diagonal se‐

quence.
– Insert counter-hold tool -3067- in hole in cylinder block -A-
and tighten bolts.
Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 103
2.3 Removing and installing sealing flange

on gearbox side
♦ Guide piece -T10122/6- or -T10122/6A- from fitting tools
-T10122B- or -T10122C-
♦ Assembly aid -T10122/1- from fitting tools -T10122B- or -

T10122C-

04.2021
♦ Hand drill with plastic brush attachment

♦ Safety glasses
♦ Sealant ⇒ Electronic parts catalogue (ETKA)
Removing
– Remove flywheel ⇒ page 104 .
– Detach intermediate plate from sealing flange and dowel
pins -arrows-.
– Unscrew bolts -1 … 8-.
– Prise off sealing flange.

Installing
Note
♦ Observe use-by date of silicone sealant.

♦ The sealing flange must be installed within 5 minutes of
applying the silicone sealant.
♦ In order to prevent the lubrication system from being soiled
with sealant residue cover the open section of the sump with
a clean cloth.
CAUTION
Risk of eye injury caused by sealant residue.
– Remove sealant remaining on cylinder block with flat scraper

or rotating plastic brush.

04.2021
– Clean sealing surfaces. They must be oil and grease free.

– Clean crankshaft journal. If there is any rust, lightly coat
crankshaft journal with oil.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
2 mm).
– Apply silicone sealant as shown to clean sealing surface of

sealing flange.
♦ Thickness of sealant bead: 2 to 3 mm.

04.2021
Note
♦ The sealing flange must be installed within 5 minutes after

applying the silicone sealant.
♦ The bead of sealant must not be thicker than specified, oth‐
erwise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
♦ Check sealing flange; it must be free of kinks and damage.
♦ The sealing lip must face engine following installation. If
the sealing lip »folds out« during installation, oil leaks may
occur.
– Check guide -T10122/6- -(B)-; it must be clean and free of

sharp edges.
– Attach assembly aid -T10122/1- -(A)- to guide -(B)-.

– Push sealing flange -C-, leading with the outer side, onto
guide -B-.
– Remove assembly aid -A-.

04.2021
– Put guide -A- with sealing flange -B- onto crankshaft journal.
– It is not necessary to tighten the bolts -arrows-.

– Push sealing flange -B- over guide -A- onto crankshaft jour‐
nal.
– Remove guide -A-.
– Tighten new bolts evenly in the sequence shown.

1 -1 to 8- Screw in by hand as far as stop
2 -1 to 8- 9 Nm
Note
After installing the sealing flange, wait about 30 minutes for the
sealant to dry. Only then fill with engine oil.

quence.
Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 103

04.2021
3 Crankshaft
⇒ o3.1 verview - crankshaft”, page 111
⇒ d3.2 imensions”, page 113
⇒ o3.3 f main bearing shells”, page 113
⇒ n3.4 eedle bearing in crankshaft”, page 115
⇒ a3.5 xial clearance of crankshaft”, page 117
⇒ r3.6 adial clearance of crankshaft”, page 118
⇒ a3.7 nd installing sender wheel”, page 119
3.1 Assembly overview - crankshaft
Note
Secure engine to repair stand using engine and gearbox sup‐

port -VAS 6095- when dismantling/assembling engine ⇒ page
40 .
3. Crankshaft 111
04.2021
1 - Cylinder block
2 - Bearing shell for cylinder
block
❑ With oil groove.
❑ Moisten with oil.
❑ Do not interchange
used bearing shells
(mark).
❑ Marking of crankshaft
bearing shells (classifi‐
cation) ⇒ page 113
3 - Crankshaft
❑ After removing, place
it down so that the
sender wheel ⇒ Item 8
(page 112) is not dam‐
aged and the crank‐
shaft does not rest on
the sender wheel
❑ If the crankshaft is
renewed, the bearing
shells must be realloca‐
ted to bearing cap ⇒
page 113
❑ Axial clearance ⇒ page
117
❑ Radial clearance ⇒
page 118
❑ Do not rotate crank‐
shaft when checking ra‐
dial clearance
❑ Crankshaft dimensions
⇒ page 113 .
4 - Bearing shell for bearing
cap
❑ Without oil groove.
❑ Do not interchange used bearing shells (mark).
❑ Marking of crankshaft bearing shells (classification) ⇒ page 113
5 - Bolt
❑ Renew
❑ Tightening sequence ⇒ page 113
6 - Bearing cap
❑ Bearing cap 1: belt pulley end.
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
7 - Bolt
❑ 10 Nm +90° further
❑ Renew
❑ Sender wheel must be renewed if bolts are loosened ⇒ page 119
8 - Sender wheel
❑ For engine speed sender -G28-
❑ Can only be installed in one position, holes are offset.
❑ Always renew sender wheel if securing bolts have been unscrewed

04.2021
9 - Thrust washers
❑ For bearing 3
10 - Bolt
❑ Renew
Crankshaft tightening sequence
1. Tighten bolts -1 … 10- and -arrows A- by hand.

2. Tighten bolts -1 … 10- initially to 65 Nm.
3. Turn bolts -1 … 10- 90° further using a rigid wrench.
4. Tighten bolts -arrows A- initially to 20 Nm.
5. Turn bolts -arrows A- 90° further using a rigid wrench.
3.2 Crankshaft dimensions

(Dimensions in mm)
Honing dimension Main journal ∅ Conrod journal ∅
1)
Basic dimension 52.00 47.80

1)No provision has yet been made to recondition worn crank‐
shafts.
3.3 Allocation of main bearing shells

Bearing shells of the correct thickness are allocated to the cylin‐
der block at the factory. Coloured dots are used to identify the
thickness of the bearing shells.
Which bearing shell is to be inserted at each place in the cylin‐
der block (upper bearing shell) is marked by letters on the lower
sealing surface or on the front side of cylinder block.
Which bearing shell is to be inserted at each place in bearing
cap (lower bearing shell) is marked by letters on the crankshaft.
3. Crankshaft 113
04.2021
The first letter is allocated to bearing cap one, the second to

bearing cap two, etc.
Marking on bearing shell for cylinder block:
Note
The marking on the cylinder block can be found engraved either

in the sump sealing surface or in the front end (gearbox side) of
the cylinder block.
Identification on cylinder block is allocated to upper bearing

shell (bearing shell for cylinder block).
– Make a note of the letters and determine the colour marking

for installation with regard to the table.

04.2021
Marking on bearing shell for bearing cap:
Identification on crankshaft is allocated to lower bearing shell

(bearing shell for bearing cap).
– Make a note of the letters and determine the colour marking
for installation with regard to the table.
S = black
R = red
G = yellow
B = blue
W = white
3.4 Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO 22-1 -VAS 251 621-
3. Crankshaft 115
04.2021
♦ Internal puller -VAS 251 635-
♦ Pin -VW 207 C-
Condition:
• The front edges of the inner puller must be free of chips.
• Gearbox has been removed.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller -VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 -VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-
and-cage assembly -arrow-.

04.2021
Installing
– Clean bearing seat in crankshaft and apply as thin coating of

grease.
– Drive needle bearing into crankshaft to installation depth us‐
ing drift -VW 207 C-.
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

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

shaft
3. Crankshaft 117
04.2021
♦ Universal dial gauge holder -VW 387-
♦ Dial gauge -VAS 6079-
– Screw dial gauge -VAS 6079- with universal dial gauge hold‐
er -VW 387- onto cylinder block and set against crank web
with projection of approx. 2 mm.
– Press crankshaft against dial gauge by hand and set gauge
to “0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 … 0.23 mm
• Wear limit: 0.30 mm
3.6 Measuring radial clearance of crank‐

shaft
♦ Plastigage

04.2021
Note
♦ Do not interchange used bearings.

♦ Bearing shells worn down to nickel layer must be renewed.
– Remove crankshaft bearing cap, and clean bearing cap and

bearing journal.
– Place a length of Plastigage corresponding to the width of
the bearing on the bearing journal or bearing shell.
• The Plastigage must be positioned in the centre of the bear‐
ing shell.
– Fit crankshaft bearing cap, and tighten using old bolts
-1 to 10- ⇒ page 113 . Make sure not to rotate crankshaft
while tightening.
Note
Disregard bolts -arrows A-.
– Remove crankshaft bearing cap again.

– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.017 … 0.037 mm
• Wear limit: 0.15 mm
3.7 Removing and installing sender wheel

Removing
– Remove engine.
– Remove sealing flange on gearbox side ⇒ page 106 .
– Remove top section of sump ⇒ page 245 .
– Remove balancer shaft timing chain ⇒ page 190 .
3. Crankshaft 119
04.2021
– Unscrew conrod bearing cap.

– Remove crankshaft bearing cap.
– Remove crankshaft and unscrew sender wheel.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Renew sender wheel -2- each time bolts -1- are loosened.
Note
♦ The second time the bolts are tightened, the contact points
in the sender wheel for the countersunk heads are deformed
so much that the bolt heads seat on the crankshaft -3-,
-arrows- and the sender wheel is loose under the bolts.
♦ The sender wheel can only be installed in one position; the
holes are offset.
– When the sender wheel is renewed, the adaption values

must be erased if this function is available in the engine/mo‐
tor control unit. To do this, connect vehicle diagnostic tester,
switch on ignition, and select the following menu option:
♦ 0001 - Reset adaptation values of engine ctrl.
module
♦ Reset adaption values crankshaft sender wheel
Specified torques
♦ ⇒ o3.1 verview - crankshaft”, page 111

04.2021
4 Balancer shaft
⇒ o4.1 verview - balance shaft”, page 121
⇒ a4.2 nd installing balance shaft”, page 123
⇒ o4.2.3 il seal for balance shaft (inlet side)”, page 128
4.1 Assembly overview - balance shaft
Note
♦ After working on the chain drive, adapt learnt values in en‐

gine control unit. To do this, switch on ignition, and select
the following menu options on vehicle diagnostic tester:
newing chain
4. Balancer shaft 121

04.2021
1 - Bolt
❑ Renew
2 - Balancer shaft
❑ Exhaust side
❑ Renew only in pairs
❑ Lubricate bearing with
engine oil
❑ Renewing ⇒ page 126
3 - Gear ring for needle bear‐
ing
❑ Renew each time bal‐
ance shaft is removed.
❑ The gear ring for nee‐
dle bearing is colour
coded. A gear ring
for needle bearing with
the same colour coding
must be installed
4 - Tube for balancer shaft
❑ Fitting position ⇒ page
122
5 - Cylinder block
6 - Oil seal for balance shaft,
inlet side
7 - Balancer shaft
❑ Inlet side
❑ Renew only in pairs
engine oil
8 - Gear ring for needle bearing
❑ Renew each time balance shaft is removed.
❑ The gear ring for needle bearing is colour coded. A gear ring for needle bearing with the same colour
coding must be installed
9 - Bolt
❑ Renew
Tube for balancer shaft - installation position

04.2021
The apertures -arrow- must face towards chain side.
4.2 Removing and installing balance shaft

⇒ a4.2.1 nd installing inlet side balance shaft”, page 123
⇒ a4.2.2 nd installing exhaust side balance shaft”, page 126
4.2.1 Removing and installing inlet side bal‐

ance shaft
Needle bearing must be renewed after each removal. Install
new needle bearing with same colour code.
Removing
– Remove toothed belt for coolant pump ⇒ page 322 .
– Remove timing chain cover (top) ⇒ page 159 .
– Remove lower timing chain cover ⇒ page 162 .
– Remove camshaft timing chain and drive chain for balance
shafts ⇒ page 171 .
– Unscrew bolt -2-.
Note
The drive sprocket bolt has a left-hand thread.

04.2021
– Detach drive sprocket -1- for toothed belt for coolant pump.
– Remove intermediate shaft sprocket -1-.
– Unscrew bolt -2- for balance shaft on inlet side and pull out
balance shaft.
Installing
– Lubricate bearing points of balance shaft -arrows- with en‐

gine oil.
– Install balance shaft for inlet side and tighten bolt -2-.

04.2021
– Renew O-ring -1- and lubricate with engine oil.
– Lubricate bearing mounting with engine oil and install; dowel

pin -arrow- for bearing mounting must engage in bore in
cylinder block.
Note
♦ The idler gear must always be renewed. Otherwise no tooth

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

tioned between markings on faces of gear teeth.
– Tighten bolt -1- for idler gear; tightening sequence ⇒ page
189 .

04.2021
– Check markings on idler gear/balance shaft -arrow-.

– Install drive chain for balance shafts and camshaft timing
chain ⇒ page 171 .
– Install timing chain cover (bottom) ⇒ page 162 .
– Install upper timing chain cover ⇒ page 159 .
– Renew oil seal for balance shaft on inlet side ⇒ page 128 .
– Fit toothed belt for coolant pump ⇒ page 322 .
Specified torques
♦ ⇒ o4.1 verview - balance shaft”, page 121
4.2.2 Removing and installing exhaust side

balance shaft
Needle bearing must be renewed after each removal. Install
new needle bearing with same colour code.
Removing
shafts ⇒ page 171 .
– Unscrew bolt -1- for balance shaft on exhaust side and pull
out balance shaft.

04.2021
Installing
– Check installation position of tube for balance shaft. The

apertures -arrow- must face towards chain side.
– Lubricate bearing points of balance shaft -arrows- with en‐
gine oil.
– Install balance shaft for exhaust side.
– Before tightening bolt -1-, check that balance shaft rests flat
against crankcase.

04.2021
Note
If the balancer shaft does not rest flat, the pipe for balancer
shaft must be inserted again.

– Install drive chain for balance shafts and camshaft timing
chain ⇒ page 171 .
Specified torques
♦ ⇒ o4.1 verview - balance shaft”, page 121
4.2.3 Renewing oil seal for balance shaft (in‐

let side)
♦ Thrust piece -T10353/1-
– Remove toothed belt for coolant pump ⇒ page 322 .

– Detach drive sprocket -1- for toothed belt for coolant pump.
– Press screwdriver -1- firmly onto section -2- of oil seal
-arrow B-.

04.2021
– Lever out oil seal -arrow A-.

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

• The marking “Luftseite” (or “Outside”) -arrow- should be legi‐
ble from the outside.
Note
– Apply thrust piece -T10353/1- to oil seal -1- and press into
cylinder block as far as stop using bolt -2- (take care not to
tilt oil seal).
– Fit toothed belt for coolant pump ⇒ page 322 .

04.2021
5 Pistons and conrods

⇒ o5.1 verview - pistons and conrods”, page 130
⇒ a5.2 nd installing pistons”, page 134
⇒ p5.3 istons and cylinder bores”, page 136
⇒ n5.4 ew conrod”, page 139
⇒ r5.5 adial clearance of conrods”, page 139
5.1 Assembly overview - pistons and conrods

04.2021
1 - Bolts
❑ Renew after removal
❑ Apply engine oil to
thread and contact sur‐
face
❑ Use old bolts to meas‐
ure radial clearance.
❑ 45 Nm +90°
2 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ Conrod bearing cap on‐
ly fits in one position
and only on the appro‐
priate conrod due to
the cracking procedure
separating the cap from
the conrod
❑ Mark allocation to cylin‐
der and conrod in col‐
our -A-
❑ Installation position:
Marking -B- faces to‐
wards pulley end.
❑ Separating new conrod
⇒ page 139 .
3 - Bearing bushes
132
❑ Renew worn bearing
shells
❑ Apply engine oil before
installing
❑ Axial clearance
♦ New: 0.10 to 0.35 mm
♦ Wear limit: 0.40 mm
❑ Measuring radial clearance ⇒ page 139
4 - Connecting rod
❑ Renew as set only.
❑ Mark allocation to cylinder and to conrod bearing cap
❑ Installation position: Marking -B- faces towards pulley end.
❑ Separating new conrod ⇒ page 139 .
❑ Measuring radial clearance ⇒ page 139
5 - Pressure relief valve
❑ 27 Nm
6 - Oil spray jet
❑ For piston cooling
7 - Retaining ring
8 - Piston pin
❑ Apply engine oil before installing
9 - Piston
5. Pistons and conrods 131

04.2021
❑ Installing with piston installation sleeve -T40347- ⇒ page 134
❑ Installation position: arrow on piston crown faces towards pulley end
❑ Mark allocation to cylinder
❑ Checking piston and cylinder bore ⇒ page 136
10 - Compression rings
❑ Offset gaps by 120°
❑ Installation position: “TOP” or “R” marking must face upwards towards piston crown.
❑ ⇒ Fig. ““Installing compression rings”“, page 133
❑ ⇒ Fig. ““Checking piston ring gap”“, page 136
❑ ⇒ Fig. ““Checking ring-to-groove clearance”“, page 137
❑ ⇒ Fig. ““Allocation of piston rings only in connection with 3-part oil scraper ring”“, page 132
11 - Oil scraper ring
❑ 2-part or 3-part, depending on version
❑ Install in such a way that upper gap of three-part oil scraper ring is offset by 120° relative to adjacent
compression ring
❑ ⇒ Fig. ““Checking piston ring gap”“, page 136
❑ ⇒ Fig. ““Checking ring-to-groove clearance”“, page 137
❑ ⇒ Fig. ““Installing oil scraper ring, 3-part”“, page 133
❑ ⇒ Fig. ““Allocation of piston rings only in connection with 3-part oil scraper ring”“, page 132
Bearing shells - installation position
– Position bearing shells in centre of conrod and conrod bear‐

ing cap when fitting.
Distance -a- must be identical on both sides.
Allocation of piston rings only in connection with 3-part oil scra‐
per ring

04.2021
1- Compression ring with chamfer -arrow A- on upper inner

side. »TOP« marking and lettering point inwards
2- Compression ring shoulder -arrow B- on lower outer
side. »TOP« marking and lettering point inwards
3- Oil scraper ring, three-piece design
Installing compression rings
• »TOP« marking and lettering point upwards.

• Compression ring -2- should not be opened using piston ring
pliers -VAS 211 003- any further than necessary to just push
it over piston -1-.
Installing oil scraper ring, 3-part

04.2021
– Note installation position of spring:

• Butts of plates -2, 3- and spring -1- must have an offset of at
least 90° to each other.
– Install by hand.
Installation sequence:
1. Insert spring -1- into groove.
2. Insert plate -3- in bottom of groove.
3. Insert plate -2- in top of groove.
5.2 Removing and installing pistons
Note
If pistons with 3-part oil scraper ring are installed without the
piston installation sleeve -T40347-, the oil scraper ring will be
damaged.

♦ Pin -VW 222 A-
♦ Piston installation sleeve -T40347- (not shown)

Removing
– Remove engine, and secure it to engine and gearbox sup‐
port -VAS 6095-.

04.2021
– Remove cylinder head ⇒ page 145 .

– Mark piston installation position and corresponding cylinder
number.
– Mark conrod installation position and corresponding cylinder
number ⇒ Item 4 (page 131) .
– Remove conrod bearing cap and withdraw piston and con‐
rod upwards.
– Remove retaining ring from piston pin eye.
– Remove retaining ring -2- from piston pin eye.

– Drive out piston pin -3- using drift -VW 222A-.
Note
If the piston pin is difficult to move, heat the piston to approx.

60°C.
– Remove piston -1- from conrod -4-.

Installing
note the following:
• Renew bolts that are tightened with turning further angle
after each removal.
• Arrow on piston crown points to belt pulley end.
– Install oil scraper ring: procedure for 3-part oil scraper ring ⇒
page 133 .
– Install compression rings ⇒ page 133 .
– Oil contact surfaces of bearing shells and cylinder wall with
engine oil.

04.2021
– Carefully push piston -1- into cylinder -arrow- by hand using

piston installation sleeve -T40347-.
– Install conrod bearing cap, noting installation position ⇒ Item
2 (page 131) .
– Install cylinder head ⇒ page 145 .
– Install upper part of sump ⇒ page 245 .
Specified torques
♦ ⇒ page 130
5.3 Checking pistons and cylinder bores

Checking piston

♦ Micrometre 75 - 100 mm -VAS 6071-
– Using a micrometer, measure approx. 15 mm from the lower
edge, perpendicular to the piston pin axis.
♦ Difference between actual and nominal diameter max.
0.04 mm.
Piston diameter
Basic dimension mm 82.421)
• 1)
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear down.
Checking piston ring gap

04.2021
– Push in piston ring at right angles.

– Push piston ring from above to approx. 15 mm from bottom
end of cylinder.
– Push in using a piston without piston rings.
Piston ring gap in connection New Wear limit
with two-part oil scraper ring
1st compression ring 0.30 to 0.40 0.80
2nd compression ring 0.40 to 0.50 0.80
Oil scraper ring 0.20 to 0.40 0.80
Piston ring gap in connec‐ New Wear limit

tion with three-part oil scra‐
per ring
1st compression ring 0.30 to 0.60 mm
0.40 mm
2nd compression ring 0.40 to 0.70 mm
0.50 mm
Oil scraper ring Cannot be Cannot be
measured measured
Checking ring-to-groove clearance
– Clean annular groove of piston before check.

Ring-to-groove clearance New Wear limit
in connection with two-
part oil scraper ring
1st compression ring 0.06 to 0.09 mm 0.20 mm
2nd compression ring 0.03 to 0.06 mm 0.15 mm
Oil scraper rings Cannot be measured

04.2021
Ring-to-groove clearance New Wear limit

in connection with three-
part oil scraper ring
1st compression ring Cannot be measured
2nd compression ring Cannot be measured
Oil scraper rings Cannot be measured
Checking cylinder bores
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support -VAS 6095-, as measurements
may be incorrect.

♦ Cylinder gauge -VAS 6078-
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Measure at 3 points -c-, in direction -a- and direction -b-,

using cylinder gauge -VAS 6078-.
♦ Deviation from nominal dimension: max. 0.08 mm

Piston diameter Cylinder bore
diameter
Basic dimension mm 82.421) 82.51
• 1)Dimensions without graphite coating (thickness
0.02 mm). The graphite coating wears away.

04.2021
5.4 Separating new conrod

On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap
cannot be removed by hand:
– Mark allocation of conrod to cylinder.
– Clamp conrod -1- in a vice below the dashed line using
aluminium vice clamps.
– Unscrew both bolts -2- about 5 turns.

– Using a plastic hammer, carefully knock against conrod
bearing cap in -direction of arrow- until it is loose.
5.5 Checking radial clearance of conrods

♦ Plastigage
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten it using old bolts ⇒ Item
1 (page 131) . When tightening, make sure not to rotate
crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.02 to 0.06 mm
• Wear limit: 0.09 mm.

04.2021
– Renew conrod bolts.
5.6 Removing and installing oil spray jets

♦ Multi-point bit -T10545-
Note
The crankshaft must be removed to allow for removing the oil

spray jet for cylinder 4.
Removing
insulation.
– Turn crankshaft via vibration damper securing bolt in direc‐
tion of engine rotation until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using TORX bit -T10545-.
– Remove oil spray jets -2-.

Installing
NOTICE
Risk of damage to oil spray jets caused by deformation.
– Do not bend oil spray jets.
1- Pressure relief valve - specified torque ⇒ Item 5 (page

131)

04.2021
2- Oil spray jet

• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
– Install upper part of sump ⇒ page 245 .
– Install noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.

04.2021
15 – Cylinder head, valve gear

1 Cylinder head
⇒ o1.1 verview - cylinder head”, page 142
⇒ a1.2 nd installing cylinder head”, page 145
⇒ a1.3 nd installing vacuum pump”, page 152
⇒ c1.4 ompression”, page 154
1.1 Assembly overview - cylinder head
Note
♦ Renew cylinder head bolts.

♦ Always renew self-locking nuts, bolts which have been tight‐
ened with turning further angle, as well as oil seals and
gaskets.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder
head.
♦ After fitting a new cylinder head or cylinder head gasket, the
engine oil and coolant must be changed.
142 Rep. gr.15 - Cylinder head, valve gear

04.2021
1 - Dowel pin
2 - Cylinder head gasket
❑ Renew
❑ Observe installation po‐
sition: Part number to
cylinder head
3 - Cylinder head
ling ⇒ page 145
❑ Check for distortion ⇒
page 145 .
4 - Bolt
❑ Renew
❑ Note procedure when
loosening ⇒ page 144 .
❑ Note procedure when
tightening ⇒ page 144 .
5 - Heat shield
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 9 Nm
8 - Heat shield
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - Union
❑ For coolant hose
12 - O-ring
❑ Renew
❑ Moisten with coolant
13 - Cylinder head bolt
❑ Renew
❑ Note procedure when loosening ⇒ page 144 .
❑ Note procedure when tightening ⇒ page 144 .
14 - O-ring
❑ Renew
15 - Union
❑ For coolant hose
16 - Bolt
❑ 9 Nm
17 - Support
❑ For engine cover panel
18 - Engine lifting eye
19 - Bolt
1. Cylinder head 143

04.2021
❑ Renew
❑ 8 Nm +90°
20 - Partition
21 - Support
22 - Engine lifting eye
23 - Bolt
❑ Renew
❑ 8 Nm +90°
24 - Dowel pin
Loosening cylinder head bolts

– Loosen cylinder head bolts in the sequence -1 … 10-.
Tightening sequence for cylinder head
– Tighten cylinder head bolts in the sequence -1 … 10- as

follows:
Stage Bolts Specified torques/angle specifica‐
tions
1 -1 to 10- Screw in by hand as far as stop
2 -1 to 10- 50 Nm
5 -Arrows- 8 Nm
6 -Arrows- Turn 90° further

04.2021
Checking cylinder head for distortion
– Use straight edge 500 mm -VAS 6075- and feeler gauge to

measure cylinder head for distortion at several points.
♦ Max. permissible distortion: 0.05 mm
1.2 Removing and installing cylinder head

♦ Standard blade scraper (blade width min. 40 mm)

Removing
Note
♦ Before the cylinder head is removed, the engine support and

engine mounting must be reinstalled temporarily, because
the eyes of the support bracket are secured to the cylinder
head.
♦ Fit the cable ties in the original position when installing.
♦ Seal open channels of intake and exhaust system with suita‐
ble plugs from engine bung set -VAS 6122-.
♦ Cover the openings in the gearbox with a cloth to prevent
any coolant from getting into the clutch housing.


04.2021

– Remove camshafts ⇒ page 199 .
– Reinstall engine support and engine mounting, and tighten
bolts by hand.
– Detach spindles of support bracket -10 - 222 A-.
– Remove front exhaust pipe with catalytic converter ⇒ page
550 .
– Remove Lambda probe 1 before catalytic converter -GX10-
⇒ page 497 .
– Release hose clip -2- and detach right charge air hose from
charge air cooler.

04.2021

– Unplug electrical connector -1- at charge pressure sender
-G31- and detach air pipe (right-side).
– Remove air pipe between turbocharger and charge air cool‐
er ⇒ page 410 .
– Release hose clips -arrows- and detach coolant hoses.
– Swivel coolant line -1- to side.

1 - For oil pressure switch -F1-

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

04.2021
5 - For piston cooling jet control valve -N522-

– Unscrew bolt -1- and nut -3- and remove bracket -2- for
intake manifold.
1- For throttle valve module -GX3-

2- For intake manifold sender -GX9-.
3- For fuel pressure sender -G247-.
– Remove connector -4- from retainer.
– Move electrical wiring harness clear and press to one side.
– Remove connector -3- for knock sensor 1 -G61- from retain‐
er and disconnect it.

04.2021
– Separate electrical connectors -2, 4-.

– Separate connectors and lay wiring harnesses to one side:
1- For intake manifold flap valve -N316-.

2- For coolant shut-off valve -N82-.
3- For coolant temperature sender -G62-
4- For stage 3 oil pressure switch -F447-
– Unscrew bolts -arrows- and nut -1-.
– Remove heat shield -2-.

– Remove bolt -1- and loosen bolt -3-.

04.2021
– Remove bracket -2- for turbocharger.

– Unscrew nuts -arrows-.
– Detach turbocharger from cylinder head and tie up to rear.

– Unscrew cylinder head bolts in sequence -1 to 10-.
Note
Make sure all hoses/pipes and wiring are removed.
– Take off cylinder head and set it down on a soft surface

(foam plastic).

04.2021
Installing
NOTICE
Using unauthorised sanding or abrasive media may lead to
secondary damage such as, for example, damage to the tur‐
bocharger or the conrod bearings.
– Do not use sandpaper, grinding wheels, abrasive or scour
pads or any other sanding or abrasive media.
– Sealing surface (see fig.) must not project.
– Discolouration (dark spots, see fig.) do not need to be
removed.
– When removing the sealant residue, make sure no loose
particles get into the open channels of the engine.
– Ensure that all adjacent workspaces are clean, and that
none of the above mentioned sanding or abrasive media
are used.
– Do not use any other means rather than a standard blade

scraper to remove the sealant residue from the cylinder
head and cylinder block.
Only use the blade scraper at a flat angle and with care; the
sealing surfaces must not be damaged!
– Remove any loose remains using a lint-free cloth.
– If necessary, remove oil or coolant from the blind holes of
the cylinder head screws.
– Do not remove new cylinder head gasket from packaging
until it is ready to be fitted. The coating and the indented
area of the cylinder head gasket must not be damaged.
– Position cylinder head gasket.
– Note centring pins in cylinder block -arrows-.

04.2021
– Check installation position of cylinder head gasket. Charac‐

teristic: the part number should be legible from the inlet side.
– If crankshaft has been turned in the meantime, position cyl‐
inder number 1 piston to TDC and then turn crankshaft back
slightly. When doing so, ensure that timing chain is not dam‐
aged.
– Fit cylinder head.
– Insert and tighten cylinder head bolts. Tightening sequence
⇒ Fig. ““Tightening sequence for cylinder head”“, page 144
Note
♦ If a new cylinder head is installed, contact surfaces between

roller rocker fingers and running surface of cam must be
oiled.
♦ After fitting a new cylinder head or cylinder head gasket, the
engine oil and coolant must be changed.
♦ Renew gaskets, oil seals and self-locking nuts.
♦ Hose connections and air duct pipes must be free of oil and
grease before assembly.
logue (ETKA).
♦ Spray the worm screws of the used hose clips with penetrat‐
ing spray before installing.
– Install camshafts, but do not fit camshaft timing chain yet ⇒

page 207 .
– Support engine in its installation position again ⇒ page 51 .
– Removing engine mounting and engine support.
– Now, install camshaft timing chain ⇒ page 210 .
The remaining assembly steps are basically a reverse of the
dismantling procedure, when doing this note as follows:
– Change engine oil ⇒ Maintenance; Booklet ; Engine oil:
Draining; Renewing oil filter and replenishing engine oil.
– Fill with new coolant ⇒ page 278 .
Specified torques
♦ ⇒ o1.1 verview - cylinder head”, page 142
♦ ⇒ o4.1 verview – intake manifold”, page 445
♦ ⇒ o3.1 verview - coolant pipes”, page 343
♦ ⇒ o1.1 verview - turbocharger”, page 374
♦ ⇒ o1.1 verview – silencers”, page 501
1.3 Removing and installing vacuum pump

Removing:

04.2021
– Press release tabs on vacuum hose -1-, and remove hose

from vacuum pump.
– Release fastener -arrow-, detach wiring duct upwards from
bracket and press forwards.
NOTICE
Risk of damage to coolant pipes caused by deformation.
– Never attempt to reshape the coolant pipe.
– Unscrew bolts -1, 2 and 3-, and carefully swivel coolant line
to one side slightly.
– Remove high-pressure pump with »roller tappet« ⇒ page
488 .
– Unscrew bolts -arrows-, and remove vacuum pump.
Note
Dismantling of the vacuum pump is not permitted.

04.2021
Installing:
• Specified torques ⇒ page 197

– Clean sealing surfaces.
– Position drive lug of vacuum pump carrier so that it engages
in slot of camshaft when vacuum pump is fitted.
– Position new gasket on vacuum pump, insert 2 bolts, and fit
vacuum pump with gasket on cylinder head.
– When doing so, ensure that vacuum pump is flush with
flange.
quence.
1.4 Checking compression
Note
In addition to the compression test, a pressure loss test can al‐

so be performed using pressure loss tester -VAS 522 001-. The
corresponding procedure is described in the operating manual
of the pressure loss tester.

04.2021

equipment required
♦ Spark plug socket -3122 B-

♦ Compression tester -V.A.G 1763-
♦ Adapter -V.A.G 1381/1-
♦ Adapter -V.A.G 1381/5A-
Test sequence
Note
♦ Engine oil temperature min. 30°C

♦ Battery voltage at least 12.7 V

– Release ignition coil connectors and, at the same time, pull
connectors off ignition coils.
– Unscrew ignition coil bolts, and pull out ignition coils.

04.2021
1- For injectors -N30- to -N33-

2- For injectors 2 -N532- to -N535-
– Unscrew spark plugs using spark plug socket -3122 B-.
– Check compression using compression tester -V.A.G 1763-,
adapter -V.A.G 1381/1- and adapter -V.A.G 1381/5A-.
Note
Using compression tester: ⇒ Operating instructions.
– Start engine until tester shows no further pressure increase.

Compression pressures bar
New 11.0 to 14.0
Wear limit 7.0
Maximum difference between cylinders 3.0
– Install spark plugs ⇒ Maintenance; Booklet ; Spark plugs:
Renewing.
– Install ignition coils ⇒ page 581 .
Note
Faults will have been stored in the memory because connectors

have been disconnected. Read and clear the event memory
after the measurement.

04.2021
2 Cover for timing chain

⇒ o2.1 verview - cover for timing chain”, page 157
⇒ a2.2.1 nd installing upper timing chain cover”, page 159
⇒ a2.2.2 nd installing timing chain cover (bottom)”, page 162
2.1 Assembly overview - cover for timing chain
2. Cover for timing chain 157

04.2021
1 - Bolt
❑ 9 Nm
❑ Renew
2 - Exhaust camshaft control
valve 1 -N318-
ling ⇒ page 218
3 - Oil seals
❑ Renew if damaged
❑ To remove, cover must
be removed.
4 - Timing chain cover (top)
ling ⇒ page 159
5 - Seal
6 - Cap
7 - Bolt
❑ Tightening sequence ⇒
page 161
❑ 9 Nm
8 - Seal
9 - O-ring
❑ Renew
❑ Moisten with engine oil
10 - Not installed
11 - Engine
12 - Dowel pins
❑ For centring cover
13 - Lower timing chain cover
❑ With shaft seal
14 - Oil seal
❑ For vibration damper
15 - Plug
❑ Renew
16 - Bolt
❑ Renew
❑ Tightening sequence for version with 15 bolts ⇒ page 165
❑ Tightening sequence for version with 8 bolts ⇒ page 166
17 - O-ring
❑ Renew
❑ Lubricate before assembling.
18 - Dipstick guide tube
❑ To remove, unbolt coolant pipe from intake manifold

04.2021
19 - Bolt
❑ 9 Nm
20 - Inlet camshaft control valve 1 -N205-
2.2 Removing and installing timing chain

cover
⇒ a2.2.1 nd installing upper timing chain cover”, page 159
⇒ a2.2.2 nd installing timing chain cover (bottom)”, page 162
2.2.1 Removing and installing upper timing

chain cover
♦ Spring-type clip pliers -VAS 6362-
♦ Torque wrench -V.A.G 1783-
♦ Open-end spanner insert AF 10 -V.A.G 1783/1-

Removing

04.2021
• Engine cold.
– Briefly open filler cap -arrow- for coolant expansion tank in
order to reduce residual pressure in cooling system.
– Release hose clip -1-, disconnect coolant hose and push
towards right.
– Push release button on plug-in connector -1-, and pull off

breather line.
– Unclip breather line -2-, and place it aside.
– Remove camshaft control valve 1 -N205- and exhaust cam‐
shaft control valve 1 -N318- ⇒ page 218 .

04.2021
– Pull guide tube for oil dipstick off upper timing chain cover
-arrow-.
Note
Disregard -item 2-.
– Unclip wiring harness for camshaft control valves, and lay it

to one side.
– Unscrew bolts -1 to 6- and detach top cover for timing chain.
– Remove bolts -3, 5- if necessary.

Installing
– Renew oil seals.

– Fit cover on cylinder head, and screw in bolts by hand.
When doing so, ensure that cylinder head gasket is seated
properly on cylinder head.

04.2021
– Tighten bolts -1 to 6- in the specified sequence. Use torque

wrench -V.A.G 1783- and open-end spanner insert AF 10
-V.A.G 1783/1- for bolts -3- and -5-.
– Install camshaft control valve 1 - N205- and exhaust cam‐
shaft control valve 1 - N318- ⇒ page 218 .
– Fit engine cover panel ⇒ page 81 .
Specified torques
2.2.2 Removing and installing timing chain

cover (bottom)
Note
Due to the adhesive strength of the sealant, the cover is bent

when being removed. For this reason, the cover always needs
to be renewed.

♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)

Removing
– Remove engine support ⇒ page 98 .
– Remove vibration damper ⇒ page 88 .
– Drain engine oil ⇒ Maintenance; Booklet ; Engine oil: Drain‐
ing; Renewing oil filter and replenishing engine oil.
– Remove valve for oil pressure control -N428- ⇒ page 259 .
– Remove tensioner for poly V-belt ⇒ page 87 .
– Move retaining clip -2- for electrical wiring harness clear.

04.2021

– Unclip guide tube for oil dipstick from timing chain cover
(top) -arrow-.
– Pull dipstick guide tube out of the timing chain cover.
Note
Depending on version, the cover may be secured with only 8

bolts.
– Lever lower timing chain cover off.

04.2021
Installing
Note
♦ Note expiry date of silicone sealant.

♦ Engine oil: capacities and specifications
♦ The cover must be installed within 5 minutes after applying
the silicone sealant.
♦ Renew bolts which must be tightened further to a torque
angle.
♦ Renew seal and O-ring.
♦ Danger of soiling lubrication system. Cover open parts of
engine.
– Remove sealant residues from cylinder block with a flat scra‐

per.
– Remove any oil and grease from sealing surfaces.
– Check that both dowel pins for centring the cover -arrows-
are fitted.

3 mm).

04.2021
Tightening cover with 15 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

edges -arrows 2- of new cover, as shown in illustration.
– Install cover immediately and tighten bolts.
Note
Do not tighten bolts -3- and -6- with turning further angle until
after the vibration damper has been installed. The bolts must
be unscrewed again for installing the vibration damper. Note the
different torques for steel bolts and aluminium bolts!
Stage Steel bolts Specified torque/turning further angle

for steel bolts
1 -1 to 15- 8 Nm
2 -1 to 15- 45°

04.2021
Stage Aluminium bolts Specified torque/turning further angle

for aluminium bolts
1 -1 to 15- 4 Nm
2 -1 to 15- 45°
Tightening cover with 8 bolts
– Apply silicone sealant to clean sealing surface -arrow 1- and

edges -arrows 2- of new cover, as shown in illustration.
Note
♦ The cover must be installed within 5 minutes after applying

– Install cover immediately and tighten bolts.

04.2021
Note
after the vibration damper has been installed. The bolts must
be unscrewed again for installing the vibration damper. Note the
different torques for steel bolts and aluminium bolts!
Stage Steel bolts Specified torque/turning further angle

for steel bolts
1 -1 to 8- 8 Nm
2 -1 to 8- 45°
Stage Aluminium bolts Specified torque/turning further angle

for aluminium bolts
1 -1 to 8- 4 Nm
2 -1 to 8- 45°
Continued for all:
– Install valve for oil pressure control -N428- ⇒ page 259 .
– Install tensioner for poly V-belt ⇒ page 95 .
– Install front right wheel housing liner ⇒ General body repairs,
– Replenish engine oil, and check oil level ⇒ Maintenance;
Booklet ; Engine oil: Draining; Renewing oil filter and replen‐
ishing engine oil.
Specified torques
♦ ⇒ Fig. ““Engine support - specified torque and installation
sequence”“, page 99

04.2021
3 Chain drive
⇒ o3.1 verview - camshaft timing chains”, page 168
⇒ a3.2 nd installing camshaft timing chain”, page 171
⇒ o3.3 verview - drive chain for balance shaft”, page 187
⇒ a3.4 nd installing drive chain for balance shaft”, page 190
⇒ t3.5 iming chain”, page 190
⇒ v3.6 alve timing”, page 191
3.1 Assembly overview - camshaft timing

chains
Note

newing chain

04.2021
1 - Bolt
❑ Renew aluminium bolts
after removal
❑ Aluminium bolts 4 Nm
+90°
❑ Steel bolts: 9 Nm
2 - Chain tensioner
❑ Is spring-loaded
❑ Secure with locking tool
-T40267- before remov‐
ing.
3 - Tensioning rail for timing
chain
4 - Guide pin
❑ 20 Nm
5 - Bolt
❑ Renew
page 170
6 - Clamping sleeve
❑ Not fitted on all bearing
saddles, depending on
version
❑ Is pulled into cylinder
head together with se‐
curing bolt
7 - Timing valves
❑ Left-hand thread
❑ Depending on version,
remove using remov‐
al tool -T10352/2- or -
T10352/4-.
❑ Checking ⇒ page 169
❑ 35 Nm
8 - Bearing saddle
❑ Depending on version, with spring pin; for allocation refer to ⇒ Electronic parts catalogue (ETKA)
9 - Guide rail for camshaft timing chain
10 - Camshaft case
11 - Camshaft timing chain
12 - Guide rail for camshaft timing chain
13 - Guide pin
❑ 20 Nm
14 - Triple chain sprocket
❑ Crankshaft
❑ Fitting position ⇒ page 170
Checking control valve
3. Chain drive 169

04.2021
– It must be possible to press in piston -1- approx. 3 mm

against spring force. It must move freely, without sticking.
Bearing saddle - specified torque and tightening sequence
If a spring pin is installed, it is pulled into the cylinder head

together with bolt -1-.
Bearing saddle with spring pin and steel bolts
Stage Bolt Specified torque/turning further angle
for steel bolts
1 -1- 3 Nm
2 -1 to 6- 9 Nm
Bearing saddle without spring pin and with aluminium bolts
Stage Bolt Specified torque/turning further angle
for aluminium bolts
1 -1 to 6- 4 Nm
2 -1 to 6- 180°
Triple chain sprocket - installation position

04.2021
• The two sections -arrows- must be aligned.
3.2 Removing and installing camshaft timing chain

equipment required
♦ Depending on version assembly tool -T10352/2- or -

T10352/4-
♦ Pin -T40011-
3. Chain drive 171

04.2021
♦ Assembly lever -T40243-

♦ Locking tool -T40267-
♦ Camshaft clamp -T40271-
Components of assembly tool -T10531-:

♦ Support -T10531/1-
♦ Clamping pin -T10531/2-
♦ Turning over tool -T10531/3-
♦ Flange nut -T10531/4-
Removing
insulation.
– Turn vibration damper to “TDC position” using counter-hold
tool -T10355-.

04.2021
• The markings -1- on the camshaft sprockets must align with

markings -2- and -3-.
• The notch on the vibration damper must align with the mark‐
ing on the lower timing chain cover -arrow-.
Note
♦ The timing valves have left-hand threads.

♦ Depending on the version, different timing valves may be
installed. Use the appropriate assembly tool -1-.
– Turn assembly tool -T10352/2- or -T10352/4- in

-direction of arrow- to remove left and right timing valves.
– Remove bolts -arrows- and detach bearing saddle.
3. Chain drive 173

04.2021
– Screw in lever -T40243- -arrows-.
– Press together retaining ring -1- of chain tensioner and hold

it in that position.
– Slowly push lever -T40243- in -direction of arrow-, and hold
– Secure chain tensioner with locking pin -T40267-.

04.2021
– Remove lever -T40243-.

– Screw camshaft clamp -T40271/2- onto cylinder head, and
insert it in teeth of chain sprocket (direction of arrow -2-). If
necessary, turn inlet camshaft using assembly tool -T40266-
-arrow 1-.
– Bolt camshaft clamp -T40271/1- to cylinder head.
A second mechanic is required for the following work step.

– Using assembly tool -T40266-, locate exhaust camshaft in
direction of arrow -A-. Remove bolt -1- and guide tensioning
rail -2- downwards. Turn exhaust camshaft clockwise -A-
until camshaft clamp -T40271/1- can be inserted in teeth of
chain sprocket -C-.
– Remove guide rail -1-. To do this, use a screwdriver to re‐
lease catch -arrow-, and press off guide rail forwards.
3. Chain drive 175

04.2021
– Unscrew bolts -arrows-, and remove chain tensioner -1-.
– Press tensioning bar of oil pump chain tensioner in direction

of -arrow- and lock it with locking pin -T40011-.
– Unscrew bolt -1-, and remove chain tensioner.

– Unscrew bolts -1-, and remove guide rail -2-.

04.2021
– Remove camshaft timing chain from camshaft sprockets and

fit it onto camshaft journals -arrows-.
– For vehicles with all-wheel drive: unbolt right drive shaft from
gearbox.
– Remove chain tensioner -1- for balance shaft timing chain.

– Unscrew bolts -1-. Remove tensioning rail -2- and guide rails
-3- and -4-.
3. Chain drive 177

04.2021
– Loosen tensioning bolt -A-, and unscrew cotter pin -B-.
– Remove triple chain sprocket. To do this, remove timing

chain for oil pump drive.
shaft.
Installing
– Check if crankshaft is positioned at TDC. The flat section on

crankshaft -arrow- must be in horizontal position.
– Using a permanent felt tip marker, make a marking on cylin‐
der block -1-, as shown in illustration.
– Mark tooth -1- of triple chain sprocket which is aligned with
marking -2- using a permanent felt tip marker.

04.2021
– Turn idler gear and balance shaft so that markings -arrow-

are aligned as shown in illustration. Do not loosen bolt -1-.
The markings on idler gear and balance shaft are difficult to
see.
– Fit drive chain for balance shafts. Position chain links with
coloured markings -arrows- at markings on chain sprockets.
– Install guide rail -1-, and tighten bolts -arrows-.
3. Chain drive 179

04.2021
– Fit camshaft timing chain onto camshaft journals with col‐

oured markings -arrows- properly aligned.
– Fit timing chain for oil pump drive onto triple chain sprocket.
– Swing triple sprocket towards engine (-direction of arrow-),

and fit it onto crankshaft. The markings -arrows- must align.

04.2021
I - Screw clamping pin -T10531/2- into crankshaft, and tighten it

by hand.
II - Fit turning over tool -T10531/3-. Screw on flange nut -
T10531/4- by hand. Slightly move turning over tool back and
forth with a 32 mm open-end spanner. While doing so, retighten
flange nut until the chain sprocket is securely seated on the
crankshaft splines. Now, tighten tensioning bolt -A-.
– Position link of drive chain for balance shafts with coloured
marking -arrow- at marking of triple sprocket. Install tension‐
ing rail -1- and guide rail -2-. Tighten bolts -3-.
– Install chain tensioner -1-.
– Make sure that adjustment has been carried out correctly:

chain links with coloured markings -arrows- must be posi‐
tioned at markings on chain sprockets.
– Fit camshaft timing chain on inlet camshaft, exhaust cam‐

shaft and crankshaft. Position chain links with coloured
markings -arrows- at the markings on chain sprockets.
3. Chain drive 181

04.2021
– Install guide rail -2-, and tighten bolts -1-.
– Install upper guide rail -1-.

04.2021
I - Turn exhaust camshaft in -direction of arrow A- using assem‐

bly tool -T40266-, and remove camshaft clamp -T40271/1- from
between teeth of chain sprocket -B-.
II - Release tension from camshaft in -direction of arrow C- until
timing chain rests against guide rail -1-. Counterhold camshaft
in this position, install tensioning rail -2- and tighten bolt -3-.
Note
Failure to counterhold the camshaft while the tensioning rail is

being installed may cause the timing chain to jump!
– Install chain tensioner -1-, and tighten bolts -arrows-.
– Install chain tensioner -2-. The retaining clip -arrow- must be

seated in recess in top section of sump. Tighten bolt -1-, and
remove locking pin -T40011-.
3. Chain drive 183

04.2021
– Using assembly tool -T40266-, turn inlet camshaft in

-direction of arrow 1- until camshaft clamp -T40271/2- can
be removed from between teeth of chain sprocket -2-. Re‐
lieve tension from camshaft.
– Remove camshaft clamp -T40271/1- and -T40271/2-.

– Screw in and tighten bolts -arrows-. Specified torque ⇒ Item

4 (page 143) .

04.2021
– Moisten holes -arrows- with engine oil.
Note
If a spring pin -1- is installed, it must be driven back in the event

that the bearing saddle is re-used. The spring pin must be flush
with the cylinder head side of the bearing saddle.
– Fit bearing saddle. Do not tilt bearing saddle, while doing so.
Screw in bolts -1 to 6- by hand.
– If a spring pin is installed, it is pulled into the cylinder head

– Remove locking tool -T40267-.
3. Chain drive 185

04.2021
– Tighten bolts -arrows- for bearing saddle. Specified torque ⇒

page 170 .
– Install timing valves ⇒ Item 7 (page 169) .

– Turn engine two revolutions in direction of engine rotation.
Note
Due to the ratio, the coloured chain links no longer align with
the markings after the engine has been turned.
– Remove turning over tool, and install lower timing chain cov‐
er ⇒ page 164 .

04.2021
Note
after the vibration damper has been installed. The bolts must be
unscrewed again for installing the vibration damper.

Further installation is carried out in reverse order of removal,
observing the following:
– After working on the chain drive, adapt learnt values in en‐
0001 - Engine electronics functions
0001 - Basic setting
Timing chain length compensator, reset after renew-
ing chain
Specified torques
♦ ⇒ o3.1 verview - camshaft timing chains”, page 168
♦ ⇒ o3.3 verview - drive chain for balance shaft”, page 187
3.3 Assembly overview - drive chain for

balance shaft
Note

newing chain
3. Chain drive 187

04.2021
1 - Guide pin
❑ 20 Nm
2 - Tensioning rail
❑ For timing chain
3 - Balancer shaft
❑ Exhaust side
❑ Must always be re‐
newed if removed
engine oil
4 - Guide pin
❑ 20 Nm
5 - Slide rail
❑ For timing chain
6 - Chain tensioner
❑ 85 Nm
❑ Insert with locking fluid;
locking fluid ⇒ Electron‐
ic parts catalogue (ET‐
KA)
7 - Seal
8 - Cylinder block
9 - O-ring
10 - Pivot pin
❑ Lubricate with engine
oil
189
11 - Intermediate gear
❑ If bolt ⇒ Item 13 (page 188) has been loosened, idler gear will need to be renewed.
12 - Thrust washer
13 - Bolt
❑ Renew
❑ If bolt has been loosened, idler gear ⇒ Item 11 (page 188) will need to be renewed
14 - Slide rail
❑ For balancer shaft timing chain
15 - Guide pin
❑ 20 Nm
16 - Balancer shaft
❑ Inlet side
❑ Must always be renewed if removed
❑ Lubricate bearing with engine oil
17 - Triple chain sprocket

04.2021
18 - Drive chain for balance shafts

Bearing mounting - installation position
• Renew O-ring -1- and lubricate with oil.

• Dowel pin -arrow- for bearing mounting must engage in bore
in cylinder block.
• Lubricate bearing mounting.
Tightening sequence - idler gear
Note
♦ The idler gear must always be renewed. Otherwise no tooth

backlash is set, which may result in damage to the engine.
♦ The new idler gear is coated with a solid film lubricant that
wears off after a short period as a result of which the tooth
backlash is automatically set.
– With new bolt tighten as follows.

1. Pre-tighten to 10 Nm using torque wrench.
2. Turn idler gear.
There must be no play in idler gear; otherwise loosen bolt and
tighten again.
3. Tighten to 25 Nm using torque wrench.
4. Use fixed wrench to turn 90° further.
3. Chain drive 189

04.2021
3.4 Removing and installing drive chain for

balance shaft
The procedure “Removing and installing drive chain for balance
shaft” is part of the procedure “Removing and installing cam‐
shaft timing chain” ⇒ page 171 .
3.5 Checking timing chain
Note
If complaints (e.g. noise) indicate a stretched camshaft timing

chain, check timing chain as described below.

– Remove sealing plug -arrow-. The sealing cap must be re‐
newed.
– Turn vibration damper in direction of engine rotation

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

04.2021
Note
Visible notches are those located to the right from the chain
tensioner housing -arrow-.
♦ If 6 or fewer notches are visible, the camshaft timing chain

must not be renewed.
♦ If 7 or more notches are visible, renew camshaft timing chain
⇒ page 171 .
3.6 Checking valve timing

♦ Dial gauge set, 4-part -VAS 6341-
♦ Dial gauge adapter -T10170 A-

– Remove noise insulation -1- ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove right wheel and front part of right wheel housing

liner/entire right wheel housing liner ⇒ General body repairs,
3. Chain drive 191

04.2021

– Using 24 mm socket, turn crankshaft via vibration damper
in direction of engine rotation until markings -1- and -2- are
almost at top.
– Remove ignition coil with output stage for cylinder 1 ⇒ page

581 .
– Remove spark plug for cylinder 1 using spark plug socket
and extension -3122 B-.
– Screw dial gauge adapter -T10170/A- into spark plug hole to
stop.
– Insert dial gauge -VAS 6341- with extension -T10170A/1-

as far as it will go and secure in place with self-locking nut
-arrow-.
– Slowly turn crankshaft in engine DOR to maximum needle
deflection. Once maximum needle deflection is reached (re‐
verse point of needle), piston is at »TDC«.
Note
♦ Use a ratchet spanner with a 24 mm socket to turn the

vibration damper.
♦ If the crankshaft has been turned beyond “TDC” turn engine
another two revolutions in direction of engine rotation. Do
not turn engine in opposite direction to normal rotation.
• Notch on vibration damper must align with arrow marking on

timing chain cover (bottom) -arrow-.

04.2021
• The markings -1- on the camshaft chain sprockets must be

aligned with markings -2- and -3- on cylinder head.
3. Chain drive 193

04.2021
4 Valve gear
⇒ o4.1 verview - valve gear”, page 194
⇒ a4.2 nd installing camshaft”, page 199
⇒ a4.3 nd installing camshaft control valve 1N205”, page 218
⇒ a4.4 nd installing exhaust camshaft control valve 1N318”,
page 218
⇒ a4.5 nd installing valve stem seals”, page 218
4.1 Assembly overview - valve gear
Note
♦ Cylinder head and cylinder head cover must be renewed

together.
♦ After installing camshafts wait for approx. 30 minutes before
starting engine. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully
at least 2 rotations to ensure that none of the valves make
contact when the starter is operated.
♦ Always renew gaskets and seals.
the following menu option on vehicle diagnostic tester:
newing chain
Part I
Part II ⇒ page 197

04.2021
1 - Outlet valve
❑ Do not rework. Only
lapping in is permitted.
❑ Valve dimensions ⇒
page 231
❑ Checking valve guides
⇒ page 230
2 - Cylinder head
3 - Valve stem seal
❑ Renewing ⇒ a4.5.1 nd
installing valve stem
seals (cylinder head
installed)”, page 218
⇒ a4.5.2 nd installing
valve stem seals (cyl‐
inder head removed)”,
page 224
4 - Valve springs
5 - Valve spring plate
6 - Valve cotters
7 - Hydraulic compensation
element
❑ Do not interchange
❑ Oil contact surface
8 - Retaining clip
❑ For hydraulic compen‐
sation element.
9 - Roller rocker fingers
ling ⇒ a4.2 nd installing
camshaft”, page 199
❑ Mark installation posi‐
tion for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.
10 - Exhaust camshaft
❑ Check radial clearance with Plastigage (roller rocker fingers removed).
❑ Radial clearance: 0.024 to 0.066 mm.
❑ Runout: max. 0.04 mm
11 - Spring
❑ No replacement part
12 - Ball
❑ For sliding piece
❑ Installing ⇒ page 217
13 - Cylinder head cover
❑ With integrated camshaft bearings.
❑ Clean sealing surface; reworking not permitted.
❑ Remove sealant residue.
14 - Bolt
4. Valve gear 195

04.2021
❑ Renew
❑ Loosening ⇒ page 196
15 - Inlet camshaft
❑ Check radial clearance with Plastigage (roller rocker fingers removed).
❑ Radial clearance: 0.024 to 0.066 mm.
❑ Runout: max. 0.04 mm
16 - Dowel pins
17 - Dowel pins
18 - Inlet valve
❑ Do not rework. Only lapping in is permitted.
❑ Valve dimensions ⇒ page 231
❑ Checking valve guides ⇒ page 230
Cylinder head cover - release
– Loosen cylinder head cover bolts in the sequence -1 to 6-.

Tightening sequence for cylinder head cover
Note

♦ Take care to keep cylinder head cover level.

04.2021

tions
1 -1 to 6- Screw in by hand in several stages
as far as stop
2 -1 to 6- 8 Nm
Distinguishing between valve stem oil seals
-A- valve stem oil seal with one sealing lip

♦ Press on using valve shaft seal fitting tool -3365-
-B- valve stem oil seal with two sealing lips
♦ Only for exhaust side of certain engines; allocation ⇒ Elec‐
tronic parts catalogue (ETKA)
♦ Press on using valve shaft seal fitting tool -T40376/1-
Part II
Part I ⇒ page 194
4. Valve gear 197

04.2021
1 - Cylinder head
2 - O-ring
❑ Lubricate with engine
oil
3 - Actuator for camshaft ad‐
justment
❑ Allocation ⇒ page 418
4 - Bolt
❑ 5 Nm
5 - Support
❑ 9 Nm
6 - O-ring
7 - Plug
8 - O-ring
❑ Renew
9 - Hall sender 3 -G300-
❑ Assembly overview ⇒
page 579
10 - Bolt
❑ Specified torque ⇒
page 579
11 - Oil separator
ling ⇒ page 255
12 - Bolt
13 - Seal
14 - Vacuum pump
15 - Bolt
❑ Renew
❑ 8 Nm +180°
16 - Seal
17 - O-ring
❑ Renew
18 - Hall sender -G40-
❑ Assembly overview ⇒ page 579
19 - Bolt
❑ Specified torque ⇒ page 579

04.2021
20 - Bolt
❑ 9 Nm
21 - Bracket
❑ For activated charcoal filter system solenoid valve 1 -N80-
4.2 Removing and installing camshaft

equipment required
♦ Depending on version assembly tool -T10352/2- or -

T10352/4-
♦ Assembly lever -T40243-
♦ Camshaft clamp -T40271-
♦ Sealant ⇒ Electronic parts catalogue (ETKA)
4. Valve gear 199

04.2021
Removing
Note
♦ Sealing surfaces at bottom of cylinder head cover and top of

cylinder head must not be machined.
♦ Camshaft bearings are integrated in cylinder head and in
cylinder head cover. The camshaft timing chain must be re‐
lieved of tension before you remove the cylinder head cover.
♦ Fit the cable ties in the original position when installing.

– Pull off coolant hose -arrow-.
– Pull off connectors -1- and -2-. Open retainer -3-.

– Remove ignition coils ⇒ page 581 .
– Unscrew bolt -1- for earth wire, and disconnect coolant ho‐
ses -2 and 3-. Seal lines with suitable plugs from the engine
bung set -VAS 6122-.
– Pull off connectors -arrows-.

– Release fastener -arrow-, and remove wiring duct -4- up‐
wards from retainer.

04.2021
– Unscrew bolts -1, 2 and 3-. Swivel coolant pipe to one side.
NOTICE
Risk of damage to coolant pipes caused by deformation.
– Never attempt to reshape the coolant pipe.
– Remove upper coolant pipe ⇒ page 345 .

– Separate connector -1- from activated charcoal filter sole‐
noid valve 1 -N80-.
– Press release tabs on crankcase breather hose -2- and de‐

tach hose.
– Unscrew bolts -arrows- and remove crankcase breather.
– Remove high-pressure pump ⇒ page 488 .
– Remove vacuum pump ⇒ page 152 .
insulation.
– Turn vibration damper to “TDC position” using counter-hold
tool -T10355-.
4. Valve gear 201

04.2021
• The markings -1- on the camshaft sprockets must align with

markings -2- and -3-.
• The notch on the vibration damper must align with the mark‐
ing on the lower timing chain cover -arrow-.
Note
♦ The timing valves have left-hand threads.

♦ Depending on the version, different timing valves may be
installed. Use the appropriate assembly tool -1-.
– Turn assembly tool -T10352/2- or -T10352/4- in

-direction of arrow- to remove left and right timing valves.
– Remove bolts -arrows- and detach bearing saddle.

04.2021
– Screw in lever -T40243- -arrows-.
– Press together retaining ring -1- of chain tensioner and hold

– Slowly push lever -T40243- in -direction of arrow-, and hold
– Secure chain tensioner with locking pin -T40267-.
4. Valve gear 203

04.2021
– Remove lever -T40243-.

– Screw camshaft clamp -T40271/2- onto cylinder head, and
insert it in teeth of chain sprocket (direction of arrow -2-). If
necessary, turn inlet camshaft using assembly tool -T40266-
-arrow 1-.
– Bolt camshaft clamp -T40271/1- to cylinder head.

– Using assembly tool -T40266-, locate exhaust camshaft in
direction of arrow -A-. Remove bolt -1- and guide tensioning
rail -2- downwards. Turn exhaust camshaft clockwise -A-
until camshaft clamp -T40271/1- can be inserted in teeth of
chain sprocket -B-.
– Check installation position -C- of camshaft clamp -
T40271/1-.
– Remove guide rail -1-. To do this, use a screwdriver to re‐
lease catch -arrow-, and press off guide rail forwards.

04.2021
– Press tensioning bar of oil pump chain tensioner in direction

of -arrow- and lock it with locking pin -T40011-.
– Unscrew bolt -1-, and remove chain tensioner.

– Unscrew bolts -1-, and remove guide rail -2-.
– Remove camshaft timing chain from camshaft sprockets,

and guide it downwards.
– Fit turning over tool -T10531/3-. At “TDC position” the flat
section -1- faces upwards. Screw on flange nut -T10531/4-.
Turn crankshaft with a 32 mm open-end spanner anti-clock‐
wise to move it out of “TDC position”.
4. Valve gear 205

04.2021
– Turn inlet camshaft in -direction of arrow 1- using assembly

tool -T40266-, remove camshaft clamp -T40271/2- from be‐
tween teeth of chain sprocket -arrow 2-, and bring camshaft
into rest position.
– Turn exhaust camshaft in -direction of arrow 1- using assem‐

bly tool -T40266-, remove camshaft clamp -T40271/1- from
between teeth of chain sprocket -arrow 2-, and bring cam‐
shaft into rest position.
– Unscrew and remove cylinder head cover bolts in the se‐

quence -1 to 6-.

04.2021
– Starting on chain side, lever off cylinder head cover -2- using
appropriate tool, e.g. screwdriver -1-.
– Remove camshafts, and cover open parts of engine.

Installing camshafts
Note
♦ Sealing surfaces must be free of oil and grease.

♦ Ensure that all roller rocker fingers are properly seated on
valve stem ends.
– If crankshaft has been turned in the meantime, position cyl‐

inder number 1 piston to TDC and then turn crankshaft back
slightly.
– Remove sealant residue from groove in cylinder head cover
and from sealing surfaces.
– Oil running surfaces of both camshafts.
– Fit inlet camshaft -A- in cylinder head. Turn cams for cylinder
4 -arrows- upwards.
4. Valve gear 207

04.2021
– Make sure that plungers of the actuators for camshaft ad‐

justment are retracted.
– Fit exhaust camshaft in cylinder head cover as shown in

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

04.2021
– Apply sealant onto clean sealing surface of cylinder head

cover, as shown in illustration -arrows-.
NOTICE
Risk of damage to engine due to excess sealant in lubrication
system.
– Do not apply sealant bead thicker than specified.
♦ Thickness of sealant bead: 1.5 to 2.5 mm.

– Hold camshaft in place, and fit cylinder head cover with cam‐
shaft fitted on cylinder head.
– Slightly press on cylinder head cover with one hand, and
turn camshafts slightly while doing so, until cylinder head
cover is properly seated on cylinder head and is »free of
stress«.
– Renew bolts for cylinder head cover.

– Tighten bolts in several stages, tightening sequence ⇒ page
196 .
Note
Take care to keep cylinder head cover level.
– Turn inlet camshaft in -direction of arrow A- using assembly

tool -T40266- until the markings -1- and -2- align. Insert
camshaft clamp -T40271/2- between teeth of chain sprocket
-B-.
4. Valve gear 209

04.2021
– Turn exhaust camshaft in -direction of arrow A- using as‐

sembly tool -T40266- until the markings -1- and -2- align.
Insert camshaft clamp -T40271/1- between teeth of chain
sprocket -B-. Marking -2- is slightly offset towards right.
– Turn crankshaft on hexagon to “TDC position”. At “TDC posi‐

tion” the flat section -1- faces upwards.
Installing camshaft timing chain

04.2021
– Fit camshaft timing chain onto camshaft journals with col‐

oured markings -arrows- properly aligned.
– Fit camshaft timing chain on inlet camshaft, exhaust cam‐
shaft and crankshaft. Position chain links with coloured
markings -arrows- at the markings on chain sprockets.
– Install guide rail -2-, and tighten bolts -1-.
– Install upper guide rail -1-.
4. Valve gear 211

04.2021
I - Turn exhaust camshaft in -direction of arrow A- using assem‐

bly tool -T40266-, and remove camshaft clamp -T40271/1- from
between teeth of chain sprocket -B-.
II - Release tension from camshaft in -direction of arrow C- until
timing chain rests against guide rail -1-. Hold camshaft in this
position, install tensioning rail -2-, and tighten bolt -3-. Then,
relieve tension from camshaft.
Note
Failure to counterhold the camshaft while the tensioning rail is

being installed may cause the timing chain to jump!
– Using assembly tool -T40266-, turn inlet camshaft in

-direction of arrow 1- until camshaft clamp -T40271/2- can
be removed from between teeth of chain sprocket -2-. Then,
relieve tension from camshaft.

04.2021
– Remove camshaft clamp -T40271/1- and -T40271/2-.

– Screw in and tighten bolts -arrows-. Specified torque ⇒ Item
4 (page 143) .
– Moisten holes -arrows- with engine oil.
Note
If a spring pin -1- is installed, it must be driven back in the event

that the bearing saddle is re-used. The spring pin must be flush
with the cylinder head side of the bearing saddle.
– Fit bearing saddle. Do not tilt bearing saddle, while doing so.
Screw in bolts -1 to 6- by hand.
4. Valve gear 213

04.2021
– If a spring pin is installed, it is pulled into the cylinder head

– Remove locking tool -T40267-.
– Tighten bolts -arrows- for bearing saddle. Specified torque ⇒

page 170 .
– Install chain tensioner -2-. The retaining clip -arrow- must be

seated in recess in top section of sump. Tighten bolt -1-, and
remove locking pin -T40011-.

04.2021

– Install timing valves ⇒ Item 7 (page 169) .

– Turn engine two revolutions in direction of engine rotation.
Note
Due to the ratio, the coloured chain links no longer align with
the markings after the engine has been turned.
– Unscrew flange nut -T10531/4-, and remove turning over

tool -T10531/3-.
4. Valve gear 215

04.2021
Note
after the vibration damper has been installed. The bolts must be
unscrewed again for installing the vibration damper.

– Install vacuum pump ⇒ page 152 .
– Installing high-pressure pump ⇒ page 488 .
Further installation is carried out in reverse order of removal,
observing the following:
– After working on the chain drive, adapt learnt values in en‐
0001 - Engine electronics functions
0001 - Basic setting
Timing chain length compensator, reset after renew-
ing chain
Specified torques
♦ ⇒ o3.1 verview - camshaft timing chains”, page 168
♦ ⇒ o3.3 verview - drive chain for balance shaft”, page 187
♦ ⇒ o4.1 verview - valve gear”, page 194
♦ ⇒ o3.1 verview - air filter housing”, page 441
♦ ⇒ o7.1 verview - high-pressure pump”, page 486
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐

04.2021
Installing ball for sliding piece

♦ Spacers -T40191-
Installing
CAUTION
The ball for the sliding piece may pop out! Risk of eye injury!
– Insert spring -1- into camshaft.
– Place ball -2- onto spring in camshaft.

– Using spacer -T40191/1-, press ball and spring downwards
in -direction of arrow A-, and hold them in this position.
– Slide sliding piece -3- in -direction of arrow B-.
4. Valve gear 217

04.2021
4.3 Removing and installing camshaft con‐

trol valve 1 -N205-
Removing
– Pull connector -1- off exhaust camshaft control valve 1 -

N318-, and pull connector -3- off camshaft control valve 1
-N205-.
– Place a clean cloth under camshaft control valves.
– Unscrew bolts -arrows-, and remove exhaust camshaft con‐
trol valve 1 -N205- -item 4- and exhaust camshaft control
valve 1 -N318- -item 2-.
Installing
– Check seals for damage. If the seals are to be replaced,
remove cover ⇒ page 159 .
– Lubricate sealing surfaces of oil seals to inlet camshaft con‐
trol valve 1 -N205-/exhaust camshaft control valve 1 -N318-
with engine oil.
Specified torques
4.4 Removing and installing exhaust cam‐

shaft control valve 1 -N318-
Procedure ⇒ a4.3 nd installing camshaft control valve 1N205”,
page 218 .
4.5 Removing and installing valve stem

seals
⇒ a4.5.1 nd installing valve stem seals (cylinder head instal‐
led)”, page 218
⇒ a4.5.2 nd installing valve stem seals (cylinder head re‐
moved)”, page 224
4.5.1 Removing and installing valve stem seals (cylinder head installed)

04.2021

equipment required
♦ Spark plug socket -3122 B-

♦ Valve stem seal puller -3364-
♦ Valve stem seal fitting tool -3365-
♦ Valve stem oil seal fitting tool -T40376/1- depending on ver‐
sion
♦ Adapter -T40012-
♦ Dismantling and assembling device for valve cotters -VAS
5161-
♦ Guide plate -VAS 5161/19C-
Removing valve stem oil seals
– Mark allocation of roller rocker fingers and hydraulic com‐
pensation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic com‐
pensation elements and place down on a clean surface.
4. Valve gear 219

04.2021
– Unscrew spark plugs using spark plug socket and extension

-3122 B-.
– Screw guide plate -VAS 5161/19C- to cylinder head, as

shown in illustration, using knurled screws -VAS 5161/12-.
– Set piston of respective cylinder to “bottom dead centre”.

– Screw adapter -T40012- into spark plug thread.
– Connect compressed air with pressure rating of at least

6 bar.
– Strike tight valve cotters with drift -VAS 5161/3- and a plastic
hammer.
For inlet side
– Screw retainer -VAS 5161/6- with guide fork -VAS 5161/5-

into centre thread of guide plate -VAS 5161/19C-.
– Insert assembly cartridge -VAS 5161/8- into guide plate -
VAS 5161/19C-.
– Attach pressure fork -VAS 5161/2- to retainer -VAS 5161/6-.

04.2021
For exhaust side

into outer thread of guide plate -VAS 5161/19C-.
– Press installation cartridge -VAS 5161/8- down and turn
knurled screw of installation cartridge -VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw back and forth slightly to press apart
valve cotters and capture them in the assembly cartridge.
– Release pressure fork -VAS 5161/2-.
– Remove installation cartridge -VAS 5161/8-.
– Pull off valve stem seals using valve stem seal puller -3364-.
– If valve stem seal puller -3364- cannot be used on account

of restricted space, drive out roll pin -arrow- with a drift and
remove impact extractor attachment.
4. Valve gear 221

04.2021
– Place lower part of valve stem seal puller -3364- onto valve
stem seal.
– Insert punch -1- into bore in lower part of puller.

– Place installation lever on puller and pull out valve stem seal
-arrow-.
Installing valve stem seals
Distinguishing between valve stem oil seals ⇒ page 197

– Place plastic sleeve -A-, enclosed with new valve stem seals
-B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool -3365-.

04.2021
Note
Depending on the version of valve stem seals, valve stem seal

fitting tool -T40376/1- may have to be used.
– Take out plastic sleeve.

– Insert valve spring and valve spring plate.
– Install removal and installation device for valve cotters -VAS
5161- as shown.
Inlet side
Exhaust side
4. Valve gear 223

04.2021
Note
If the valve cotters have been removed from the installation

cartridge, they must first be inserted into the insertion device
-VAS 5161/18-.
Press assembly cartridge -VAS 5161/8- onto insertion device

from above and pick up valve cotters.
– Press installation cartridge -VAS 5161/8- down with pressure

fork -VAS 5161/2-, and turn installation cartridge knurled
screw back and forth whilst pulling upwards.
– Relieve pressure fork -VAS 5161/2- whilst pulling on knurled
screw.
– Remove removal and installation device -VAS 5161-.
The remaining assembly steps are basically a reverse of the
dismantling procedure, when doing this note as follows:
– Install camshafts ⇒ page 199 .
4.5.2 Removing and installing valve stem seals (cylinder head removed)

04.2021

equipment required
♦ Valve stem seal puller -3364-

♦ Valve stem seal fitting tool -3365-
♦ Valve stem oil seal fitting tool -T40376/1- depending on ver‐
sion
♦ Dismantling and assembling device for valve cotters -VAS
5161-
♦ Guide plate -VAS 5161/19C-
♦ Engine and gearbox support -VAS 6095-
♦ Cylinder head tensioning device -VAS 6419-
Removing valve stem oil seals
– Mark allocation of roller rocker fingers and hydraulic com‐
pensation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic com‐
pensation elements and place down on a clean surface.
– Insert cylinder head tensioning device -VAS 6419- into en‐
gine and gearbox support -VAS 6095-.
4. Valve gear 225

04.2021
– Tension cylinder head on cylinder head tensioning device as

– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion
chamber from which valve stem oil seal is to be removed.
– Allow compressed air to flow into air cushion until it lies
against valve disc.
– Bolt guide plate -VAS 5161/19C- to cylinder head using
knurled screws -VAS 5161/12- as shown.
– Insert drift -VAS 5161/3- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
For inlet side

into centre thread of guide plate -VAS 5161/19C-.
– Insert assembly cartridge -VAS 5161/8- into guide plate -
VAS 5161/19C-.
– Attach pressure fork -VAS 5161/2- to retainer -VAS 5161/6-.

04.2021
For exhaust side

into outer thread of guide plate -VAS 5161/19C-.
– Press installation cartridge -VAS 5161/8- down and turn
knurled screw of installation cartridge -VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw back and forth slightly to press apart
valve cotters and capture them in the assembly cartridge.
– Release pressure fork -VAS 5161/2-.
– Remove installation cartridge -VAS 5161/8-.
– Pull off valve stem seals using valve stem seal puller -3364-.
4. Valve gear 227

04.2021
Installing valve stem seals
Distinguishing between valve stem oil seals ⇒ page 197

– Place plastic sleeve -A-, enclosed with new valve stem seals
-B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool -3365-.
Note
Depending on the version of valve stem seals, valve stem seal

fitting tool -T40376/1- may have to be used.
– Remove plastic sleeve.

– Insert valve spring and valve spring plate.
– Remove removal and installation device for valve cotters
-VAS 5161- as shown.
Inlet side
Exhaust side

04.2021
Note
If the valve cotters have been removed from the installation

cartridge, they must first be inserted into the insertion device
-VAS 5161/18-.
Press assembly cartridge -VAS 5161/8- onto insertion device

from above and pick up valve cotters.
– Press installation cartridge -VAS 5161/8- down with pressure

fork -VAS 5161/2-, and turn installation cartridge knurled
screw back and forth whilst pulling upwards.
– Relieve pressure fork -VAS 5161/2- whilst pulling on knurled
screw.
– Remove removal and installation device for valve cotters
-VAS 5161-.
– Install camshafts ⇒ page 199 .
4. Valve gear 229

04.2021
5 Inlet and exhaust valves

⇒ v5.1 alve guides”, page 230
⇒ v5.2 alves”, page 231
⇒ d5.3 imensions”, page 231
5.1 Checking valve guides

♦ Universal dial gauge holder -VW 387-
♦ Dial gauge -VAS 6079-
Test sequence
– Insert valve in guide. Valve stem end must be flush with

guide. On account of differing stem diameters, only use inlet
valve in inlet valve guide and exhaust valve in exhaust valve
guide.
– Determine rock.

04.2021
Wear limit
Inlet valve guide Exhaust valve guide
0.80 mm 0.80 mm
Note
♦ If the wear limit is exceeded, repeat the measurement with

new valves. If the wear limit is exceeded again, renew the
cylinder head.
♦ If the valve is to be renewed as part of a repair, use a new
valve for the calculation.
5.2 Checking valves

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

Valve dimensions
Note
Never rework the inlet and exhaust valves. Only lapping-in is

permitted.
Dimension Inlet valve Outlet valve

∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45
5. Inlet and exhaust valves 231

04.2021
17 – Lubrication
1 Sump, oil pump
⇒ o1.1 verview - sump/oil pump”, page 232
⇒ a1.2 nd installing oil level and oil temperature senderG266”,
page 235
⇒ a1.3 nd installing lower part of sump”, page 236
⇒ a1.4 nd installing oil pump”, page 242
⇒ a1.5 nd installing upper part of sump”, page 245
⇒ o1.6 il:”, page 250
1.1 Assembly overview - sump/oil pump
Note
If large quantities of swarf or metal particles (caused, for exam‐

ple, by partial seizure of the crankshaft or conrod bearings) are
found in the engine oil when performing repairs, clean the oil
passages thoroughly and renew the engine oil cooler in order to
prevent subsequent damage.
232 Rep. gr.17 - Lubrication

04.2021
1 - Nut
❑ 9 Nm
2 - Oil level and oil tempera‐
ture sender -G266-
ling ⇒ page 235
3 - O-ring
4 - Oil drain plug/sealing plug
❑ Sheet metal sump:
30 Nm
❑ Plastic sump: turn as
far as stop using as‐
sembly tool -T10549-
5 - Seal / O-ring
❑ Renew seal after each
removal
❑ Renew O-ring in case
of leaks.
6 - Gasket/sealant
❑ Renew seal after each
removal
7 - Bolt
❑ For baffle plate and oil
suction pipe
❑ 4 Nm +45°
8 - Baffle plate
❑ If the top section of
sump is renewed, the
baffle plate must be renewed as well.
9 - O-ring
10 - Oil intake tube
❑ Clean strainer if soiled
11 - Centring sleeve
12 - Bolt
13 - Upper part of sump
❑ If the top section of sump is renewed, the baffle plate must be renewed as well.
14 - Cylinder block
15 - Drive chain for oil pump
❑ Mark direction of rotation before removing.
16 - Bolt
❑ 9 Nm
1. Sump, oil pump 233

04.2021
17 - Chain tensioner
18 - O-ring
19 - Valve for oil pressure control -N428-
20 - Bolt
❑ Specified torque ⇒ Item 1 (page 257)
21 - Oil strainer
22 - Oil pump
23 - Bolt for oil pump
❑ 8 Nm +90°
24 - O-ring
25 - Bolt for oil suction pipe
❑ 4 Nm +45°
26 - Bolt for sump
27 - Lower part of sump
❑ Sheet-metal or plastic
Top section of sump - specified torques and tightening se‐

quence
• Renew bolts after removing.

• Always use 18 bolts.
tions
1 -1 to 18- 8 Nm
2 -1, 2- Turn 180° further

04.2021

tions
1.2 Removing and installing oil level and

oil temperature sender -G266-
Removing
– Drain engine oil ⇒ Maintenance; Booklet ; Engine oil: Drain‐
insulation.
– Undo nuts -1- and remove oil level and oil temperature send‐
er -G266- -item 4-.
Installing

04.2021

– Renew oil seal -2-.
– Replenish engine oil and check oil level ⇒ Maintenance;
ishing engine oil.
Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 232
1.3 Removing and installing lower part of

sump
⇒ a1.3.1 nd installing bottom section of sump, plastic sump”,
page 236
⇒ a1.3.2 nd installing bottom section of sump, sheet-metal
sump”, page 237
1.3.1 Removing and installing bottom section

of sump, plastic sump
♦ Used oil collector and extractor -VAS 6622A-

Removing

insulation.
– Place used oil collection and extraction unit -VAS 6622A-
under engine, and drain engine oil.

04.2021
Note
Please observe disposal instructions!
– Unscrew bolts -1 … 20-, and remove sump.
Installing
– Install baffle plate, specified torque ⇒ Item 7 (page 233) .

– Tighten new bolts -1- to -20- in three stages in the sequence
shown:
Stage Tightening sequence and
specified torque
1. Bolts -1- to -20- Screw in by hand as far as
stop
2 Bolts -1- to -20- Tighten to 8 Nm
3. Bolts -1- to -20- Turn 90° further
ishing engine oil.
1.3.2 Removing and installing bottom section

of sump, sheet-metal sump

04.2021
♦ Wedge -T10383/2-
♦ Cutting tool -T10561-
♦ Applicator gun -VAS 6966-
♦ Commercially available scraper

♦ Hand drill with plastic brush attachment
♦ Safety glasses

04.2021
Components of cutting tool -T10561-
1- Bolt
2- Washer
3- Bracket
4- Knife
5- Guide
6- Handle
7- Inserts for support (rod) for conversion of handle
8- Bolt
9- Support
Removing

insulation.
– Place used oil collection and extraction unit -VAS 6622A-
under engine, and drain engine oil.
– Unscrew securing bolts for oil pan, but leave 2 of them.

04.2021
– Loosen 2 bolts on oil sump, but do not unscrew completely.

– Cut through seal between oil sump -4- and engine -1-.
– Use cutting tool -T10561- to do this.
Note
♦ The sump is sealed with liquid sealant -2- ⇒ Electronic parts

catalogue.
♦ When hardened, the sealant has a high adhesive strength.
– Separation is made centrally between bolts -3-.

– Position cutting tool -T10561- on seal -arrows- without it tilt‐
ing.
– Drive in cutting tool -T10561- -3- using a hammer as far as it
will go -arrow-.
– Do not tilt cutting tool -T10561- when doing this.

– Do not cutting tool -T10561- sideways.

04.2021
– Do not lever with cutting tool -T10561-.

– Repeat this procedure on several position until the oil pan
has come off.
– Use wedge -T10383/2- to further loosen detached positions.
– Using a plastic hammer carefully drive in wedge.
– Drive in wedge -T10383/2- only to same depth as sealing
surface.
– Carefully detach sump (bottom section) from adhesive bond.
– Fit wedge -T10383/2- at another position and detach the
bonded joint in the same way.
– Carefully detach lower part of sump from adhesive bond
using a commercially available scraper.
Installing
CAUTION
– Remove remaining sealant from sealing surfaces, e.g. using

rotating plastic brush.
– Clean sealing surfaces. They must be free of oil and grease.
– Apply the bead of silicone sealant onto the sealing surface of
the bottom section of sump, as shown in illustration.
♦ Thickness of sealant bead: 2 to 3 mm

04.2021
Note

♦ The sump must be installed within 5 minutes after applying
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Tighten new bolts -1- to -20- in two stages in the sequence

shown:
Stage Tightening sequence and

specified torque
1. Bolts -1- to -20- Tighten to 8 Nm
2. Bolts -1- to -20- Turn 45° further
ishing engine oil.
1.4 Removing and installing oil pump


04.2021
Removing
– Remove sump (bottom section) ⇒ page 236 .

– Unscrew bolt -1-, and remove baffle plate -2-.
– Pull spring of chain tensioner in -direction of arrow- us‐
ing assembly tool -T10118- and secure it with locking pin
-T40265-.
– Unscrew bolts -arrows- and remove oil pump.

04.2021
Installing
– Check that both centring sleeves for centring oil pump are
present.
– Before installing oil pump, check strainer in oil suction pipe
and oil galleries in upper part of sump for soiling.
– Guide oil pump chain sprocket into drive chain and install oil
pump.
– Pull spring of chain tensioner in -direction of arrow- using
assembly tool -T10118- and remove locking pin -T40265-.
– Slowly relieve tension from assembly tool -T10118-.

– Fit O-rings ⇒ Item 9 (page 233) onto baffle plate, and mois‐
ten them with engine oil.
– Insert new baffle plate, and bolt it on.
– Install bottom section of sump ⇒ page 236 .
ishing engine oil.
Specified torques

04.2021
1.5 Removing and installing upper part of

sump
♦ Hand drill with plastic brush

♦ Safety glasses
Note
If the top section of sump is renewed, the baffle plate must be

renewed as well.
Removing
– Remove sump (bottom section) ⇒ page 236 .
– Remove rear sealing flange ⇒ page 106 .
– Remove oil pump ⇒ page 242 .

04.2021
Top section of sump with 14 bolts
– Unscrew bolts -1 to 14- and detach top section of sump from

bonded joint.
– Lever off upper part of sump on gearbox side first. When lev‐
ering off, exercise caution to ensure the timing chain cover is
not bent in the process.

04.2021
Top section of sump with 18 bolts
– Unscrew bolts -1 to 18- and detach top section of sump from

bonded joint.
– Lever off upper part of sump on gearbox side first. When lev‐
ering off, exercise caution to ensure the timing chain cover is
not bent in the process.
Installing
Note
♦ Observe use-by date of silicone sealant.

♦ The sump (top section) must be installed within 5 minutes
after applying the silicone sealant.
♦ Replace bolts that are tightened with specified tightening
angle.
♦ Renew gaskets, oil seals and self-locking nuts.
– Remove sealant residues from cylinder block with a flat scra‐

per.
CAUTION
– Remove sealant residue from sump (top section) using a

rotating plastic brush, for example.

04.2021
Note
Check timing chain cover for deformation. To do this, fit sump

upper part first without sealant and check gap between cover
and sump upper part. If deformation is evident and cover can‐
not be aligned, renew cover after top section of sump has been
installed.

– Check oil passages in top section of sump and in crankcase
for soiling.
2 mm).
Note
Danger of blocking lubrication system with excess sealant. Do

not apply sealant bead thicker than specified.
– Apply silicone sealant onto clean sealing surface of top sec‐

tion of sump as illustrated -arrow-.
• Thickness of sealant bead: 2 to 3 mm.
– Apply silicone sealant between cylinder block and lower tim‐
ing chain cover, as shown in illustration -arrows-.

04.2021
Note
♦ After applying the silicone sealant, the top part of the sump
must be fitted within 5 minutes.
• Sump upper part and crankcase must be flush on gearbox

side.
– Immediately fit top section of sump, and screw in bolts as far
as stop.
– Tighten top section of sump. Specified torque ⇒ page 234

– Screw in new bolts -arrows-. Specified torques ⇒ page 165 .

04.2021
– Install rear sealing flange ⇒ page 106 .

– Install oil pump ⇒ page 242 .
– Insert new baffle plate, and bolt it on.
– Install bottom section of sump ⇒ page 236 .
quence.
ishing engine oil.
Specified torques
1.6 Engine oil:

Capacities and specifications ⇒ Maintenance; Booklet ; Engine
oil: Capacities and specifications.
Change engine oil ⇒ Maintenance; Booklet ; Engine oil: Drain‐
Check engine oil level ⇒ Maintenance; Booklet ; Engine oil lev‐
el: Checking.

04.2021
2 Engine oil cooler

⇒ o2.1 verview - engine oil cooler”, page 251
⇒ a2.2 nd installing engine oil cooler”, page 251
2.1 Assembly overview - engine oil cooler
ling ⇒ page 95
2 - Seal
❑ Renew
3 - O-ring
4 - Mechanical switching
valve
ling ⇒ page 253
5 - Engine oil cooler
❑ Observe notes ⇒ page
232
ling ⇒ page 251
6 - Seal
❑ Renew
7 - Connection
8 - Bolt
❑ Renew
❑ 8 Nm +45°
2.2 Removing and installing engine oil

cooler
2. Engine oil cooler 251

04.2021
Removing
CAUTION

– Remove bracket for ancillaries ⇒ page 95 .
– Unscrew bolts -4 and 5- and remove engine oil cooler -3-
together with seal -2-.
Installing
Note
♦ Renew gaskets and seals.

logue (ETKA).
– Install engine oil cooler -3- with new seal -2-.

04.2021
– Install bracket for ancillaries ⇒ page 95 .

ishing engine oil.
Specified torques
♦ ⇒ o2.1 verview - engine oil cooler”, page 251
Removing and installing mechanical switching valve
Removing
– Remove engine oil cooler ⇒ page 251 .
– Remove mechanical switching valve -1- from ancillary brack‐
et -arrow-.
Installing
Note
♦ Renew O-rings if damaged.

logue (ETKA).
– Moisten O-rings of mechanical switching valve with engine

oil, and install switching valve.
– Install engine oil cooler ⇒ page 251 .
2. Engine oil cooler 253

04.2021
3 Crankcase ventilation
⇒ o3.1 verview - crankcase breather system”, page 254
⇒ a3.2 nd installing oil separator”, page 255
3.1 Assembly overview - crankcase breather system
1 - Cylinder head cover

2 - Seal
3 - Hose
❑ To activated charcoal
filter solenoid valve 1 -
N80-
4 - Oil separator
ling ⇒ page 255
5 - Seal
6 - Hose
❑ For crankcase ventila‐
tion.
❑ To turbocharger
7 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt
by hand to ensure it
is screwed into old
thread. Then tighten
bolt to specified torque.
❑ 4 Nm
8 - Seal
9 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt
by hand to ensure it
is screwed into old
thread. Then tighten bolt to specified torque.
Tightening sequence - oil separator

04.2021
– Tighten bolts in the sequence -1 … 7- to 9 Nm.
3.2 Removing and installing oil separator

Removing
– Release ignition coil connectors and, at the same time, pull
connectors off ignition coils.
– Unscrew ignition coil bolts “3 and 4”, and pull out ignition
coils.
– Release hose clip -1- and detach hose from activated char‐
coal filter solenoid valve 1 -N80-.
– Remove bolt -2- and detach crankcase breather hose -3-

from oil separator.
– Remove bolts -arrows- and detach oil separator.
Installing
Note
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue (ET‐
KA).
Specified torques
♦ ⇒ o3.1 verview - crankcase breather system”, page 254
3. Crankcase ventilation 255

04.2021
4 Oil filter, oil pressure switch

⇒ o4.1 verview - oil filter”, page 256
⇒ o4.2 verview - oil pressure switches/oil pressure control”,
page 256
⇒ a4.3 nd installing piston cooling jet control valveN522”, page
258
⇒ a4.5 nd installing oil pressure switch”, page 260
⇒ a4.4 nd installing oil pressure regulating valveN428”, page
259
⇒ o4.6 il pressure”, page 264
4.1 Assembly overview - oil filter
ling ⇒ page 95
2 - Seal
❑ Renew
3 - Oil filter element
ling ⇒ Maintenance;
Booklet ; Engine oil:
Draining; Renewing oil
filter and replenishing
engine oil.
4 - O-ring
❑ Renew
5 - Oil filter housing
❑ 25 Nm
6 - Oil drain connection
❑ Different versions may
be fitted
7 - O-ring
❑ Not a replacement part.
Included in items sup‐
plied with item 6
8 - Bolt
page 84
4.2 Assembly overview - oil pressure switches/oil pressure control

04.2021
1 - Bolt
❑ Renew
❑ 4 Nm +90°
2 - Valve for oil pressure con‐
trol -N428-
❑ Checking ⇒ Vehicle di‐
agnostic tester
ling ⇒ page 259
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - Bolt
❑ Renew
❑ 4 Nm +45°
6 - Piston cooling jet control
valve -N522-
❑ Checking ⇒ Vehicle di‐
agnostic tester
ling ⇒ page 258 .
7 - Seal
❑ Renew oil pressure
switch each time it has
been loosened.
8 - Oil pressure switch -F1-
❑ Blue or grey insulation
❑ Checking ⇒ Vehicle diagnostic tester
❑ 20 Nm
9 - Oil pressure switch for reduced oil pressure -F378-
❑ Brown insulation
❑ 20 Nm
10 - Seal
❑ Renew oil pressure switch each time it has been loosened.
11 - Seal
❑ Renew oil pressure switch each time it has been loosened.
12 - Stage 3 oil pressure switch -F447-
❑ 20 Nm
4. Oil filter, oil pressure switch 257

04.2021
installation position of stage 3 oil pressure switch -F447-
4.3 Removing and installing piston cooling

jet control valve -N522-
Removing
Note
Place a cloth underneath ancillary bracket to catch any escap‐

ing engine oil.
– Separate connector -arrow- from piston cooling jet control

valve -N522-.
– Unscrew bolt -1-, and remove piston cooling jet control valve
-N522- -2-.
Installing
Note
♦ Renew O-rings.
♦ Insert piston cooling jet control valves -N522- immediately in
hole to avoid loss of oil.
– Check oil level ⇒ Maintenance; Booklet ; Engine oil: Drain‐

Specified torques
♦ ⇒ o4.2 verview - oil pressure switches/oil pressure control”,
page 256

04.2021
4.4 Removing and installing oil pressure

regulating valve -N428-
Removing

insulation.
– Remove poly V-belt ⇒ page 85 .
– Place used oil collection and extraction unit -VAS 6622- un‐
der engine.

– Unscrew bolt -2- and pull out valve for oil pressure control
-N428-.
Installing

04.2021
Note
Renew O-ring.
Specified torques
page 256
4.5 Removing and installing oil pressure

switch
⇒ a4.5.1 nd installing oil pressure switchF1”, page 260
⇒ a4.5.2 nd installing oil pressure switch for reduced oil pres‐
sureF378”, page 261
⇒ a4.5.3 nd installing stage 3 oil pressure switchF447”, page
262
4.5.1 Removing and installing oil pressure

switch -F1-
♦ T-bar and socket, 24 mm -T40175-
Removing

04.2021
Note
♦ Place a cloth underneath ancillary bracket to catch any es‐

caping engine oil.
♦ Renew the seal each time the oil pressure switch has been
loosened.
– Separate electrical connector -arrow- on oil pressure switch

-F1-.
– Unscrew oil pressure switch -1-.
Installing
note the following:
Note
Screw oil pressure switch -F1- immediately into bore to avoid

loss of oil.

Specified torques
page 256
4.5.2 Removing and installing oil pressure

switch for reduced oil pressure -F378-

04.2021
Removing
Note
♦ Place a cloth underneath ancillary bracket to catch any es‐

caping engine oil.
♦ Renew the seal each time the oil pressure switch has been
loosened.

for reduced oil pressure -F378-.
– Unscrew oil pressure switch for reduced oil pressure -1-.
Installing
note the following:
Note
Screw oil pressure switch for reduced oil pressure -F378- imme‐
diately into bore to avoid loss of oil.

Specified torques
page 256
4.5.3 Removing and installing stage 3 oil

pressure switch -F447-

04.2021
Note
Renew the seal each time the oil pressure switch has been
loosened.
Removing
er ⇒ page 410 .
– Separate connector -1- from stage 3 oil pressure switch
-F447-.
– Unscrew bolts -arrows- and remove toothed belt guard.
Note
Use cloth to catch escaping engine oil.
– Remove oil pressure switch, stage 3 -F447- -item 2- using

articulated wrench, 24 mm -T40175-.
Installing
Note
Screw stage 3 oil pressure switch -F447- immediately into bore

to avoid loss of oil.


04.2021
Specified torques
page 256
4.6 Checking oil pressure

⇒ e4.6.1 ngine oil pressure”, page 264
⇒ o4.6.2 il pressure and oil spray jets”, page 266
4.6.1 Checking engine oil pressure

♦ Oil pressure tester -V.A.G 1342-
Conditions for testing

• Oil level OK.
• Engine oil temperature at least 80°C (radiator fan must have
run once)
Note
♦ The oil pump is regulated and has 2 pressure levels. The

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

04.2021
Test sequence

for reduced oil pressure -F378-.
– Place a cloth underneath ancillary bracket to catch any es‐
caping engine oil.
– Unscrew oil pressure switch for reduced oil pressure -1-.
– Screw oil pressure tester -V.A.G 1342- into oil filter bracket
in place of the oil pressure switch.
– Screw oil pressure switch for reduced oil pressure -F378-
into oil pressure tester and connect connector.
– Connect oil pressure tester to earth.
– Start engine, and check oil pressure at the specified engine
speed levels.
• Oil pressure at idling speed: 0.85 to 1.6 bar
• Oil pressure at 2000 rpm: 1.2 to 1.6 bar
– Stop engine.
insulation.
– Pull connector -1- off valve for oil pressure control -N428-.
Unclip cable and route it towards bottom to prevent it from
being trapped in the belt drive. With disconnected connector
the oil pump operates at high pressure level.
– Start engine, and check oil pressure at the specified engine

speed levels.
• Oil pressure at idling speed: 0.85 to 4.0 bar

04.2021

Installing
– Install oil pressure switch.
– Connect connector -1- to valve for oil pressure control -
N428-. Route cable carefully.

insulation.
– Read engine control unit event memory, and clear all en‐
tries.
Specified torques
page 256
4.6.2 Checking oil pressure and oil spray jets

♦ Oil pressure tester -V.A.G 1342-
♦ Test instrument/DSO adapter -VAS 5571-

04.2021
Note
During this check procedure, the piston cooling jet control valve
-N522- and the oil passage to the oil spray jets for cooling the
pistons are checked.
Conditions for testing

• Oil level OK.
• Engine oil pressure OK.
• Oil pressure tester -V.A.G 1342- is connected as described
in section ⇒ e4.6.1 ngine oil pressure”, page 264 .
Test sequence
– Pull connector -arrow- off piston cooling jet control valve

-N522-. Connect connector and control valve to test instru‐
ment/DSO adapter -VAS 5571-.
– Start engine and allow to idle.
– Observe oil pressure tester, disconnect connector for control
valve, and connect it again. A pressure variation must be
indicated on the oil pressure tester.
Note
If the engine runs at idling speed, the oil passage to the oil
spray jets is closed. When the connector is pulled off, the oil
passage to the oil spray jets is opened. If no pressure variation
is indicated, the piston cooling jet control valve -N522- is defec‐
tive, or the oil passage to the oil spray jets is blocked.

04.2021
19 – Cooling
1 Cooling system/coolant
⇒ d1.1 iagram - coolant hoses”, page 268
⇒ a1.2 nd adding coolant”, page 278
⇒ c1.3 ooling system for leaks”, page 287
⇒ c1.4.1 ooling system”, page 291
⇒ c1.4.2 ooling system, quick reference guide”, page 313
1.1 Connection diagram - coolant hoses

⇒ w1.1.1 ith manual gearbox”, page 268
⇒ w1.1.2 ith dual clutch gearbox or automatic gearbox”, page
269
⇒ w1.1.3 ith dual clutch gearbox, engine code CHHA”, page
271
⇒ w1.1.4 ith dual clutch gearbox and auxiliary radiator on right
side”, page 273
⇒ w1.1.5 ith dual clutch gearbox and auxiliary radiator on right
and left sides”, page 275
1.1.1 Vehicles with manual gearbox
Note
♦ Blue = large coolant circuit.

♦ Red = small coolant circuit.
♦ Brown = heater circuit.
♦ Yellow = gear oil cooling circuit.
♦ The arrows point in the direction of coolant flow.
268 Rep. gr.19 - Cooling

04.2021
1 - Radiator for engine cool‐

ant
2 - Radiator outlet coolant
temperature sender -G83-
3 - Actuator for engine tem‐
perature regulation -N493-
4 - Cylinder head/cylinder
block
5 - Restrictor
6 - Auxiliary heater
❑ Equipment version
7 - Coolant expansion tank
8 - Cap for coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 291
9 - Non-return valve
10 - Exhaust manifold
❑ Integrated in cylinder
head
11 - Turbocharger
12 - Heat exchanger for heat‐
er
13 - Restrictor
15 - Auxiliary pump for heat‐
ing -V488-
16 - Radiator outlet coolant -
G62-
17 - Coolant shut-off valve -N82-
18 - Restrictor
19 - Coolant pump
1.1.2 Vehicles with dual clutch gearbox or

automatic gearbox
Note

1. Cooling system/coolant 269

04.2021

ant
block
5 - Restrictor
tank
valve ⇒ page 291
head
11 - Turbocharger
er
13 - Restrictor
ing -V488-
G62-
❑ Not applicable for automatic gearbox
18 - Restrictor
19 - Coolant pump
20 - Coolant valve for gearbox -N488-
❑ Installed behind gear oil cooler in the case of automatic gearbox
22 - Gear oil cooler

04.2021
1.1.3 Vehicles with dual clutch gearbox, en‐

gine code CHHA
Note


04.2021

ant
block
5 - Restrictor
tank
valve ⇒ page 291
head
11 - Turbocharger
er
13 - Restrictor
ing -V488-
G62-
18 - Restrictor
19 - Circulation pump -V55-
20 - Coolant pump

04.2021
1.1.4 Vehicles with dual clutch gearbox and

auxiliary radiator on right side
Note

♦ Green = auxiliary radiator.

04.2021

ant
block
5 - Restrictor
tank
valve ⇒ page 291
head
10 - Turbocharger
er
12 - Restrictor
ing -V488-
G62-
16 - Coolant shut-off valve -
N82-
17 - Restrictor
18 - Circulation pump -V55-
19 - Coolant pump
23 - Auxiliary radiator
❑ Location: in front right wheel housing

04.2021
1.1.5 Vehicles with dual clutch gearbox and

auxiliary radiator on right and left sides
Note


04.2021
❑ Location: in front right
wheel housing
page 352
ling ⇒ page 369
page 321
ling ⇒ page 341
block
❑ Renew coolant after re‐
placing
page 142
ling ⇒ page 145
5 - Restrictor
tank
valve ⇒ page 291
10 - Turbocharger
11 - Heat exchanger for heater
❑ Renew coolant after replacing
12 - Restrictor
14 - Auxiliary pump for heating -V488-
15 - Radiator outlet coolant -G62-
17 - Coolant pump

04.2021
18 - Restrictor
❑ Fitting location: front left wheel housing
23 - Radiator for engine coolant
❑ Renew coolant after replacing
1.1.6 Sharan with additional heat exchanger
Note


04.2021

ant
block
5 - Restrictor
tank
valve ⇒ page 291
head
11 - Turbocharger
12 - Restrictor
er
❑ Front
14 - 2nd heat exchanger for
heater unit
❑ Rear
15 - Heater coolant shut-off
valve -N279-
16 - Auxiliary pump for heating -V488-
❑ Not applicable for automatic gearbox
20 - Restrictor
21 - Coolant pump
❑ Installed behind gear oil cooler in the case of automatic gearbox
1.2 Draining and adding coolant

04.2021

equipment required
♦ Adapter for cooling system tester -V.A.G 1274/8-

♦ Hose clamp pliers -VAS 6340-
♦ Cooling system charge unit -VAS 6096-
♦ Refractometer -T10007 A-
♦ Vehicle diagnostic tester

04.2021
Draining
CAUTION

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

– Pull off connector of radiator outlet coolant temperature
sender.

04.2021
– Disconnect coolant hose with plug-in connector -1- from low‐

er right of radiator, and drain coolant.

04.2021
Preparing cooling system for filling:

04.2021
Note
♦ Due to the differing constitution of tap water in the various

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

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

04.2021
♦ The temperature reading on the refractometer corresponds

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

• Coolant (40%) and distilled water (60%) for frost protection
to -25°C
• Coolant (50%) and distilled water (50%) for frost protection
to -36°C
• Coolant: ⇒ Electronic parts catalogue (ETKA).
– Connect coolant hose with plug-in connector -1- to radiator

at bottom right ⇒ page 349 .
– Connect connector of radiator outlet coolant temperature
sender.
– Fill coolant expansion tank of -VAS 6096- with 10 litres of
pre-mixed coolant in correct mixture ratio; mixture ratio ⇒
page 284 .
Sharan:
– Unbolt coolant expansion tank -arrows- and tilt forwards

slightly.

04.2021
All:
– Screw adapter for cooling system tester -V.A.G 1274/8- onto

coolant expansion tank -1-.
– Attach cooling system charge unit -VAS 6096- to adapter
-V.A.G 1274/8-.
– Feed vent hose -2- into a small container -3-.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Fit hose -4- to compressed air supply with a pressure of
6 … 10 bar.
functions.
♦ 0001 - Fill/bleed cooling system
Filling with coolant:
– Open valve -B-; turn lever in direction of flow to do this.

04.2021
• In cooling system, vacuum is generated by suction jet pump;

needle of gauge must move into green area.
– Also briefly open valve -A- (turn lever in direction of flow to
do this) so that hose on -VAS 6096- coolant reservoir fills
with coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• Vacuum continues to be generated in the cooling system by
the suction jet pump; the needle of gauge must remain in
green range.
– Close valve -B-.
– Pull off compressed air hose.
• The needle on the gauge should stop in the green zone.
The vacuum level in the cooling system is then sufficient for
subsequent filling.
Note
♦ If the needle does not reach the green zone, repeat the
process.
♦ If vacuum drops, cooling system must be checked for leaks.
♦ The subsequent filling must be performed »slowly«.
– Open valve -A- slowly.

• Vacuum in cooling system causes coolant to be extracted
from -VAS 6096- coolant reservoir and coolant system to be
filled.
• The coolant level must be above the max. marking after
filling.
– Remove cooling system charge unit -VAS 6096- from cool‐
ant expansion tank.
insulation.
– On vehicles with auxiliary heater, switch on auxiliary heater
for about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in button should not light up.
– Start engine and run it for max. 2 min. at a speed of approx.
1,500 rpm.
– Fill coolant up to the overflow hole of the coolant expansion
tank while the engine is running.
– Tighten cap of coolant expansion tank until it engages.
– Then run engine at idling speed until radiator fan cuts in.
– Check coolant level.

04.2021
• When the engine is at operating temperature, the coolant

level must be at the »weld seam« -arrow-.
• When the engine is cold, the coolant level must be approx.
5 mm above the max. marking -arrow-.
Note
This excessive amount of coolant level is necessary since the

coolant level may decrease automatically due to bleeding proc‐
ess.
1.3 Checking cooling system for leaks

04.2021

equipment required

♦ Cooling system tester -V.A.G 1274 B-
Note
To perform the leakage test correctly, first run a self-test on the

cooling system tester -V.A.G 1274 B-.

04.2021
Self-test of cooling system tester -V.A.G 1274 B-
– Operate cooling system tester -V.A.G 1274 B- several times.

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

er for 30 seconds.
If no pressure builds up or if the pressure drops again:
The cooling system tester -V.A.G 1274 B- is leaking and should
not be used.
Checking cooling system for leaks
• Engine at operating temperature.

04.2021
CAUTION

– Fit cooling system tester -V.A.G 1274 B- with adapter -
V.A.G 1274/8- to coolant expansion tank.
– Build up pressure of approx. 1.5 bar using hand pump of

cooling system tester.
• The pressure must not drop by more than 0.2 bar within
10 minutes.
– If the pressure drops by more than 0.2 bar, locate and rectify
leaks.
Note
The pressure drop of 0.2 bar within 10 minutes depends on the

how far the coolant can cool down. The colder the engine, the
lower the pressure drop. If necessary, repeat the check while
the engine is cold.

04.2021
Check pressure relief valve in cap.
– Screw cap -1- into adapter for cooling system tester -V.A.G
1274/9- -2-.
– Connect adapter for cooling system tester -V.A.G 1274/9- to
cooling system tester -V.A.G 1274 B- using connecting hose
supplied.
– Build up pressure using hand pump of cooling system tester.
• The pressure relief valve must open at a pressure of 1.6 to
1.8 bar.
– Renew filler cap, if pressure relief valve does not open as
described.
1.4 Flushing cooling system

⇒ c1.4.1 ooling system”, page 291
⇒ c1.4.2 ooling system, quick reference guide”, page 313
1.4.1 Flushing cooling system
Note
♦ The coolant must be drained before the system is flushed.

Then the cooling system must be filled with distilled water.
♦ The cooling system is then flushed with approx. 19 litres
of distilled water. Then, the distilled water is replaced by
coolant (mixture ratio 50:50).
♦ Never reuse old coolant.
♦ For a quick reference guide, refer to ⇒ c1.4.2 ooling sys‐
tem, quick reference guide”, page 313 . The quick reference
guide contains the basic steps of the procedure. It might be
helpful to print out the guide and tick off the corresponding
work steps after having performed them.

04.2021

equipment required
♦ Coolant flushing and filling device -VAS 531 007-

♦ Test adapter -VAS 691 005/5-
♦ Suction-jet pump from cooling system charge unit -VAS
6096-
♦ Refractometer -T10007 A-
♦ Compressed air connection with 6 … 10 bar(g)

04.2021

Schematic overview of coolant flushing and filling device -VAS
531 007-:

04.2021
1 - Container with distilled wa‐

ter
❑ Fill with 30 l of distilled
water
❑ 19 litres of this are re‐
quired for flushing
❑ 11 litres are a safety re‐
serve and remain in the
canister
2 - Container with coolant
❑ Fill with 30 l of coolant
❑ Anti-freeze to ap‐
prox. -36°C (mixture ra‐
tio 50:50)
❑ 18 litres of this are re‐
quired for flushing
❑ 12 litres are a safety re‐
serve and remain in the
canister
3 - Empty container
❑ For used coolant
4 - Empty container
❑ For used coolant
5 - Suction hose
❑ Comes from connection
2 on sight glass
6 - Sight glass
❑ When opaque, clean
sight class with a nylon
brush
7 - Pump
❑ Cut-out pressure ap‐
prox. 1.5 bar
8 - Valve block
❑ With pressure gauge and shut-off taps
9 - Drain hose
❑ Connected to valve block for releasing pressure
10 - Flushing hose
❑ Connected to breather hose of coolant expansion tank for flushing
❑ Comes from connection 1 on sight glass
❑ Seal with plugs when not in use
11 - Plug
12 - Hose clamps
❑ Qty. 4
13 - Cleaning adapter
❑ Approx. 15 cm in length
❑ For cleaning coolant flushing and filling device after flushing
❑ Connected between valve block and flushing hose ⇒ Item 10 (page 294) (10)
14 - Extraction adapter
❑ Approx. 100 cm in length

04.2021
❑ Connected to suction hose ⇒ Item 5 (page 294) (5) for extracting coolant
Procedure:
– With coolant hose pulled off, pour approximately 1 litre of
distilled water into the coolant expansion tank.
– Drain coolant into drip tray.
– Re-connect detached coolant hoses.
Preparing coolant flushing and filling device -VAS 531 007-:
– Fill container »1« with 30 l of distilled water.
– Fill container »2« with 30 l of coolant. Mixture ratio is 50:50
for anti-freeze protection down to approx. -36°C.
– Empty containers »3« and »4«.
– Remove valve block from plug-in connector on equipment
trolley.
– Connect coolant flushing and filling device -VAS 531 007- to
battery.
Bleeding coolant flushing and filling device -VAS 531 007-:
– Connect suction hose -A- to container »1« with distilled wa‐

ter.
– Connect drain hose -arrow- to plug-in connector -B- on valve
block.
– Close shut-off taps -A- and -B-.

04.2021
Note
Do not fit the valve block onto the test adapter -VAS 691 005/5-
yet. The filler hose must be bled first.
– Switch on pump for -VAS 531 007-.

– Open cut-off tap -A-.
– Open shut-off tap -B- briefly to bleed filler hose.
– Close shut-off taps -A- and -B-.
Connecting coolant flushing and filling device -VAS 531 007-:

– Screw test adapter -2- (-VAS 691 005/5-) onto coolant ex‐
pansion tank -1-.
– Pull drain hose -arrow- off plug-in connector -B- on valve

block.

04.2021
– Fit valve block -1- onto test adapter -2-.
– Connect suction-jet pump -2- from -VAS 6096- to plug-in

connector -B- on valve block -1-.
Filling cooling system with distilled water:

04.2021
– Place end of vent hose -8- of suction-jet pump into a con‐

tainer.
– Connect compressed air hose -6- to suction-jet pump -7-.
– Open shut-off tap -B- on valve block -5-.
• The suction-jet pump reduces pressure in the cooling sys‐
tem to below atmospheric pressure. The pointer of the pres‐
sure gauge must fall to at least -0.85 bar.
– Close shut-off tap -B-.
– Pull off compressed air hose -6-.
– Observe pressure gauge. The pointer of the pressure gauge
must remain stationary at -0.85 bar at least. The vacuum in
the cooling system is then sufficient for subsequent filling.
Note
♦ If the vacuum drops, the cooling system must be checked for leaks.
♦ The vacuum that builds up depends on the pressure in the compressed air system.
• The pump of the -VAS 531 007- must be switched on.

04.2021
– »Slowly« open shut-off tap -A-.

• The vacuum in the cooling system causes the distilled water
to be drawn into the cooling system, and thus causes the
cooling system to be filled. In addition, the pump of the -VAS
531 007- feeds distilled water into the coolant expansion
tank.
– Fill cooling system until pressure of approx. 1 bar can be
read off gauge.
After filling, the pressure in the coolant expansion tank must be
released. Proceed as follows to do this:
– Close shut-off tap -A- after filling.
– Remove suction-jet pump -2- from valve block -1- .
– Connect drain hose -arrow- to plug-in connector. Open shut-

off tap -B-, and leave it open so that the pressure in the
cooling system releases.

04.2021
– With ignition switched off, release and pull off electrical con‐
nector -1- on engine temperature sender -G62- -3-.
Note
If the connector of the coolant temperature sender -G62- is

pulled off, the actuator for engine temperature regulation -N493-
will open and the radiator fan will start to operate as soon as the
engine is started.
– Temporarily, install air filter housing so that corresponding

location on cylinder head remains free. Air filter housing can
be placed on battery, for example.
– Start engine and increase speed for approximately 1 minute.
Then, switch off engine.
Flushing cooling system with distilled water:
• Shut-off tap -A- is closed; shut-off tap -B- is open.

– Remove breather hose -2- from coolant expansion tank -1- .
– Connect breather hose -2- from coolant expansion tank to
flushing hose -1-.

04.2021
– Seal connection on coolant expansion tank using plug -3-.

Secure plug with a hose clip.
– Close shut-off tap -B-.
Note
♦ Flushing of the cooling system will now begin. Please note

the fill level of the tanks in order to assure correct flushing
capacities.
♦ The engine is running at idling speed during the entire flush‐
ing process.
– Start engine and allow to idle.

– Set heater temperature to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
1 – Flushing cylinder block with distilled water:

04.2021
– Clamp off breather hoses for heat exchanger and cylinder

head with hose clamps.
– Open shut-off tap -A- on valve block.
• Pump approx. 9 litres of distilled water through engine.
– Close shut-off tap -A-.
2 – Flushing cylinder head with distilled water:

04.2021
– Clamp off breather hoses for heat exchanger and radiator

with hose clamps.
3) Flushing heat exchanger for heater with distilled water:

04.2021
– Clamp off breather hoses for radiator and cylinder head with
hose clamps.
4 Flushing entire cooling system
– Remove any hose clamps.

04.2021
Flushing cooling system with coolant
– Connect suction hose -A- to container -2- for coolant.

1 – Flushing cylinder block with coolant:
– Clamp off breather hoses for heat exchanger and cylinder

head with hose clamps.
• Pump approx. 5 litres of coolant through engine.

04.2021

2 – Flushing cylinder head with coolant:
– Clamp off breather hoses for heat exchanger and radiator

with hose clamps.
3) Flushing heat exchanger for heater with coolant:

04.2021
– Clamp off breather hoses for radiator and cylinder head with
hose clamps.
4 Flushing entire cooling system
– Remove any hose clamps.

04.2021
The flushing process is now completed. Switch off the pump,

and switch off the engine.
Removing coolant flushing and filling device -VAS 531 007-:
– Open shut-off tap -B-, and leave it open so that the pressure
in the cooling system releases.
– Pull plug -3- off coolant expansion tank, and reconnect
breather hose -2-.
– Use plug to seal flushing hose -1-.
– Remove valve block -1- and test adapter -2-.
– If anti-freeze protection down to approx. -36°C is required,

drain coolant expansion tank empty, and fill it with coolant
concentrate.
Note
The coolant flushing and filling device -VAS 531 007- can be
used for extracting coolant ⇒ page 310 .
– The coolant level must be at the »weld seam« -arrow-.

04.2021
– Reattach electrical connector -1- on coolant temperature

sender -G62- -3-.
– Install air filter housing at its final installation position.

– Separating the connectors caused entries to be stored in
the event memory of the engine control unit. Clear event
memory ⇒ Vehicle diagnostic tester.
– Tighten cap of coolant expansion tank until it engages.
– Then run engine at idling speed until radiator fan cuts in.
Check coolant level and anti-freeze protection
– If the frost protection is not sufficient, extract coolant from
coolant expansion tank. Ensure correct anti-freeze protec‐
tion by filling more coolant concentrate.
– After each time coolant concentrate has been filled, run en‐
gine at increased engine speed for about 2 minutes, and
check anti-freeze protection again.
• Anti-freeze protection must be guaranteed down to -25°C as
a minimum and, in countries with arctic conditions, down
to approx. -36°C. Increasing the anti-freeze protection is
permissible only if climatic conditions require stronger anti-
freeze protection. It may, however, be increased only to a
maximum of -48°C. Otherwise, the cooling effect will be im‐
paired.
• When the engine is at operating temperature, the coolant
level must be at the »weld seam« -arrow-.

04.2021
• When the engine is cold, the coolant level must be approx.

5 mm above the max. marking -arrow-.
Note
This excessive amount of coolant level is necessary since the

coolant level may decrease automatically due to bleeding proc‐
ess.
Extracting coolant:

04.2021
Note
Use the extraction adapter ⇒ Item 14 (page 294) (14) for extracting the coolant.
– Detach suction hose -5- from container -2-.

– Fit extraction adapter -12- onto plug-in connector of suction
hose -5-.
– Switch on pump -7-, and open shut-off taps -A- and -B- on
valve block -8-.
– Use extraction adapter -12- to extract any excess coolant.
– Close shut-off taps on valve block, and switch off pump.
Cleaning coolant flushing and filling device -VAS 531 007-:

04.2021
Note
♦ If coolant remains in the sight glass for longer periods of time, the sight glass may become opaque.
Therefore, the sight glass must be flushed with distilled water after the flushing procedure has been
completed.
♦ If the sight glass is opaque, it must be cleaned with a nylon brush.
♦ Use cleaning adapter ⇒ Item 13 (page 294) (13) for flushing.
– Connect suction hose -5- to container -1- for distilled water.

– Fit flushing hose -10- onto cleaning adapter -9-. Fit cleaning
adapter -9- to plug-in connector -B- on valve block -8-.
– Open shut-off valves -A- and -B- on valve block -8-.
– Switch on pump -7-, and pump distilled water through hoses
until coolant has been flushed out of sight glass -6-.
– Switch off pump, and close shut-off taps.
– Remove cleaning adapter, and seal flushing hose with plug.

04.2021
1.4.2 Flushing cooling system, quick refer‐

ence guide
Note
The quick reference guide contains the basic steps of the pro‐
cedure. It might be helpful to print out the guide and tick off
the corresponding work steps after having performed them. For
a detailed description of the necessary work steps, refer to ⇒
c1.4.1 ooling system”, page 291 .
Step Measure Volume of flush‐

ing medium
1 Draining coolant ---
2 Fill cooling system with distilled water ---
3 Pull connector off coolant temperature sender -G62- ---
4 Run engine at idling speed ---
5 Clamp off breather hose for heat exchanger -1- and cylinder head -2-; flush 9 l of distilled wa‐
cooling system ter
6 Clamp off breather hose for heat exchanger -1- and radiator -3-; flush cooling 2 l of distilled wa‐
system ter
7 Clamp off breather hose for cylinder head -2- and radiator -3-; flush cooling 2 l of distilled wa‐
system ter
8 Remove all clamps; flush cooling system 6 l of distilled wa‐
ter
9 Clamp off breather hose for heat exchanger -1- and cylinder head -2-; flush 5 l of coolant
cooling system (anti-freeze
-36°C)
10 Clamp off breather hose for heat exchanger -1- and radiator -3-; flush cooling 5 l of coolant
system (anti-freeze
-36°C)
11 Clamp off breather hose for cylinder head -2- and radiator -3-; flush cooling 2 l of coolant
system (anti-freeze
-36°C)
12 Remove all clamps; flush cooling system 6 l of coolant
(anti-freeze
-36°C)
13 Switch off engine ---
14 Drain coolant expansion tank empty, and fill with coolant concentrate ---
15 Fit connector of coolant temperature sender -G62- ---
16 Detach coolant flushing and filling device, and close coolant expansion tank ---
17 Run engine until radiator fan starts to operate. ---
18 Check frost protection ---

04.2021
1 - Breather hose of heat ex‐

changer for heater unit
2 - Breather hose for cylinder
head
3 - Breather hose of radiator
for engine coolant

04.2021
2 Coolant pump, regulation of cooling

system
⇒ o2.1 verview - coolant pump, thermostat”, page 315
⇒ o2.2 verview - electric coolant pump”, page 317
⇒ o2.3 verview - coolant temperature sender”, page 321
⇒ a2.4 nd installing toothed belt for coolant pump”, page 322
⇒ a2.5 nd installing coolant pump”, page 324
⇒ a2.6.1 nd installing auxiliary pump for heatingV488”, page
327
⇒ a2.7.1 nd installing coolant shut-off valveN82”, page 330
⇒ a2.7.2 nd installing coolant valve for gearboxN488, vehicles
with 6-speed dual clutch gearbox”, page 332
⇒ a2.8 nd installing actuator for engine temperature regula‐
tionN493”, page 337
⇒ a2.9 nd installing coolant temperature senderG62”, page 340
⇒ a2.10 nd installing radiator outlet coolant temperature send‐
erG83”, page 341
2.1 Assembly overview - coolant pump, thermostat
2. Coolant pump, regulation of cooling system 315

04.2021
1 - Connection
2 - O-ring
❑ Renew
3 - Centring pin
4 - Bolt
page 317
5 - Seal
❑ Renew
6 - Coolant pump
ling ⇒ page 324
❑ New coolant pump: re‐
move protective cap
7 - Bolt
❑ Tightening sequence ⇒
page 317
8 - Toothed belt
❑ For coolant pump
ling ⇒ page 322
9 - Bolt
❑ 9 Nm
10 - Toothed belt guard
11 - Bolt
❑ Left-hand thread
❑ If bolt has been loos‐
ened, it must be re‐
newed
12 - Toothed belt drive sprocket
❑ Observe installation position
13 - Oil seal for balance shaft, inlet side
14 - Balancer shaft
15 - Seal
❑ Renew
16 - Bolt
❑ 9 Nm
17 - Union
18 - Spring
19 - Seal
❑ Renew
20 - Actuator for engine temperature regulation -N493-

04.2021
Actuator for engine temperature regulation -N493- - tightening

torque and sequence
– Tighten bolts in the sequence -1 … 5- to 9 Nm.

Coolant pump - specified torque and tightening sequence
– Tighten bolts for coolant pump in the sequence -1 … 4- to 9

Nm.
2.2 Assembly overview - electric coolant pump

Auxiliary pump for heating -V488-, coolant shut-off valve -N82-

04.2021
1 - Coolant hose
2 - Coolant shut-off valve -
N82-
ling ⇒ page 330
3 - Auxiliary pump for heating
-V488-
❑ with holder
❑ May vary depending on
version
ling ⇒ page 327
4 - Bracket
❑ for auxiliary pump for
heating -V488-
5 - Bolt
❑ 20 Nm
6 - Clip
7 - Coolant hoses
8 - Coolant hose
9 - Bolt
❑ 9 Nm
Coolant valve for gearbox -N488-, vehicles with 6-speed dual

clutch gearbox or automatic gearbox

04.2021
1 - Bolt
❑ 9 Nm
2 - Coolant hose
3 - Nut
❑ 9 Nm
4 - Coolant hose
5 - Coolant valve for gearbox
-N488-
ling ⇒ page 332
6 - Bracket
❑ For coolant valve for
gearbox -N488-
❑ Shape may differ
Coolant valve for gearbox -N488-, vehicles with 7-speed dual

clutch gearbox

04.2021
1 - Coolant hose
2 - Hose clamp
3 - Bolts
❑ 25 Nm
4 - Bracket
❑ For coolant valve for
gearbox -N488-
5 - Coolant hose
6 - Nuts
❑ 9 Nm
7 - Coolant valve for gearbox
-N488-
ling ⇒ page 334
Gearbox oil cooling pump -V478-
Note
The gearbox oil cooling pump -V478- is not installed in all vehicles.

04.2021
1 - Bracket
❑ For gearbox oil cooling
pump -V478-
2 - Sleeve
3 - Bolt
❑ 5 Nm
4 - Electrical connector
5 - Coolant hose
6 - Spring-type clip
7 - Gearbox oil cooling pump
-V478-
❑ Fitting location: below
actuator for engine
temperature regulation
-N493-
❑ To remove, remove
charge air pipe be‐
tween throttle valve
module and charge air
cooler
8 - Coolant hose
9 - Rubber mounting
10 - Bolt
❑ 20 Nm
11 - Nut
❑ 8 Nm
2.3 Assembly overview - coolant temperature sender

04.2021
1 - Retaining clip
❑ Check for firm seating
2 - O-ring
❑ Renew
ling ⇒ page 341
G62-
❑ On cylinder head (gear‐
box end).
ling ⇒ page 340
6 - O-ring
❑ Renew
7 - O-ring
❑ Renew
8 - Bolt
❑ Renew
❑ 4 Nm +45°
2.4 Removing and installing toothed belt

for coolant pump
♦ Insert tool -T10360-
Removing

04.2021

er ⇒ page 410 .
– Lift retaining clip -1-, detach upper coolant connection and
push it to one side.
– Separate electrical connector -1- on oil pressure switch -2-.

04.2021
Note
– Loosen bolt on drive sprocket -1- for coolant pump using

torque wrench -V.A.G 1410- and insert tool -T10360-, and
unscrew it by 3 turns. To do this, counter hold at vibration
damper.
Note
If tool cannot be used on account of starter securing bolt (on

vehicles with manual gearbox), unscrew respective securing
bolt by approx. 15 mm.
– Remove toothed belt -2-.

Installing
note the following:
– Renew bolt for drive sprocket.
– Installation position of drive gear: Collar on drive gear faces
gearbox.
– Fit toothed belt and tighten securing bolt.
Specified torques
♦ ⇒ o2.1 verview - coolant pump, thermostat”, page 315
2.5 Removing and installing coolant pump

Removing

04.2021

er ⇒ page 410 .
– Remove throttle valve module ⇒ page 453 .
– Lift retaining clip -1-, detach upper coolant connection and
push it to one side.
– Disconnect connectors -2, 3 and 4-. Unscrew securing bolts

-1-, and lay bracket to one side.
– Separate electrical connector -1- on oil pressure switch -2-.

04.2021

– Unscrew bolts -1 … 4-, and remove toothed belt from cool‐
ant pump.
– Unscrew bolts -1 … 4- completely, and detach coolant pump

from actuator for engine temperature regulation -N493-.
Installing

– Fit coolant pump, and install toothed belt.
– Ensure correct seating of centring rings -arrows- and seal
-3-.

04.2021
– Tighten bolts -1 … 4- when the toothed belt is fitted. Speci‐

fied torque and tightening sequence ⇒ page 317 .
– If a new coolant pump has been installed, pull off protective

cap -1-.

Specified torques
2.6 Removing and installing electric cool‐

ant pump
⇒ a2.6.1 nd installing auxiliary pump for heatingV488”, page
327
2.6.1 Removing and installing auxiliary pump

for heating -V488-

04.2021
♦ Hose clamps to 25 mm -3094-
♦ Hose clamp pliers -VAS 6340-
Removing

04.2021
Note
Fit all heat insulation sleeves in the original position when instal‐
ling.
CAUTION

insulation.

er ⇒ page 410 .
– Open heat insulation sleeve -3-.

– Clamp off coolant hoses on auxiliary pump for heating -
V488- using hose clamps -3094-.

04.2021
Note

– Unscrew bolt -2-, and remove auxiliary pump for heating
-V488-.
Installing
Note
KA).
– Check coolant level and top up as needed ⇒ page 286 .

Specified torques
♦ ⇒ o2.2 verview - electric coolant pump”, page 317
2.7 Removing and installing coolant valves

⇒ a2.7.1 nd installing coolant shut-off valveN82”, page 330
with automatic gearbox”, page 335
2.7.1 Removing and installing coolant shut-

off valve -N82-

04.2021
Removing

– Remove bolt -1- and press air pipe (left-side) towards left
slightly.
– Use hose clamps -3094- to clamp off coolant hoses on cool‐

ant shut-off valve -N82-.
Note
Cover the openings in the gearbox with a cloth to prevent any

coolant from getting into the clutch housing.
– Release hose clip -1- and remove coolant hose.

– Unscrew bolt -arrows- and detach coolant shut-off valve -
N82-.

04.2021
Installing
Note
KA).

Specified torques
2.7.2 Removing and installing coolant valve

for gearbox -N488-, vehicles with 6-
speed dual clutch gearbox

04.2021
Removing

insulation.
er ⇒ page 410 .
– Clamp off coolant hoses on coolant valve for gearbox -N488-

using hose clamps -3094-.
Note
Cover the openings in the gearbox with a cloth to prevent any

coolant from getting into the clutch housing.

– Unscrew nuts -arrows-, and remove coolant valve for gear‐
box -N488-.
Installing
Note
KA).

04.2021
Specified torques

for gearbox -N488-, vehicles with 7-
speed dual clutch gearbox
Removing
– Remove radiator cowl ⇒ page 364 .
er ⇒ page 410 .
– Disconnect coolant hose -1- from charge air pipe, and push
it upwards.

04.2021

– Open hose clips, and pull off coolant hoses.
– Unscrew nuts -arrows-, and remove coolant valve.
Installing
Note
KA).
– Check coolant level ⇒ page 286 .

Specified torques

for gearbox -N488-, vehicles with auto‐
matic gearbox

04.2021
Removing

filter housing.

04.2021

– Unscrew nuts -arrows-, and remove coolant valve for gear‐
box -N488-.
Installing
Note
KA).

Specified torques
2.8 Removing and installing actuator for

engine temperature regulation -N493-
Removing
– Remove coolant pump ⇒ page 324 .
– Remove throttle valve module -GX3- ⇒ page 453 .
– Unscrew coolant pipe from intake manifold -arrows-.

04.2021
– Lift retaining clips -1- and disconnect coolant hoses.
– Pull connector -1- off actuator for engine temperature regula‐

tion -N493-.
– Detach actuator for engine temperature regulation -N493-

from centring pins, and pull it off engine oil cooler.
Installing
Note
Renew gaskets, seals and O-rings.
– Moisten new O-rings -4- and gasket of actuator with coolant.

04.2021
– Check whether the two centring pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push actuator for engine temperature regulation -N493- -3-
onto connecting piece and centring pins in cylinder block.
Note
Check correct seating of connection. If connection is »tilted« it

may leak.
– Tighten bolts for actuator for engine temperature regulation

-N493- ⇒ page 317 .
– Install coolant pump ⇒ page 324 .

Further installation is carried out in the reverse order of remov‐
al; note the following:
– Check cooling system for leaks after all coolant hoses have
been connected ⇒ page 287 .
– Perform adaption of actuator for engine temperature regula‐
tion -N493-. Proceed as follows to do this:
functions.
♦ 0001 - Engine electronics
♦ Actuator for engine temperature regulation N493
Specified torques

04.2021
2.9 Removing and installing coolant tem‐

perature sender -G62-
Removing
• Engine cold.
– Briefly open cap -arrow- of coolant expansion tank to reduce
residual pressure in cooling system, and then tighten cap
again until it engages.

– Remove bolt -1- and press air pipe (left-side) towards left
slightly.

04.2021
Note
♦ Cover the openings in the gearbox with a cloth to prevent

any coolant from getting into the clutch housing.
♦ Insert new coolant temperature sender -G62- immediately
into connection to avoid loss of coolant.
– Remove bolt -2- and detach coolant temperature sender

-G62- -item 3-.
Installing
Note
Renew O-rings.

Specified torques
♦ ⇒ o2.3 verview - coolant temperature sender”, page 321
2.10 Removing and installing radiator outlet

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

04.2021
– Pull out retaining clip -2-, and pull off radiator outlet coolant
temperature sender -G83-.
Note
♦ Use a cloth to catch the escaping coolant.

♦ Insert new coolant temperature sender at radiator outlet -
G83- into connection immediately to avoid loss of coolant.
Installing
Note
Renew O-ring.

Specified torques

04.2021
3 Coolant pipes
⇒ o3.1 verview - coolant pipes”, page 343
⇒ a3.2 nd installing coolant pipes”, page 343
⇒ a3.3 nd installing upper coolant pipes”, page 345
3.1 Assembly overview - coolant pipes
1 - Coolant pipe
❑ On top of engine
ling ⇒ page 345
2 - Bolts
❑ 9 Nm
3 - Bolts
❑ 9 Nm
4 - Coolant line
5 - Bolts
❑ 9 Nm
6 - Coolant pipe
❑ to radiator cowl
❑ Only for vehicles with
auxiliary radiator
7 - Coolant pipe
❑ On front of engine
ling ⇒ page 343
8 - Bolts
❑ 6 Nm
3.2 Removing and installing coolant pipes

⇒ a3.2.1 nd installing front coolant pipe”, page 343
3.2.1 Removing and installing front coolant

pipe
3. Coolant pipes 343

04.2021
Removing

04.2021
Note
– Clamp off coolant hoses -1 and 2- with hose clamps, up to

25 mm in diameter -3094-.
– Release hose clips and detach coolant hoses.
– Unscrew bolts -arrows- and remove front coolant pipe.
Installing
Note
KA).

Specified torques
3.3 Removing and installing upper coolant

pipes

04.2021
Removing
– Remove Ignition coil with output stage for cylinder “3” ⇒

page 581 .
– Release fasteners -arrows- and detach wiring duct -1- from
bracket.
– Clamp off coolant hoses before and after coolant pipe using
hose clamps up to 25 mm -3094-.

– Unscrew bolt -1- and remove coolant pipe (top).
Installing

04.2021
Note
KA).

Specified torques

04.2021
4 Radiator, radiator fan

⇒ o4.1 verview – radiator”, page 348
⇒ o4.2 verview - auxiliary radiator”, page 352
⇒ o4.3 verview – radiator cowl and radiator fan”, page 353
⇒ a4.4 nd installing radiator”, page 356
⇒ a4.5 nd installing radiator cowl”, page 364
⇒ a4.6 nd installing radiator fan”, page 367
⇒ a4.7 nd installing auxiliary radiator”, page 369
4.1 Assembly overview – radiator

⇒ o4.1.1 verview - radiator, Golf, Passat, Touran, Tiguan, Ar‐
teon”, page 348
⇒ o4.1.2 verview - radiator/radiator fan, Sharan”, page 350
4.1.1 Assembly overview - radiator, Golf, Passat, Touran, Tiguan, Arteon

04.2021
1 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect ⇒ page 349
2 - O-ring
❑ Renew
ling ⇒ page 341
ant
ling ⇒ page 356
5 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect ⇒ page 349
6 - O-ring
7 - Charge air cooler
ling ⇒ page 401
8 - Air duct
9 - Air duct
10 - Radiator mounting
11 - Condenser
ling ⇒ Heating, air conditioning; Rep. gr. 87; Refrigerant circuit; Removing and installing condenser
12 - Rubber mounting
❑ for charge air cooler
13 - O-ring
14 - Retaining clip
❑ For radiator outlet coolant temperature sender -G83-.
Connecting coolant hose with plug-in connector
4. Radiator, radiator fan 349

04.2021
– Remove old O-ring -2- in coolant hose -3- if damaged.

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

04.2021
1 - Condenser
ling ⇒ Heating, air con‐
ditioning; Rep. gr. 87;
Refrigerant circuit; Re‐
moving and installing
condenser
2 - 5 Nm
3 - Rubber mounting
4 - Sealing strip
5 - Right sealing strip
❑ Between radiator and
condenser
❑ If the locking lugs are
broken or have sheared
off, tighten radiator
mounting to 5 Nm
ant
ling ⇒ page 359
8 - 5 Nm
9 - Radiator cowl
ling ⇒ page 364
10 - Left sealing strip
❑ Between radiator and
condenser
❑ If the locking lugs are broken or have sheared off, tighten radiator mounting to 5 Nm
Connecting coolant hose with plug-in connector
– Remove old O-ring -2- in coolant hose -3- if damaged.

– Moisten O-ring with coolant, and insert it into coolant hose.

04.2021
– Push coolant hose into connection -1- until it audibly engag‐

es.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.
4.2 Assembly overview - auxiliary radiator

⇒ o4.2.1 verview - right auxiliary radiator”, page 352
⇒ o4.2.2 verview - left auxiliary radiator”, page 353
4.2.1 Assembly overview - right auxiliary ra‐

diator
Note
On vehicles with dual clutch gearbox, an auxiliary radiator may

be installed at front right (depending on version).
1 - Air duct
ling ⇒ page 369
3 - Hose retainer
4 - Coolant hose
❑ Return line
5 - Coolant hose
❑ Supply line
❑ Top
7 - Nuts
❑ 9 Nm
8 - Bracket
❑ For additional cooler
❑ Bottom
10 - Support
11 - Bolt
❑ 3.5 Nm

04.2021
4.2.2 Assembly overview - left auxiliary radi‐

ator
Note

be installed at front left (depending on version).
1 - Air duct
2 - Protective grille
❑ Depending on equip‐
ment
ling ⇒ page 369
4 - Hose retainer
5 - Connecting piece
6 - Hose clamps
7 - Nut
❑ 9 Nm
8 - Bracket
9 - Nut
❑ 9 Nm
10 - Rubber grommet
11 - Air duct
❑ Depending on equip‐
ment
12 - Rubber grommet
13 - Support
14 - Bolt
❑ 3.5 Nm
4.3 Assembly overview – radiator cowl and

radiator fan
⇒ o4.3.1 verview - radiator cowl and radiator fan, Golf, Passat,
Arteon”, page 353
⇒ o4.3.2 verview - radiator cowl and radiator fan, Sharan”, page
354
⇒ o4.3.3 verview - radiator cowl and radiator fan, Touran, Ti‐
guan”, page 355
4.3.1 Assembly overview - radiator cowl and radiator fan, Golf, Passat, Arteon

04.2021
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
ling ⇒ page 364
3 - Bolt
❑ 5 Nm
4 - Radiator fan -V7-
ling ⇒ page 367
5 - Radiator fan 2 -V177-
ling ⇒ page 367
4.3.2 Assembly overview - radiator cowl and radiator fan, Sharan

04.2021

ling ⇒ page 367
2 - Radiator fan 2 -V177-
ling ⇒ page 367
3 - Radiator cowl
ling ⇒ page 364
4 - Washer
5 - Bolt
❑ 5 Nm
6 - Bolt
❑ 5 Nm
7 - Washer
4.3.3 Assembly overview - radiator cowl and radiator fan, Touran, Tiguan

04.2021
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
ling ⇒ page 364
ling ⇒ page 368
4.4 Removing and installing radiator

⇒ a4.4.1 nd installing radiator, Golf, Passat, Touran, Tiguan,
Arteon”, page 356
⇒ a4.4.2 nd installing radiator, Sharan”, page 359
4.4.1 Removing and installing radiator, Golf,

Passat, Touran, Tiguan, Arteon
Removing
– Remove coolant hose at top left from radiator -arrow-.

04.2021

– Remove radiator grille ⇒ General body repairs, exterior;
Rep. gr. 66; Radiator grille/front panel; Removing and instal‐
ling radiator grille.
Golf, Passat, Tiguan, Arteon:
– Unclip air ducts -1- on both sides at top from lock carrier -2-
-arrow-.
– To do this, release catches -3- in -direction of arrow-, and
pull off air ducts. Disregard arrows below.
– Working through opening in lock carrier, press locking tabs
for radiator on left and right -1-. Press radiator off charge air
cooler.

04.2021
Touran:
– Working through opening in lock carrier, press locking tabs

for radiator on left and right -1-. Press radiator off charge air
cooler.
All vehicles:
– Swing radiator towards engine, and lift it out of charge air
cooler mountings. Remove radiator downwards.

04.2021
Installing
– If there are minor dents in the fins, refer to ⇒ page 8 .

– Renew O-rings.
– Insert radiator at an angle into lower charge air cooler
mounting, and engage radiator in charge air cooler -arrow-.
Ensure proper engagement by pulling.
– Install radiator cowl ⇒ page 364 .
– Connect coolant hose with plug-in connector ⇒ page 349 .
Specified torques
♦ ⇒ o4.1 verview – radiator”, page 348
4.4.2 Removing and installing radiator, Shar‐

an
Removing
– Release hose clips -1, 2- and remove right charge air hose.
– Unscrew securing bolts -arrows- for charge air cooler -2- on

right and left.

04.2021
– Remove front bumper cover ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Remove guide profile -1- from lock carrier -2-. To do this,
unscrew bolts -arrows-.
– Unclip air duct -3- on left and right, and push it to one side.
– Detach top coolant hose from radiator -arrow-.
– Unscrew bolt -arrow- for refrigerant lines -1- at top right of

radiator -2-.

04.2021
– Release catches -arrows- for radiator mountings on left and

right, or pinch them off using side cutters.
Note
The radiator mounting will be reused when reinstalling the radi‐

ator. If the locking lugs of the radiator mounting are broken or
pinched off, bolt the radiator mounting to the lock carrier. For
bolts, refer to ⇒ Electronic parts catalogue (ETKA).
– Push radiator towards engine, and remove sealing strips on

left and right between radiator and condenser.
– Press catches -1- on both sides in -direction of arrow A- to
release them.

04.2021
– Pull off condenser in -direction of arrow B-.

– Secure condenser to lock carrier with cable ties.
– Remove radiator downwards.
Installing
– Move radiator -1- to installation position from below. While

doing this, make sure that the sealing strip is properly seat‐
ed.
– Tighten securing bolts -arrows- for charge air cooler -2-.
– Cut through cable ties, and »attach« and engage condenser
on radiator.
– Tighten bolt -arrow- for refrigerant lines -1- at top right of
radiator -2-.
– Install right sealing strip between radiator and condenser as


04.2021
Note
To allow for installing the sealing strips, lift the radiator module
out of the rubber mountings, and push it towards the engine.
– Install left sealing strip between radiator and condenser as

– Insert radiator module -1- at bottom into rubber mountings

-arrows-.

04.2021
– Fit radiator mountings -1- on left and right onto radiator.

When doing so, note the installation position -arrow-.
– Engage radiator module in lock carrier. If the locking lugs of

the radiator mounting are broken or have sheared off, bolt
the radiator mounting to the lock carrier to 5 Nm.
Further assembly is carried out in the reverse order of removal.
During this procedure, observe the following:
Specified torques
♦ ⇒ page 350
4.5 Removing and installing radiator cowl

♦ Protective mat -VAS 531 003-
Removing

04.2021

insulation.
– Detach coolant hose at bottom right from clip.
CAUTION
Danger of injury; the radiator fans can run at any time.
– Disconnect electrical connectors:
– Separate connector -1- for radiator fan. To do this, push

locking tab -A- in direction of arrow, and press release
mechanism.

04.2021
– Press locking tabs on left and right of radiator cowl simulta‐

neously -arrow B-, pull radiator cowl upwards off radiator,
and remove it downwards.
– Cover radiator using protective mat -VAS 531 003-.
Installing
Install in reverse order of removal.
Specified torques

04.2021
4.6 Removing and installing radiator fan

⇒ a4.6.1 nd installing radiator fan, Golf, Passat, Arteon”, page
367
⇒ a4.6.2 nd installing radiator fan, Sharan”, page 367
⇒ a4.6.3 nd installing radiator fan, Touran, Tiguan”, page 368
4.6.1 Removing and installing radiator fan,

Golf, Passat, Arteon
Removing
Note
Attach cable ties in all the same places when installing.

– Unclip electrical connector -7-.

– Unscrew and remove bolts -1- for radiator fan -2-.
– Unscrew and remove bolts -5- for radiator fan -4-.
Installing
Specified torques
♦ ⇒ o4.3.1 verview - radiator cowl and radiator fan, Golf, Pas‐
sat, Arteon”, page 353

Sharan
Removing
Note
Fit all cable ties in the original position when installing.

– Open cable tie for respective connector -4 or 5-.

04.2021
– Release and pull off respective connector -4 or 5-.

– Unscrew bolts -arrows- for relevant radiator fan.
– Guide out wiring harness.
– Remove radiator fan.
Installing
• Specified torques ⇒ o4.3.2 verview - radiator cowl and radia‐
tor fan, Sharan”, page 354

Touran, Tiguan
Removing
Note
Reinstall all cable ties in the same locations when installing.

– Separate electrical connector:
– Unscrew bolts -arrows- and remove radiator fan -V7-.

Installing

04.2021
Specified torques
♦ ⇒ o4.3.3 verview - radiator cowl and radiator fan, Touran,
Tiguan”, page 355
4.7 Removing and installing auxiliary radia‐

tor
⇒ a4.7.1 nd installing right auxiliary radiator”, page 369
⇒ a4.7.2 nd installing left auxiliary radiator”, page 371
4.7.1 Removing and installing right auxiliary

radiator
Note

be installed at front right (depending on version).

Removing
insulation.
bumper cover.
– Pull air duct -A- in direction of arrow off auxiliary radiator.

04.2021
Note
Place a cloth underneath to catch escaping coolant.
– Clamp off coolant hoses -A- and -B- with hose clamps
-3094-. Open spring-type clips, and remove hoses from aux‐
iliary radiator.
– Unscrew bolts -arrows-. Remove auxiliary radiator -A- up‐

wards from bracket.
Installing
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Front bumper; Removing and installing bumper
cover.
– Install wheel housing liner ⇒ General body repairs, exterior;
insulation.
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44;
Wheels, tyres; Wheel change.
Specified torques
♦ ⇒ page 352

04.2021
4.7.2 Removing and installing left auxiliary

radiator
Note

be installed at front left (depending on version).

Removing
insulation.
– Remove left wheel and front part of left wheel housing lin‐
er/entire left wheel housing liner ⇒ General body repairs,
– If fitted, unclip air duct -1- -arrows-.

04.2021
– Move coolant hose on retainer to one side. To do so, release

fasteners -arrows A-, and pull off -arrows B-.
– Clamp off coolant hoses -1- and -2- (before plug-in connec‐
tors) with hose clamps -3094-.
– Lift retaining clips -1- and -2-. Pull off coolant hoses.
– Unscrew nuts -arrows-, and remove auxiliary radiator -1-
together with bracket. If fitted, lay aside wiring harness.

04.2021
– Pull off air duct -1- -arrow-.
– Unscrew bolts -4-, and remove auxiliary radiator -2- upwards

from bracket -3-.
Installing
note the following:
– Install radiator together with air duct.
– Install wheel housing liner ⇒ General body repairs, exterior;
insulation.
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44;
Wheels, tyres; Installing tyres.
Specified torques
♦ ⇒ page 353

04.2021
21 – Turbocharging/supercharging
1 Turbocharger
⇒ o1.1 verview - turbocharger”, page 374
⇒ a1.2 nd installing turbocharger”, page 380
⇒ a1.3 nd installing charge pressure positionerV465”, page 392
⇒ c1.4 harge pressure positionerV465”, page 393
1.1 Assembly overview - turbocharger

Part I
Charge pressure positioner -V465- version 1 ⇒ page 375
Charge pressure positioner -V465- version 2 ⇒ page 377
374 Rep. gr.21 - Turbocharging/supercharging

04.2021
1 - O-ring
❑ Renew
2 - Bolt
❑ 9 Nm
3 - Coolant supply line
4 - O-ring
❑ Renew
5 - Seal
❑ Renew
6 - Nut
❑ Renew
❑ 25 Nm
7 - Turbocharger
ling ⇒ page 380
8 - Oil supply line
9 - Heat shield
10 - Bolt
❑ 9 Nm
11 - Nut
❑ 9 Nm
12 - Bolt
❑ 9 Nm
13 - O-ring
❑ Renew
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 9 Nm
16 - Connection
17 - O-ring
❑ Renew
18 - Bolt
❑ 9 Nm
Charge pressure positioner -V465- version 1
1. Turbocharger 375
04.2021
1 - Bolt
❑ 9 Nm
2 - Oil return line
3 - O-ring
❑ Renew
4 - Bolt
❑ 10 Nm
5 - Charge air pressure con‐
troller -V465-
❑ Before removing
charge pressure posi‐
tioner -V465-, check its
availability in ⇒ Elec‐
tronic parts catalogue
(ETKA).
❑ Adjusting ⇒ page 393
6 - Nut
❑ Tighten with torque
wrench -VAS 6854-.
❑ 10 Nm
7 - Bolt
❑ 9 Nm
8 - Connection
9 - O-ring
❑ Renew
10 - Bolt
❑ 9 Nm
11 - Turbocharger air recircu‐
lation valve -N249-
❑ Note installation position ⇒ page 379
12 - O-ring
❑ Renew
13 - Turbocharger
14 - O-ring
❑ Renew
15 - Bolt
❑ 9 Nm
16 - Bolt
❑ 9 Nm
17 - Bolt
❑ 9 Nm
18 - Coolant distribution housing
19 - O-ring
❑ Renew

04.2021
20 - O-ring
❑ Renew
21 - Bolt
❑ Coat thread with high-temperature paste ⇒ Electronic parts catalogue (ETKA).
❑ 30 Nm
22 - Bracket
❑ for turbocharger
23 - Bolt
❑ 30 Nm
24 - Bolt
❑ 9 Nm
Charge pressure positioner -V465- version 2
1. Turbocharger 377
04.2021
1 - Bolt
❑ 9 Nm
2 - Turbocharger air recircula‐
tion valve -N249-
❑ Note installation posi‐
tion ⇒ page 379
3 - O-ring
❑ Renew
4 - Turbocharger
ling ⇒ page 380
5 - O-ring
❑ Renew
6 - Bolt
❑ 9 Nm
7 - Coolant distribution hous‐
ing
8 - Bolt
❑ 9 Nm
9 - O-ring
❑ Renew
10 - Bolt
❑ Coat thread with
high-temperature paste
⇒ Electronic parts cata‐
logue (ETKA).
❑ 30 Nm
11 - Bolt
❑ 30 Nm
12 - Bracket
❑ for turbocharger
13 - Oil return line
14 - Bolt
❑ 9 Nm
15 - O-ring
❑ Renew
16 - Bolt
❑ 9 Nm
17 - O-ring
❑ Renew
18 - Bolt
❑ 10 Nm
19 - Charge air pressure controller -V465-
❑ Cannot be replaced individually

04.2021
20 - Clip
21 - Ball socket
22 - Nut
❑ 10 Nm
23 - Threaded rod
24 - Nut
❑ 10 Nm
25 - Ball socket
26 - Clip
27 - Bolt
❑ 9 Nm
28 - Connection
29 - O-ring
❑ Renew
Installation location of turbocharger air recirculation valve -

N249-
– Note installation position -arrows-.
1. Turbocharger 379
04.2021
1.2 Removing and installing turbocharger

⇒ a1.2.1 nd installing turbocharger, Golf, Passat, Tiguan, Ar‐
teon”, page 380
⇒ a1.2.2 nd installing turbocharger, Sharan, Touran”, page 387
1.2.1 Removing and installing turbocharger,

Golf, Passat, Tiguan, Arteon
Note
♦ The turbocharger is removed upwards.

♦ If a mechanical fault is discovered on the turbocharger (e.g.
a destroyed compressor impeller), it is not sufficient to just
renew the turbocharger. To avoid any subsequent damage,
the following work must be carried out:
♦ Check air filter housing, air filter element and air inlet hoses
for contamination.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
♦ If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the
charge air cooler.
♦ If bearing damage is evident on the removed turbocharger,
change the engine oil and filter.


04.2021
♦ Golf: tensioning strap -T10038-
Removing
550 .
– Remove air filter housing with air pipe leading to turbocharg‐
er ⇒ page 443 .
– Unscrew bolt -1-, and open hose clip -2-.
– Pull charge air pipe off turbocharger.

– If fitted, unbolt earth wires -arrows-.
– Pull off coolant hose -arrow-.
1. Turbocharger 381
04.2021
– Pull off connectors -1- and -2-. Open retainer -3-.

– Pull off connectors -arrows-, and lay wiring harness to one
side.
– If fitted, unscrew bolt -1- for earth wire, and disconnect cool‐
ant hoses -2 and 3-. Seal lines with suitable plugs from the
engine bung set -VAS 6122-.
– Release fastener -arrow-, and remove wiring duct -4- up‐
wards from retainer.
– Unscrew bolts -1, 2 and 3-. Swivel coolant pipe to one side.
– Remove actuators for camshaft adjustment -1-.

04.2021
– Remove ignition coils with output stages -arrows- ⇒ page

581 .

⇒ page 497 .
– Unscrew bolts -arrows-, and pull oil supply pipe -2- off turbo‐
charger -1-.
– Open hose clip -3-, and pull hose -4- off turbocharger.
– Unscrew bolts -1- and -2-.
1. Turbocharger 383
04.2021
– Turn fitting with crankcase breather hose -3- towards rear

and detach.
– Remove bracket -2- for turbocharger from below. To do this,
unscrew bolt -1- and loosen bolt -3-.
– Unscrew bolts -arrows-, and pull coolant pipe -2- off turbo‐
charger -1-.
– Unscrew bolts -arrows-, and pull oil return pipe -2- off turbo‐
charger -1-.

04.2021
Golf:
Note
The following procedure is necessary to provide more space

between the cylinder head and plenum chamber bulkhead.
– Unscrew bolts -1, 2, 3- and remove pendulum support.

– Pull engine back approx. 20 mm with tensioning strap -
T10038-.
1. Turbocharger 385
04.2021
All vehicles:

– Remove turbocharger from cylinder head, and remove it up‐
wards.
Installing
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts.

♦ Check O-rings for camshaft adjusting elements for damage.
Undamaged O-rings can be re-used.
♦ Lubricate turbocharger studs with high-temperature paste.
For high-temperature, paste refer to ⇒ Electronic parts cata‐
logue (ETKA).
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
logue (ETKA).
– Install front exhaust pipe with catalytic converter ⇒ page

550 .
– Align exhaust system free of stress ⇒ page 532 .
– Check oil level.

04.2021
Note
After installing turbocharger, run engine for about 1 minute at

idling speed. Do not rev up immediately to ensure that the tur‐
bocharger is fully primed with oil.
Specified torques
♦ ⇒ o8.1 verview - Lambda probe”, page 496
1.2.2 Removing and installing turbocharger,

Sharan, Touran
Note
♦ Turbocharger is removed downwards.

♦ If a mechanical fault is discovered on the turbocharger (e.g.
a destroyed compressor impeller), it is not sufficient to just
renew the turbocharger. To avoid any subsequent damage,
the following work must be carried out:
♦ Check air filter housing, air filter element and air inlet hoses
for contamination.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
♦ If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the
charge air cooler.
♦ If bearing damage is evident on the removed turbocharger,
change the engine oil and filter.

1. Turbocharger 387
04.2021
Removing
– Remove air filter housing with air pipe leading to turbocharg‐
er ⇒ page 443 .
– Unscrew bolt -1-, and pull charge air pipe off turbocharger.
– Unscrew bolts -arrows- for coolant pipe -1-.

⇒ page 497 .

04.2021

– Unscrew bolts -arrows-, and pull oil supply pipe -2- off turbo‐
charger -1-.
– Open hose clip -3-, and pull hose -4- off turbocharger.
– Separate electrical connectors -1, 3-.
– Unscrew bolts -1- and -2-.
1. Turbocharger 389
04.2021
– Turn fitting with crankcase breather hose -3- towards rear

and detach.
– Loosen bolt securing right drive shaft to wheel hub ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40; Drive shaft; Remov‐
ing and installing drive shaft.
– Remove subframe together with steering rack ⇒ Running
gear, axles, steering; Rep. gr. 40; Subframe; Removing and
installing subframe with steering rack.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40; Drive shaft; Removing and installing drive shaft.
550 .
– Remove bracket for catalytic converter ⇒ Item 1 (page 537) .
– Remove bracket -2- for turbocharger from below. To do this,
unscrew bolt -1- and loosen bolt -3-.
– Unscrew bolts -arrows-, and pull coolant pipe -2- off turbo‐
charger -1-.

04.2021
– Unscrew bolts -arrows-, and pull off coolant pipes -1- and
-2-.
– Remove lower coolant hose to heater heat exchanger

-arrow-. To do this, pull out retaining clip slightly.
– Unscrew bolts -arrows-, and pull oil return pipe -2- off turbo‐
charger -1-.
1. Turbocharger 391
04.2021
– Remove turbocharger downwards.

– Seal turbocharger openings with engine bung set -VAS
6122-.
Installing
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Only for plug-in con‐
nectors: The seal and sealing surface must be moistened
with oil lightly.
♦ Install only approved clips to secure hose connections
⇒ “ETKA” (Electronic parts catalogue).
♦ Renew seals, gaskets and self-locking nuts.
♦ The connecting clamp of turbocharger and catalytic convert‐
er must be renewed after removal.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute
at idling speed. Do not rev up immediately to ensure that the
turbocharger is fully primed with oil.
Specified torques
♦ ⇒ o2.1 verview – emission control”, page 534
1.3 Removing and installing charge pres‐

sure positioner -V465-
Note
♦ Before removing charge pressure positioner -V465-, check

its availability in ⇒ Electronic parts catalogue (ETKA).
♦ Shape and layout of charge pressure positioner -V465- on
turbocharger may differ depending on manufacturer. The re‐
moval and installation procedure is demonstrated on one of
the versions. The procedure for the others is essentially the
same.
Removing
– Remove catalytic converter/particulate filter ⇒ page 550 .

04.2021
– Loosen lock nut -2- a quarter of a turn, counterholding on

hex -arrow- of control rod to do this.
– Unscrew control rod from actuating lever -1-, ensuring that
lock nut is not turned when doing this.
– Unscrew bolts -3- and remove charge pressure positioner
-V465-.
Installing
• If charge pressure positioner is renewed, transfer installation
position of lock nut to new charge pressure positioner.
– Bring charge pressure positioner -V465- into installation po‐
sition and tighten bolts -3-.
– Screw control rod into actuating lever -1- as far as lock nut
-2-.
– Connect electrical connector -4-.
– Adjust charge pressure positioner ⇒ page 393 .
– After renewing charge pressure positioner -V465-, learnt val‐
ues must be adapted.
1.4 Adjusting charge pressure positioner -

V465-
♦ Torque wrench -VAS 6854-
1. Turbocharger 393
04.2021
♦ Setting gauge -T40346-
♦ Open-end spanner insert (10 mm) -V.A.G 1783/1-
♦ Open-jaw spanner (5 mm)

Removing
onto turbocharger.

insulation.

04.2021
– Unscrew bolts -arrows-, and place catalytic converter to one

side
– Switch on ignition, and select following menu option on vehi‐

cle diagnostic tester:
♦ Adaption/Adjusting turbocharger
– Follow instructions of vehicle diagnostic tester.
Adjusting
– Insert setting gauge -T40346-.

– Loosen lock nut -1-.
– Adjust linkage -arrow -of charge pressure positioner -V465-
according to instructions on vehicle diagnostic tester.
– Tighten lock nut -1- to specified torque.
– Remove setting gauge -T40346-.
1. Turbocharger 395
04.2021
Specified torques

04.2021
2 Charge air system

⇒ o2.1 verview - charge air system”, page 397
⇒ o2.2 verview - charge-air hose connections”, page 401
⇒ a2.3 nd installing charge air cooler”, page 401
⇒ a2.4 nd installing charge pressure senderG31”, page 407
⇒ c2.5 harge air system for leaks”, page 407
⇒ a2.6 nd installing air intake pipe between turbocharger and
charge air cooler”, page 410
2.1 Assembly overview - charge air system

⇒ o2.1.1 verview - charge air system, Golf, Passat, Touran,
⇒ o2.1.2 verview - charge air system, Sharan”, page 399
2.1.1 Assembly overview - charge air system, Golf, Passat, Touran, Tiguan,
Arteon
Note
♦ Installing screw-type clips for charge air hose connections ⇒ page 401 .
♦ Check all air hoses and pipes for firm seating and leaks before carrying out tests or repairs.
2. Charge air system 397

04.2021
1 - Air intake pipe

ling ⇒ page 410
2 - Grommet
3 - Spacer sleeve
4 - Bolt
❑ 7 Nm
5 - Charge air hose
6 - Sealing strip
ling ⇒ page 401
Note
If there are minor dents in the fins,

refer to ⇒ page 8 .
8 - Sealing strip
9 - Rubber mounting
11 - Bolt
❑ 7 Nm
12 - Spacer sleeve
13 - Grommet
14 - Bolt
❑ 5 Nm
15 - Charge air pressure sender -G31-
16 - O-ring

04.2021
❑ Renew
17 - Charge air hose
18 - Air intake pipe
2.1.2 Assembly overview - charge air sys‐

tem, Sharan
Note
♦ Installing screw-type clips for charge air hose connections ⇒

page 401 .
♦ Check all air hoses and pipes for firm seating and leaks
before carrying out tests or repairs.

04.2021
1 - Charge air hose

❑ To throttle valve
2 - Screw-type clips
❑ Specified torque ⇒
page 401
3 - Air intake pipe
4 - Grommet
5 - Spacer sleeve
6 - Bolt
❑ 7 Nm
7 - Charge air pressure send‐
er -G31-
ling ⇒ page 407
8 - Bolt
❑ 5 Nm
ling ⇒ page 401
Note
If there are minor dents in the fins,

refer to ⇒ page 8 .
❑ Right
❑ To turbocharger
13 - Air intake pipe
❑ Left

04.2021
2.2 Assembly overview - charge-air hose

connections
Fitting hose connections with fluted union
Note
The screw-type clips -A- on the charge air pipes must be tight‐
ened 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 opera‐
tion.
– Check all air hoses and pipes for firm seating and leaks
before carrying out tests or repairs.
– Clean hose unions and air intake pipes and hoses. They
must be free of oil and grease before installation.
– Secure all hose connections with the correct type of hose
logue (ETKA).
– Spray the worm screws of the used hose clips with penetrat‐
ing spray before installing.
2.3 Removing and installing charge air

cooler
⇒ a2.3.1 nd installing charge air cooler, Golf, Passat, Touran,
⇒ a2.3.2 nd installing charge air cooler, Sharan”, page 406
2.3.1 Removing and installing charge air

cooler, Golf, Passat, Touran, Tiguan,
Arteon
Removing

04.2021

bumper cover.
– Removing radiator ⇒ page 356 .
– Lift retaining clip -arrow- and disconnect coolant hose (top
left) from radiator.
Touran
– Remove right and left headlights ⇒ Electrical system; Rep.
gr. 94; Headlights; Removing and installing headlights.
Note
The securing bolts of the centre guide profile are covered by the
headlights.
All vehicles

04.2021
– If fitted, remove centre guide profile -A- from lock carrier

-arrows-.
– Unclip air ducts on both sides from lock carrier.
– Using diagonal pliers, pinch off fasteners -arrows- for radia‐
tor mounting on left and right. Push charge air cooler at top
slightly towards engine.
Note
The radiator mounting will be reused when reinstalling the radi‐

ator. It will then be bolted to lock carrier. For bolts, refer to
– Release hose clips -1, 2- and remove right charge air hose.
– If fitted, unclip air ducts on both sides from condenser.

04.2021
– Have a second mechanic release retaining clips -1- on left

and right in direction of arrow -A-. Remove condenser -3-
upwards from mountings -arrows B-.
– Secure condenser to lock carrier.
– Take out charge air cooler from underneath.
Installing

– If there are minor dents in the fins, refer to ⇒ page 8 .
– Renew O-rings.
– Insert radiator at an angle into lower charge air cooler
mounting, and engage radiator in charge air cooler -arrow-.
Ensure proper engagement by pulling.
– Fit radiator mounting -1- onto charge air cooler. When doing
so, note the installation position -arrow-.

04.2021
– Swing charge air cooler together with radiator into lock carri‐
er. Ensure proper seating of radiator mountings in lock carri‐
er.
– Use bolts -arrows- to secure radiator mountings, whose fas‐
teners have been pinched off, to lock carrier. For bolts, refer
to ⇒ Electronic parts catalogue (ETKA).
• Specified torque: 5 Nm
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Front bumper; Removing and installing bumper
cover.
– Connect coolant hose with plug-in connector ⇒ page 349 .

04.2021
Note
♦ Hose connections as well as hoses for charge air system

must be free of oil and grease when installing.
logue (ETKA).
♦ In order to be in a position to securely attach the charge air
hoses on their connections, the worm screws of the used
hose clips have to the sprayed with penetrating spray before
installing.
Specified torques
♦ ⇒ o4.1 verview – radiator”, page 348
♦ ⇒ o2.1 verview - charge air system”, page 397
2.3.2 Removing and installing charge air

cooler, Sharan
Removing
– Removing radiator ⇒ page 359 .
– Secure condenser to lock carrier with cable ties.
– Lift charge air cooler -1- out of rubber mountings -arrows-.
Installing
– Insert charge air cooler -1- into rubber mountings -arrows-.

When doing this, note sealing strip between charge air cool‐
er and condenser.

04.2021
– Further assembly is carried out in the reverse order of re‐

moval.
2.4 Removing and installing charge pres‐

sure sender -G31-
Removing
insulation.
– Unscrew bolts -1-, and pull charge pressure sender -G31-

out of air pipe.
Installing
Note
Renew O-ring.
Specified torques
♦ ⇒ o2.1 verview - charge air system”, page 397
2.5 Checking charge air system for leaks


04.2021
♦ Charge air system tester -V.A.G 1687-
– Release hose clamps -1, 2- and remove air pipe.

– Connect adapter -V.A.G 1687/10- with adapter -V.A.G
1687/14- to turbocharger.
– Connect charge air system tester -V.A.G 1687- to adapter.

04.2021
Prepare charge air system tester -V.A.G 1687- as follows:
– Pull pressure control valve -2- upwards, unscrew it com‐

pletely, and close valves -3- and -4-.
– Connect charge air system tester -V.A.G 1687- to com‐
pressed air -1- via commercial adapter.
Note
♦ If there is water in the inspection glass -6-, drain it via the

drain plug.
♦ The test pressure must not exceed 0.2 bar. Otherwise there
is a risk of damage to the engine.
– Open valve -3-.

– Adjust pressure to 0.2 bar with pressure control valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.2 bar.
– Check charge air system for leaks by listening, touching,
with commercially available leak detector spray or using ul‐
trasonic tester -V.A.G 1842-.
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore a holding pressure test is not possible.
♦ Ultrasonic tester -V.A.G 1842- ⇒ operating instructions
♦ Before removing the adapters, depressurise the test circuit
by detaching the hose coupling.
Installing
Assemble in reverse order of dismantling.

04.2021
2.6 Removing and installing air intake pipe

between turbocharger and charge air
cooler
insulation.
– Lay aside wiring harness -1- and -2-.

– Battery in engine compartment: remove battery ⇒ Electrical
system; Rep. gr. 27; Battery; Removing and installing bat‐
tery.
– Move clear wiring harnesses -1- at air intake pipe.
– Loosen screw-type clip -2-.


04.2021
– Remove air intake pipe -4- upwards.

Installing
– Install in reverse order of removal, observing the following:
Specified torques ⇒ page 397

04.2021
24 – Mixture preparation - injection

1 Injection system
⇒ o1.1 f fitting locations - injection system”, page 412
1.1 Overview of fitting locations - injection

system
Note
The intake manifold injectors are not fitted on all engines.
Components A to H are not shown in the exploded view.
412 Rep. gr.24 - Mixture preparation - injection

04.2021
1 - Inlet camshaft control

valve 1 -N205-
❑ Fitting location ⇒ page
157
ling ⇒ page 218
2 - Exhaust camshaft control
valve 1 -N318-
157
ling ⇒ page 218
3 - Lambda probe 1 after cat‐
alytic converter -GX7-
❑ Consisting of:
Lambda probe after cat‐
alytic converter -G130-
Lambda probe 1 heater

after catalytic converter
-Z29-
423
ling ⇒ a8.2.2 nd instal‐
ling Lambda probe 1
after catalytic conver‐
terGX7”, page 499
4 - Exhaust cam actuator
❑ Exhaust cam actuator
A for cylinder 1 -N580-
B for cylinder 1 -N581-
A for cylinder 2 -N588-
❑ Exhaust cam actuator B for cylinder 2 -N589-
❑ Exhaust cam actuator A for cylinder 3 -N596-
❑ Exhaust cam actuator A for cylinder 4 -N604-
❑ Fitting location ⇒ page 418
5 - Lambda probe 1 before catalytic converter -GX10-
❑ Consisting of:
Lambda probe -G39-
Lambda probe heater -Z19-

❑ Removing and installing ⇒ a8.2.1 nd installing Lambda probe 1 before catalytic converterGX10”, page
497
6 - Turbocharger air recirculation valve -N249- and charge pressure positioner -V465-
❑ Components fitted directly on turbocharger
❑ Removing and installing ⇒ o1.1 verview - turbocharger”, page 374
1. Injection system 413

04.2021
❑ 9 Nm
8 - Brake light switch -F- and brake pedal switch -F47-
❑ Removing and installing ⇒ Brake system; Rep. gr. 45; Overview of fitting locations; Overview of fitting
locations - ABS/ESP.
9 - Electrical connectors
❑ For Lambda probe 1 before catalytic converter -GX10-.
❑ For Lambda probe 1 after catalytic converter -GX7-.
10 - High-pressure pump with fuel pressure regulating valve -N276-
❑ Assembly overview - high-pressure pump ⇒ page 486 .
12 - Engine control unit -J623-
❑ 9 Nm
14 - Vacuum unit for intake manifold flaps
15 - Connector for injectors (intake manifold)
16 - Intake manifold flap air flow control valve -N316-
17 - Engine speed sender -G28-
❑ Oil seal
❑ Renew bolt
❑ 4 Nm and turn 45° further
18 - Electrical connectors for
❑ Knock sensor 1 -G61-
❑ Intake manifold flap valve -N316-
❑ Fuel pressure sender -G247-
❑ Intake manifold flap potentiometer -G336-
❑ Hall sender -G40-
❑ Injectors (combustion chamber) N30 to N33
19 - Fuel pressure sender for low-pressure -G410-
❑ Fuel pressure sender for low pressure -G410- must be installed using adapter.
❑ 15 Nm

04.2021
20 - Knock sensor 1 -G61-

❑ To remove, coolant pump must be removed together with thermostat.
❑ 20 Nm
21 - Intake manifold sender -GX9-
❑ Consisting of:
Intake air temperature sender -G42-
Intake manifold pressure sender -G71-

22 - Throttle valve module -GX3-
❑ Consisting of:
Throttle valve drive for electronic power control -G186-
Throttle valve drive angle sender 1 for electronic power control -G187-
Throttle valve drive angle sender 2 for electronic power control -G188-
❑ After throttle valve module -GX3- has been renewed, or after it has been removed and then reinstal‐
led, it must be adapted to engine control unit -J623- ⇒ Vehicle diagnostic tester.
23 - Ignition coils with output stages
24 - Fuel pressure sender -G247-
❑ 27 Nm
25 - Activated charcoal filter solenoid valve 1 -N80-
26 - Intake manifold flap potentiometer -G336-
27 - Radiator outlet coolant temperature sender -G83-
28 - Charge air pressure sender -G31-
29 - Valve for oil pressure control -N428-
30 - Oil pressure switch -F1-, oil pressure switch for reduced oil pressure -F378- and piston cooling jet
control valve -N522-
A - Injectors, direct injection
❑ No. 1 cyl. injector -N30-

04.2021
B - Injectors, intake manifold injection
❑ Not installed on all engines.
❑ Injector 2 for cylinder 1 -N532-
C - Fuel pump control unit -J538-
❑ Removing and installing ⇒ Rep. gr. 20; Fuel pump
D - Clutch position sender -G476-
❑ Only fitted to vehicles with a manual gearbox
E - Gas pedal module -GX2-
❑ Consisting of:
Acceleration pedal position sender -G79-
Accelerator position sender 2 -G185-

❑ Removing and installing ⇒ Rep. gr. 20; Accelerator mechanism; Assembly overview - accelerator
pedal module
F - Radiator fan control unit -J293-
❑ Installed in radiator fan.
G - Stage 3 oil pressure switch -F447-
❑ Testing, removing and installing ⇒ page 261 .
H - Left electrohydraulic engine mounting solenoid valve -N144- and right electrohydraulic engine mounting
solenoid valve -N145-
❑ Not installed on all vehicles (depending on gearbox type).
Accelerator pedal module -GX2-

04.2021
2 - Connector for accelerator pedal module

Fitting location brake light switch - F-/brake pedal switch -F63-
and vacuum sender -G608-
1- Brake light switch -F-/brake pedal switch -F63-

2- Vacuum sender -G608-
♦ On brake servo in engine compartment
Clutch position sender -G476- -2-

04.2021
• On mounting bracket for clutch pedal -arrow-

Removing and installing ⇒ Rep. gr. 30; Clutch mechanism
Fuel pump control unit -J538- -1-
Exhaust cam actuator
1 - Exhaust cam actuator B for cylinder 1 -N581-

2 - Exhaust cam actuator A for cylinder 1 -N580-

04.2021

Ignition coils with output stages
1 - Ignition coil 1 with output stage -N70-

5 - Fuel pressure regulating valve -N276-
6 - Activated charcoal filter solenoid valve 1 -N80-
Injectors (combustion chamber)
1 - No. 1 cyl. injector -N30-

Intake manifold injectors

04.2021
1 - Injector 2 for cylinder 1 -N532-

Top view
1 - Fuel supply line

2 - Coolant line
3 - Connector for injectors (intake manifold)
Fuel pressure sender in high-pressure system

04.2021

Variable intake manifold
1 - Vacuum unit for intake manifold flaps

Intake manifold flap potentiometer -G336-
Bend aside retaining tabs to allow for pulling potentiometer out

of intake manifold
Electrical connectors
1 - For injectors (combustion chamber).

2 - For knock sensor 1 -G61-.
3 - Stage 3 oil pressure switch -F447-
4 - For intake manifold flap valve -N316-, fuel pressure sender
-G247-, intake manifold flap potentiometer -G336-, coolant tem‐
perature sender -G62- and Hall sender -G40-.
High-pressure pump and Hall sender

04.2021

2 - Fuel pressure regulating valve -N276-
3 - Fuel line leading to fuel rail for injectors (intake manifold)
4 - High-pressure pipe leading to fuel rail of direct injectors
5 - Fuel pressurisation line from fuel tank
Pfeile - Securing bolts
Engine speed sender -G28- -1-
Lambda probes
1 - Connector for Lambda probe 1 after catalytic converter

-GX7-
2 - Connector for Lambda probe 1 before catalytic converter
-GX10-
Lambda probe 1 before catalytic converter -GX10- -1-

04.2021
Lambda probe 1 after catalytic converter -GX7- -1-

04.2021
2 Injectors
⇒ o2.1 verview - fuel rail with injectors”, page 424
⇒ a2.2 nd installing fuel rail”, page 426
⇒ a2.3 nd installing injectors”, page 427
⇒ s2.4 eals on injectors”, page 435
⇒ i2.5 njectors”, page 438
2.1 Assembly overview - fuel rail with injec‐

tors
⇒ o2.1.1 verview - fuel rail with injectors, direct injection”, page
424
⇒ o2.1.2 verview - fuel rail with injectors, indirect injection”,
page 426
2.1.1 Assembly overview - fuel rail with injectors, direct injection

04.2021
1 - Bolt
❑ 9 Nm
2 - Fuel rail for injectors (com‐
bustion chamber)
ling ⇒ a2.2 nd installing
fuel rail”, page 426
3 - Fuel pressure sender -
G247-
❑ Moisten taper and
thread with clean en‐
gine oil
ling ⇒ page 460
❑ 27 Nm
4 - Support ring
5 - O-ring
6 - Spacer ring
7 - Injection valve
❑ Ensure correct installa‐
tion position
ling ⇒ page 427
❑ Cleaning ⇒ page 438
8 - Sealing grommet
❑ Not fitted in all injectors
9 - Combustion chamber seal
❑ Renew after removing
injector ⇒ page 427
10 - Union
❑ For high-pressure pipe on fuel rail
❑ Lubricate thread with clean engine oil
❑ Counterhold on fuel rail when tightening
❑ 40 Nm
11 - Bolt
❑ 5 Nm
12 - High-pressure pipe
❑ Moisten ball with clean engine oil
❑ Union nut 27 Nm, wait for 1 minute and retighten to 27 Nm
2. Injectors 425
04.2021
2.1.2 Assembly overview - fuel rail with injec‐

tors, indirect injection
Note
1 - Retaining clip
❑ for fuel pressure sender
for low pressure -G410-
2 - O-ring
3 - Adapter
❑ Must be screwed on‐
to fuel pressure sender
for low pressure -G410-
-item 4-
❑ 15 Nm
4 - Fuel pressure sender for
low-pressure -G410-
❑ Must be screwed onto
adapter -item 3-
ling ⇒ page 469
❑ 15 Nm
5 - Fuel rail for injectors (in‐
take manifold)
6 - Bolt
❑ 9 Nm
❑ To fuel rail for injectors
(intake manifold)
❑ Install free of tension.
8 - Retaining clip
9 - O-ring
10 - Injection valve
❑ Ensure correct installation position
11 - O-ring
2.2 Removing and installing fuel rail
Note
In this section, the work procedure for direct injection engines is

described.

04.2021
Removing
Note
– Remove intake manifold ⇒ page 447 .

– Separate electrical connector -1- on fuel pressure sender
-G247-.

– Move clear wiring duct -2- at fuel rail, and pull fuel rail off
injectors.
Note
If injectors remain inserted in the fuel rail, disconnect the rele‐

vant connector.
Installing
– Install intake manifold ⇒ page 447 .
Specified torques
♦ ⇒ o2.1.1 verview - fuel rail with injectors, direct injection”,
page 424
2.3 Removing and installing injectors

⇒ a2.3.1 nd installing injectors, direct injection”, page 427
⇒ a2.3.2 nd installing injectors, indirect injection”, page 432
2.3.1 Removing and installing injectors, di‐

rect injection
Note
Injectors from different manufacturers are used. For allocation

to the engine, refer to ⇒ ETKA (Electronic parts catalogue).
Distinguishing between combustion chamber injectors
2. Injectors 427
04.2021
Version -A-
Pull injector out of cylinder head ⇒ page 430
Version -B- with bead -arrow-
Pull injector out of cylinder head ⇒ page 431
♦ Tool set for FSI engines -T10133 C-
Removing
Note
Injectors must only be removed when the engine is cold.

04.2021
– Removing fuel rail ⇒ page 426 .

– If the injectors remain in the fuel rail, carefully pull the injec‐
tors out of the fuel rail.
Remove injectors if they remain in cylinder head.
– Cover any open intake ports with a clean cloth.
– Remove support ring -5- from injector -2-.
– Separate connector from injector that is to be removed, and
pull off support ring.
– Fit impact sleeve -T10133/18- over injector.
– Carefully loosen injector with light blows of a plastic hammer

-1- onto impact sleeve.
2. Injectors 429
04.2021
Removing injectors, version A
Note
To pull out injector, use a torque wrench set to 5 Nm.
– Insert puller -T10133/2A- into groove in injector.

– Fit puller T10133/16A.
– Pull out injector by turning bolt with torque wrench -1-.
– If torque limit of »5 Nm« has been reached and the injector
still cannot be pulled out, remove puller and use impact
sleeve again to release injector.
Note
If the torque limit is exceeded, the injector may become dam‐

aged.

04.2021
Removing injectors, version B
– Bolt puller -T10133/20- -A- to slide hammer -T10133/3- -B-.

– Position puller -A- behind groove -arrow- on injector.
– Pull out injector -1- with soft blows.
Installing
• Use the entire repair kit when installing.

• Renew support ring after removal.
• Renew combustion chamber seal before reinstalling the in‐
jector.
• The combustion chamber seal on the injector must not be
oiled or greased.
– Renewing seals on injector ⇒ page 435 .
– Clean hole in cylinder head using nylon brush -T10133/4-
-A-.
– Push injector into cylinder head bore (free of oil and grease)
as far as it will go by hand. Ensure injectors are positioned
correctly -arrow- in cylinder head.
2. Injectors 431
04.2021
• Lug -1- and hole -arrow- in cylinder head must face each
other.
• It should be possible to insert the injector easily. If not, wait
until the combustion chamber ring seal has contracted suffi‐
ciently.
– Fit support ring onto injector.
– Lightly lubricate O-rings for injectors with clean engine oil.
– Installing fuel rail ⇒ page 426 .
– Install intake manifold ⇒ page 447 .
2.3.2 Removing and installing injectors, indi‐

rect injection
Note
Removing
– Release fasteners -arrows- and detach wiring duct -1- from
bracket.
Note
Disregard -item 2-.
– Unscrew bolt -1- for upper coolant pipe -arrow-.

04.2021
2 - for fuel pressure sender for low pressure -G410-

3 - For intake manifold sender -GX9-.
4 - Intermediate connector for injectors (intake manifold)
– Move clear wiring harness -1- at engine lifting eye.
– Unscrew bolts -arrows- at fuel rail.
– Unscrew bolt -5- for retainer of connector.
– Lay fuel hose -1- at intake manifold to one side.
2. Injectors 433
04.2021
CAUTION
– Release hose clip -2-, and remove coolant hose.

– Carefully pull out fuel rail with injectors upwards.
– Pull off retaining clip -2-, and pull injector -3- off fuel rail -1-.
Installing
– Renew O-rings -1, 4- for injector -2-.

– Before installing O-rings, lightly moisten them with clean en‐
gine oil.
– Secure injector in fuel rail using retaining clip -3-.
– Connect connectors.
– Push fuel rail with injectors by hand as far as stop into hole
in intake manifold (which must be free of oil and grease).
Continue installation in reverse order of removal.
Specified torques
♦ ⇒ o2.1.2 verview - fuel rail with injectors, indirect injection”,
page 426

04.2021
2.4 Renewing seals on injectors
Note
♦ Injectors from different manufacturers are used. For alloca‐

tion to the engine, refer to ⇒ ETKA (Electronic parts cata‐
logue).
♦ In the case of version -B- injectors (with bead -arrow-), an
M8 washer must be fitted onto the injector before installing
the seal. This prevents the calibration sleeve from being
pushed up behind the seal.

♦ Tool set for FSI engines -T10133C-
♦ M8 washer, only for version -B- injectors
Note
♦ In this section, the work procedure for the combustion cham‐

ber seals (Teflon ring seal) is described.
♦ The combustion chamber ring seal must always be renewed
prior to reinstalling the injector.
– Clean injector carefully.
2. Injectors 435
04.2021
– Carefully cut oil seal open with a knife -arrow-. Avoid contact
between knife blade and valve body under all circumstan‐
ces.
– Remove old seal and clean seal groove in area of seal
-arrow-. Remove any deposits (coking) with a brass wire
brush.
– Put new seal -1- on assembly cone -T10133/5-.
– Using assembly sleeve -T10133/6- (knurled section points to

seal -1-), slide seal onto assembly cone as far as possible.
– Rotate assembly sleeve -T10133/6- (knurled section no lon‐
ger points to seal).
– Now push oil seal to end of assembly cone.

– Only for version -B- injectors: fit M8 washer -A- onto injector.

04.2021
– Place the assembly cone -T10133/5- with seal onto the in‐
jector from front.
– Slide seal with assembly sleeve -T10133/6- onto injector.

– Remove assembly cone -T10133/5-, and push combustion
chamber ring seal into groove for combustion chamber ring
seal using assembly sleeve -T10133/6- -arrow-.
– Push on calibration sleeve -T10133/7- as far as washer -A-

or injector, and simultaneously turn it slightly (approx. 180°).
2. Injectors 437
04.2021
– Pull calibration sleeve -T10133/7- off again, turning in oppo‐

site direction.
– Push on calibration sleeve -T10133/8- as far as washer -A-
or injector, and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again, turning in oppo‐

site direction.
– Remove washer -A-.
– Renew O-ring on injector. Before installing new O-ring, light‐
ly moisten it with clean engine oil.
2.5 Cleaning injectors
Note
In this section, the work procedure for injectors (combustion

chamber) is described.

♦ Ultrasonic cleaning unit -VAS 6418-
♦ Mounting plate for injection modules -VAS 6418/1-
♦ Cleaning fluid -VAS 6418/2-
Cleaning
– Close drain tap -arrow- of ultrasonic cleaning unit -VAS
6418- at right-hand side of housing.

04.2021
– Fill ultrasonic cleaning unit with 2120 ml of water which was

allowed to stand for a while and with cleaning fluid -VAS
6418/2-.
Mixing ratio for cleaning fluid
• 2100 ml of water which was allowed to stand for a while and
20 ml of cleaning fluid -VAS 6418/2-.
– Remove injectors ⇒ page 427 .
– Fit mounting plate for injection modules -VAS 6418/1- onto
cleaning unit.
Note
♦ Before starting ultrasonic cleaning unit -VAS 6418-, it is es‐

sential that the safety information described in the operating
manual is observed.
♦ The ideal fluid level is reached when the cleaning agent is
approx. 1 to 4 mm above the base of the mounting plate.
The ultrasonic cleaner -VAS 6418- could become damaged
if the fluid level is too low.
– Insert injectors into guides of mounting plate for injection

modules -VAS 6418/1- as far as stop.
– Switch on cleaning unit by pressing on/off button -C-.
2. Injectors 439
04.2021
– Use rotary knob -A- to set cleaning time to 30 minutes.

– Set rotary knob -B- to a temperature of 50°C.
– Press button ► -D- to start the cleaning process.
Note
♦ Temperature-controlled cleaning is now activated. During

the warm-up period, ultrasonic waves are activated to mix
the cleaning fluid. Once the preselected temperature is
reached, the ultrasonic waves are switched to continuous
operation.
♦ The cleaning time must be at least 30 minutes and cleaning
only starts at a temperature of at least 50°C.
– Each time after cleaning injectors (combustion chamber),

renew combustion chamber seal (Teflon ring seal) ⇒ page
435 .
– Install injectors (combustion chamber) ⇒ page 427 .

04.2021
3 Air filter
⇒ o3.1 verview - air filter housing”, page 441
⇒ a3.2 nd installing air filter housing”, page 443
3.1 Assembly overview - air filter housing
3. Air filter 441

04.2021
1 - Air duct (bottom section)

❑ On lock carrier
2 - Air duct (top section)
❑ On lock carrier
3 - Cover
❑ For air duct
4 - Bolt
❑ 2 Nm
5 - Seal
6 - Air intake hose
7 - Screw-type clamp
8 - Air intake hose
10 - Bolts
❑ 1.5 Nm
11 - Air filter upper part
❑ Remove dirt, leaves
and salt residues
12 - Air filter element
❑ Use only genuine air
filter elements ⇒ Elec‐
tronic parts catalogue
(ETKA).
❑ Renewal intervals
⇒ Maintenance; Book‐
let ; Service tables
ling ⇒ Maintenance;
Booklet ; Air filter:
Cleaning housing and
renewing filter cartridge
13 - Application
❑ For air filter lower part
14 - Air filter lower part
❑ Remove dirt, leaves and salt residues
15 - Rubber buffer
16 - O-ring
17 - Water drain hose
❑ Release by turning
❑ With valve
❑ Cleaning
18 - Air duct
❑ On air cleaner (bottom section)

04.2021
3.2 Removing and installing air filter hous‐

ing
Removing
– Unscrew bolts -1-.

– Release catch -arrow- and remove cover -2-.
– Release fasteners -arrows- and detach air duct (top section)

-1-.
Golf, Passat, Touran, Arteon
– Pull off vacuum hose -1-.

– Release hose clip -2- and detach air intake hose.
– Pull air filter housing -3- upwards out of rubber mountings,
and swing it out.
3. Air filter 443

04.2021
Sharan
– Pull off vacuum hose -1-.

– Release hose clip -2- and detach air intake hose.
– Pull air filter housing -4- upwards out of rubber mountings,
and swing it out.
Installing
Note
♦ Use a silicone-free lubricant when installing the air hose.

logue (ETKA).
– Check air intake hose for salt residue, dirt and leaves (clean
air side).
– Check intake port for dirt as far as the air filter element.
– Install air filter housing. Note water drain hose while doing
this.
Note
Make sure to route the water drain hose downwards without

kinks.

04.2021
4 Intake manifold
⇒ o4.1 verview – intake manifold”, page 445
⇒ a4.2 nd installing intake manifold”, page 447
⇒ a4.3 nd installing throttle valve moduleGX3”, page 453
⇒ t4.4 hrottle valve moduleGX3”, page 456
4.1 Assembly overview – intake manifold
4. Intake manifold 445

04.2021
1 - Bolt
❑ 20 Nm
2 - Support for intake manifold
3 - Nut
❑ 10 Nm
4 - Bonded rubber bush
❑ 5 Nm
5 - Bolt
❑ 7 Nm
6 - Throttle valve module -
GX3-
❑ Including throttle valve
drive (electric throttle
operation) -G186-, an‐
gle sender 1 for throt‐
tle valve drive (elec‐
tric throttle operation) -
G187- and angle send‐
er 2 for throttle valve
drive (electric throttle
operation) -G188-.
ling ⇒ page 453
7 - Seal
8 - Intake manifold
ling ⇒ page 447
9 - Intake manifold flap poten‐
tiometer -G336-
❑ Bend aside retaining
tabs to allow for pulling
potentiometer out of intake manifold
10 - Support
❑ 5 Nm
11 - O-ring
12 - Bolt
❑ 2.5 Nm
Consisting of:
♦ Intake air temperature sender -G42-
♦ Intake manifold pressure sender -G71-
14 - Bolt
❑ Tighten in several stages and in diagonal sequence
❑ 9 Nm
15 - Support

04.2021
❑ 5 Nm
16 - Bracket
❑ For electrical connector.
17 - Bolt
❑ 5 Nm
18 - Nut
❑ 9 Nm
❑ Tighten in several stages and in diagonal sequence
19 - Seal
20 - Vacuum hose
22 - Vacuum hose
23 - Bracket
❑ For electrical connectors
24 - Bolt
❑ 5 Nm
4.2 Removing and installing intake mani‐

fold
♦ Multi-point bit -T10347-
Removing

04.2021

– Detach air duct -1- in lock carrier, an pull it out in
– Unscrew bolts -arrows- for coolant pipe.

insulation.


04.2021
– Pull connector -1- off charge pressure sender -G31-.

– Loosen hose clip -2- of charge air hose, and pull charge air
hose downwards off throttle valve module -GX3-.
er ⇒ page 410 .
– Remove intake manifold support. To do this, unscrew nut -2-
and bolt -3-.
– Remove rubber bush -1- for intake manifold support.

– Separate connectors, and lay wires to one side:
1- For intake manifold flap potentiometer -G336-.

04.2021
2- for fuel pressure sender for low pressure -G410-

3- Central connector for injectors (intake manifold)
4- For intake manifold sender -GX9-.
5- For Hall sender -G40-.
6- For throttle valve module -J338-
– Separate electrical connectors -1, 2, and 3- underneath in‐
take manifold.
– Separate connector -1- at intake manifold flap valve -N316-.

– Release fasteners -arrow-, and pull wiring duct slightly up‐
wards.
– Unscrew bolts -2- and -3-, and carefully pull coolant line
slightly upwards.
– Lay fuel hose -1- at intake manifold to one side.

04.2021
CAUTION
– Release hose clip -2-, and remove coolant hose.

– Vehicles with auxiliary radiator: unscrew bolts -arrows-, and
push coolant pipe slightly downwards.
If intake manifold is secured with studs and nuts at position -A-:
– Remove high-pressure pipe completely ⇒ page 492 .

If intake manifold is secured with bolts at position -A-:
– Unbolt retaining clip -arrow- for high-pressure pipe.

04.2021
Continued for all:
– Unscrew nuts or bolts -A- from intake manifold, and unscrew

bolts -arrows- using socket Torx T30 -T10347-.
– Slightly pull off intake manifold from cylinder head and un‐
screw bolts -arrows-for bracket -A-.
– Take intake manifold off cylinder head.
Note
Seal intake ports with a clean cloth.

04.2021
Installing
– If the union on the high-pressure pump has been detached,

renew union.
– Fit intake manifold on cylinder head and tighten bracket -A-
for electrical connectors.
– Tighten nuts or bolts -A- hand-tight.
– Tighten bolts -arrows- diagonally and in several stages using

socket Torx T30 -T10347-.
– Tighten nuts or bolts -A-.
– If high-pressure pipe was removed, install high-pressure
pipe ⇒ page 492 .
– Continue installation in reverse order of removal.
Specified torques
4.3 Removing and installing throttle valve

module -GX3-
Throttle valve module -GX3- consists of
♦ Throttle valve drive for electronic power control -G186-
♦ Throttle valve drive angle sender 1 for electronic power con‐
trol -G187-
♦ Throttle valve drive angle sender 2 for electronic power con‐
trol -G188-
Removing

04.2021

insulation.

– Release hose clip -2- and pull off right charge air hose from
charge air cooler.
Note
Disregard -item 1-.

04.2021

– Release hose clip -2- on charge air hose, and pull charge air
hose off throttle valve module -GX3-.
– Remove air intake hose downwards.
– Detach electrical connector -1- from throttle valve module.
– Unscrew bolts -arrows- on throttle valve module from under‐

neath and detach throttle valve module.
Installing
– Install in reverse order of removal.
– Clean sealing surface for O-ring.
– Renew seal.
If a new throttle valve module is installed or the throttle valve
module was cleaned, perform throttle valve module adaption.
Proceed as follows to do this:
functions.
♦ Checking throttle valve adaptation

04.2021
Specified torques
4.4 Cleaning throttle valve module -GX3-
Note
♦ GX3
♦ If a new engine control unit -J623- is installed, the throttle
valve module must be adapted.
♦ Contamination and coking in end stop can result in incorrect
adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.

♦ Acetone (commercially available)
♦ Brush
– Remove throttle valve module ⇒ page 453 .
– Open throttle valve by hand and lock it in open position with

a wedge (plastic or wood) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.
– Clean throttle valve housing thoroughly, especially around

the points -arrows- where the throttle valve closes, using
commercially available acetone and a small brush.

04.2021
– Wipe the inside of the throttle valve housing with a lint-free

cloth.
– Allow acetone to dry off completely.
– Adapt throttle valve module. Proceed as follows to do this:
functions.
♦ Checking throttle valve adaptation

04.2021
5 Senders and sensors

⇒ o5.1 verview - actuator for structure-borne sound and control
unit for structure-borne sound, Golf, Passat, Touran, Tiguan”,
page 458
⇒ o5.2 verview - actuator for structure-borne sound and control
unit for structure-borne sound, Arteon”, page 459
⇒ a5.3 nd installing fuel pressure senderG247”, page 460
⇒ f5.4 uel pressure senderG247”, page 464
⇒ a5.5 nd installing fuel pressure sender for low-pressur‐
eG410”, page 469
⇒ a5.6 nd installing intake manifold senderGX9”, page 470
⇒ a5.7 nd installing pressure differential sender for particulate
filterG1037”, page 471
5.1 Assembly overview - actuator for struc‐

ture-borne sound and control unit for
structure-borne sound, Golf, Passat,
Touran, Tiguan
Note
Control unit for structure-borne sound -J869- is secured to

bracket with a bolt or 2 nuts (depending on version).

04.2021
1 - Actuator for structure-

borne sound -R214-
❑ Fitting location: in ple‐
num chamber
❑ Remove plenum cham‐
ber for removing
⇒ General body re‐
pairs, exterior; Rep.
gr. 50; Plenum cham‐
ber bulkhead; Remov‐
ing and installing ple‐
num chamber cover.
❑ Attached to bracket
with nut, item -5-
2 - Bracket
❑ For actuator for struc‐
ture-borne sound -
R214- and control
unit for structure-borne
sound -J869-.
❑ Can only be renewed
with windscreen re‐
moved
3 - Control unit for structure-
borne sound -J869-
num chamber
ber for removing
num chamber cover.
❑ Secured with a bolt or 2
nuts (depending on ver‐
sion)
4 - Connector
❑ for control unit for structure-borne sound -J869-
5 - Nut
❑ for actuator for structure-borne sound -R214-
❑ 7 Nm
6 - Nut
❑ 9 Nm
7 - Bolt/nut
❑ 3 Nm
8 - Bolt
❑ 9 Nm
9 - Connector
5.2 Assembly overview - actuator for structure-borne sound and control unit
for structure-borne sound, Arteon
5. Senders and sensors 459

04.2021
1 - Actuator for structure-

borne sound -R214-
num chamber
ber for removing
num chamber cover.
❑ Attached to bracket
with nut, item -8-
2 - Bracket
❑ For actuator for struc‐
ture-borne sound -
R214- and control
unit for structure-borne
sound -J869-.
❑ Can only be renewed
with windscreen re‐
moved
3 - Control unit for structure-
borne sound -J869-
num chamber
ber for removing
num chamber cover.
4 - Connector
5 - Connector
6 - Bolt
7 - Nut
❑ 9 Nm
8 - Nut
❑ 7 Nm
9 - Bolt
❑ 9 Nm
5.3 Removing and installing fuel pressure

sender -G247-
If fuel pressure sender -G247- fails, fuel pressure regulating
valve -N276- is switched off, electric fuel pump is fully actuated,

04.2021
and engine is operated with available fuel pressure. This re‐

duces the engine torque drastically.
♦ Hexagon key extension, 27 mm -T40218-
Removing


04.2021

insulation.

– Loosen hose clip -2- of charge air hose, and pull charge air
hose downwards off throttle valve module -GX3-.
– Remove intake manifold support. To do this, unscrew secur‐
ing nut -2- and bolt -3-.

04.2021
– Remove rubber bush -1- for intake manifold support.

– Release connector for fuel pressure sender -G247- -1- using
assembly tool -T10118-.
– Pull off connector -arrow- from alternator, otherwise the bit

can be caught on the connector!
– Loosen and unscrew fuel pressure sender -G247- -1- using

bit 27 mm -T40218-.
Installing
– Lubricate sealing cone and thread of fuel pressure sender
-G247- with clean engine oil.
– Continue installation in reverse order of removal.
Specified torques
page 424

04.2021
5.4 Checking fuel pressure sender -G247-

⇒ f5.4.1 uel pressure senderG247 using pressure sensor tester‐
VAS 6394”, page 464
⇒ f5.4.2 uel pressure senderG247 using vehicle diagnostic test‐
er (Guided Functions)”, page 467
5.4.1 Checking fuel pressure sender -G247-

using pressure sensor tester -VAS
6394-
Note
For this check, the fuel pressure sender -G247- must be re‐
moved.

♦ Pressure sensor tester -VAS 6394-
♦ Adapter -VAS 6394/2-
♦ Test adapter -VAS 5570-
Procedure:
CAUTION
– Remove fuel pressure sender -G247- ⇒ page 460 .

– Instead of fuel pressure sender -G247-, screw in adapter
-VAS 6394/2- and tighten it to torque specified for fuel pres‐
sure sender -G247-.
– Open plug -2- of digital pressure gauge -VAS 6394/1-, screw

previously removed fuel pressure sender -G247- into open‐
ing, and tighten it to specified torque.

04.2021
– Use test adapter -VAS 5570- to establish electrical connec‐

tion between vehicle and fuel pressure sender -G247-.
Note
For the steps below, the engine must be started. Therefore,

install the intake hose and the air filter housing.
– Connect vehicle diagnostic tester.

– Switch on ignition.
– In self-diagnosis, select “Engine electronics”.
– Select “Measured values”.
– Select “Fuel pressure” from the list.
Display field shows the actual value reported to the engine
control unit by the fuel pressure sender -G247-.
– Switch on digital pressure gauge -VAS 6394/1- by briefly
pressing -A- button once.

04.2021
Note
When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.
Digital pressure gauge -VAS 6394/1- should display 0 bar; if

this is not the case, press key -C- briefly once for zero point
compensation.
– Connect digital pressure gauge -VAS 6394/1- to adapter
-VAS 6394/2-.
– Start the engine.

– Compare pressure displayed on digital pressure gauge -VAS
6394/1- with actual value displayed on vehicle diagnostic
tester.
• A maximum pressure deviation of 5 bar is permissible.
– If the deviation is greater than 5 bar, test a new fuel pressure
sender -G247-.
CAUTION
– Screw new fuel pressure sender -G247- into digital pressure

gauge -VAS 6394/1-.
– Repeat test with new fuel pressure sender -G247-, and com‐
pare both measured values.
If measured values again fail to correspond:
– Check electrical wiring between fuel pressure sender -G247-
and engine control unit ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
If measured values correspond this time:
– Install new fuel pressure sender -G247- ⇒ page 460 .
Specified torques
page 424

04.2021
5.4.2 Checking fuel pressure sender -G247-

using vehicle diagnostic tester (Guided
Functions)
Note
♦ For this check, removal of the fuel pressure sender -G247-

is not required. However, a vehicle diagnostic tester with the
following functionality is required:
♦ Diagnosis-capable systems
♦ 0001 - Repair groups
♦ 24 - Mixture preparation/injection
♦ G247 - Check fuel pressure sender

♦ Pressure gauge -VAS 6550-
♦ ⇒ Vehicle diagnostic tester

Condition:
• 1/
4 of fuel tank filled with fuel.
– Pull off supply line -1-. Separate plug-in connectors ⇒ Fuel
supply system - petrol engines; Rep. gr. 20; Plug-in connec‐
tors; Separating plug-in connectors.

04.2021
CAUTION
– Collect escaping fuel with a cleaning cloth.

– Connect hose -VAS 6550/1- to connection -A- of pressure
tester -VAS 6550-.
– Connect hose -VAS 6550/1- to fuel supply line -1- leading to

engine.
– Connect hose -VAS 6550/2- to connection -B- of pressure
tester -VAS 6550-.
– Use hose -VAS 6550- to connect fuel line leading to fuel
tank with pressure tester -VAS 6550/2-.
– Ensure plug-in connectors are secure properly by pulling.
– Ensure that drain tap -C- on pressure tester -1- is closed.
– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Use ⇒ Vehicle diagnostic tester to check fuel pressure send‐
er -G247-. To do this, select following function:

04.2021
♦ Diagnosis-capable systems
♦ 0001 - Repair groups
♦ 24 - Mixture preparation/injection
♦ G247 - Check fuel pressure sender
5.5 Removing and installing fuel pressure

sender for low-pressure -G410-
Removing
– Pull out securing clip -1-.

– Pull fuel pressure sender for low pressure -G410- out of fuel
rail.
– Unscrew fuel pressure sender for low-pressure -G410- -1-
from adapter -2-.

04.2021
Installing
– Renew O-ring -arrow-.

– Screw fuel pressure sender for low-pressure -G410- -1- into
adapter -2-.
– Carefully push fuel pressure sender for low pressure -G410-
into fuel rail as far as stop.
– Insert securing clip -1- into groove.

– Connect electrical connector -2-.
Specified torques
♦ ⇒ o2.1.2 verview - fuel rail with injectors, indirect injection”,
page 426
5.6 Removing and installing intake mani‐

fold sender -GX9-
The intake manifold sender -GX9- consists of intake air temper‐
ature sender -G42- and intake manifold pressure sender -G71-.
Removing

04.2021

– Release fasteners -arrows-, and pull intake manifold sender
-GX9- off intake manifold.
Installing
Specified torques
5.7 Removing and installing pressure dif‐

ferential sender for particulate filter -
G1037-
– Separate connector -1- at pressure differential sender for
particulate filter -G1037-.
– Unscrew bolt -arrow-.

– Carefully pull pressure sensor in a straight line off hoses.

04.2021
Note
If the elbow stud -2- breaks off, use long-nose pliers to pull the
remaining piece out of the hose.
Installing
– Before installing, blow out hoses from pressure differential

sender to emission control module with compressed air in
direction of emission control module.
– Fit elbow stud -2- onto pressure sensor -1-.
– Moisten connection on pressure sensor and elbow stud with
lubricant (water).
– Fit pressure sensor with elbow stud -arrow- onto hoses.
– Tighten pressure sensor, and connect connector.

04.2021
6 Engine control unit

⇒ a6.1 nd installing engine control unitJ623”, page 473
⇒ a6.2 nd installing engine (motor) control unitJ623 with protec‐
tive housing”, page 477
6.1 Removing and installing engine control

unit -J623-
⇒ a6.1.1 nd installing engine control unitJ623, Golf, Passat,
Touran, Tiguan, Arteon”, page 473
⇒ a6.1.2 nd installing engine control unitJ623, Sharan”, page
474
6.1.1 Removing and installing engine control

unit -J623-, Golf, Passat, Touran, Ti‐
guan, Arteon
Removing
– If the engine control unit is to be renewed, switch on ignition,
and select the following menu options on vehicle diagnostic
tester:
♦ 0001 - Renew engine control unit
– Switch off ignition and remove ignition key.
Note
If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine (mo‐
tor) control unit will be the consequence. For this reason, the
battery always needs to be disconnected prior to removing the
engine control unit from its bracket ⇒ Electrical system; Rep.
gr. 27; Battery; Disconnecting and connecting battery.
– Release fastener -arrow A-, and remove engine control unit

-J623- -arrow B-.
– Release and pull off connectors for engine (motor) control

unit -J623-.
6. Engine control unit 473

04.2021
Installing

– Insert lower edge of engine control unit -J623- into bracket
-arrow A-, and engage engine control unit in bracket at up‐
per edge.
• When doing this, ensure that lugs of engine control unit en‐
gage in notches at top and bottom of bracket -arrows B-.
– Connect battery ⇒ Electrical system; Rep. gr. 27; Battery;
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
6.1.2 Removing and installing engine control

unit -J623-, Sharan
Note
Removing and installing anti-theft engine control unit ⇒ page

480 .
Removing
and select the following menu option on vehicle diagnostic
tester:
– Switch off ignition and remove key from ignition lock.
– Remove windscreen wiper arms: ⇒ Electrical system; Rep.
gr. 92; Windscreen wiper system; Removing and installing
windscreen wiper arms.

04.2021

exterior; Rep. gr. 50; Bulkhead; Assembly overview - plenum
chamber cover.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50; Bulkhead; Assembly overview - bulk‐
head.
– Pull seal together with engine wiring harness upwards in
-direction of arrow- out of cable guide.
– If fitted, unclip cover -1- at sides from mountings -2-

-arrows-, and remove it.
– Push guides -2- outwards.
– Remove engine control unit -1- upwards.

– Slide connector locking devices -1- on engine control unit in
-direction of arrow- and pull off both connectors.

04.2021
Installing:
– Attach connectors to engine control unit and slide locking
devices inwards until they engage.
– Push engine control unit -1- into side guides -2- in the
– Install plenum chamber bulkhead ⇒ General body repairs,

exterior; Rep. gr. 50; Bulkhead; Assembly overview - bulk‐
head.
– Install plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50; Plenum chamber bulkhead; Assembly
overview - plenum chamber cover.
– Wiper arms ⇒ Electrical system; Rep. gr. 92; Windscreen
wiper system; Removing and installing wiper arms.

04.2021
6.2 Removing and installing engine (mo‐

tor) control unit -J623- with protective
housing
⇒ a6.2.1 nd installing engine control unitJ623 with protective
housing, Golf, Passat, Touran, Tiguan, Arteon”, page 477
⇒ a6.2.2 nd installing engine control unitJ623 with protective
housing, Sharan”, page 480
6.2.1 Removing and installing engine con‐

trol unit -J623- with protective housing,
Golf, Passat, Touran, Tiguan, Arteon
♦ Hot air blower -VAS 1978/14A- with nozzle attachment from
wiring harness repair set -VAS 1978 B-
♦ Small grinder with cutting disc, commercially available

Removing
tester:
Note
If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine (mo‐
tor) control unit will be the consequence. For this reason, the
battery always needs to be disconnected prior to removing the
engine control unit from its bracket ⇒ Electrical system; Rep.
gr. 27; Battery; Disconnecting and connecting battery.
To remove protective housing -1-, unscrew shear bolts -arrows-

as follows:

04.2021
– Make groove (for a screwdriver) in head of shear bolt -1-

using a small grinder -2-.
Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
– Select settings on hot air blower as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.

04.2021
– Unscrew shear bolt -1- with screwdriver -2-.
– Remove protective housing from engine (motor) control unit

-J623-.
– Release fastener -arrow A-, and remove engine control unit
-J623- -arrow B-.
– Release and pull off connectors for engine (motor) control

unit -J623-.

04.2021
Installing

– Insert lower edge of engine control unit -J623- into bracket
-arrow A-, and engage engine control unit in bracket at up‐
per edge.
– It is essential that the engine (motor) control unit -J623- be
provided with the protective housing again.
– Clean the threaded holes for the shear bolts of thread-lock‐
ing agent residues. A thread chaser is suitable for cleaning.
– Always use new shear bolts.
– Connect battery ⇒ Electrical system; Rep. gr. 27; Battery;
6.2.2 Removing and installing engine con‐

trol unit -J623- with protective housing,
Sharan

04.2021
♦ Hot air blower -VAS 1978/14A- with nozzle attachment from

wiring harness repair set -VAS 1978 B-
♦ Small grinder with cutting disc, commercially available

Note
The shear-head bolt threads may coated with locking com‐

pound. To simplify removal, the shear-head bolts can be heated
using hot air blower -VAS 1978/14-. When doing this, ensure
that no adjacent cables, connectors or components are dam‐
aged!
Removing
tester:
– Remove windscreen wiper arms: ⇒ Electrical system; Rep.
gr. 92; Windscreen wiper system; Removing and installing
windscreen wiper arms.
num chamber cover.
– Remove plenum chamber bulkhead ⇒ General body repairs,
num chamber bulkhead.
– Pull seal together with engine wiring harness upwards in
-direction of arrow- out of cable guide.

04.2021
– If fitted, unclip cover -1- at sides from mountings -2-

-arrows-, and remove it.
– Push guides -2- aside.
– Remove engine control unit -1- upwards.

– Bend upwardly projecting tabs -1- of locking bar outwards.
– Make groove (for a screwdriver) in head of shear bolt -1-

using a small grinder -2-.

04.2021
Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
Set hot air blower as shown in illustration.

• Turn potentiometer for temperature adjustment -2- to maxi‐
mum heater output
• Two-stage switch for air flow rate -3- set to position 3.
Note
♦ Risk of damage to adjacent components caused by hot air

blower. Risk of overheating.
♦ If necessary, cover adjacent components.
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.

04.2021
– Unscrew shear bolt -1- with screwdriver -2-.
– Slide connector locking devices -1- on engine control unit in

-direction of arrow- and pull off both connectors.
Installing:
– Attach connectors to engine control unit and slide locking
devices inwards until they engage.
– Screw on a new locking bar -3- with new shear-head bolts
-2- and tighten bolts uniformly until just before heads shear
off.
Disregard item -1-.

– Push engine control unit -1- into side guides -2- in the

04.2021
– Install plenum chamber bulkhead ⇒ General body repairs,

exterior; Rep. gr. 50; Plenum chamber bulkhead; Removing
and installing plenum chamber bulkhead.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50; Plenum chamber bulkhead; Removing and
installing plenum chamber cover.
– Wiper arms ⇒ Electrical system; Rep. gr. 92; Windscreen
wiper system; Removing and installing wiper arms.
functions.

04.2021
7 High-pressure pump
⇒ o7.1 verview - high-pressure pump”, page 486
⇒ a7.2 nd installing high-pressure pump”, page 488
⇒ a7.3 nd installing high-pressure pipe”, page 492
7.1 Assembly overview - high-pressure pump

04.2021
1 - Bolts for high-pressure

pump
❑ Tighten one turn al‐
ternately until flange
of high-pressure pump
makes contact with
vacuum pump
❑ Final specified torque
Bolts M6: 8 Nm + turn
90° further, renew bolts
after removing
Bolts, M8: 20 Nm
2 - Fuel pressure regulating

valve -N276-
❑ For fuel pressure regu‐
4 - High-pressure pump
❑ Fuel tank contains elec‐
tric fuel pump which
pumps fuel to me‐
chanical high-pressure
pump.
❑ When installing the
high-pressure pump, it
is essential to ensure
that no dirt enters the
fuel system.
❑ Install fuel lines free of
stress.
❑ Check O-ring and re‐
new if damaged.
ling ⇒ page 488
5 - O-ring
6 - Roller tappet
❑ Installation position: roller faces towards camshaft
7 - Connecting piece for fuel line
❑ Only for engines with intake manifold injectors
❑ When renewing high-pressure pump, the connecting piece may have to be transferred from the old
pump
❑ Loosen and tighten connecting piece using a »long« 15 mm socket
❑ Union, 15 Nm
❑ Plug, 20 Nm
❑ Renew
9 - Fuel line
❑ Only for engines with intake manifold injectors
❑ To fuel rail for injectors (intake manifold).
10 - High-pressure pipe
❑ To fuel rail for injectors (combustion chamber).
7. High-pressure pump 487

04.2021
❑ Moisten ball of high-pressure pipe with engine oil
❑ High-pressure pipe must be free of tension when installed (make sure all parts are clean)
❑ Union nut 27 Nm, wait for 1 minute and retighten to 27 Nm
11 - High-pressure pipe union
❑ When detaching from high-pressure pipe, hold connection to prevent it from twisting
❑ If the connecting piece is released, it must be renewed.
❑ 40 Nm
❑ Renew
7.2 Removing and installing high-pressure

pump
♦ Tool insert, 17 mm -V.A.G 1331/6-
Note
♦ High-pressure pump may only be removed when the engine

is cold.
♦ When installing the high-pressure pump, it is essential to
ensure that no dirt enters the fuel system.
♦ Collect escaping fuel with a cleaning cloth.
♦ Check O-ring of high-pressure pump and renew it if dam‐
aged.
♦ If high-pressure pipe connection ⇒ Item 11 (page 488) is
released, it must be renewed.
♦ The intake manifold injectors are not fitted on all engines.
Removing
– Release fastener -arrow- and detach wiring duct -4- from
coolant pipe.

04.2021
– Unscrew bolts -1, 2- and -3-.

– Unscrew bolt -1- for air pipe.
– Push air pipe aside slightly and unscrew pipe clamp -arrow-.

04.2021
CAUTION
– Counterhold on hexagon -A- and unscrew union nut -arrow-.

– Pull electrical connector -1- from fuel pressure regulating
valve -N276-.
– Remove fuel hoses -2- and -3-.

– Carefully pull out high-pressure pump. When doing so, en‐
sure that high-pressure pipe is not bent.
– Remove roller plunger.
Installing
– Before inserting roller plunger, check it for damage and re‐

new it, if necessary.
– Insert roller plunger into vacuum pump as shown.
– Turn crankshaft until roller tappet is at bottom dead centre.
– Moisten ball of high-pressure pipe with engine oil.
– Inspect O-ring of high-pressure pump, and coat it slightly
with clean engine oil.
– Insert high-pressure pump into vacuum pump. When doing
this, take note of high-pressure pipe.

04.2021
– Tighten bolts -arrows- one turn alternately until flange of

high-pressure pump makes contact with vacuum pump.
– Tighten bolts to specified torque, tightening torque ⇒ page
486 .
– Tighten union nut of high-pressure pipe hand-tight.
– Install clamp -arrow-, and tighten it to 5 Nm.
– Counterhold on hexagon -A-, and tighten union nut -arrow-.
– Wait at least 1 minute and check tightening torque.

– Connect fuel hoses -2- and -3-, and secure them with spring-
type clips.

04.2021
– Connect connector -1- to fuel pressure regulating valve -

N276-.
quence.
Note
Upon completion of any repair work, start the engine and check
the fuel system for leaks.
Specified torques
7.3 Removing and installing high-pressure

pipe
♦ Socket, 17 mm -T10456-
♦ Tool insert, 17 mm -V.A.G 1331/6-

04.2021
Removing
er ⇒ page 410 .
– Unbolt clamp -arrow-.
CAUTION
– Loosen union nut on fuel rail -arrow- using socket AF 17 mm

-T10456-.
– Counterhold on hexagon -A-, and loosen union nut -arrow-.
Remove high-pressure pipe.

04.2021
Installing
– Moisten balls of high-pressure pipe with engine oil and install

high-pressure pipe.
– Tighten union nuts by hand and align high-pressure pipe
free of stress.
– Install clamp -arrow-, and tighten it to 5 Nm.
– Tighten union nut on fuel rail -arrow- using socket AF 17 mm
-T10456-.
– Counterhold on hexagon -A-, and tighten union nut -arrow-

using tool insert, AF 17 mm -V.A.G 1331/6-.

04.2021
– Wait at least 1 minute and check tightening torque of union

nuts.
quence.
Note
Upon completion of any repair work, start the engine and check
the fuel system for leaks.
Specified torques

04.2021
8 Lambda probe
⇒ o8.1 verview - Lambda probe”, page 496
⇒ a8.2.1 nd installing Lambda probe 1 before catalytic conver‐
terGX10”, page 497
⇒ a8.2.2 nd installing Lambda probe 1 after catalytic conver‐
terGX7”, page 499
8.1 Assembly overview - Lambda probe

Lambda probe connectors
♦ 5-pin connector for lambda probe 1 before catalytic convert‐

er -GX10-
♦ 4-pin connector for lambda probe 1 after catalytic converter
-GX7-
Note
♦ New lambda probes are coated with an assembly paste.

This paste must not get into the slots on the Lambda probe
body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste
⇒ Electronic parts catalogue (ETKA)
♦ During installation, it is essential that wiring of lambda probe
is reattached in same positions. The wire must be prevented
from touching the exhaust pipe.

04.2021

❑ Consisting of:

-Z29-
❑ Specified torque:
55 Nm
❑ ⇒ a8.2.2 nd instal‐
ling Lambda probe 1
terGX7”, page 499
2 - Lambda probe 1 before
catalytic converter -GX10-
❑ Consisting of:
Lambda probe -G39-
Lambda probe heater -

Z19-
55 Nm
❑ ⇒ a8.2.1 nd installing
Lambda probe 1 be‐
fore catalytic conver‐
8.2 Removing and installing Lambda probe

⇒ a8.2.1 nd installing Lambda probe 1 before catalytic conver‐
⇒ a8.2.2 nd installing Lambda probe 1 after catalytic conver‐
terGX7”, page 499
8.2.1 Removing and installing Lambda probe

1 before catalytic converter -GX10-
Lambda probe 1 before catalytic converter -GX10- consists of
♦ Lambda probe -G39-
♦ Lambda probe heater -Z19-
8. Lambda probe 497

04.2021
♦ Lambda probe open ring spanner set -3337-
Removing
– Separate 5-pin connector for lambda probe 1 before catalytic

converter -GX10-.
– Unscrew Lambda probe 1 before catalytic converter -GX10-
-1- using tool from Lambda probe open ring spanner set
-3337-.
Installing
When installing, note the following:

04.2021
Note

body.
Specified torques
8.2.2 Removing and installing Lambda probe

1 after catalytic converter -GX7-
Lambda probe 1 after catalytic converter -GX7- consists of
♦ Lambda probe after catalytic converter -G130-
♦ Lambda probe 1 heater after catalytic converter -Z29-
♦ Lambda probe open ring spanner set -3337-
Removing
– Separate 4-pin connector for lambda probe 1 after catalytic

converter -GX7-.
– Unscrew Lambda probe -1-, using tool from Lambda probe
open ring spanner set -3337-.
8. Lambda probe 499

04.2021
Installing
When installing, note the following:
Note

body.
Specified torques

04.2021
26 – Exhaust system
1 Exhaust pipes and silencers
⇒ o1.1 verview – silencers”, page 501
⇒ a1.2 nd installing silencer”, page 514
⇒ e1.3 xhaust pipes from silencers”, page 525
⇒ e1.4 xhaust system free of stress”, page 532
⇒ e1.5 xhaust system for leaks”, page 533
1.1 Assembly overview – silencers

⇒ o1.1.1 verview - silencer, Golf, front-wheel drive”, page 501
⇒ o1.1.2 verview - silencers, titanium version”, page 503
⇒ o1.1.3 verview - silencers, Golf CJSB; Passat CJXA, DNUA;
Arteon”, page 505
⇒ o1.1.4 verview - silencers, Passat with engine codes CJSA,
CJSC”, page 507
⇒ o1.1.5 verview - silencer, Passat CHHB, CXDA”, page 509
⇒ o1.1.6 verview - silencers, Sharan”, page 511
⇒ o1.1.7 verview - silencers, Touran”, page 511
⇒ o1.1.8 verview - silencers, Tiguan”, page 513
1.1.1 Assembly overview - silencer, Golf, front-wheel drive
1. Exhaust pipes and silencers 501

04.2021
1 - Front clamping sleeve

❑ Align exhaust system
free of tension be‐
fore tightening ⇒ page
532 .
❑ Tighten bolted connec‐
tions evenly to 30 Nm
2 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
ling ⇒ page 514
❑ Cutting point ⇒ page
525
❑ Aligning exhaust sys‐
tem free of tension ⇒
page 532 .
3 - Bolt
❑ 20 Nm
4 - Bracket
5 - Retainer
6 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
ling ⇒ page 514
525
❑ Aligning exhaust system free of tension ⇒ page 532 .
7 - Rear clamp
❑ Only for repair work
❑ Align exhaust system free of tension before tightening ⇒ page 532 .
❑ Tighten bolted connections evenly to 30 Nm
Installation position of rear clamp
502 Rep. gr.26 - Exhaust system

04.2021
– Fit clamp in position shown.

• Bolted connections facing to left.
• Bolt -arrow- must not protrude beyond lower edge of clamp.
1.1.2 Assembly overview - silencers, titanium version

04.2021

532 .
2 - Centre silencer
ling ⇒ page 514
525
page 532 .
3 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
repair purposes.
ling ⇒ page 514
❑ Separating point
-arrow- ⇒ page 525
page 532 .
4 - Retainer
5 - Bracket
6 - Bolt
❑ 20 Nm
7 - Rear clamp

04.2021

1.1.3 Assembly overview - silencers, Golf CJSB; Passat CJXA, DNUA; Arteon

04.2021
1 - Clamping sleeve
❑ 30 Nm
532 .
506
❑ Tighten threaded con‐
nections evenly.
2 - Centre silencer
ling ⇒ page 516
❑ Separating exhaust
pipes from silencers ⇒
page 528
page 532 .
3 - Retainer
4 - Rear right silencer
❑ Middle and rear left si‐
lencers are combined
in one unit as original
equipment. Can be re‐
repair purposes.
❑ Separating point
-arrow-
❑ Separating exhaust pipes from silencers ⇒ page 528
❑ ⇒ a2.5 nd installing exhaust flap control unitJ883/J945, Passat CJXA, Arteon”, page 568
5 - Mounting with retaining loop
6 - Bolt
❑ 20 Nm
7 - Rear left silencer
❑ Middle and rear right silencers are combined in one unit as original equipment. Can be renewed
individually for repair purposes.
❑ Separating point -arrow-, only for Passat
❑ ⇒ a2.5 nd installing exhaust flap control unitJ883/J945, Passat CJXA, Arteon”, page 568
8 - Mounting with retaining loop
Installation position of clamp

04.2021

1.1.4 Assembly overview - silencers, Passat with engine codes CJSA, CJSC

04.2021

532 .
2 - Front silencer
❑ Centre and rear silenc‐
ers are combined in
one unit when fitted in
the factory. Can be re‐
repair purposes.
ling ⇒ page 514
525
page 532 .
3 - Retainer
4 - Bolt
❑ M8: 20 Nm
❑ Securing bolt for rear
axle ⇒ Rep. gr. 42;
Subframe; Assembly
overview - subframe
5 - Bracket
6 - Rear silencer
❑ Front, centre and rear
silencers are combined
in one unit when fitted
in the factory. Can be renewed individually for repair purposes.
❑ Cutting point ⇒ page 525
7 - Bracket
8 - Rear clamp
9 - Bracket

04.2021

1.1.5 Assembly overview - silencer, Passat CHHB, CXDA

04.2021

532 .
2 - Centre silencer
ling ⇒ page 514
525
page 532 .
3 - Retainer
4 - Rear clamp
532 .
5 - Rear left silencer
❑ Middle and rear right si‐
lencers are combined
in one unit as original
equipment. Can be renewed individually for repair purposes.
6 - Bracket
7 - Bolt
❑ 20 Nm
8 - Rear right silencer
❑ Middle and rear left silencers are combined in one unit as original equipment. Can be renewed
9 - Bracket

04.2021
1.1.6 Assembly overview - silencers, Sharan
Note
♦ Renew seals and self-locking nuts after they have been re‐
moved.
♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to
the bodywork. If necessary, loosen clamp and align silencers
and exhaust pipe so that sufficient clearance is maintained
to the bodywork at all points and the mountings are evenly
loaded.
1 - Bracket
❑ 25 Nm
2 - Mounting
3 - Rear silencer
tem free of stress
4 - Clamping sleeve
❑ Turn clamp in such a
way that there is suffi‐
cient clearance to adja‐
cent components
5 - Centre silencer
6 - Nuts
❑ Renew
❑ 25 Nm
1.1.7 Assembly overview - silencers, Touran

04.2021
1 - Clamping sleeve
❑ 30 Nm
532 .
512
❑ Tighten threaded con‐
nections evenly.
2 - Front silencer
❑ Centre and rear silenc‐
ers are combined in
one unit when fitted in
the factory. Can be re‐
repair purposes.
ling ⇒ page 522
❑ Separating exhaust
pipes from silencers ⇒
page 531
page 532 .
3 - Mounting with retaining
loop
4 - Bolt
❑ 20 Nm
5 - Centre silencer
❑ Front and rear silencers
are combined in one
unit when fitted in the
factory Can be renewed individually for repair purposes.
❑ Separating points -arrows-
6 - Rear silencer
❑ Front, centre and rear silencers are combined in one unit when fitted in the factory. Can be renewed
❑ Separating points -arrows-
Installation position of clamp

04.2021

1.1.8 Assembly overview - silencers, Tiguan
Note
♦ Renew seals and self-locking nuts after they have been re‐
moved.
♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to
the bodywork. If necessary, loosen clamp and align silencers
and exhaust pipe so that sufficient clearance is maintained
to the bodywork at all points and the mountings are evenly
loaded.

04.2021
1 - Bolt
❑ 25 Nm
2 - Bracket
3 - Mounting
4 - Clamping sleeve
❑ Turn clamp in such a
way that there is suffi‐
cient clearance to adja‐
cent components
5 - Rear silencer
tem free of stress
1.2 Removing and installing silencer

⇒ a1.2.1 nd installing silencer, Golf, front-wheel drive”, page
514
⇒ a1.2.2 nd installing silencers, Golf CJSB; Passat CJXA,
DNUA; Arteon”, page 516
⇒ a1.2.3 nd installing silencer, Passat with engine codes CJSA,
CJSC”, page 517
⇒ a1.2.4 nd installing silencer, Passat CHHB, CXDA”, page
520
⇒ a1.2.5 nd installing silencer, Sharan”, page 522
⇒ a1.2.6 nd installing silencer, Touran ”, page 522
⇒ a1.2.7 nd installing silencer, Tiguan”, page 523
1.2.1 Removing and installing silencer, Golf,

front-wheel drive
Removing
– Remove rear tunnel cross-piece -2-.

04.2021
– Loosen bolt connections for front clamp -arrow-.
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following
work.
– Detach exhaust hanger -1-, and unbolt exhaust hanger -2-

from body. Remove silencer.
Installing

04.2021
Specified torques
♦ ⇒ o1.1 verview – silencers”, page 501
♦ Underbody cladding; Assembly overview - underbody clad‐
ding ⇒ General body repairs, exterior; Rep. gr. 66; Under‐
body cladding; Overview of fitting locations - underbody
cladding
1.2.2 Removing and installing silencers, Golf

CJSB; Passat CJXA, DNUA; Arteon
Removing
– If fitted, remove rear left underbody cladding ⇒ General body
repairs, exterior; Rep. gr. 66; Underbody cladding; Overview
of fitting locations - underbody cladding.
CAUTION
work.
– Loosen clamp -arrows-, and push it forwards.
Note
♦ Centre silencer as well as both rear silencers are combined

in one unit when fitted in the factory. In the event of repairs,
they need to be renewed individually.
♦ Cut exhaust pipe ⇒ page 528 .
– Unscrew bolt -1-, and place exhaust pipe -2- on tunnel

cross-piece.

04.2021
– Press rubber mounting -arrow- off exhaust pipe pin -1-.
– If fitted, pull connectors from exhaust flap control units on

right and left off rear silencer.
– Unscrew bolt -2- for rear right silencer -1-.
– Unscrew bolt -2- for rear left silencer -1-.
Installing
Specified torques
♦ ⇒ page 505
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Overview of fitting locations - underbody cladding
1.2.3 Removing and installing silencer, Pas‐

sat with engine codes CJSA, CJSC

04.2021
♦ Chain pipe cutter -VAS 6254-
Or
♦ Pneumatic sabre saw -V.A.G 1523B-
Note
To allow for removing the silencers without having to remove

the rear axle, the rear silencer must be cut off.
Removing
– Remove rear left vehicle level sender -G76- ⇒ Running gear,
axles, steering; Rep. gr. 43; Vehicle level sender; Removing
and installing rear vehicle level sender -G76-/-G77-.
– Remove bolts -2- and position vehicle level sender so that it

does not become damaged.
– Loosen clamp -arrow-, and push it to rear.

04.2021
CAUTION
work.
– Unscrew bolts -1- for rear silencer, and detach exhaust

hanger -2-.
– Remove cross piece -1-, and unscrew bolt -2-.
– Push exhaust system towards rear. Cut through rear silencer

at right angles at separating point -arrow- using chain pipe
cutter -VAS 6254- or pneumatic sabre saw -V.A.G 1523B-.

04.2021
– Remove rear silencer towards rear. Remove front silencer

with centre silencer towards front.
Installing
– Position clamp for rear silencer centrally at side marks
-arrows- when installing.
– Turn clamp in such a way that there is sufficient clearance to

adjacent components.
– Install rear left vehicle level sender -G76- ⇒ Running gear,
axles, steering; Rep. gr. 43; Vehicle level sender; Removing
and installing rear vehicle level sender -G76-/-G77-.
Specified torques
♦ ⇒ o1.1.4 verview - silencers, Passat with engine codes
CJSA, CJSC”, page 507
1.2.4 Removing and installing silencer, Pas‐

sat CHHB, CXDA

04.2021
CAUTION
work.
– Detach exhaust hanger -1-, and unbolt exhaust hangers

-2, 3 and 4- from body. Remove exhaust system -A-.
Installing
Specified torques
♦ ⇒ o1.1.5 verview - silencer, Passat CHHB, CXDA”, page 509
cladding

04.2021
1.2.5 Removing and installing silencer, Shar‐

an
Removing rear silencer
– Loosen clamp -arrow-.

– Detach exhaust hangers -1, 2- and -3-.
– Remove rear silencer -A-.
Removing centre silencer
– Unbolt cross piece -1-.

– Loosen clamp -2-.
– Release threaded connection on flange -3-.
– Remove centre silencer -A-.
– Assemble in reverse order of dismantling.
Specified torques ⇒ page 511 .
1.2.6 Removing and installing silencer, Tour‐

an
Removing
– Remove rear tunnel cross-piece ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Removing and
installing tunnel cross-piece.

04.2021
CAUTION
work.
– Loosen clamp -1- and push to rear.

– Press rubber mounting -3- off exhaust pipe pin.

– Unscrew bolts -4-, -5- and -2-.
– Carefully lower exhaust system.
Installing
Specified torques
♦ ⇒ page 511
1.2.7 Removing and installing silencer, Ti‐

guan
♦ Tensioning strap -T10038-

04.2021
Removing
CAUTION
work.
– Loosen clamp -arrows- and push to rear.
– Secure exhaust pipe -1- on propshaft with tensioning strap

-2-.
– Unscrew bolts -1- for mounting -2-.
– Remove silencer -3-.

04.2021
Installing
1.3 Separating exhaust pipes from silenc‐

ers
⇒ e1.3.1 xhaust pipes/silencers, Golf, front-wheel drive”, page
525
⇒ e1.3.2 xhaust pipes silencers, Passat with engine codes
CJSA, CJSC”, page 526
⇒ e1.3.3 xhaust pipes and silencers, Passat CHHB, CJXA,
CXDA, DNUA; Golf CJSB; Arteon”, page 528
⇒ e1.3.4 xhaust pipes/silencers, Touran”, page 531
1.3.1 Separating exhaust pipes/silencers,

Golf, front-wheel drive
♦ The connecting pipe can be cut through at the cutting loca‐
tion in order to renew the centre and rear silencers separate‐
ly.
♦ The separating point is marked with indentations on the out‐
side of the exhaust pipe.
Or

04.2021
– Cut through exhaust pipe at right angles at separating point

-arrow- using chain pipe cutter -VAS 6254- or body saw
-VAS 6780-.
– Position clamp centrally at side marks -arrows- when instal‐
ling.
– Install clamping sleeve so that end of bolt -arrow- does not

extend beyond lower edge of clamping sleeve.

– Tighten bolted connections evenly to 30 Nm.
1.3.2 Separating exhaust pipes silencers,

Passat with engine codes CJSA, CJSC
♦ The connecting pipe can be cut through at the separating
point in order to renew the front, centre and rear silencers
separately.
♦ The separating point is marked with indentations on the out‐
side of the exhaust pipe.

04.2021
♦ The procedure for separating the rear silencer and centre si‐
lencer is described in ⇒ a1.2.3 nd installing silencer, Passat
with engine codes CJSA, CJSC”, page 517 .
Or
Separating front silencer and centre silencer
– Cut through exhaust pipe at right angles at separating point

-arrow- using chain pipe cutter -VAS 6254- or body saw
-V.A.G 1523B-.
ling.

04.2021

– Tighten threaded connections evenly. Specified torque ⇒
Item 8 (page 508)
1.3.3 Separating exhaust pipes and silenc‐

ers, Passat CHHB, CJXA, CXDA,
DNUA; Golf CJSB; Arteon
Or
♦ The connecting pipe -1- can be cut through at the separating

points in order to renew the rear silencers separately.

04.2021
♦ For individual renewal of the centre silencer, a cutting point

is provided in the connecting pipe.
♦ The separating point -arrow- is marked with indentations on

the outside of the exhaust pipe.
♦ A second mechanic is required for the procedure.
Separating right rear silencer
– Unscrew bolt -2- for rear right silencer -1-.

– Cut through exhaust pipe -1- at right angles at separating
point -arrow- using chain pipe cutter -VAS 6254- or pneu‐
matic sabre saw -V.A.G 1523B-.

04.2021
Separating left rear silencer, only Passat
– Unscrew bolt -2- for rear left silencer -1-.

– Cut through exhaust pipe of rear silencer -1- at right angles
at separating point -arrow- using chain pipe cutter -VAS
6254- or pneumatic sabre saw -V.A.G 1523B-.
Installing rear silencer

04.2021
– Position clamp -1- centrally at side marks -arrows- when

installing.
– Tighten threaded connections evenly. Specified torque ⇒
page 501 .
Separating and connecting centre silencer, only Golf
– Cut through exhaust pipe of centre silencer at right angles at

separating point -arrow- using chain pipe cutter -VAS 6254-
or body saw -V.A.G 1523B-.
– Position clamp -arrow- centrally relative to side marks when
installing.

1.3.4 Separating exhaust pipes/silencers,

Touran
♦ The connecting pipe can be cut through at the separating
points in order to renew the front, centre and rear silencers
separately.
♦ The separating points are marked with indentations on the
outside of the exhaust pipe.

04.2021
– The connecting pipe can be cut through at the respective
separating point -arrows- in order to renew the front, centre
and rear silencers separately.
– Cut through exhaust pipe at right angles in position of sepa‐
rating point -arrows- using chain pipe cutter -VAS 6254-.
– Installation position of clamp ⇒ page 512

ling.
Specified torques
♦ ⇒ page 511
1.4 Aligning exhaust system free of stress

• The exhaust system must be aligned when cold.

04.2021
– Push exhaust system towards front of vehicle until preload‐

ing at mounting for exhaust pipe -a- = 5 mm.
Aligning tailpipes, Golf
– Align rear silencer so that there is an equal distance be‐

tween bumper and exhaust pipes.
– Tighten clamp evenly.
1.5 Checking exhaust system for leaks

– Start engine and run it at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.
– Check (by listening) points of connection between exhaust
manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.

04.2021
2 Emission control
⇒ o2.1 verview – emission control”, page 534
⇒ o2.2 verview - bracket and pipes for pressure differential
sender for particulate filterG1037”, page 549
⇒ a2.3 nd installing catalytic converter”, page 550
⇒ a2.4 nd installing holder of pressure differential sender for
particulate filterG1037”, page 567
⇒ a2.5 nd installing exhaust flap control unitJ883/J945, Passat
CJXA, Arteon”, page 568
2.1 Assembly overview – emission control

⇒ o2.1.1 verview - emission control, Golf, Passat, Touran, Ar‐
teon”, page 534
⇒ o2.1.2 verview - exhaust gas treatment, Sharan”, page 537
⇒ o2.1.3 verview - exhaust gas treatment, Tiguan”, page 538
⇒ o2.1.4 verview - emission control, vehicles with particulate
filter and front-wheel drive”, page 543
⇒ o2.1.5 verview - emission control, vehicles with particulate
filter and all-wheel drive”, page 546
2.1.1 Assembly overview - emission control, Golf, Passat, Touran, Arteon

04.2021
1 - Bolt
❑ 20 Nm
2 - Bracket
3 - Bolt
Specified torque and tighten‐
ing sequence ⇒ page 536
4 - Nut
5 - Bracket
❑ For catalytic converter
6 - Catalytic converter
❑ With front exhaust pipe
❑ Protect catalytic con‐
verter from damage by
knocks and impact
ling ⇒ page 550
page 532 .
❑ Renew
536
page 536
8 - Seal
❑ Renew
9 - Turbocharger
10 - Nut
Specified torque and tightening sequence ⇒ page 536
11 - Nut
❑ 30 Nm
❑ Tighten threaded connections evenly.
Installation position of front clamping sleeve
2. Emission control 535

04.2021
– Fit clamp in position shown. Bolt -arrow- must not protrude

beyond lower edge of clamp.
Installation position of screw-type clip for catalytic converter
– Fit screw-type clip in position shown. Make sure there is

sufficient clearance between bolted connection and other
components.
Catalytic converter - specified torque and tightening sequence
– Tighten bolted connections in stages in the sequence

shown:

04.2021
Stage Screw-type clip/ Torque setting

nuts
1 -1, 3, 4- Screw in by hand as far as stop
• It should still be possible to move
catalytic converter and bracket.
2 -2- Tighten screw-type clip to 15 Nm.

Note installation position ⇒ page 536
3 -1, 3, 4- Tighten to 20 Nm
2.1.2 Assembly overview - exhaust gas treatment, Sharan
1 - Bracket
❑ Renew
537
page 538
3 - Seal
❑ Renew
4 - Turbocharger
ling ⇒ page 374
knocks and impact
ling ⇒ page 550
page 532 .
6 - Bracket
7 - Bolts
❑ 20 Nm
8 - Nuts
9 - Bolts

04.2021

components.

shown:
nuts

3 -1, 3, 4- Tighten to 20 Nm
2.1.3 Assembly overview - exhaust gas treatment, Tiguan

04.2021
1 - Bolt
❑ Pressed into holder
2 - Bracket
knocks and impact
ling ⇒ page 550
page 532 .
❑ Renew
540
page 540
5 - Seal
❑ Renew
6 - Turbocharger
ling ⇒ page 380
7 - Bolt
❑ 20 Nm
8 - Bracket
ling bracket with lock washers ⇒ page 541
9 - Securing clip
❑ Not fitted in all vehicles
❑ Removing and installing lock washers ⇒ page 541
10 - Pop rivet
❑ If bracket is to be renewed, drill out pop rivet ⇒ page 541
11 - Nut

04.2021


components.

shown:

04.2021

nuts

3 -1, 3, 4- Tighten to 20 Nm
Removing and installing bracket with retaining washers:
Note
Depending on the equipment level of the vehicle, a securing

clip ⇒ Item 9 (page 539) for the bracket of the catalytic convert‐
er may be installed. When the vehicle »hits the ground«, the
retaining washer prevents the catalytic converter from slipping
out of the bracket. The retaining washer can also be retrofitted
if necessary. For retrofit parts, refer to ⇒ Electronic parts cata‐
logue (ETKA).
To detach bracket from catalytic converter:
– Remove connector for Lambda probe 1 after catalytic con‐

verter -GX7- from retainer, disconnect it, and lay electrical
wires to one side.
onto turbocharger.

insulation.

04.2021
– If fitted, remove middle underbody cladding ⇒ General body

repairs, exterior; Rep. gr. 66; Underbody cladding; Remov‐
ing and installing underbody cladding.
– Unscrew bolts -arrows-, and lower catalytic converter as far

as possible.
– Drill out pop rivets ⇒ Item 10 (page 539) , and detach lock
washer.
– Detach bracket from catalytic converter.
– Check if pop rivets can be inserted into mounting on catalytic

converter. If necessary, widen holes to 7 mm with a drill.
– Fit bracket -1- to mountings on catalytic converter.

04.2021
– Secure retaining washers -3- with rivets as shown in illustra‐

tion, parallel to rubber part -2-.
quence.
2.1.4 Assembly overview - emission control,

vehicles with particulate filter and front-
wheel drive
If particulate filter was renewed, learnt values must be adap‐
ted with ⇒ Vehicle diagnostic tester via Guided Engine Func-
tions Adapt particulate filter learnt values .

04.2021
1 - Holder for pressure differ‐

ential sender for particulate fil‐
ter -G1037-
page 549
ling ⇒ page 567
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Union nut
❑ Apply high-temperature
paste to threads
❑ 45 Nm
5 - Union nut
paste to threads
❑ 45 Nm
❑ Consisting of:

-Z29-
55 Nm
ling Lambda probe 1
terGX7”, page 499
7 - Nut
8 - Particulate filter
9 - Temperature sender after particulate filter -G527-
❑ Apply high-temperature paste to threads
❑ 45 Nm
10 - Clamping sleeve
❑ Tighten threaded connections evenly.
11 - Union
12 - Union
13 - Bolt
❑ 20 Nm

04.2021
14 - Bracket
15 - Temperature sender before particulate filter -G506-
❑ 45 Nm
16 - Bolts
❑ 20 Nm
17 - Bracket
❑ Protect catalytic converter from damage by knocks and impact
19 - Turbocharger
❑ Renew
21 - Seal
❑ Renew


04.2021

components.

shown:
nuts

3 -1, 3, 4- Tighten to 20 Nm
2.1.5 Assembly overview - emission control,

vehicles with particulate filter and all-
wheel drive

04.2021
1 - Temperature sender after

particulate filter -G527-
paste to threads
❑ 45 Nm
2 - Nut
❑ 9 Nm
3 - Temperature sender be‐
fore particulate filter -G506-
paste to threads
❑ 45 Nm
❑ Consisting of:

-Z29-
55 Nm
ling Lambda probe 1
terGX7”, page 499
5 - Lambda probe 1 before
catalytic converter -GX10-
❑ Consisting of:
Lambda probe -G39-
Lambda probe heater -

Z19-
❑ Specified torque: 55 Nm
❑ ⇒ a8.2.1 nd installing Lambda probe 1 before catalytic converterGX10”, page 497
6 - Bolts
❑ 20 Nm
7 - Pressure differential sender for particulate filter -G1037-
8 - Bolt
❑ 8 Nm
9 - Pressure pipes
10 - Heat shield
11 - Nut
❑ 8 Nm
12 - Bolt
❑ 9 Nm

04.2021
13 - Bolt
❑ 20 Nm
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 9 Nm
16 - Bracket
❑ For pressure line
17 - Union nut
❑ 45 Nm
18 - Union nut
❑ 45 Nm


components.

04.2021

shown:
nuts

3 -1, 3, 4- Tighten to 20 Nm
2.2 Assembly overview - bracket and pipes for pressure differential sender for

04.2021
1 - Heat shield
2 - Nut
❑ 8 Nm
3 - Elbow stud
4 - Pressure differential send‐
er for particulate filter -G1037-
❑ Securing bolt, 8 Nm
ling ⇒ page 471
5 - Bracket
6 - Bolt
❑ 9 Nm
7 - Heat shield
8 - Nut
❑ 8 Nm
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 20 Nm
13 - Pressure line
14 - Bolt
❑ 20 Nm
15 - Turbocharger
2.3 Removing and installing catalytic con‐

verter
⇒ a2.3.1 nd installing catalytic converter, vehicles without partic‐
ulate filter”, page 550
⇒ a2.3.2 nd installing catalytic converter, vehicles with particu‐
late filter and front-wheel drive”, page 558
⇒ a2.3.3 nd installing catalytic converter, vehicles with particu‐
late filter and all-wheel drive”, page 562
2.3.1 Removing and installing catalytic con‐

verter, vehicles without particulate filter
♦ High-temperature paste ⇒ Electronic parts catalogue (ET‐
KA).

04.2021
♦ Four-wheel drive vehicles: counter-hold tool -T10172-
♦ Engine support -T10533-
Removing
Note

wires to one side.
onto turbocharger.

04.2021

insulation.
Tiguan
– Remove middle underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66; Underbody cladding; Removing and
installing underbody cladding.
– Release retainers -arrows- for heat shield -1-.
– Loosen clamp -2- and push to rear.
– Lower front silencer -3- slightly and remove heat shield -1-.
– Push clamp -2- back onto both exhaust pipes.
Vehicles with front-wheel drive:

– Remove heat shield for right drive shaft.

04.2021

– Lower subframe ⇒ Running gear, axles, steering; Rep.
gr. 40; Subframe; Lowering subframe.
– Unscrew bolts -arrows- and remove heat shield -1-.

– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.

04.2021
– Mark position of propshaft relative to bevel box flange.
– Counterhold at rear final drive when loosening or tightening

propshaft.
– Unbolt front of propshaft from bevel box -arrows-.
– Remove pendulum support ⇒ page 76 .

04.2021
– When pulling off or pushing on propshaft, always ensure that

sleeve -arrow- is not damaged.
– Fit engine support -T10533- between subframe and gear‐

box; tighten bolts hand-tight.
♦ Bolt -3- = original pendulum support bolt

♦ Screw a bolt M8 x 30 mm -1- fitted with a washer -2- into
threaded hole in noise insulation.
♦ -A- thin end
♦ -B- thick end
– Using engine support -T10533-, push engine as far forwards
as possible.
– Pull propshaft off bevel box, and lay it to left side.
– Mask off propshaft in front area or cover it with a cloth to
prevent any damage to surface protection.
– Remove lambda probe 1 after catalytic converter -GX7- ⇒
page 499 .
All vehicles

04.2021
– If fitted, remove cross piece -1-.

Note
♦ Risk of damage to the flexible joint.

♦ Do not allow the flexible joint to kink by more than 10°. Do
not damage wire mesh on decoupling element.
Golf, Passat, Tiguan, Arteon
– Loosen clamp -arrow-, and push it to rear. When doing this,

have a second mechanic hold the exhaust pipe.

04.2021
Sharan
– Separate catalytic converter/silencer connection on flange

-arrows-. When doing this, have a second mechanic hold the
exhaust pipe.
Installing
– Insert screwdriver -2- into recess -arrow- on turbocharger,

and lever out seal -1-.
– Insert new seal.
– Fit screw-type clip in position shown to the turbocharger.
– Fit catalytic converter to turbocharger. Attach screw-type clip

of catalytic converter loosely without tightening it.
– Tighten nuts and screw-type clip:
Golf, Passat, Touran, Arteon ⇒ page 536
Sharan ⇒ page 538
Tiguan ⇒ page 540

04.2021
– Note installation position of screw-type clip:

Golf, Passat, Touran, Arteon ⇒ page 536
Sharan ⇒ page 537
Tiguan ⇒ page 540
– If present, install propshaft ⇒ Rep. gr. 39; Propshaft; Remov‐
ing and installing propshaft.
quence.
Specified torques
cladding

verter, vehicles with particulate filter
and front-wheel drive
Removing
Note

wires to one side.
onto turbocharger.

04.2021

page 499 .
– Remove cross piece -1-.
– Unscrew temperature sensors -1- and -2- from particulate

filter ⇒ page 570 .
– Unscrew pipes for pressure differential sender from particu‐

late filter.

04.2021

All vehicles
– Unscrew bolts -1- and -2-, and lay aside pipes.


04.2021
Note



Installing



04.2021
– Tighten nuts and screw-type clip ⇒ page 546 .

– Note installation position of screw-type clip ⇒ page 545 .
– Secure subframe ⇒ Running gear, axles, steering; Rep.
– Install temperature sensors ⇒ page 570 .
quence.
Specified torques
cladding

verter, vehicles with particulate filter
and all-wheel drive
Removing
Note

wires to one side.
onto turbocharger.

04.2021

page 499 .
– Unscrew bolt -arrow- for pressure lines (next to tube fitting
for Lambda probe) from above.
– Unscrew nuts -arrows-, move clear bracket -1- for pressure

line, and move it aside.


04.2021
– Unscrew temperature sender before particulate filter -G506-

-arrow- from particulate filter.
– Unscrew temperature sender after particulate filter -G527-

-arrow- from particulate filter.
– Unscrew union nut -arrow- for pressure lines, and move

aside pressure lines.

04.2021
Note



04.2021
Installing


– Tighten nuts and screw-type clip ⇒ page 548 .
– Note installation position of screw-type clip ⇒ page 548 .
– Secure subframe ⇒ Running gear, axles, steering; Rep.
– Install temperature sensors ⇒ page 572 .
quence.
Specified torques
♦ ⇒ o2.1.5 verview - emission control, vehicles with particulate
filter and all-wheel drive”, page 546
cladding

04.2021
2.4 Removing and installing holder of pres‐

sure differential sender for particulate
filter -G1037-
– Pull off connector -1- of pressure differential sender for par‐
ticulate filter -G1037-.
– Remove catalytic converter ⇒ page 550 .

– Unscrew bolts -arrows- and nut -1-. Detach cover section.
– Unscrew bolts -arrows-, and detach bracket with hoses.
Installing
The assembly steps are basically a reverse of the dismantling
procedure.
Specified torques

04.2021
2.5 Removing and installing exhaust flap

control unit -J883/J945-, Passat CJXA,
Arteon
Note
The description of work is applicable for the left exhaust flap

control unit -J883- and the right exhaust flap control unit 2
-J945-.
Removing
– Separate electrical connector:

– Unscrew nuts -arrows-, and remove exhaust flap control unit
-1-.
Installing
– The key on exhaust flap control unit -1- must engage in

grooves -arrows- on exhaust flap.
– Tighten new nuts of exhaust flap control unit to 3 Nm.
– Connect electrical connector.

04.2021
3 Exhaust gas temperature regulation

⇒ o3.1 verview – exhaust gas temperature regulation”, page
569
⇒ a3.2 nd installing parts of exhaust gas temperature regula‐
tion”, page 570
3.1 Assembly overview – exhaust gas tem‐

perature regulation
Assembly overview - exhaust gas temperature regulation, front-
wheel drive

❑ 45 Nm
❑ 45 Nm
Assembly overview - exhaust gas temperature regulation, all-

wheel drive
3. Exhaust gas temperature regulation 569

04.2021

❑ 45 Nm
❑ 45 Nm
3.2 Removing and installing parts of ex‐

haust gas temperature regulation
⇒ a3.2.1 nd installing exhaust gas temperature sender, vehicles
with front-wheel drive”, page 570
⇒ a3.2.2 nd installing exhaust gas temperature sender, vehicles
with all-wheel drive”, page 572
3.2.1 Removing and installing exhaust gas

temperature sender, vehicles with
front-wheel drive
♦ Tool set -T10395A- with suitable insert
Removing
• Observe safety precautions when working on the exhaust
system ⇒ page 3 .
– Loosen centre left underbody cladding working towards ex‐
haust system, and push it downwards slightly ⇒ General
body repairs, exterior; Rep. gr. 66; Underbody cladding; As‐
sembly overview - underbody cladding.

04.2021
– Detach electrical connectors -1, 2- from bracket, disconnect

them, and move aside electrical wire.

-arrow-.

-arrow-.
Installing
• Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
– Place temperature sender after particulate filter -G527- in
installation position:

04.2021
• Angle -α- = max. 15°.

Specified torques
♦ ⇒ page 569
cladding; Assembly overview - underbody cladding
3.2.2 Removing and installing exhaust gas

temperature sender, vehicles with all-
wheel drive
♦ Tool set -T10395A- with suitable insert
Removing
• Observe safety precautions when working on the exhaust
system ⇒ page 3 .
– Loosen centre left underbody cladding working towards ex‐
haust system, and push it downwards slightly ⇒ General
body repairs, exterior; Rep. gr. 66; Underbody cladding; As‐
sembly overview - underbody cladding.
– Detach electrical connectors -1, 2- from bracket, disconnect
them, and move aside electrical wire.

04.2021

-arrow-.

-arrow-.
Installing
• Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
– Place temperature sender before particulate filter -G506- in

04.2021
• Angle -α- = max. 15°.

– Place temperature sender after particulate filter -G527- in
• Angle -α- = max. 15°.

Specified torques
♦ ⇒ page 569
cladding; Assembly overview - underbody cladding

04.2021
4 Secondary air system

⇒ o4.1 verview - secondary air system”, page 575
⇒ a4.2 nd installing secondary air pump motorV101”, page 576
⇒ s4.3 top buffer for secondary air pump”, page 576
⇒ a4.4 nd installing secondary air inlet valveN112”, page 577
4.1 Assembly overview - secondary air system
1 - Air filter housing

ling ⇒ page 443
2 - Connecting cable
❑ From secondary air
pump motor -V101- to
air filter housing
3 - Connecting cable
❑ From secondary air in‐
let valve -N112- to sec‐
ondary air pump motor
-V101-
4 - Sender 1 for secondary air
pressure -G609-
5 - Seal
of secondary air inlet
valve -N112-
6 - Secondary air inlet valve
-N112-
ling secondary air inlet
valve -N112- ⇒ page
577
7 - Bolt
❑ 9 Nm
8 - Electrical connection
❑ For secondary air inlet
valve -N112-
9 - Electrical connection
❑ For sender 1 for sec‐
ondary air pressure -
G609-
10 - Nut
❑ 8 Nm
11 - Secondary air pump motor -V101-
❑ ⇒ a4.2 nd installing secondary air pump motorV101”, page 576
❑ ⇒ s4.3 top buffer for secondary air pump”, page 576
4. Secondary air system 575

04.2021
4.2 Removing and installing secondary air

pump motor -V101-
Removing
insulation.
– Open locking element -arrows- and pull off the lines -1- from
secondary air pump motor -V101- -2-.
– Separate connector -2- of secondary air pump motor -V101-.
– Unscrew nuts -arrows-, and remove secondary air pump mo‐

tor -V101- -1- together with bracket.
Installing
• Specified torques ⇒ page 575
4.3 Renewing stop buffer for secondary air

pump
NOTICE
Danger of damage to secondary air pump
– Only renew stop buffers individually one after the other.
Removing
– Remove secondary air pump motor ⇒ page 576 .
– Unscrew secondary air pump motor bracket.
– Unscrew damaged stop buffer -1-.

04.2021
Installing
– Screw in stop buffer -1-.

Repeat procedure for remaining stop buffers.
– Mount secondary air pump motor bracket.
– Install secondary air pump motor ⇒ page 576 .
Specified torques
Component Specified torque
Stop buffer 5 Nm
4.4 Removing and installing secondary air

inlet valve -N112-
• The flange must not be separated from the secondary air
inlet valve.
• Always renew secondary air inlet valve together with flange.
Removing
– Remove battery tray ⇒ Electrical system; Rep. gr. 27; Bat‐
tery; Removing and installing battery tray.
er ⇒ page 410 .
– Pull connector -3- off sender 1 for secondary air pressure
-G609- -1-, and unclip sender.
4. Secondary air system 577

04.2021
– Release both retaining tabs -arrow- of sender 1 for secon‐

dary air pressure -G609-, and pull sender 1 for secondary air
pressure -G609- -1- off connecting wire -2-.
– Pull connector -3- off secondary air inlet valve -N112- -2-.
– Pull off connecting pipe -1-. To do this, press retaining ring

together on both sides.
– Unscrew bolts -arrows- from secondary air inlet valve -N112-
-1-.
– Unscrew bolts -arrows-, and remove secondary air inlet

valve -N112- -1-.
Installing
• Renew seal ⇒ Electronic parts catalogue (ETKA)
Specified torques
♦ ⇒ o4.1 verview - secondary air system”, page 575

04.2021
28 – Ignition system
1 Ignition system
⇒ o1.1 verview - ignition system”, page 579
⇒ a1.2 nd installing ignition coils with output stage”, page 581
⇒ a1.3 nd installing knock sensor 1G61”, page 583
⇒ a1.4 nd installing Hall sender”, page 585
⇒ a1.5 nd installing engine speed senderG28”, page 586
1.1 Assembly overview - ignition system
1. Ignition system 579

04.2021
1 - Bolt
❑ Renew
❑ 8 Nm + turn 90° further.
❑ The specified torque in‐
fluences the function of
the knock sensor.
ling ⇒ page 583
3 - Spark plug
❑ 30 Nm
❑ Remove and install us‐
ing spark plug socket
and extension -3122
B-.
❑ Renew spark plugs
⇒ Maintenance; Book‐
let ; Spark plugs: Re‐
newing
4 - Spark plug connector
❑ Assembling ⇒ page
583
5 - Ignition coil with output
stage
❑ Ignition coil 1 with out‐
put stage -N70-
put stage -N127-
put stage -N291-
put stage -N292-
ling ⇒ page 581
6 - Bolt
❑ 10 Nm
7 - Nut
❑ for earth wire
❑ Depending on version.
❑ 10 Nm
8 - Bolt
❑ 9 Nm
❑ Check O-ring for damage before installing
10 - O-ring
11 - O-ring
580 Rep. gr.28 - Ignition system

04.2021
13 - Bolt
❑ 9 Nm
14 - O-ring
15 - Engine speed sender -G28-
16 - Bolt
❑ 4 Nm + turn 45° further.
❑ Renew
1.2 Removing and installing ignition coils

with output stage
♦ Puller -T10530-
Note
♦ The ignition coils are easier to remove when the engine is

warm. The grease added during installation of the ignition
coils makes it easier to remove them and the ignition plug
connectors when the engine is warm.
♦ Ignition coils with output stage and spark plug connectors
are available individually for repairs ⇒ Electronic parts cata‐
logue (ETKA)
♦ If the spark plugs are to be renewed, refer to ⇒ Mainte‐
nance; Booklet ; Spark plugs: Renewing.
Removing:

– If fitted, unbolt earth wires -arrows-.
– Release connectors, and pull all connectors simultaneously
off ignition coils.

04.2021
– Unscrew securing bolt for ignition coil to be removed.

– Insert puller -T10530- into hole -1- in ignition coil.
– Turn knurled nut -2- clockwise until puller is fixed in position.

– Using puller -T10530-, carefully pull ignition coil vertically
upwards to remove.

04.2021
Note
♦ Ignition coils with output stage and spark plug connectors

are available individually for repairs ⇒ Electronic parts cata‐
logue (ETKA)
♦ The spark plug connectors are removed from the ignition
coils by hand.
Assembling ignition coil with output stage and spark plug con‐
nector
– Slide spark plug connector -1- by hand onto ignition coil as

far as stop.
The vent drilling -2- must be centred relative to connector hous‐
ing -3- while doing so.
Installing ignition coil with output stage and spark plug connec‐
tor
– Press ignition coils onto spark plugs by hand evenly (do not
use tools).
– Tighten ignition coils to 10 Nm.
1.3 Removing and installing knock sensor

1 -G61-
Removing
– Pull connector -2- off knock sensor 1 -G61-.

04.2021
– Remove actuator for engine temperature regulation -N493-

⇒ page 337 .
Note
The knock sensor I -G61- is located under the intake manifold

behind the coolant pump.
– Unscrew knock sensor 1 -G61- -arrow-.
Installing
– Install in reverse order of removal.

– Note installation position of knock sensor 1 -G61-.
– Install actuator for engine temperature regulation -N493- ⇒
page 337 .
Specified torques
♦ ⇒ o1.1 verview - ignition system”, page 579

04.2021
1.4 Removing and installing Hall sender

⇒ a1.4.1 nd installing Hall senderG40”, page 585
⇒ a1.4.2 nd installing Hall sender 3G300”, page 585
1.4.1 Removing and installing Hall sender -

G40-
Removing
– Remove intake manifold ⇒ page 447 .
– Unscrew bolt -1-, and remove Hall sender -2-.

Installing
– Check O-ring and renew if damaged.
Specified torques
1.4.2 Removing and installing Hall sender 3

-G300-
Removing
– Unscrew bolt -1-, and remove Hall sender -2-.

04.2021
Installing
– Check O-ring and renew if damaged.
Specified torques
1.5 Removing and installing engine speed

sender -G28-
Removing
insulation.
– Disconnect coolant hose -1- from charge air pipe, and push
it upwards.
Vehicles with coolant valve

04.2021
– Unscrew nuts -arrows-, and push coolant valve -1- to one

side.
All vehicles
– Separate electrical connector -1- from engine speed sensor

-G28-.
– Unscrew securing bolt -arrow-, and pull out engine speed
sender -G28-.
Installing
insulation.
Specified torques

GTI D4B802E46CA-4-Cyl Direct Injection Engine (1 8 L and 2 0 L 4 V EA 888 Gen III Turbocharger Chain Drive)

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GTI D4B802E46CA-4-Cyl Direct Injection Engine (1 8 L and 2 0 L 4 V EA 888 Gen III Turbocharger Chain Drive)

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Copyright © 2021 Volkswagen AG, Wolfsburg D4B802E46CA

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

4 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579

1.1 Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

1.2 Safety measures when working on vehicles with a start/stop system

1.4 Safety precautions when working on ignition system

Risk of damage to components

1.5 Safety precautions when working on the cooling system

2 Rep. gr.00 - Technical data

1.6 Safety precautions when working on exhaust system

Risk of damage to flexible joint

2.1 Engine number/engine data

The engine code is also stamped on the cylinder block behind

4 Rep. gr.00 - Technical data

Codes CHHA CHHB CNTA CNTC CJSA CJSB CJSC CJXA

Codes CJXE DEDA CXDA CXDB DLBA DHGA DJHC DLRB

Codes CJXE DEDA CXDA CXDB DLBA DHGA DJHC DLRB

Codes DKTA DKTB DNUA DNUC CJXH

6 Rep. gr.00 - Technical data

3.1 Rules for cleanliness

3.2 Foreign objects in engine

3.3 Contact corrosion

3.4 Routing and attachment of lines

before removal. Make sketches or take photographs if nec‐

3.5 Fitting radiator and condensers

3.6 Checking vacuum system

8 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

♦ Engine support -T10359 A-

1. Removing and installing engine 9

♦ Release lever -80 - 200-

The engine is removed downwards with gearbox. To do this, the

– Open cap -arrow- for coolant expansion tank.

10 Rep. gr.10 - Removing and installing engine

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

– Unclip lower part of air duct -1- and remove it.

– Battery in engine compartment: Remove battery tray -1-

1. Removing and installing engine 11

– Press release tabs on vacuum hose -1-, and remove hose

– Lift retaining clips -arrows- and disconnect coolant hoses

12 Rep. gr.10 - Removing and installing engine

Continued for all vehicles:

– Detach electrical connectors -1, 2- from bracket, unplug con‐

1. Removing and installing engine 13

– Release hose clips -1, 2-, and remove coolant hoses.

– Lift retaining clip -arrow- and disconnect coolant hose (top

14 Rep. gr.10 - Removing and installing engine

Golf, Passat, Arteon:

– Separate connector -1- on engine control unit -J623- ⇒ page

– Release catch using a screwdriver -arrow- and detach cover

1. Removing and installing engine 15