VW-4-Cylinder Injection Engine (2 0 L Engine)

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Transporter 2010 ➤
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg K0058982120

Transporter 2004 ➤ , Transporter 2010 ➤
4-cylinder injection engine (2.0 l engine) - Edition 12.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety instructions . . . . . . . . . . .s.w.ag. e.n.A.G.. V. o. l. .w.a.ge. n. A. G. d. o.e.s . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.1 Safety precautions when working d by
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2.2 Safety precautions when ise
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2.3 Safety precautions when ss
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2.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.1 Rules for cleanliness when working on fuel supply system/injection system . . . . . . . . . . . . 7
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3.2 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.3 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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1.2 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.3 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . en

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1.4 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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1.5 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.7 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing toothed belt, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.4 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.3 Measure oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.2 Coolant hose schematic diagram, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.3 Coolant hose schematic diagram for vehicles with an additional heat exchanger, 2010 ►
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1.4 Coolant hose schematic diagram for vehicles with an additional heat exchanger in countries
with hot to very hot climates, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Coolant hose schematic diagram, vehicles with auxiliary heater, 2010 ► . . . . . . . . . . . . . . 86
1.6 Coolant hose schematic diagram for vehicles with additional heat exchanger and auxiliary
heater, 2010 ► . . . . . . . . . . .ks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1.7 Checking coolinglkssystem wage for leaks . . . . .e.s n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1.8 Draining and ed byfilling
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2 Coolant ut pump, regulation of cooling system . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ss overview - coolant pump, thermostat . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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2.2 Assembly overview - Y thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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2.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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2.5 Testing Y-thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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3.1 Assembly overview - radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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3.2 Assembly overview - radiator, radiator fan, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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3.3 Assembly overview - radiator cowl with radiator fan V7 and right radiator fan V35 . . . . . . . 105
3.4 Assembly overview - radiator cowl with radiator fan V7 , 2010 ► . . . . . . . . . . . . . . . . . . . . 106
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3.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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3.6 Removing and installing radiator cowl with radiator fan V7 , 2010 ► . . . . . . . . . . . . . . . . . . 108
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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1.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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2 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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2.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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2.2 Assembly overview - lower part of intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . 113
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3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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3.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.3 Checking quantity injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.1 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.2 Separating exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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1.2 Removing and installing spark plugs . . . . . .ed. b.y.V. . . . . . . . . . . . . . . . . . . . . . . . t .gu. a.ra. . . . . . 133
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1.3 Test data, spark plugs . . . . . . . . . . . . . .th.or.i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e o. . . 134
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Contents iii
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iv Contents
00 – Technical data
1 Identification
(VRL008754; Edition 12.2015)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data

The engine number -arrow- (“engine code” and “serial number”)
can be found at the joint between engine and gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.
Engine codes AXA AXA

Manufactured 09.03 … 09.09 09.09 ►
Emissions fulfil EU 4 standard EU 5 standard
EU 2 depends on vap. EU 2 depends on vap.
press.1) press.1)
Capacity l 2.0 2.0
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Output ksw
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not 85/5200 85/5200
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Torque ed by Nm at rpm ara170/2700 ... 4700
nte
170/2700 ... 4700
ris
Bore utho Diameter, mm e o 82.5
ra 82.5
s a c
Stroke s mm 92.8 92.8
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Compression ratio 10.5 10.5

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Injection system Motronic ME 7.5 Motronic ME 7.5

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Ignition system Motronic ME 7.5 Motronic ME 7.5

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RON 95 unleaded 95 unleaded

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Firing order 1-3-4-2 1-3-4-2

spec
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Catalytic converter yes yes

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Exhaust gas recirculation yes yes

Secondary air system yes yes
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Lambda control yes yes

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Electronic power control yes yes

Knock control yes yes
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Valves per cylinder 2 2

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Leakage diagnosis system no no

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1) Dependent on vapour pressure

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1. Identification 1
2 Safety instructions
⇒ “2.1 Safety precautions when working on cooling system”, page
2
⇒ “2.2 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.3 Safety precautions when working on injection system”,
page 4
⇒ “2.4 Safety precautions when working on ignition system”, page
5
2.1 Safety precautions when working on

cooling system
WARNING
When the engine is warm, the cooling system is under pres‐

sure.
Hot steam/hot coolant can escape - risk of scalding.
Cover filler cap on expansion tank with a cloth and open care‐
fully to dissipate pressure.
Caution
Observe the following during all assembly work, particularly in

the engine compartment due to the restricted space:
♦ Route lines of any kind and cables so that original routing
is restored.
♦ Ensure that there is sufficient clearance to all moving or
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Rep. gr.00 - Technical data
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ For fitting spring-type clips, hose clamping pliers - VAS 6340-
or
♦ Hose clip pliers - VAS 6362- .
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
AG. Volkswagen A
2.2 Safety precautions
Vol
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♦ Hose connections are secured with couplings or spring-type

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or clamp-type clips.
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♦ Always renew clamp-type clips with spring-type clips.

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spec
♦ Fuel hoses on engine must be secured with spring-type clips

urposes, in part or in wh
only. The use of clamp or screw-type clips is not permissible.

t to the co
♦ Spring-type clip pliers - VAS 5024 A- or pliers - V.A.G 1921-

are recommended for installation of spring-type clips.
rrectnes
WARNING
s o
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When doing any repair work, especially in the engine compart‐

form
mer
ment, pay attention to the following due to the cramped condi‐

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

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fluid and vacuum) and electrical wiring in their original po‐

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When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
WARNING
Fuel supply lines are under pressure! Before loosening hose

connections, wrap a cloth around the connection. Then release
pressure by carefully pulling hose off connection.
2. Safety instructions 3
4-cylinder injection engine (2.0 l engine) - Edition 12.2015 AG. Volkswagen AG d
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♦ Even before work commences, the extraction hose of anedac‐ by gu
ara
tivated fume extraction system has to be placed in thehovicinity
ris nte
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of the assembly opening of the fuel tank to extract any
s aut escap‐ ra
c
ing fumes. If no exhaust gas extraction system is savailable, a
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radial fan with a displacement greater than 15 m3/h can be
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
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♦ For safety reasons, fuses SD14 and SD30 must be removed
h re
from fuse holder before fuel system is opened because fuel
hole
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pump can be activated by door contact switch in driver door.
es, in part or in w
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♦ Fuse No. SD14 and SD30 -arrows- are located in the E-box
fuse holder in the engine compartment.
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2.3 Safety precautions when working on in‐
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jection system
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WARNING
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Fuel system is under pressure! Before opening the system

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4 Rep. gr.00 - Technical data

♦ Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ For safety reasons, if the battery has not been disconnected,
fuse No. SD 14 and SD 30 -arrows- must be removed from E-
box fuse holder in the engine compartment before fuel system Volkswagen AG
is opened. Otherwise fuel pump will be activated by driver door swagen AG. does
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Note the following if testers and measuring instruments have to

be used during a road test:
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♦ Test and measuring instruments must always be secured to
orm
rear seat and operated by a second person from this location.
m
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If test and measuring instruments are operated from front pas‐
or c
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injuries when the airbag is triggered.
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2.4 Safety precautions when working on ig‐
nition system
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ If the engine is to be turned at starter speed without starting:
2. Safety instructions 5
– Pull fuses SD 22 and SD 25 out of fuse holder in engine com‐

partment.
Note
Removing the fuses interrupts voltage supply to the injectors and

the ignition coils.
Note the following if testers and measuring instruments have to

be used during a road test: agen
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If test and measuring instruments are operated from front
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possibility that the person sitting in this seat may receive serious
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injuries when the airbag is triggered.
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trol unit since faults will have been registered as a result of
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removing fuse ⇒ Vehicle diagnostic tester.
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6 Rep. gr.00 - Technical data

3 Repair instructions
⇒ “3.1 Rules for cleanliness when working on fuel supply system/
injection system”, page 7
⇒ “3.2 General notes on injection”, page 7
⇒ “3.3 General notes on ignition system”, page 7
3.1 Rules for cleanliness when working on

fuel supply system/injection system
When working on the fuel supply and injection system, observe
the following “5 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
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♦ The battery must be disconnected only with ignition switched
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of at least 11.5 V is necessary.
hole
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♦ Do not use sealants containing silicone. Particles of silicone
es, in part or in w
drawn into the engine will not be burnt in the engine and dam‐
t to the co
age the Lambda probe.
♦ If, after fault finding, repairs or component tests, the engine
rrectness of i
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
l purpos
In this case, the control unit must be adapted ⇒ Vehicle diag‐

nostic tester.
nf
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♦ Certain tests may lead to a fault being detected by the control

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unit and stored. Therefore, after completing all the checks and
atio
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repairs, read the event memory and clear it if necessary ⇒ Ve‐

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♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It

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3.3 General notes on ignition system

♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
3. Repair instructions 7
♦ Certain tests may lead to a fault being detected by the control

unit and stored. Therefore, after completing all the checks and
repairs, read the event memory and clear it if necessary ⇒ Ve‐
hicle diagnostic tester.
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted ⇒ Vehicle diag‐
nostic tester.
Safety precautions ⇒ page 5 .
Test data, spark plugs ⇒ page 134
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Rep. gr.00 - Technical data
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 9
⇒ “1.2 Securing engine to assembly stand”, page 14
⇒ “1.3 Installing engine”, page 15
1.1 Removing engine
♦
♦ Lifting tackle - VAS 2024A-
♦ Engine support - T10229-
with studs - T10229/1-
♦ Support clamp - VW 313-
♦ Engine and gearbox sup‐
port - VW 540- or engine
and gearbox support - VAS
6095-
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♦ Workshop hoist -oV.A.G
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1. Removing and installing engine 9

♦ Torque wrench (5... 50 Nm)

- V.A.G 1331-
♦ Torque wrench (40...
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Not illustrated:
♦ Container for removed parts - V.A.G 1698-

♦ Engine bung set - VAS 6122-
♦ Grease - G 000 100-
♦ Cable ties
10 Rep. gr.10 - Removing and installing engine

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♦ Before carrying out further work, disconnect battery earth ss c
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strap. For this reason, first check whether a coded radio is fit‐ e
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♦ The engine is removed downwards with gearbox.
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, is n
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removed must be replaced in the same position when engine
hole
spec
is installed.
es, in part or in w
t to the co
♦ Leave ignition key in ignition lock to prevent steering lock from
engaging.
♦ It is advisable to remove the front wheels before beginning
rrectness of i
engine removal. The vehicle can then be lowered on hoist until
l purpos
the brake disc splash plates are just above the floor. This pro‐
vides a more ergonomic working position regarding accessi‐
bility of engine compartment components.
nf
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♦ To prevent damage to removed components, place them in
m
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atio
the container for removed parts - V.A.G 1698- .
om
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– Before removing, read event memories of all control units

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⇒ Vehicle diagnostic tester.
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– With ignition switched off, disconnect earth strap from battery.

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Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
♦ Route lines of any kind and cables so that original routing
is restored.
hot components.
WARNING
The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Wear eye protection and protective clothing to avoid eye inju‐
ries and skin contact. Before loosening hose connections,
wrap a cloth around the connection. Then release pressure by
carefully opening the connection point.

– Pull off supply hose -3- and return hose -2- (with blue mark).
Collect escaping fuel with a cleaning cloth.
– Pull off breather hose -1- (with white mark).
Note
To do this, press down release button on hose coupling.
– Seal lines so that fuel system is not contaminated by dirt.

Observe rules for cleanliness ⇒ page 7 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body - front; Noise insulation .
WARNING

sure.
– Open and close coolant expansion tank cap to release pres‐ AG. Volkswagen AG d
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– Drain coolant ⇒ page 89 . rised ara
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– Remove throttle valve module/air mass meter connecting
s au ra
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hose ⇒ page 110 .
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– Pull coolant hoses -3- and -4- off throttle valve control module.
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– Pull crankcase breather hose -7- off cylinder head cover.
ot
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– Pull hose -8- off crankcase breather on connecting pipe to oil
hole
filter bracket.
spec
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– Open retainers and lay complete hose guide -9- to side.
t to the co
– Pull connecting hose to solenoid valve 1 - N80- off line -5-.
rrectness of i
– Pull vacuum hose off brake servo.
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– Disconnect all electrical wiring from gearbox, alternator and

starter and lay to side.
nform
ercia
– Pull off or disconnect all other electrical connections as nec‐

essary from engine and lay to side.
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– Detach all connecting, coolant and vacuum hoses/lines from

n in
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engine.
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– Remove poly V-belt ⇒ page 21 .

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– Unbolt power-assisted steering vane pump at ancillaries

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bracket and place to one side; hoses remain connected ⇒ Cop py
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Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power- yri
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assisted steering; Removing and installing vane pump .
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– Remove air conditioning compressor from ancillaries bracket
AG.
and secure it to one side so that refrigerant lines and hoses

are not strained: ⇒ Heating, air conditioning; Rep. gr. 87 ; Air
conditioning compressor bracket .

– Unclip line from slave cylinder of hydraulic clutch at connection

-arrow- (pull clip): ⇒ Power transmission; Rep. gr. 30 ; Clutch
mechanism; Assembly overview - hydraulic system .
– Remove selector mechanism from gearbox ⇒ Power trans‐
mission; Rep. gr. 34 ; Selector mechanism .
– Unclip selector cable.
– Remove drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shafts .
– Remove front exhaust pipe ⇒ page 127 .
– Remove front torque reaction support ⇒ page 17 .
– Screw stud - T10229/1- hand tight into thread -1- on cylinder

block.
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– Attach engine support - T10229- to stud -1- screwed into the
spec
hole in cylinder block. Tighten threaded support - T10229/1-
es, in part or in w
t to the co
to engine support to approx 50 Nm using M16×35/8.8 bolts
-2-.
rrectness of i
Note
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Studs -1- must be secured to engine support - T10229- .
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– Bolt engine support - T10229- to front of cylinder block
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-arrows-, tightening M12×25/8.8 bolts to approx. 50 Nm.

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– Guide engine support - T10229- onto mounting pins -2- on

engine and gearbox jack - V.A.G 1383/A- . Raise engine
slightly.
– Move engine to 0° position for removal by turning the adjuster
screw -1-.
– Unbolt engine side of assembly mounting from above

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

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1.2 Securing engine to assembly stand

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When working on the engine, secure it with engine and gearbox

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– Unbolt gearbox. gh ht
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– Attach lifting tackle - 2024A- as follows and lift from engine and
gearbox jack - V.A.G 1383 A- using workshop crane.
Belt pulley end: 1st hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 7
WARNING
Use locking pins -arrows- to secure hooks and locating pins.
Note
♦ The holes marked with 1 … 4 of the support bar point to the

belt pulley.
♦ The holes in the hook rails are counted up from the hook.
– Using engine and gearbox support -VW 540- , secure engine

to support clamp -VW 313- or to engine and gearbox support
- VAS 6095- .
1.3 Installing engine

Installation is carried out in the reverse order; note the following:
WARNING
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♦ Route all the various lines (e.g. for fuel, hydraulics, coolant
ce
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and refrigerant, brake fluid and vacuum) and electrical
an
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wiring in their original positions.

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– Check clutch release bearing for wear and renew if necessary.

t to the co
– Lightly lubricate clutch release bearing, release bearing guide

sleeve and splines on input shaft with grease ⇒ Vehicle diag‐
rrectne
nostic tester.
– Check whether dowel sleeves for centring engine/gearbox
ss
have been fitted in cylinder block, insert if necessary.

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– Hook intermediate plate
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flange and slide onto rante
dowel sleeves -arrows-.
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– When swinging engine in, ensure that there is clearance be‐
ce
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un
tween drive shafts.
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– After installing, align engine mountings free of tension by rock‐
rm
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ing engine.
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– Join connector of line to hydraulic clutch slave cylinder of
h re
hole
clutch: ⇒ Rep. gr. 30 ; Clutch operation; Assembly overview
spec
- Hydraulic system .
es, in part or in w
t to the co
– Fit selector mechanism on gearbox ⇒ Power transmission;
Rep. gr. 34 ; Selector mechanism .
rrectness of i
– Attach (clipped) gear selector cable.
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– Install air conditioner compressor ⇒ Heating, air conditioning

system; Rep. gr. 87 ; Air conditioning compressor .
nform
ercia
– Install vane pump for power-assisted steering ⇒ Running

gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted
m
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steering; Removing and installing vane pump .
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tion in
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– Install drive shafts: ⇒ Running gear, axles, steering; Rep. gr.
thi
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40 ; Drive shaft; Removing and installing drive shafts .
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– Install front exhaust pipe ⇒ page 127 .
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– Install poly V-belt ⇒ page 21 . Cop py
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– Install noise insulation ⇒ General body repairs, exterior; Rep. p by
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– Replenish coolant ⇒ page 89 .
– Carry out road test and read all event memories ⇒ Vehicle
diagnostic tester.
Observe applicable safety measures when carrying out a road
test ⇒ page 4 .
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 17
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 18
♦ ⇒ “2.1 Assembly overview - emission control”, page 127
♦ ⇒ “1.1 Assembly overview - silencers”, page 124
♦ Noise insulation; Assembly overview - noise insulation ⇒
Noise insulation; Rep. gr. 66 ; Assembly overview - noise in‐
sulation .
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 17
2.1 Assembly overview - assembly mount‐

ings
Engine assembly mountings
Specified torque
Component Specified torque
Bolt -A- 50 Nm + 90°
Bolt -B- 50 Nm + 90°
Front support mounting with torque reaction support

Specified torque
Bolt -A- 50 Nm + 90°
Bolt -B- 20 Nm + 90°
Bolt -C- 90 Nm +180°
Rear support mounting with torque reaction support

Specified torque
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Bolt
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Bolt -D- 50 Nm + 90°
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Gearbox assembly mounting

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Specified torque
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Bolt -A- 50 Nm + 90°
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Bolt -B- 50 Nm + 90°

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⇒ “1.3 Assembly overview - cylinder block”, page 20
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⇒ “1.4 Removing and installing poly V-belt”, page 21
⇒ “1.5 Removing and installing ancillary bracket”, page 23
rrectness of i
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
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⇒ “1.7 Removing and installing sealing flange on pulley end”,
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page 25
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1.1 Assembly overview - poly V-belt drive
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1 - Poly V-belt
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❑ Mark direction of rota‐
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❑ Removing and installing Prote AG.
⇒ page 21 .
2 - Bolt
❑ Renew after removing
❑ 10 Nm + 90°
3 - Belt pulley and vibration
damper
❑ Can only be installed in
one position, holes are
offset.
❑ Note position when in‐
stalling toothed belt
⇒ page 47 .
4 - Bolt
❑ 25 Nm
5 - Tensioning element
6 - Alternator
7 - Bracket for ancillaries
8 - Bolt
❑ Observe tightening se‐
quence ⇒ page 23 .
❑ 45 Nm
9 - Banjo bolt
❑ 30 Nm
10 - Seal
18 Rep. gr.13 - Crankshaft group

11 - Pressure line
12 - Vane pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted steer‐
ing .
13 - Belt pulley
1.2 Assembly overview - cylinder block (pulley end)
1 - Bolt
❑ 10 Nm
2 - Engine mounting
3 - Toothed belt guard
❑ Upper part
❑ Centre part
5 - Nut
❑ 20 Nm
6 - Washer
7 - Tensioning roller
❑ Check semi-automatic
toothed belt tensioning
roller ⇒ page 57
8 - Toothed belt agen
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❑ 20 Nm
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❑ rear
11 - O-ring
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12 - Coolant pump
❑ Check for ease of move‐
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ment.
orm
❑ Note installation position

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❑ Removing and installing ⇒ page 98

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13 - Bolt
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❑ 15 Nm
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14 - Crankshaft pulley
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❑ Use counterhold tool - 3415- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
1. Cylinder block (pulley end) 19

❑ Turning further can be done in several stages.
❑ The turning further angle can be checked using a commercial protractor e.g. Hazet 6690.
❑ 90 Nm + 90°
❑ Lower part
17 - Bolt
❑ Install using locking fluid ⇒ Electronic Parts Catalogue (ETKA)
❑ 10 Nm
18 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
❑ Note position when installing toothed belt ⇒ page 47 .
19 - Bolt
❑ 10 Nm + 90°
20 - Bolt
❑ 45 Nm
1.3 Assembly overview - cylinder block
1 - Connector
❑ For knock sensor 1 -
G61- .
2 - Knock sensor 1 - G61-
3 - Bolt n AG. Volkswagen AG do
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5 - Knock sensor 2 - G66-

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7 - Oil dipstick
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❑ Engine oil ⇒ page 77 .

spec
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8 - Coolant pipe
9 - Bolt
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❑ 40 Nm
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10 - Bracket
❑ For ignition transformer
- N152- .
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11 - Bolt
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❑ 15 Nm
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14 - Retainer
15 - O-ring
16 - Bolt
❑ 10 Nm
17 - Oil filter bracket ksw
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18 - Bolt aut or
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20 - Bolt
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❑ 15 Nm
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21 - Engine speed sender - G28-
22 - O-ring
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23 - Union
24 - Bolt
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❑ 15 Nm
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25 - Thermostat
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❑ Checking: heat thermostat in water.
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❑ Opening begins at approx. 85°C.

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❑ Ends at approx. 105°C.

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❑ Opening lift at least 7 mm. C py
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❑ Note installation position ⇒ page 99 . p by
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26 - Bolt
❑ Observe tightening sequence ⇒ page 23 .
❑ 45 Nm
27 - Bracket for ancillaries
❑ Observe tightening sequence ⇒ page 23 .
28 - Cylinder block
❑ Removing and installing sealing flange and flywheel ⇒ page 29 .
❑ Removing and installing crankshaft ⇒ page 31 .
❑ Dismantling and assembling pistons and conrods ⇒ page 34 .
1.4 Removing and installing poly V-belt

Special tools and workshop equipment required
♦ 16 mm open-end spanner - T10241-
♦ Twist drill(4 mm in diameter)
Removing
– Mark direction of rotation of poly V-belt.

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

-direction of arrow- using 16 mm open-end spanner - T10241- .
– Lock tensioning element with a twist drill (4 mm in diameter).
– Remove poly V-belt.
Installing
Note
♦ Before installing the poly V-belt, ensure that all sub-assem‐

blies (alternator, air conditioner compressor
n AG. Voland vane
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♦ When fitting poly V-belt,richeck
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direction of belt rotation and nte
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♦ For vehicles without air conditioning, put poly V-belt over al‐
ce
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un
ternator last.
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♦ For vehicles with air conditioning, put poly V-belt over air con‐
rm
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ditioner compressor last.
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After completing repair, always:
hole
spec
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– Start engine and check that belt runs properly.
Belt drive without air conditioner compressor t to the co

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1.5 Removing and installing ancillary brack‐

et
Procedure
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– Place ancillary bracketolkon
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th bracket as shown in following tightening se‐
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1- Bolt -A- 45 Nm
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2- Bolt -B- 45 Nm
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5- Bolt -E- 45 Nm
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6- Bolt -F- 45 Nm
rrectness of i
1.6 Renewing crankshaft oil seal - belt pulley end
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Special tools and workshop
nform
ercia
equipment required
m
at
♦ Oil seal extractor - 3203-
om
ion
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♦ Counterhold tool - 3415-

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♦ Assembly tool - T10053-

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♦ Torque wrench (40... py by
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200 Nm) - V.A.G 1332-
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Removing
– Remove toothed belt ⇒ page 47 .
– Remove crankshaft pulley. To do this, lock toothed belt pulley
using counterhold - 3415- .
– To guide oil seal extractor - 3203- , screw centre bolt into

crankshaft by hand to stop.
– Unscrew inner part of oil seal extractor - 3203- 9 turns (approx.
20 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor.
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– Position oil seal extractor - 3203- . Screw forcibly as far as
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– Loosen knurled screw and turn inner part against crankshaft
is n
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until the oil seal is pulled out.
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spec
Installing
t to the co
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Note
ss
The oil seal sealing lip must not be additionally oiled or greased.
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mer
– Remove oil residues from crankshaft journal with a clean cloth.

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– Fit guide sleeve - T10053/1- onto crankshaft journal.

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– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐

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– Press seal in with fitting sleeve - T10053- and bolt - T10053/2-

to stop.
– Install crankshaft pulley. To do this, lock toothed belt pulley

Note
Thread and shoulder must be free of oil and grease.
– Install and tension toothed belt ⇒ page 47 .

– Install poly V-belt ⇒ page 21 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Body - front; Noise insulation . en AG. V
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♦ ⇒ “1.2 Assembly overview - cylinder block (pulley
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1.7 Removing and installing sealing flange on pulley end
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Not illustrated:
♦ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)

♦ Hand drill with plastic brush attachment
♦ Flat scraper
♦ Eye protection
Removing
– Remove toothed belt ⇒ page 47 .

wage 4-cylinder injection
ot g engine (2.0 l engine) - Edition 12.2015
lks es n
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– Remove crankshaftthoris pulley. To do this, lock toothed belt pulley tee
or
using counterhold
au - 3415- . ac
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– Drain off engine oil.
un
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itte
– Remove sump ⇒ page 74 .
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– Unbolt front sealing flange.
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– Remove sealing flange; if necessary, loosen using light blows
h re
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with a rubber headed hammer.
spec
– Remove sealant residues from cylinder block with a flat scra‐
t to the co
per.
– Cover oil seal with a clean cloth.
rrectne
– Remove residual sealant on sealing flange using a rotating
ss
plastic brush (wear eye protection).
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cial p
f in
– Clean sealing surfaces. They must be free of oil and grease.
form
mer
Installing
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♦ Observe use-by-date of sealant.
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♦ The sealing flange must be installed within 5 minutes of ap‐
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plying the silicone sealant. Prote AG.
♦ Before applying sealant bead, cover the sealing surface of the

sealing ring with a clean cloth.
♦ The sealant bead -arrow- must not be thicker than 2 … 3 mm,
otherwise excess sealant can enter sump and block the strain‐
er in oil pump suction pipe, as well as drip onto the sealing
surface of crankshaft oil seal.
– Cut off nozzle on tube at front marking (diameter of nozzle

approx. 3 mm).
– Apply silicone sealant bead as shown to clean sealing surface
of sealing flange.
– Fit sealing flange immediately and lightly tighten all bolts.
Note
♦ When fitting sealing flange with oil seal installed use guide
sleeve - T10053/1- .
♦ Sealing compound must dry for approx. 30 minutes after in‐
stallation. Only then fill with engine oil.
♦ Thread and shoulder must be free of oil and grease.
– Tighten sealing flange securing bolts diagonally and alternate‐

ly.
– Remove excess sealant.
– Install sump ⇒ page 74 .

– Install crankshaft pulley. To do this, lock toothed belt pulley

Install toothed belt and adjust the valve timing ⇒ page 47 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Body - front; Noise insulation .
Specified torques
♦ ⇒ “1.2 Assembly overview - cylinder block (pulley end)”, page
19
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 73
sulation .
AG. Volkswagen AG d
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2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 29
2.1 Assembly overview - cylinder block, gearbox end
1 - Bolt
❑ Use counterhold tool - n AG. Volkswagen AG do
3415- to loosen and olkswage es n
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tractor e.g. Hazet 6690.
spec
es, in part or in w
❑ 90 Nm + 90°
t to the co
2 - Crankshaft pulley
3 - Bolt
rrectness of i
❑ 15 Nm
l purpos
4 - Seal
nform
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❑ Do not additionally oil or

grease the oil seal seal‐
m
ing lip.
com
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❑ Before installing, re‐

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move oil residue from

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crankshaft journal using

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a clean cloth.
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❑ Renew ⇒ page 25
Co
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5 - Sealing flange
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❑ Must seat on dowel
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sleeves.
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❑ Remove sump in order

to remove and install.
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts Catalogue (ETKA) .
❑ Removing and installing ⇒ page 25 .
6 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 31 .
❑ Dismantling and assembling pistons and conrods ⇒ page 34 .
7 - Bolt
❑ 60 Nm + 90°
8 - Flywheel
❑ Lock with counterhold - 3067- to remove and install.
9 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
2. Cylinder block, gearbox end 29

10 - Sealing flange with oil seal

❑ Renew complete only.
❑ Remove sump in order to remove and install.
❑ Do not additionally oil or grease the oil seal sealing lip.
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❑ Before installing, remove oil residue from crankshaft journal agen
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3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 31
⇒ “3.2 Removing and installing sender wheel”, page 33
⇒ “3.3 Crankshaft dimensions”, page 33
3.1 Assembly overview - crankshaft
Note
Before removing crankshaft, make sure that a suitable surface for

storing crankshaft is prepared to ensure that the sender wheel
⇒ Item 8 (page 32) is not damaged and is not touching any other
item.
1 - Oil pump agen

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sleeves
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cylinder block are fitted.

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⇒ page 77 .
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2 - Bolt
ole,
❑ 15 Nm spec
t to the co
3 - Chain sprocket
❑ For oil pump drive.
rrectne
4 - Bearing shells 1, 2, 3, 4 and

5
ss
❑ Classification for order‐

o
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ing spare parts

inform
⇒ page 32 .
mer
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om
oil groove.
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❑ For cylinder block with

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(mark).
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5 - Bolt
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❑ To measure radial clear‐

ance, tighten to 65 Nm
but not further.
❑ 65 Nm + 90°
6 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing cap 3 with recesses for thrust washers.
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
7 - Bearing shell 3
❑ Classification for ordering spare parts ⇒ page 32 .
3. Crankshaft 31
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❑ Do not interchange used ut bearing shells (mark).
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8 - Sender wheel
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❑ For engine speed sender - G28- .
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spec
9 - Bolt
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❑ 10 Nm + 90°
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10 - Thrust washer
❑ For bearing cap 3.
ss
❑ Note fixing arrangement.
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11 - Crankshaft
form
mer
❑ Axial clearance new: 0.07 … 0.23 mm wear limit: 0.30 mm
atio
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❑ Measure radial clearance with Plastigage , new: 0.01…0.04 mm, wear limit: 0.15 mm
n
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❑ Do not rotate crankshaft when checking radial clearance.

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❑ Crankshaft dimensions ⇒ page 33 .

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Identification of crankshaft upper bearing
Upper bearing shells of the proper thickness are allocated to the
cylinder block in the factory. Coloured dots are used to identify
the thickness of the bearing shells.
Which bearing thickness is to be used at each position is marked
by letters on the lower sealing surface of the cylinder block.
S = Black
R = Red
G = Yellow
Note
♦ Arrow points in direction of travel (forwards).

♦ If the colour code is not embossed or no longer readable, use
middle value bearing shell (red).
♦ Lower bearing shells for the crankshaft are supplied with col‐
our mark yellow as spare parts.

3.2 Removing and installing sender wheel

Removing and installing sender wheel
– Renew sender wheel -2- each time bolts -1- are loosened.
Note
♦ The second time the bolts are tightened, the contact points in
AG. Volkswagen
the sender wheel for the countersunk wheads
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ss
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3.3 Crankshaft dimensions
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(Dimensions in mm)
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spec
Honing dimen‐ Crankshaft bearing Conrod
es, in part or in w
sion journal diameter journal diameter
t to the co
Basic dimension 54.00 -0.017 47.80 -0.022
-0.037 -0.042
rrectness of i
Stage I 53.75 -0.017 47.55 -0.022
l purpos
-0.037 -0.042
Stage II 53.50 -0.017 47.30 -0.022
nf
-0.037 -0.042
ercia
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Stage III 53.25 -0.017 47.05 -0.022
m
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-0.037 -0.042
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3. Crankshaft 33
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 34
⇒ “4.2 Piston and cylinder dimensions”, page 36
⇒ “4.3 Checking piston and cylinder bore”, page 36
4.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to n AG. Volkswagen AG do
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❑ “TOP” faces towards d b ua
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piston crown. tho tee
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❑ Checking ring gap ss
⇒ page 35 .
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❑ Checking ring-to-groove
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clearance ⇒ page 35 .
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2 - Piston
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❑ Mark installation posi‐
hole
tion and cylinder num‐
spec
es, in part or in w
ber.
t to the co
❑ Arrow on piston crown
points to belt pulley end.
rrectness of i
❑ Install using piston ring
clamp.
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❑ Checking ⇒ page 36 .
3 - Piston pin
nf
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❑ If difficult to remove,
m
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heat piston to 60°C.
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❑ Remove and install us‐

or
thi
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ing drift - VW 222- .

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4 - Circlip
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5 - Conrod bolt
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6 - Conrod
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❑ Renew as set only.
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❑ Mark cylinder allocation
-A- with coloured pen.
❑ Installation position:
Marking -B- faces to‐
wards pulley end.
7 - Bearing shell
❑ Note installation position.
❑ Do not interchange used bearing shells.
❑ Check for secure seating.
❑ Axial clearance new: 0.10 … 0.35 mm wear limit: 0.4 mm
❑ Check radial clearance using Plastigage: New: 0.01…0.05 mm, wear limit: 0.12 mm. Do not rotate
crankshaft when checking radial clearance.
8 - Cylinder block
❑ Checking cylinder bores ⇒ page 36 .
❑ Piston and cylinder dimensions ⇒ page 36 .

9 - Conrod bearing cap

❑ Note installation position.
10 - Nut
❑ Oil threads and contact surface.
❑ To measure radial clearance, tighten to 30 Nm but not further.
❑ 30 Nm + 90°
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Checking piston ring gap ho ris nte
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♦ Feeler gauges
nform
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– Insert ring at right angles from above and push down into cyl‐
inder approx. 15 mm from bottom end of cylinder.
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Piston ring New Wear limit
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dimensions in mm
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1st compression ring 0,20 ... 0,40 0,8
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2nd compression ring 0.20 ... 0.40 0.8

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Oil scraper ring 0.25 ... 0.50 0.8
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Checking ring-to-groove clearance
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♦ Feeler gauges
– Clean annular groove before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 ... 0.09 0.20
2nd compression ring 0.05 ... 0.08 0.20
Oil scraper ring 0.03 ... 0.06 0.15
4. Pistons and conrods 35

4.2 Piston and cylinder dimensions

Honing dimen‐ Piston diameter Cylinder bore di‐
sion ameter
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4.3 Checking piston and cylinder bore
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♦ External micrometer 75 … 100 mm
h re
hole
Checking piston
spec
es, in part or in w
t to the co
– Measure pistons approx. 10 mm from the lower edge of skirt,
at 90° to the piston pin axis.
Deviation from nominal dimension max. 0.04 mm
rrectness of i
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♦ Internal dial test indicator 50 … 100 mm
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Checking cylinder bores
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– Take measurements at 3 positions in both lateral direction

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-A- and longitudinal direction -B-. Difference between actual C py
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and nominal diameter max. 0.08 mm.
gh ht
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Prote AG.
Note
Cylinder bores must not be measured when the cylinder block is

mounted on engine and gearbox support - VW 540- on assembly
stand or engine and gearbox support - VAS 6095- , as measure‐
ments may be incorrect.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 37
⇒ “1.2 Removing and installing cylinder head”, page 39
⇒ “1.3 Checking compression”, page 43
1.1 Assembly overview - cylinder head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
1 - Cap
2 - Seal
3 - Connecting hose
❑ For crankcase ventila‐
tion. AG. Volkswagen AG d
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4 - Nut by
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❑ 10 Nm horis nte
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5 - Retainer ss c
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6 - Gasket for cylinder head

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❑ Before fitting gasket,

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coat transitions be‐

ole,
spec
tween bearing cap and

cylinder head with seal‐

t to the co
ant - D 454 300 A2- .

7 - Oil deflector
rrectne
8 - Cylinder head bolt

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❑ Remove and install Pol‐

cial p
f in
ydrive cylinder head bolt

form
mer
using special wrench,

atio
long reach - 3452- .

om
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❑ Observe sequence
or
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when loosening and

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tightening ⇒ page 39 .
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9 - Plug
t.
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C py
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❑ With seal. p by
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1. Cylinder head 37
❑ 15 Nm
10 - Seal
11 - Union
12 - Bolt
❑ 10 Nm
13 - Lifting eye
14 - Bolt
❑ 20 Nm
15 - Cylinder head gasket AG. Volkswagen AG d
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❑ Renew after removing Volksw not
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❑ After renewing, renew rised
entire coolant. nte
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❑ Note installation
s aut position: identification: part number must be readable ra
c from inlet side.
s
16 - Bolt
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❑ 15 Nm
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18 - Toothed belt
h re
hole
❑ Mark direction of rotation before removing.
spec
es, in part or in w
❑ Check for wear.
t to the co
❑ Do not kink.
rrectness of i
19 - Cylinder head
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❑ After renewing, renew entire coolant.

❑ Check for distortion ⇒ page 38 .
nform
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20 - Cylinder head cover

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Checking cylinder head for distortion

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♦ Straight edge
♦ Feeler gauges
Max. permissible distortion: 0.1 mm.
38 Rep. gr.15 - Cylinder head, valve gear

1.2 Removing and installing cylinder head
Special tools and workshop agen

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♦ Guide pins - 3450/2A- horis nte
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♦ Removal tool - 3450/3- ss c
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♦ Special wrench, long reach
pt
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♦ Drip tray - V.A.G 1306-
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- V.A.G 1331-
spec
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200 Nm) - V.A.G 1332-
rrectness of i
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♦ Spring-type clip pliers - VAS 5024A-
Prerequisite
• The engine must be no more than warm to touch.
1. Cylinder head 39
Removing
Note
♦ All cable ties which are opened or cut through when cylinder
head is removed must be replaced in the same position when
cylinder head is installed.
♦ Note safety precautions before
swa
gen starting installation
AG. Volkswagen AG
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⇒ page 3 . yV
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♦ Observe rules forho cleanliness ⇒ page 7 .
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tions:
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spec
es, in part or in w
t to the co
sitions.
rrectness of i
hot components.
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– Check whether a coded radio is fitted. In this case, obtain anti-

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

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ate
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WARNING
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en
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Hot steam may escape when expansion tank is opened. Place
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cloth over cap and open with caution.
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– Open and close coolant expansion tank cap to release pres‐
AG.
sure in cooling system.

– Drain coolant ⇒ page 89 .
WARNING


– Pull off breather hose -1- (with white mark).
Note
To do this, press down release button on hose coupling.
– Seal lines so that fuel system is not contaminated by dirt.

Observe rules for cleanliness ⇒ page 7 .
hose ⇒ page 110 .
– Pull pressure line off combination valve and unclip from guide.
filter bracket.
– Unclip Lambda probe before catalytic converter connector
-1- from retainer.
– Pull connector -2- off throttle valve control module.
– Pull connector -6- off exhaust gas recirculation valve.
– Pull off vacuum hose (on side of upper part of intake manifold).
– Pull off vacuum hose to brake
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– Remove exhaust d bgas recirculation connecting pipe. Unscrew
y ua
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upper part ofthointake manifold from intake manifold support.
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Then remove
s au intake manifold upper part ⇒ page 111 . ac
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Note
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Block off intake ports in lower part of cylinder head with a clean
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cloth.
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spec
– Pull all coolant hoses off cylinder head.

es, in part or in w
t to the co
– Pull off or disconnect all other electrical cables and hoses as

necessary from cylinder head and lay to one side.
rrectness of i
– Pull pressure line -arrow- off combination valve.

l purpos
– Release pressure line from retainers.

nform
ercia
– Remove front exhaust pipe ⇒ page 127 .

m
– Remove upper toothed belt guard.

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– Remove tensioning element for poly V-belt.

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1. Cylinder head 41
– Set camshaft pulley to marking for TDC No. 1 cylinder by turn‐

ing crankshaft. Marking on camshaft pulley must align with
arrow on cylinder head cover.
– Release tensioning roller and remove toothed belt from cam‐
shaft toothed belt pulley.
– Turn crankshaft back slightly.
– Remove cylinder head cover.
– Loosen cylinder head bolts using special wrench, long reach

- 3452- in sequence given and then remove completely.
– Carefully remove cylinder head.
Note
The cylinder head must be guided carefully to prevent damage.
Installing
Note
♦ There must be no oil or coolant in the cylinder head bolt pock‐

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♦ Do not remove new cylinder head ris
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♦ Handle new gasket very carefully. Damage will cause leakage.
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♦ Renew cylinder head bolts.

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– Also prevent dirt and emery cloth particles from getting into
wit
coolant.
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hole
– Carefully clean sealing surfaces of cylinder head and cylinder

spec
block. Ensure that surfaces are not scored or scratched (if

es, in part or in w
t to the co
abrasive paper is used, grade must not be less than 100).

– Carefully remove metal particles, emery residue and cloths.
rrectness of i
– If crankshaft is turned in the meantime, position piston of No.

1 cylinder at TDC and turn crankshaft back slightly.
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– To centre, screw guide pins - 3450/2A- into outer threaded

holes on exhaust side.
Note
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The tolerance of the centring holes Vois
lks reduced in the upper area.
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Therefore, check that the guide ise pins can be removed upwards
d ara
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before fitting the cylinder uhead.
thor
If necessary, grind down the eo
knurled surface of the guide
ss a pin slightly. ra
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– Place new cylinder head gasket in position. Inscription (Part
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– Fit cylinder head, screw in 8 remaining cylinder head bolts and
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tighten by hand.
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hole
– Remove guide pins with removal tool - 3450/3- through bolt
spec
es, in part or in w
holes. To do this, turn removal tool anti-clockwise until pins are
t to the co
free.
– Now insert both remaining cylinder head bolts and tighten
these also hand-tight.
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– Tighten cylinder head bolts in tightening sequence as follows:

Stage Tighten
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– Install upper part of intake manifold.

– Install toothed belt and adjust valve timing ⇒ page 47 .
– Fill with new coolant ⇒ page 89 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 37
♦ ⇒ “2.1 Assembly overview - intake manifold”, page 111
♦ ⇒ “2.1 Assembly overview - emission control”, page 127
1.3 Checking compression
1. Cylinder head 43
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– Pull fuses SD 22 and SD 25 out of fuse holder in engine com‐

partment.
Note
Removing the fuses interrupts voltage supply to the injectors and

the ignition coils.

hose ⇒ page 110 .
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Seal hose ends with, for example, hose clamps up to 25 mm
- 3094- .
filter bracket.
-1- from retainer.
– Pull off vacuum hose to brake servo.
– Remove connecting pipe for exhaust gas recirculation and un‐
bolt upper part of intake manifold from intake manifold support.
Then remove upper part of intake manifold ⇒ page 111 .
– Pull off spark plug connector using assembly tool - T10029- .
– Unscrew spark plugs with spark plug spanner - 3122 B- .
– Check compression using compression tester - V.A.G 1763-
and adapter - V.A.G 1763/6- .
Note
Using compression tester ⇒ operating instructions .
– Have starter actuated by a second mechanic.

– Operate starter until tester shows no w further
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Rep. gr.15 - Cylinder head, valve gear
2 Toothed belt drive

⇒ “2.1 Removing and installing toothed belt”, page 47
⇒ “2.2 Removing and installing toothed belt, 2010 ►”, page 51
⇒ “2.3 Checking semi-automatic toothed belt tensioning roller”,
page 57
2.1 Removing and installing toothed belt
♦ Support bracket - V.A.G

10-222A- with adapter -
10-222A/23-
- V.A.G 1331-
200 Nm) - V.A.G 1332-
♦ 2-hole pin wrench -
T10020-
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♦ Note safety precautions before starting installation work
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♦ Observe rules for cleanliness ⇒ page 7 .
– Remove plenum chamber bulkhead on left and right ⇒ Gen‐

eral body repairs, exterior; Rep. gr. 50 ; Plenum chamber
bulkhead .
2. Toothed belt drive 47

– Unbolt right cover and battery cover from lock carrier ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 63 ; Front bumper .
– Remove throttle valve control module/air mass meter con‐
necting hose ⇒ page 110 .
– Unbolt power-assisted steering vane pump from ancillaries
bracket and put to one side; hoses remain connected: ⇒ Run‐
ning gear, axles, steering; Rep. gr. 48 ; Vane pump .
– Remove poly V-belt tensioning element ⇒ Item 5 (page 18) .
arrow on cylinder head cover -arrows-.
– Unclip cover cap on suspension strut.
– Fit adapter - 10-222A/23- -1- on foremost suspension strut

turret and on lock carrier -arrows-.
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– Bolt support bracket - V.A.G 10-222A- to respective adapter -

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– Remove securing bolts from assembly mounting to engine

bracket and assembly mounting to body -arrows- and com‐
pletely remove assembly mounting.
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket - V.A.G 10-222A- !
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
– Unbolt engine bracket from cylinder block -arrows- and re‐

move.
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Prerequisites
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• The pistons must not be positioned at TDC.

rrectness of i
• Before tensioning toothed belt, turn tensioning roller on ec‐

centric to stop five times in both directions using 2-hole pin
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When camshaft is turned, crankshaft must not be at TDC. Valves/

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– Align mark on camshaft toothed belt pulley with mark on cyl‐

inder head cover.
– Place toothed belt on crankshaft pulley and coolant pump (ob‐
serve direction of rotation).
– Install lower and middle toothed belt guard and the vibration
damper/belt pulley ⇒ page 19 .
– Set engine to TDC No. 1 cylinder.

– Fit toothed belt to tensioning roller and camshaft toothed belt
pulley.
– Before tensioning toothed belt, turn tensioning roller on ec‐
wrench - T10020- .
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– Turn crankshaft 2 full revolutions in engine direction of rotation
until engine is again at TDC No. 1 cylinder. It is important that
the last 45° rotation (1/8 turn) is performed without interruption.
rrectness of i
– Check tension of toothed belt again, specification: pointer and
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notch align with each other.
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– Using securing bolts -arrows-, mount engine bracket on cylin‐

der block and tighten securing bolts.
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– Install assembly mounting between engine and body and tight‐

en new securing bolts.
– Bolt engine assembly mounting to engine bracket. Bring con‐
tact surfaces together using support bracket - V.A.G 10-222A-
and tighten threaded connections.
steering .
– Install poly V-belt tensioning element.
– Install upper toothed belt guard.
– Install throttle valve module/air mass meter connecting hose
⇒ page 110 .
– Install plenum chamber bulkhead on left and right ⇒ General
body repairs, exterior; Rep. gr. 50 ; Bulkhead; Assembly over‐
view - plenum chamber bulkhead .
– Install right cover and battery cover on lock carrier: ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper .
Specified torques
19
2.2 Removing and installing toothed belt, 2010 ►

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equipment required
♦ Support bracket - 10 - 222
A-
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /16-
♦ Adapter - 10 - 222 A /23-
♦ Torque wrench - V.A.G
1331-
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eral body repairs, exterior; Rep. gr. 63 ; Front bumper .
agen
Prote AG.

– Remove poly V-belt tensioning element ⇒ Item 5 (page 18) .
– Unclip cover cap on suspension strut.
– Bolt support bracket - V.A.G 10-222A- to respective adapter -
10-222A/23-

– Position support bracket - 10 222 A- together with adapter -

10 - 222 A /23- and adapter - 10 - 222 A /23-1- as shown.
– Attach engine to lifting eye on cylinder head, using additional

hook - 10-222A/2- .
– Remove securing bolts from assembly mounting to Gengine

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– Unbolt engine bracket from cylinder block -arrows- and re‐

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AG.
– Remove vibration damper/belt pulley.

– Remove centre and lower toothed belt guards.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
Installing
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When camshaft is turned, crankshaft must not be at TDC. Danger
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t to the co
– Align mark on camshaft toothed belt pulley with mark on cyl‐
rrectne
inder head cover.
– Place toothed belt on crankshaft pulley and coolant pump (ob‐ s
serve direction of rotation).
s o
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– Install lower and middle toothed belt guard and the vibration
form
mer
damper/belt pulley ⇒ page 19 .

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– Now fit toothed belt to tensioning roller and camshaft toothed cted agen
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belt pulley.
– Before tensioning toothed belt, turn tensioning roller on ec‐
centric to stop five times in both directions using pin wrench -
T10020- .

– Tension toothed belt. To do this, turn 2-hole pin wrench -

T10020- on eccentric to left in -direction of arrow- to stop.
– Then reduce tension on toothed belt until notch -1- and indi‐
cator -2- align (use mirror).
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10-222A- and tighten ⇒ page 17 .
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– Install upper toothed belt guard.
– Install throttle valve control module/air mass meter connecting
hose ⇒ page 110 .
view - plenum chamber bulkhead .
– Install right cover and battery cover on lock carrier: ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper .
Specified torques
19

2.3 Checking semi-automatic toothed belt

tensioning roller swagen AG. Volkswagen AG does
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3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 58
⇒ “3.2 Measuring axial play of camshaft”, page 61
⇒ “3.3 Removing and installing camshaft oil seal”, page 61
⇒ “3.4 Removing and installing camshaft”, page 63
⇒ “3.5 Removing and installing valve stem seals”, page 66
⇒ “3.6 Checking hydraulic compensation elements”, page 68
3.1 Assembly overview - valve gear
Note
♦ Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be
used further without reducing service life, provided the cracks
do not exceed a maximum of 0.3 mm in width, or when no more
than the first 4 turns of the spark plug thread are cracked.
♦ When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Valves will otherwise con‐
tact piston. Finally turn crankshaft over twice.
AG. Volkswagen AG d
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AG.
1 - Bolt
❑ 100 Nm
2 - Camshaft pulley
❑ With rotor for Hall send‐
er.
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3 - Seal Vol
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4 - Woodruff key
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❑ Check for secure seat‐
ing.
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5 - Nut
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❑ 20 Nm
6 - Bearing cap
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face of bearing cap 1
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ance with Plastigage;
wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm
❑ Identification and valve timing ⇒ page 60 .
❑ Checking axial clearance ⇒ page 61 .
8 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface.
❑ Set down with contact surface facing downwards.
❑ Before installing, check camshaft axial clearance ⇒ page 61 .
9 - Cotters
10 - Valve spring plate
❑ Top.
11 - Valve spring
❑ Cylinder head removed: Remove and install using valve spring compressor - 2037- .
12 - Valve stem seal
❑ Renew. ⇒ page 66 .
3. Valve gear 59
13 - Valve guide
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❑ Valve dimensions ⇒ page 72
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❑ Do not rework, only lapping-in is permitted.
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Reworking cylinder head sealing surface
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Cylinder head reworking dimension: a = at least 132.8 mm
rrectness of i
Note
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If sealing surface is reworked, valves must be set deeper by the

same distance.
nform
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Installation position of camshaft bearing caps

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Camshaft identification, valve timing

Identification
♦ Cam base diameter: a = 34 mm
♦ Can be identified by numbers and letters stamped between
inlet and exhaust cams.
No. 1 cylinder -arrow 1- 50 P
Valve timing at 1 mm opening lift
Inlet opens ATDC 6.2°
Inlet closes ABDC 42.45°
Exhaust opens BBDC 35.8°
Exhaust closes BTDC 0.45°

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auth 4-cylinder injection engine or (2.0 l engine) - Edition 12.2015
ac
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3.2 Measuring axial play of camshaft
un
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♦ Universal dial gauge bracket - VW 387-
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♦ Dial gauge
hole
spec
es, in part or in w
Checking camshaft axial clearance
t to the co
Test procedure
– Check with bucket tappets removed and first and last bearing
rrectness of i
caps fitted.
l purpos
– Wear limit: max. 0.15 mm
nform
mercia
a
3.3 Removing and installing camshaft oil seal
com
tion in
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equipment required
fo
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♦ Oil seal extractor - 2085- t. Cop py
rig
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♦ Counterhold - 3415- with yri
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pins - 3415/1-
c by lksw
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- V.A.G 1331-
200 Nm) - V.A.G 1332-
Removing
hose ⇒ page 110 .
3. Valve gear 61

– Release tensioning roller and remove toothed belt from cam‐
shaft toothed belt pulley.
– Remove camshaft. pulley. When loosening camshaft pulley

bolt, hold with counterhold - 3415- with pin - 3415/1- (first re‐
move bolts -arrows-).
– Remove Woodruff key from camshaft.
– Screw camshaft toothed belt pulley securing bolt into camshaft
to stop.
– Unscrew inner part of oil seal extractor - 2085- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible. swa
gen AG
. Volkswagen AG
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– Loosen knurled screw sand d b turn inner part against camshaft uara
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until oil seal is pulled
thorout. eo
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– Clamp flats of oilssseal extractor in vice. Remove oil seal using c
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pliers.
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Installing
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Note
es, in part or in w
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The oil seal sealing lip must not be additionally oiled or greased.
rrectness of i
– Remove oil residues from crankshaft journal with a clean cloth.

l purpos
– Position seal using guide sleeve - T10071/1- and press in onto

stop using assembly tool - T10071- and bolt - T10071/2- .
nform
ercia
– Insert Woodruff key in camshaft.

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Cop py
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– Install camshaft pulley. When tightening camshaft pulley bolt,

hold with counterhold - 3415- with pin - 3415/1- (first remove
bolts -arrows-).
Note

Install toothed belt and adjust the valve timing ⇒ page 47 .

Specified torques
♦ ⇒ “3.1 Assembly overview - valve gear”, page 58
19 G. Volkswage nA n AG d
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♦ ⇒ “1.1 Assembly overviewy V-ocylinder
lks head”, page 37 not
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3.4 Removing and installing camshaft ss
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equipment required
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with pins - 3415/1-
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200 Nm) - V.A.G 1332-
rrectness of i
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3. Valve gear 63
Not illustrated
Sealant - AMV 174 004 01-
Removing
hose ⇒ page 110 .
- 3094- .
filter bracket.
– Pull connecting hose to solenoid valve 1 - N80- off line -5-. n AG. Volkswagen AG do
swage es n
– Open retainers and lay complete hose guide -9- to side. by Volk ot g
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or
-1- from retainer. ss
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es, in part or in w
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rrectness of i
Note
l purpos
cloth.
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t
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– Release tensioning roller and remove toothed belt from cam‐ Cop py
t. rig
shaft toothed belt pulley. opyri
gh by
Vo
ht
c lksw
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Prote AG.

– Remove camshaft. pulley. When loosening camshaft pulley

bolt, hold with counterhold - 3415- with pin - 3415/1- (first re‐
. Volkswagen AG
move bolts -arrows-).swa
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– Remove Woodruff
se
db key from camshaft. ara
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– Removeaucylinder
t head cover. ra
c
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– First remove bearing caps 5, 1 and 3. Loosen bearing caps 2
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and 4 alternately and diagonally.
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Installing
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Prerequisite
spec
es, in part or in w
• The pistons must not be positioned at TDC.
t to the co
rrectness of i
Note
l purpos
♦ When camshaft is installed, No. 1 cylinder cams must point

upwards.
nform
ercia
♦ When installing bearing cap, bear in mind central offset of hole.

m
at
Before installing, fit bearing caps and determine installation
om
io
positions.
n
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– Oil running surfaces of the camshaft.

p
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– Insert camshaft.
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– Tighten bearing caps 2 and 4 alternately and diagonally.
C py
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– Lightly coat contact surface of bearing cap 1 with sealant -
op Vo
by c lksw
cted
AMV 174 004 01- .
agen
Prote AG.
– Install bearing caps 3, 1 and 5 and also tighten.

– Install cylinder head cover.
– Install camshaft seal ⇒ page 61 .
– Insert Woodruff key in camshaft.
– Install camshaft pulley. When tightening camshaft pulley bolt,

hold with counterhold - 3415- with pin - 3415/1- (first remove
bolts -arrows-).
Note

– Install upper part of intake manifold.

– Check coolant level and top up if necessary ⇒ page 89 .
– Install toothed belt and adjust the valve timing ⇒ page 47 .
Specified torques
19
3. Valve gear 65
3.5 Removing and installing valve stem seals

equipment required
♦ Valve assembly device -
2036-
♦ Puller - 3047 A-
♦ Spark plug socket and ex‐
tension - 3122 B-
♦ Fitting tool - 3129-
♦ Puller - T10029-
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
AG. Volkswagen AG d
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t to the co
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fo
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Cop py
ht. rig
rig ht
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66
co Vo
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agen
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♦ Valve lever - VW 541/1A-

♦ Thrust piece - VW 541/5-
♦ Pressure hose - VW 653/3-
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Removing
hole
spec
(With cylinder head installed)
es, in part or in w
t to the co
– Remove camshaft ⇒ page 63 .
– Remove tappets and place to one side with face downwards.
rrectness of i
When doing this, ensure that tappets are not interchanged.

l purpos
– Pull off spark plug connector using puller - T10029- .

– Remove spark plugs using spark plug socket and extension -
nform
ercia
3122 B- .
m
– Set piston of respective cylinder to “bottom dead centre”.

com
tion in
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3. Valve gear 67
– Fit valve assembly tool - 2036- and adjust mountings to height

of studs.
– Screw pressure hose - VW 653/3- into spark plug thread.
– Connect pressure hose to air pressure source of at least 6 bar.
– Remove valve springs using valve lever - VW 541/1 A- and
press tool - VW 541/5- .
Note
Tight valve cotters can be loosened by tapping lightly on assem‐

bly lever.
– Pull off valve stem seals using puller - 3047A- .

Installing
– Place the plastic sleeve -A- supplied on the respective valve

stem. This will prevent the new valve stem seal -B- being
damaged.
– Place new valve stem seal in fitting tool - 3129- . n AG. Volkswagen AG do
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– Oil valve stem seal sealing lip and press carefully byV
o onto the
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valve guide. ir se
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Specified torques ss
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h re
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spec
3.6 Checking hydraulic compensation ele‐

t to the co
ments
rrectne
♦ Feeler gauges
ss
♦ Wooden/plastic wedge
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
♦ Renew defective bucket tappets complete (cannot be adjusted

thi
te
sd
or repaired).
iva
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pr
cum
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♦ Irregular valve noise during starting is normal.

fo
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t.
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Cop py
Procedure
t. rig
gh ht
pyri by
Vo
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– Start engine and run until the radiator fan has switched on
c by lksw
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once
Prote AG.

– Increase speed for 2 minutes to approx. 2500 rpm.

If hydraulic bucket tappets are still noisy, locate defective tappet
(s) as follows:
hose ⇒ page 110 .
. Volkswagen AG
wa module. gen AG does
– Pull coolant hoses -3- and -4- off throttle valve Vcontrol
olks not
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Seal hose ends with, for example, hose clamps ed
by up to 25 mm ara
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- 3094- . tho
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– Pull crankcase breather hose -7- offss cylinder head cover. c
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un
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filter bracket.
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es, in part or in w
-1- from retainer.
t to the co
rrectness of i
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nform
ercia

m
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tio
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Note
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Block off intake ports in lower part of cylinder head with a clean Cop py
cloth.
ht. rig
rig ht
py by
co Vo
by lksw
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– Remove upper toothed belt guard. Prote AG.
– Remove cylinder head cover.

– Rotate crankshaft clockwise until cam of tappet to be checked
is pointing upwards.
– Determine clearance between cam and bucket tappet.
– If play exceeds 0.2 mm, renew bucket tappet. If play is less
than 0.1 mm or there is no play, continue with check as follows:
– Push bucket tappet down lightly with a wooden or plastic

wedge. If when bucket tappet is pushed down, a 0.2 mm feeler
gauge can be pushed between camshaft and bucket tappet,
bucket tappet must be renewed.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. The hydraulic compensation
elements must settle (otherwise valves will strike pistons).
– Check coolant level and top up if necessary ⇒ page 89 .

Specified torques
3. Valve gear 69
4 Inlet and exhaust valves

⇒ “4.1 Reworking valve seats”, page 70
⇒ “4.2 Checking valve guides”, page 71
⇒ “4.3 Valve dimensions”, page 72
4.1 Reworking valve seats

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♦ Depth gauge
or
ise tee
h
ut or
♦ Valve seat
ss
a
refacing tool ac
ce
le
un
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Note
erm
ab
ility
ot p
♦ When repairing engines with leaking valves, it is not sufficient
wit
is n
to rework or renew valve seats and valves. There is also a
h re
ole,
requirement to check the valve guides for wear. This is par‐
spec
ticularly important on high mileage engines.
t to the co
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
rrectne
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
s
guaranteed and the cylinder head must be renewed.
s o
cial p
f inform
The max. permissible reworking dimension is calculated as fol‐

mer
lows:
atio
om
n
c
– Insert valve and press firmly against seat.

i
or
n thi
te
sd
iva
o
pr
cum
r
Note
fo
en
ng
t.
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op py
If the valve is to be renewed as part of a repair, use a new valve
. C rig
ht ht
for the calculation.
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Measure distance -a- between end of valve stem and upper
edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension: inlet valve 33.8 mm, exhaust valve 34.1 mm
Measured distance -a- minus minimum dimension = maximum
permissible reworking dimension.
Example:
Measured distance -a- 35.1 mm
— Minimum dimension 34.1 mm
= max. perm. rework dimension 3) 1.0 mm
3) The max. permissible reworking dimension is shown as dimension “b” in the
illustrations for reworking valve seats.

Reworking inlet valve seat

Di‐ Inlet valve seat
men‐
sion
Diam‐ mm 39.2
eter a
b mm Max. permissible reworking dimension
c mm 1.8 ... 2.2
Z Lower edge of cylinder head
45° Valve seat angle
30° Upper correction angle
Reworking exhaust valve seat

Di‐ Exhaust valve seat
men‐
sion
Diam‐ mm 32.4
eter a
Diam‐ mm Max. permissible reworking dimension
eter b
c mm 2.2 ... 2.6n AG. Volkswagen AG do
lkswage es n
Z Lower edge by V of cylinder head
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ir se
45° tho Valve seat angle tee
or
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30° ss Upper correction angle
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un
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itte
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Note
erm
ab
ility
ot p
wit
Exhaust valve seat inserts are equipped with an additional narrow

is n
h re
section. When reworking, always ensure that the radius of the

ole,
spec
constriction is not damaged.

t to the co
4.2 Checking valve guides

rrectne

♦ Universal dial gauge bracket - VW 387-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Dial gauge
4. Inlet and exhaust valves 71

– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,n AG. Volkswagen A
only use inlet valve in inlet guide and exhaust valve inolexhaust
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guide. d by V ua
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ris tee
– Determine rock. Wear limit: inlet valve guide: th1.0
o mm, exhaust
or
au
valve guide: 1.3 mm ss ac
ce
le
un
– Cylinder head must be renewed if rock exceeds wear limit.
pt
an
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itte
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ab
pe
ility
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es, in part or in w
4.3 Valve dimensions
t to the co
Valve dimensions
rrectness of i
l purpos
Note
nform
Valves must not be reworked. Only lapping-in is permitted.
mercia
a
com
tio
Dimension Inlet valve Exhaust valve
n in
r
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thi
Diameter a mm 39.5 ± 0.15 32.9 ± 0.15
s
iva
do
Diameter b mm 6.98 ± 0.007 6.96 ± 0.007
r
rp
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c mm 91.85 91.15
n
t.
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α ∠° 45 45
C py
ht. rig
rig ht
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by lksw
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17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 73
⇒ “1.2 Removing and installing oil sump”, page 74
A n AG d G. Volkswage
agen
⇒ “1.3 Removing and installing
Volksw oil pump”, page 77 es not
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db ran
⇒ “1.4 Engine oil”, page
or
ise 77 tee
th or
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1.1 Assembly overview - sump/oil pump
ac
ss
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1 - Bolt
erm
ab
ility
ot p
❑ 15 Nm
wit
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2 - Retainer
hole
spec
3 - Bolt
es, in part or in w
t to the co
❑ 40 Nm
4 - Securing bolt with pressure
relief valve
rrectness of i
❑ Opening pressure: 1.3
l purpos
… 1.6 bar.
❑ 27 Nm
nform
ercia
5 - Oil spray jet

m
at
om
❑ For piston cooling.

ion
c
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or
6 - Oil dipstick
his
ate
do
riv
❑ Lugs of oil dipstick and

p
cum
or
guide tube must align

f
en
g
above one another.

n
t.
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op py
❑ The oil level must not be
t. C rig
gh ht
yri
above the max. mark! p by
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by c lksw
❑ Markings ⇒ page 77 .
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Prote AG.
7 - Bolt
❑ 20 Nm
8 - Guide tube
❑ with funnel
9 - O-ring
10 - Dowel sleeves
11 - O-ring
12 - Bolt
❑ 15 Nm
13 - Suction line
❑ Clean strainer if soiled.
14 - Baffle plate
15 - Bolt
❑ 15 Nm
1. Sump, oil pump 73

16 - Bolt
❑ 15 Nm
17 - Oil sump
❑ Clean sealing surface before fitting.
❑ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
18 - Oil drain plug
❑ 30 Nm lkswage es n
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19 - Bolt ir se
d b ran
tee
o
❑ 10 Nm auth or
ac
ss
20 - Oil level/oil temperature sender - G266-
ce
e
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pt
du
an
21 - Seal
itte
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ility
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wit
22 - Bolt
, is n
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hole
❑ 40 Nm
spec
es, in part or in w
23 - Sealing flange
t to the co
❑ With seal.
❑ Must seat on dowel sleeves.
rrectness of i
❑ Insert with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
l purpos
❑ Do not additionally oil or grease the oil seal sealing lip.

❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
nf
ercia
❑ Renewing crankshaft oil seal on belt pulley end ⇒ page 25 .
orm
m
atio
om
n in
c
24 - Chain tensioner with tensioning plate

or
thi
te
sd
a
❑ When installing, pretension spring and fit.

iv
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cu
❑ 15 Nm
o
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t.
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25 - Chain t. Cop py
rig
gh ht
26 - Bolt yri
p by
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by lksw
❑ Renew after removing cted agen
Prote AG.
❑ 20 Nm + 90°
27 - Sprocket
28 - Oil pump
❑ With 12 bar pressure relief valve.
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
1.2 Removing and installing oil sump

74 Rep. gr.17 - Lubrication

♦ Jointed wrench 10 mm - 3185-
♦ Allen key, long reach 5 mm - T10058-
♦ Hand drill with plastic brush attachment

♦ Eye protection
♦ Flat scraper
♦ Silicone sealant ⇒ Electronic Parts GCatalogue
. Volkswagen(ETKA) A AG do
agen es n
Removing olksw ot g
V
d by ua
ran
e
– Remove noise insulation
horis
⇒ General body repairs, exterior; tee
Rep. gr. 66 ; Body
aut - front; Noise insulation . or
ac
ss
ce
e
– Drain off engine oil.

nl
pt
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an
itte
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erm
ab
Note
ility
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wit
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Observe environmental regulations for disposal.

hole
spec
es, in part or in w
– Pull 3-pin connector off oil level and oil temperature sender -
t to the co
G266- . Unclip line from sump.

– Loosen or tighten sump bolts using 10 mm jointed wrench -
rrectness of i
3185- . Loosen and tighten only flywheel-end bolts using Allen

key, long reach - T10058- .
l purpos
– Remove sump. Loosen sump with light blows of a rubber

headed hammer if necessary.
nform
ercia
– Remove sealant residues from cylinder block with a flat scra‐

m
at
om
per .
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
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Prote AG.
1. Sump, oil pump 75

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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Transporter 2004 ➤ , Transporter
ut
ho 2010 ➤ eo
ra
a
4-cylinder injection engine
ss (2.0 l engine) - Edition 12.2015 c
ce
le
un
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– Remove sealant residues on sump with rotating brush, e.g.
an
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hand drill with plastic brush insert (wear safety goggles).
erm
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– Clean sealing surfaces. They must be free of oil and grease.
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t to the co
Note
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♦ Observe use-by-date of sealant.
ss
♦ The sump must be installed within 5 minutes of applying sili‐
o
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cone sealing compound.
inform
mer
♦ The sealant bead must not be thicker, otherwise excess seal‐
atio
m
ing compound will enter the oil sump and may block the oil
o
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suction line strainer.
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♦ The sump must be flush with cylinder block.

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♦ Let sealing compound dry for approx. 30 minutes after instal‐
en
ng
t.
ling oil sump. Only then fill with engine oil.
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– Cut off nozzle on tube of silicone sealant at front marking (di‐
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ameter of nozzle approx. 3 mm).
AG.
– Apply silicone sealant to clean sealing surface of sump as

shown. Sealant bead must be:
♦ 2 ... 3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
– Apply silicone sealant to clean sealing surface of sump, as

shown in diagram. (The figure shows the position of the seal‐
ant bead on the cylinder block.)
– Sealant bead must be applied with extreme care in vicinity of
-arrows-.
– Position oil sump immediately and tighten bolts as follows:
1 - Tighten all sump/cylinder block bolts only very lightly and di‐
agonally.
2 - Tighten sump/gearbox bolts lightly.
3 - Further tighten all sump/cylinder block bolts lightly using di‐
agonal sequence.
4 - Tighten bolts between sump and gearbox.
5 - Tighten diagonally all bolts between sump and cylinder block.
Specified torques
Bolts between sump and gear‐ 45 Nm
box.

1.3 Removing and installing oil pump

Removing
– Remove sump ⇒ page 74 .
– Remove baffle plate ⇒ Item 14 (page 73) .
– Remove bolt -2-.
– Remove chain sprocket from the oil-pump shaft.
– Remove bolts -1- and -5- and remove oil pump.
Installing
– Insert top dowel sleeves ⇒ Item 10 (page 73) on the oil pump.
The chain sprocket can be fitted in only one position on oil pump
shaft.
– Install sump . ⇒ page 74
Specified torques
Bolts between sump and gear‐ 45 Nm
box.
1.4 Engine oil

Oil capacities:
With oil filter 5.0 l
Engine oil specifications:
Refer to Maintenance Manual for all current data reference oil
specifications ⇒ Maintenance w; aBooklet
gen AG 18.1 . n AG doe
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Markings on oil dipstick
ed
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1 - Min. mark ho eo
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2 - Max. mark
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a - Area of min. mark: top-up with max. 0.5 l of engine oil!

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b - Oil level in middle range: Can be replenished with engine oil.

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c - Area of max. mark: do not add engine oil!

h re
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spec
es, in part or in w
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77
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Prote AG.
1. Sump, oil pump
2 Oil filter, oil pressure switch

⇒ “2.1 Assembly overview - oil filter/oil pressure switch”,
page 78
⇒ “2.2 Checking oil pressure and oil pressure switch”,
page 79
⇒ “2.3 Measure oil consumption”, page 81
2.1 Assembly overview - oil filter/oil pressure switch
1 - Seal
❑ Push on to collar of pipe.
2 - Connecting pipe
❑ For crankcase ventila‐
tion.
3 - Retaining clip
4 - Bolt
❑ 20 Nm
5 - Bracket
6 - Plug AG. Volkswagen AG d
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❑ 15 Nm olksw not
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❑ If seal is leaking, nip ss a c
open and renew.
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8 - Oil pressure switch - F1-

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❑ 0.9 bar
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❑ 25 Nm
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9 - Seal
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❑ If seal is leaking, nip
open and renew.
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10 - Oil filter bracket
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❑ With pressed-in non-re‐

turn valve.
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11 - Bolt
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❑ Fit into lugs on engine oil cooler.

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❑ Coat contact surfaces to oil filter bracket outside the seal with sealing paste - AMV 188 100 02- . co Vo
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❑ Ensure clearance to adjacent components.
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❑ See note ⇒ page 78 .

14 - Nut
❑ 25 Nm
15 - Oil filter
❑ Loosen with strap wrench.

❑ Tighten by hand.
❑ Observe installation instructions on oil filter.
16 - Plug
❑ 40 Nm
17 - Seal
❑ Captive on ⇒ Item 16 (page 79)
18 - Spring
❑ For pressure relief valve, approx. 4 bar.
19 - Piston
❑ For pressure relief valve, approx. 4 bar.
20 - Gasket
21 - Bolt
❑ 10 Nm
2.2 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester -
V.A.G 1342-
♦ Voltage tester - AG. Volkswagen AG d
V.A.G 1527B- lksw
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♦ Auxiliary measuring
rise set -
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V.A.G 1594C- utho eo
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s
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spec
es, in part or in w
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tion in
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2. Oil filter, oil pressure switch 79

Test prerequisites
• Engine oil level OK.
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• Engine oil temperature at least 80°C (radiator fan must have Volkswa not
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Procedure aut ra
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Functional check and repair of the optical and acoustic oil pres‐
ot
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sure warning: ⇒ Current flow diagrams, Electrical fault finding and
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Fitting locations
hole
spec
es, in part or in w
– Unscrew plug -arrow- from cylinder head.
t to the co
Note
rrectness of i
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After the test has been complete, the plug must always be re‐
newed.
nform
mercia
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tion in
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Cop py
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– Screw sealing plug into tester as shown.

– Screw tester into cylinder head in place of sealing plug.
– Pull connector off oil pressure switch - F1- .
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- . LED must not light up.
– If LED lights up, replace oil pressure switch - F1- .
If LED does not light up:
– Start engine and increase speed: at 0.75 ... 1.05 bar, the LED
must light up; otherwise renew oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80°C, the oil pressure should be between 2.7…
4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If specification is not attained:
– Then check suction line strainer for dirt ⇒ Item 13 (page 73) .
Note
swage es n
Mechanical damage, e.g. to bearings, could also by be
Vo the cause for
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oil pressure being too low. ir se
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If no fault is found: s
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– Renew oil pump ⇒ page 77 .
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If the specification is exceeded:
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– If necessary, renew oil filter bracket with pressure relief valve.
spec
es, in part or in w
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 37 t to the co
rrectness of i
2.3 Measure oil consumption

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nf
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♦ Vehicle diagnostic tester

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Procedure
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– Pull handbrake on.

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– Manual gearbox: gear stick in neutral.

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– Automatic gearbox: move selector lever to position “N”.

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– Connect ⇒ Vehicle diagnostic tester.
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– Switch ignition on. cop Vo
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– Carry out program “oil consumption measurement” using
AG.
⇒ Vehicle diagnostic tester.
2. Oil filter, oil pressure switch 81

4-cylinder injection engine (2.0 l engine) -geEdition
n AG. Vol12.2015
kswagen AG
d wa oes
olks not
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19 – Cooling
ris nte
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1 Cooling system, coolant
du
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⇒ “1.1 Coolant hose schematic diagram”, page 82
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⇒ “1.2 Coolant hose schematic diagram, 2010 ►”, page 83
h re
hole
⇒ “1.3 Coolant hose schematic diagram for vehicles with an ad‐
spec
es, in part or in w
ditional heat exchanger, 2010 ►”, page 84
t to the co
⇒ “1.4 Coolant hose schematic diagram for vehicles with an ad‐
ditional heat exchanger in countries with hot to very hot climates,
2010 ►”, page 85
rrectness of i
⇒ “1.5 Coolant hose schematic diagram, vehicles with auxiliary
l purpos
heater, 2010 ►”, page 86

⇒ “1.6 Coolant hose schematic diagram for vehicles with addi‐
nform
ercia
tional heat exchanger and auxiliary heater, 2010 ►”, page 87

m
at
om
i
⇒ “1.7 Checking cooling system for leaks”, page 87
on
c
in t
or
⇒ “1.8 Draining and filling coolant”, page 89
his
ate
do
priv
c
1.1 Coolant hose schematic diagram
um
for
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Cop py
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1 - Heat exchanger for heater
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Prote AG.
2 - 2. Heat exchanger for heat‐
er unit
3 - Supplementary water heat‐
er (auxiliary heater or preheat‐
er)
❑ Depending on equip‐
ment.
4 - Circulation pump - V55-
❑ Fitting location
⇒ page 83
5 - Coolant expansion tank
6 - Engine oil cooler
7 - Radiator
8 - Coolant pump
9 - Cylinder head/cylinder
block
10 - Throttle valve control mod‐
ule - J338-
11 - Heater coolant shut-off
valve - N279-
❑ Only with auxiliary cool‐
ant heater
12 - Non-return valve
❑ Only with auxiliary cool‐
ant heater
❑ Note installation posi‐
tion.
82 Rep. gr.19 - Cooling

AG. Volkswagen AG d
agen
kswTransporter 2004 ➤ , Transporter 2010 ➤
oes
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V
4-cylinder ed b injection engine (2.0 l engine) - Edition
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ara 12.2015
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Location of circulation pump - V55- . ss au ra
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The circulation pump - V55- -2- is installed front left under the
un
pt
an
vehicle.
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1.2 Coolant hose schematic diagram, 2010 ►
nform
ercia

m
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unit
tion in
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2 - Expansion tank
thi
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4 - Radiator
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5 - Coolant pump
t. rig
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6 - Cylinder head
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⇒ page 84
ule - J338-
9 - Intake manifold
1. Cooling system, coolant 83

AG. Volkswagen AG d
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agen- Edition 12.2015 oes
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Location of circulation pump - V55-orinis engine
e
compartment tee
h
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ac
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nl
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
1.3 Coolant hose schematic diagram for vehicles with an additional heat ex‐
l purpos
changer, 2010 ►
nform
ercia

m
at
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unit
ion
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ate
er unit
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3 - Y-thermostat
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❑ Assembly overview Cop py
⇒ page 97 .
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4 - Expansion tank
6 - Radiator
7 - Coolant pump
8 - Cylinder head
⇒ page 85
ule - J338-
11 - Intake manifold

Location of circulation pump - V55- in engine compartment
AG. Volkswagen AG d
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1.4 Coolant hose schematic diagram for vehicles with an additional heat ex‐ ss c
ce
le
changer in countries with hot to very hot climates, 2010 ►

un
pt
an
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unit
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spec
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3 - Expansion tank
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5 - Radiator
ss
6 - Coolant pump
o
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7 - Cylinder head
mer
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c
❑ Fitting location i
or
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⇒ page 86
t
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valve - N279- Prote AG.
12 - Non-return valve
❑ Note installation posi‐
tion.

Location of circulation pump - V55- in engine compartment
1.5 Coolant hose schematic diagram, vehicles with auxiliary heater, 2010 ►

unit
2 - Auxiliary heater
❑ Location: on auxiliary
heater
4 - Expansion tank
6 - Radiator
AG. Volkswagen AG d
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7 - Coolant pump olksw not
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8 - Cylinder head orise nte
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9 - Throttle valve control mod‐ ss c
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ility
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valve - N279-
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Prote AG.

1.6 Coolant hose schematic diagram for vehicles with additional heat exchang‐
er and auxiliary heater, 2010 ►

unit
er unit
3 - Auxiliary heater
AG. Volkswagen AG d
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7 - Radiator
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8 - Coolant pump
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9 - Cylinder head
spec
t to the co
ule - J338-
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valve - N279-
ss o
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mer
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1.7 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-

♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-
AG. Volkswagen AG d
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Test prerequisite
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• Engine at operating temperature.
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WARNING
es, in part or in w
t to the co
sure.
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nf
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olksw
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– Open filler cap on coolant
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expansion tank. gu
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coolant expansion
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– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
un
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system tester - V.A.G 1274/8- .

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– Join connection piece - V.A.G 1274 B/1- to cooling system
ility
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tester - V.A.G 1274 B- using connecting hose supplied.
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– Using hand pump on tester, build up a pressure of approx. 1.0
spec
bar.
t to the co
DANGER!
rrectne
Risk of scalding! Before the cooling system tester - V.A.G 1274
B- is disconnected from the connecting hose or the connector
s
- V.A.G 1274 B/1- , reduction of the pressure is essential. To
s o
do this, press pressure relief valve on cooling system tester -
cial p
f in
V.A.G 1274 B- until pressure gauge displays value of »0«.
form
mer
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If pressure drops:
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– Find leaks and rectify.

iv
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pr
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Check pressure relief valve in cap.

t.
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t.
– Fit cooling system tester - V.A.G 1274 B- with adapter for
rig
gh ht
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cooling system tester - V.A.G 1274/9- on cap -1-. op Vo
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– Build up pressure using hand pump of cooling system tester.
AG.
• The pressure relief valve should open at a pressure of 1.6…

1.8 bar.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.
1.8 Draining and filling coolant


equipment required
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Hose clip pliers - VAS
6340-
♦ Cooling system charge unit
- VAS 6096-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
AG. Volkswagen AG d
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Draining
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WARNING
ion in
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thi

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fully to dissipate pressure. p by
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– Open filler cap on coolant expansion tank.


Transporter 2004 ►
– Remove radiator outlet coolant temperature sender - G83-
-arrow-. To do this, pull retaining clip out of radiator flange.
Transporter 2010 ►
– Pull retaining clip -2- towards the front.
– Detach water hose leading to engine -1- from water hose lead‐
ing to radiator -3-.
lkswage es n
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Continuation for all vehicles

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– In addition to draining coolant from engine, pull the coolant

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hose off the engine oil cooler -arrow-.

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Note
t to the co
Observe environmental regulations for disposal.

rrectness of i
Filling
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Note
♦ Only distilled water may be used for mixing with coolant addi‐
tives. The use of distilled water ensures optimum protection
against corrosion.
♦ The amount of water used in the coolant mixture has a great
influence on its effectiveness. Since water quality differs from
country to country and even region to region, it is necessary
to set a standard for the quality of water to be used. Distilled
water fulfils all requirements. For this reason, we recommend
using distilled water when mixing coolant for topping up or re‐
placing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic Parts Catalogue (ETKA) . Other coolant additives may AG. Volkswagen AG d
reduce corrosion protection substantially. The resulting dam‐ lksw
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age could lead to loss of coolant and subsequent severe Vo gu
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ut or
♦ The correct coolant solution ratio helps prevent damagessdue
a ac
to freezing and corrosion as well as scaling. Moreover, the
ce
e
nl
pt
boiling temperature is raised. Therefore, the cooling system
du
an
itte
must be filled all year round with coolant additive.
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ility
♦ Because of its higher boiling point, the coolant improves en‐
ot p
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gine reliability under heavy loads, particularly in countries with
, is n
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tropical climates.
hole
spec
♦ The refractometer - T10007A- must be used to determine the
es, in part or in w
t to the co
current anti-freeze value.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
rrectness of i
protection must be guaranteed down to at least -25°C.
l purpos
♦ Read off anti-freeze figures for respective replenished anti-

freeze.
nf
ercia
o
♦ The temperature read off the refractometer - T10007A- equa‐
rm
m
tes to the »ice flocculation point«. Flakes of ice may start
atio
m
forming in the coolant below this temperature.

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n in
or c
thi
♦ Do not reuse old coolant.
te
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♦ Use only a water/coolant additive mixture as a slip agent for
o
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coolant hoses. en
ng
t.
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Cop py
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Recommended mixture ratios:
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Frost protection Coolant additive Coolant ad‐ Distilled wa‐
agen
Prote AG.
to portion ditive 4) ter4)
-25°C 40% 2.9 l 4.2 l
-36°C 50% 3.55 l 3.55 l
4) The quantity of coolant can vary depending upon vehicle equipment.
Transporter 2004►
– Install coolant temperature sender at radiator outlet - G83- with
a new seal.
Transporter 2010►
– Attach coolant hose to radiator on lower right-hand side. The
quick-release connector should click into place.

Continuation for all vehicles

– Connect coolant hose -arrow- to engine oil cooler.
– Install lower engine cover panel.
– Fill tank of cooling system charge unit - VAS 6096- with at least
8 litres of pre-mixed coolant in correct mixture ratio.
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank -1-.
– Mount cooling system charge unit - VAS 6096- on 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).
AG. Volkswagen AG d
– Connect hose -4- to compressed air. lksw
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not
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• Pressure: 6 … 10 bar. rise
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ate
do
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for
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gh ht
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– Open valve -B-; turn lever in direction of flow to do this. AG. Volkswagen AG d
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• In cooling system, vacuum is generated by suction jet pump;ed b ara
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needle of gauge must move into green area. hor eo
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c
– In addition, open valve -A- briefly by turning lever in direction
ss
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le
of flow until expansion tank hose of cooling system charge unit
un
pt
an
- VAS 6096- fills with coolant.
d
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– Close valve -A- again.
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ility
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– Leave valve -B- open for a further 2 minutes.
, is n
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hole
• In cooling system, vacuum continues to be generated by suc‐
spec
tion jet pump; needle of gauge must remain in green area.
es, in part or in w
t to the co
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
rrectness of i
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
l purpos
• If the needle does not reach the green zone, repeat the proc‐
ess.
nform
ercia
• If vacuum drops, cooling system must be checked for leaks.

m
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tion in
– Pull off compressed air hose.
r
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– Open valve -A-.
iva
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• Vacuum in cooling system causes coolant to be extracted from
fo
en
ng
coolant expansion tank of cooling system charge unit -

t.
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op
VAS 6096- and the cooling system to be filled.
C py
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– Then install cooling system charge unit - VAS 6096- again on
op Vo
by c lksw
coolant expansion tank.
cted agen
Prote AG.
Without cooling system charge unit - VAS 6096- :

– Slowly fill with coolant up to “max. mark” on expansion tank.
With or without cooling system charge unit - VAS 6096-
– Fit expansion tank cap.
– Start engine and keep engine speed at approx. 2000 rpm for
about 3 minutes.
– Run engine until fan cuts in.
WARNING

sure.
– Check coolant level and top up if necessary. When the engine

is at normal operating temperature, the coolant level must be
at the “max.” mark and when the engine is cold, between the
“min.” and “max.” marks.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 95
⇒ “2.2 Assembly overview - Y thermostat”, page 97
⇒ “2.3 Removing and installing coolant pump”, page 98
⇒ “2.4 Removing and installing thermostat”, page 99
⇒ “2.5 Testing Y-thermostat”, page 101
2.1 Assembly overview - coolant pump, thermostat
1 - Return from heat exchanger

❑ Coolant hose schematic
diagram for Transporter
2004 ► ⇒ page 82 .
2010 ► ⇒ page 83 .
2 - Junction
3 - Return from 2nd. heat ex‐
changer
❑ Only if fitted with option‐
al equipment.
2004 ► ⇒ page 82 .
2010 ► ⇒ page 83 . AG. Volkswagen AG d
agen oes
olksw not
4 - Supply to supplementary d by V gu
ara
water heater (preheater) orise nte
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❑ Coolant hose schematic ss au ra
c
ce
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un
2004 ► ⇒ page 82 .
pt
an
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ab

ility
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2010 ► ⇒ page 83 .
wit
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5 - Return from supplementary

ole,
spec
water heater (preheater)


t to the co

2004 ► ⇒ page 82 .
rrectne

2010 ► ⇒ page 83 .
ss o
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6 - Union
inform
mer
7 - Bolt
atio
m
❑ 10 Nm
o
n
c
i
or
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8 - Bolt
te
sd
iva
❑ 40 Nm
pr
cum
r
fo
en
ng
9 - Coolant pipe
t.
yi Co
op py
❑ Coolant hose schematic diagram for Transporter 2004 ► ⇒ page 82 . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
95
AG.
2. Coolant pump, regulation of cooling system
wage es n
Transporter 2004 ➤ , Transporter yV
o 2010 ➤
lks ot g
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4-cylinder injection engine ir se(2.0 l engine) - Edition 12.2015
d ran
tee
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❑ Coolant hose schematic ss diagram for Transporter 2010 ► ⇒ page 83 .
a ac
ce
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nl
10 - O-ring
pt
du
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ility
11 - To lower coolant expansion tank ot p
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❑ Coolant hose schematic diagram for Transporter 2004 ► ⇒ page 82 .
h re
hole
spec
es, in part or in w
12 - To bottom of radiator
t to the co
rrectness of i
l purpos
14 - Bolt
nf
ercia
❑ 15 Nm
orm
m
15 - Union
atio
om
n in
c
16 - O-ring
or
thi
te
sd
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17 - Thermostat
o
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f
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ng
t.
yi
❑ Checking: heat thermostat in water.
Co
Cop py
. rig
❑ Opening begins at approx. 87°C.
t
gh ht
pyri by
Vo
o
❑ Ends at approx. 105°C.
c by lksw
cted agen
Prote AG.
❑ Opening lift at least 7 mm.
❑ Note installation position ⇒ page 99 .
18 - Toothed belt
❑ Mark direction of rotation before removing.
❑ Check for wear.
❑ Do not kink.
19 - Coolant pump
❑ Check for ease of movement.
❑ Note installation position
21 - Bolt
❑ 20 Nm
22 - Throttle valve control module - J338-
23 - To upper coolant expansion tank
24 - Retaining clip
25 - Coolant temperature sender - G62-
26 - Supply from heat exchanger

AG. Volkswagen AG d
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d by Transporter
ara 2004 ➤ , Transporter 2010 ➤
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e o (2.0 l engine) - Edition 12.2015
au ra
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2.2 Assembly overview - Y thermostat
e
nl
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ab
ility
1 - Housing
ot p
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❑ Observe mounting posi‐
h re
tion relative to housing
hole
spec
⇒ Item 6 (page 97)
es, in part or in w
t to the co
2 - Seal
❑ Coat with coolant before
assembling housings
rrectness of i
⇒ Item 1 (page 97) and
l purpos
⇒ Item 6 (page 97) .

nf
ercia
3 - Spring
orm
m
atio
• Note installation position:
om
n in
or c
• Insert into housing with the
thi
te
“larger” diameter
sd
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4 - Thermostat
t.
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Cop py
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• Note installation position:
rig
gh ht
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• Insert with the “cylinder
lksw
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side” pointing towards
AG.
housing
5 - Securing clip
❑ Do not bend or stretch
excessively
6 - Housing
❑ Observe mounting posi‐
tion relative to housing
⇒ Item 1 (page 97)
Mounting position of housing

– The locking lug -1- must engage in the recess -2-.
2. Coolant pump, regulation of cooling system 97

2.3 Removing and installing coolant pump

AG. Volkswagen AG d
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Special tools and workshop Volksw not
gu
y
equipment required d b ara
rise nte
ho eo
♦ Refractometer - T10007 A- aut ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
- V.A.G 1331-
ility
ot p
♦ Spring-type clip pliers -
wit
, is n
h re
VAS 5024-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
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Prote AG.
Removing
Note
♦ Always renew gaskets and seals.

♦ The lower part of the toothed belt guard need not be removed.
♦ The toothed belt remains on the crankshaft pulley.
♦ Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.

– Remove tensioning element for poly V-belt.

– Remove upper and centre toothed belt guards.

– Remove toothed belt from coolant pump sprocket
⇒ page 47 .
– Remove bolt -1- from rear toothed belt guard -2-.
– Unscrew coolant pump securing bolts -5- and remove coolant
pump -4-.
Installing
– Moisten new O-ring -3- with coolant.
Note
The coolant pump plug faces downwards.
– Insert coolant pump -4- into cylinder block and tighten securing
bolts -5-.
– Tighten bolt -1- in rear toothed belt guard -2-.
Install and tension toothed belt ⇒ page 47 .
– Install poly V-belt ⇒ page 21 . AG. Volkswagen AG d
agen oes
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– Tighten power-assisted steering vane pump tobancillaries
yV
ol
gu
ara
bracket: ⇒ Running gear, axles, steering; Rep.
rise gr. 48 ; Hy‐
d
nte
draulic power-assisted steering autho eo
ra
ss c
ce
le
un
pt
an
d
Specified torques
itte
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rm
ab
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,

pe
ility
page 95
ot
wit
, is n
h re

hole
spec
19
es, in part or in w
t to the co
2.4 Removing and installing thermostat

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
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gh ht
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by
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Prote AG.


equipment required
♦ Refractometer - T10007 A- AG. Volkswagen AG d
agen oes
olksw not
y V gu
♦ Drip tray - V.A.G 1306- d b ara
rise nte
ho eo
♦ Torque wrench (5…50 Nm) aut ra
c
- V.A.G 1331- ss
ce
le
un
pt
an
d
itte
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VAS 5024-
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Note
Always renew gaskets and seals.

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Pull coolant hose off connection -3-.
– Remove connecting flange -3- securing bolts -4- and remove
connecting flange -3- with thermostat -1-.
Installing

– Moisten new O-ring -2- with coolant.

– Fit connection -3- with thermostat -1- into cylinder block.
Note
The brace on the thermostat must be almost vertical.
– Tighten securing bolts -4-.

Specified torques
♦ ⇒ “1.3 Assembly overview - cylinder block”, page 20
♦ Alternator; Assembly overview - alternator ⇒ Alternator; Rep.
gr. 27 ; Assembly overview - alternator
G. Volkswagen AG d
2.5 Testing Y-thermostat
olks
wage
nA oes
not
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db ara
Checking ir se nte
ho eo
ut
– Remove Y-thermostat.
ss
a ra
c
ce
le
– Pull off locking clip -1-.

un
pt
an
d
itte
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– Pull housing -2- off housing -3- slowly and carefully.
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Check distance -a- from thermostat in cold condition. The dis‐

tance -a- must be at least 5 mm.
– Place thermostat in hot water. The water must be at least 55°
C.
– Check distance -b- from thermostat in hot condition. The dis‐
tance -b- must be at least 11 mm.
– Put spring with small diameter onto thermostat.
AG. Volkswagen AG d
agen oes
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ility
ot p
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– Before assembling, apply coolant to sealing ring -arrow-.
spec
t to the co
– Observe installation position of housing.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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r
– The locking lug -1- must engage in the recess -2-.

p
cum
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fo
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.

3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator, radiator fan”, page 103
swage es n
⇒ “3.2 Assembly overview - radiator, radiator fan, 2010 y►”, Volk ot g
ua
page 104 ir se
d b ran
tee
tho
or
⇒ “3.3 Assembly overview - radiator cowl with radiator
au fan V7 and ac
ss
right radiator fan V35 .”, page 105
ce
le
un
pt
⇒ “3.4 Assembly overview - radiator cowl with radiator fan V7 ,
an
d
itte
y li
2010 ►”, page 106
erm
ab
ility
ot p
⇒ “3.5 Removing and installing radiator”, page 107
wit
is n
h re
⇒ “3.6 Removing and installing radiator cowl with radiator fan V7 , ole,
spec
2010 ►”, page 108
t to the co
3.1 Assembly overview - radiator, radiator fan
rrectne
1 - Oil cooler
For power-assisted steering
ss o
cial p
f
2 - Bolt
inform
mer
❑ 6 Nm
atio
m
3 - Cap
o
n
c
i
or
n thi
❑ Check using cooling
te
sd
a
system tester - V.A.G

iv
o
pr
c
1274 B- and adapter for
um
r
fo
en
ng
cooling system tester - yi

t.
Co
V.A.G 1274/9- . t. Cop py
rig
gh
❑ At a pressure of 1.4 …
ht
pyri by
Vo
1.6 bar, pressure relief
co lksw
by
cted agen
valve must open Prote AG.
❑ Checking ⇒ page 87
4 - O-ring
❑ Renew if damaged
5 - Connector
6 - Bolt
❑ 3 Nm
7 - Coolant expansion tank
❑ Test cooling system for
leaks using cooling sys‐
tem tester - V.A.G 1274
B- and adapter for cool‐
ing system tester -
V.A.G 1274/8- .
8 - Rubber bush
9 - Radiator
❑ After renewing, renew
entire coolant.
10 - Bolt
❑ 6 Nm
3. Radiator, radiator fan 103

11 - Condenser
12 - Retaining clip
13 - Washer
14 - O-ring
15 - Retaining clip
❑ For radiator outlet coolant temperature sender - G83- . agen
AG. Volkswagen AG d
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16 - Radiator outlet coolant temperature sender - G83- ed by gu
ara
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17 - Connector aut
h eo
ra
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❑ For radiator outlet coolant temperature sender - G83- . s
ce
e
nl
pt
du
18 - Lower coolant hose
an
itte
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erm
ab
ility
ot p
19 - Upper coolant hose
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.2 Assembly overview - radiator, radiator fan, 2010 ►
rrectness of i
1 - Oil cooler
l purpos
For power-assisted steering
nform
ercia
2 - Bolt
m
at
❑ 6 Nm
om
ion
c
in t
r
3 - Cap
o
his
ate
❑ Check using cooling
do
priv
c
system tester - V.A.G
um
for
en
g
1274 B- and adapter for

n
t.
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cooling system tester - t. Cop py
V.A.G 1274/9- .
rig
gh ht
pyri by
Vo
❑ Pressure relief valve
o
by c lksw
cted agen
must open at between Prote AG.
1.4 and 1.6 bar.
4 - O-ring
❑ Renew if damaged
5 - Connector
6 - Bolt
❑ 3 Nm
7 - Expansion tank
❑ Test cooling system for
leaks using cooling sys‐
tem tester - V.A.G 1274
B- and adapter for cool‐
ing system tester -
V.A.G 1274/8- .
8 - Rubber bush
9 - Radiator
❑ After renewing, renew

entire coolant.
AG. Volkswagen AG d
❑ Removing and installing ⇒ page 107 agen oes
olksw not
byV gu
ara
d
10 - Bolt orise nte
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❑ 6 Nm aut ra
ss c
ce
le
11 - Condenser
un
pt
an
d
itte
12 - Retaining clip
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rm
ab
pe
ility
ot
wit
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13 - Washer
h re
hole
spec
14 - Lower coolant hose
es, in part or in w
t to the co
15 - Upper coolant hose
rrectness of i
l purpos
3.3 Assembly overview - radiator cowl with radiator fan - V7- and right radiator
nform
ercia
fan - V35- .
m
a
com
tion in
r
te o
1 - Radiator fan - V7-
thi
s
iva
do
❑ Variation depending on
r
rp
cum
vehicle equipment.
fo
en
ng
t.
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2 - Nut . Cop py
rig
ht
❑ 10 Nm rig ht
py by
co Vo
by lksw
3 - Retaining clip cted agen
Prote AG.
❑ For cable guide.
ing.
4 - Fan support
5 - Radiator fan 2 - V35-
❑ Variation depending on
vehicle equipment.
6 - Bolt
❑ 6 Nm
7 - Bolt
❑ 6 Nm
8 - Bolt
❑ 5 Nm
9 - Bracket
❑ Not always fitted as this
is equipment depend‐
ant.

3.4 Assembly overview - radiator cowl with radiator fan - V7- , 2010 ►
1 - Radiator
2 - Radiator fan
3 - Bolt
❑ 5 Nm
4 - Bolt
❑ 5 Nm
5 - Locking lug
❑ Must be engaged in ra‐
diator.
6 - Fan support
⇒ page 106
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
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un
pt
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d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3.5 Removing and installing radiator

equipment required
♦ Refractometer - T10007 A-
- V.A.G 1331-
VAS 5024-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos

nform
– Remove front bumper ⇒ General body repairs, exterior; Rep.

ercia
gr. 63 ; Bumpers .
m
at
om
io
– Move lock carrier to service position ⇒ General body repairs,

n
c
in t
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐

or
his
e
sition .
at
do
priv
cum
– Pull all coolant hoses off radiator.

for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

4-cylinder injection engine (2.0elnengine) - aEdition
AG. Volksw gen AG 12.2015
ag does
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Vol gu
– Remove securing bolt -2-efor d b oil cooler
y for power-assisted ara
nte
steering. thoris eo
au ra
– Unclip oil cooler and
ss lay to one side. c
ce
le
un
pt
– Remove condenser securing bolts -3-, -6- and -8-.
an
d
itte
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rm
– Prise condenser out of retainers -4- and -5- and place to side
ab
pe
ility
(refrigerant lines remain connected).
ot
wit
, is n
– Remove radiator securing bolt -1- and push rubber mounting
h re
hole
in direction of arrow.
spec
es, in part or in w
Transporter 2004►
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Disconnect connectors -arrows-.
r
te o
thi
s
iva
Transporter 2010►
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull back locking lever -1- as far as the stop.

– Press down locking lever -2- and pull connector off.
Continuation for all vehicles:
– Carefully remove radiator forwards.
Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator, radiator fan”, page 103
♦ ⇒ “3.2 Assembly overview - radiator, radiator fan, 2010 ►”,
page 104
♦ ⇒ “3.3 Assembly overview - radiator cowl with radiator fan V7
and right radiator fan V35 .”, page 105
♦ ⇒ “3.4 Assembly overview - radiator cowl with radiator fan V7 ,
2010 ►”, page 106
3.6 Removing and installing radiator cowl

with radiator fan - V7- , 2010 ►
Removing
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier .

– Removing radiator ⇒ page 107 .

– Undo screws -arrows- and remove fan mounting together with
radiator fan - V7- from radiator.
– Push back locking lug -arrow- and remove fan mounting to‐
gether with radiator fan - V7- from radiator.
Installing
– Insert fan mounting together with radiator fan - V7- into the
radiator with the locking lug first -arrow-.
lkswage es n
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– Tighten bolts -arrows-.

ole,
spec
– Installing radiator ⇒ page 107 .

t to the co
Specified torques
♦ ⇒ “3.2 Assembly overview - radiator, radiator fan, 2010 ►”,
rrectne
page 104
♦ ⇒ “3.4 Assembly overview - radiator cowl with radiator fan V7 ,
ss
2010 ►”, page 106

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Cop py
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by
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Prote AG.

24 – Mixture preparation - injection

1 Air filter
⇒ “1.1 Assembly overview - air filter housing”, page 110
1.1 Assembly overview - air filter housing
1 - Air mass meter - G70- agen

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2 - Seal byV gu
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❑ Renew if damaged. ut
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3 - Air filter upper part s
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4 - Filter element
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ab
5 - Rubber bush
ility
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6 - Air filter lower part
, is n
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hole
7 - Rubber bush
spec
es, in part or in w
❑ Clipped into lower part
t to the co
of air filter
8 - Bolt
rrectness of i
❑ 8 Nm
l purpos
9 - Air duct
10 - To throttle valve control
nf
ercia
module - J338- .
orm
m
atio
11 - Spring-type clip
om
n in
or c
12 - To intake manifold.
thi
te
sd
iva
13 - Connection for crankcase
o
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rp
cu
breather
o
m
f
en
ng
t.
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14 - To breather pipe for injec‐ Cop py
. rig
tors ⇒ Item 8 (page 113)
ht ht
rig by
copy Vo
lksw
15 - Intake hose
by
cted agen
Prote AG.
16 - Bolt
❑ 6 Nm
110 Rep. gr.24 - Mixture preparation - injection

2 Intake manifold
⇒ “2.1 Assembly overview - intake manifold”, page 111
⇒ “2.2 Assembly overview - lower part of intake manifold with fuel
rail”, page 113
2.1 Assembly overview - intake manifold
1 - Upper part of intake mani‐

fold
2 - Bracket
❑ For hoses for crankcase
breather.
3 - Bolt
❑ 25 Nm
4 - Vacuum hose
❑ To fuel pressure regula‐
tor.
5 - Vacuum hose
❑ To connecting pipe for
throttle valve control
module/air mass meter.
6 - Bolt
❑ 20 Nm
7 - Retainer
8 - Bolt
❑ 20 Nm
olkswagen AG
en AG. V
9 - Connecting pipe olks
wag does
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❑ Between solenoid vale ise
d1
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- N80- and throttle
uthvalve
or eo
control moduless a ra
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10 - Gasket
un
pt
an
d
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ab
pe
ility

ot
wit
ule - J338-
, is n
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❑ Adapting ⇒ Vehicle di‐

hole
spec
agnostic tester
es, in part or in w
t to the co
12 - Bolt
❑ 10 Nm
rrectness of i
13 - To throttle valve control module - J338- .

l purpos
14 - Threaded union
❑ Insert with locking fluid - D 000 600 A2- .
nform
ercia
❑ 45 Nm
m
15 - Connecting pipe
com
tion in
❑ For exhaust gas recirculation.

r
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thi
s
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❑ 40 Nm
do
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cum
fo
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t.
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Cop py
t. rig
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2. Intake manifold 111

AG. Volkswagen AG d
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Transporter 2004d➤ by , Transporter 2010 ➤
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4-cylinder injection
horis
engine (2.0 l engine) - Edition 12.2015 eo
aut ra
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16 - Exhaust manifold
ce
le
un
pt
an
17 - To brake servo. d
itte
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erm
ab
18 - Intake manifold support
ility
ot p
wit
is n
19 - Bolt
h re
ole,
❑ 20 Nm
spec
20 - Gasket
t to the co
21 - Vacuum hose
rrectne
To pressure line for secondary air system.
ss o
22 - Connector
cial p
f inform
23 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
mer
atio
❑ Adapting ⇒ Vehicle diagnostic tester
om
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24 - Bolt
thi
te
sd
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❑ 20 Nm
iv
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25 - Gasket
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t.
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❑ Renew after removing Cop py
t. rig
gh ht
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26 - Bolt p by
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❑ 25 Nm
agen
Prote AG.

2.2 Assembly overview - lower part of intake manifold with fuel rail
1 - Cable channel
2 - To pressure line for secon‐
dary air system.
3 - Fuel pressure regulator
4 - O-ring
5 - Retaining clip
ing.
6 - To intake hose
7 - Breather pipe
8 - Air hose
❑ For air shroud injectors. agen
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9 - Injector, cylinder 1 - N30- d b to
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injector, cylinder 4 - N33- rise nte
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❑ Air-scavenged ss a c
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⇒ page 114 .
an
itte
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erm
10 - Nut ab
ility
ot p
❑ 25 Nm wit
, is n
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11 - Intake manifold lower part
hole
spec
es, in part or in w
12 - Gasket
t to the co

13 - Bolt
rrectness of i
❑ 25 Nm
l purpos
14 - Retaining clip
❑ Ensure correct seating
nform
ercia
on injector and fuel distributor (fuel rail).

m
at
om
15 - Bracket
ion
c
in t
or
16 - Bolt
his
ate
do
riv
❑ 20 Nm
p
cum
for
17 - Union for fuel return line

en
ng
t.
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op py
18 - Union for fuel supply line t. C rig
gh ht
pyri by
19 - Fuel distributor (fuel rail)
co Vo
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20 - Bolt
❑ 10 Nm
2. Intake manifold 113

3 Injectors olksw
agen
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⇒ “3.1 Removing and installing injectors”, page 114 rised
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⇒ “3.2 Checking injectors”, page 115 ss a ra
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⇒ “3.3 Checking quantity injected”, page 118
nl
pt
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3.1 Removing and installing injectors
erm
ab
ility
ot p
Removing
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Pull coolant hoses -3- and -4- off throttle valve module, and
seal hose ends with, for example, hose clamps up to 25 mm -
3094- .
rrectness of i
l purpos

filter bracket.
nf
ercia
or
m
m
atio
m

o
n in
or c
thi
e

t
sd
iva
-1- from retainer.
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en
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– Pull connector -2- off throttle valve control module. yi

t.
Co
op py
. C rig
ht ht
rig by
py Vo
co lksw
by
cted agen
Prote AG.
Then remove intake manifold upper part ⇒ page 111 .
Note
cloth.
WARNING
The fuel system is pressurised! Before opening the system


– Pull off connectors on all injectors.
– Remove securing bolts of fuel distributor (fuel rail).
– Pull hose off vent pipe for air shroud injectors
⇒ Item 8 (page 113) .
– Lift off fuel distributor (fuel rail) with injectors.
– Pull off retaining clip and take injectors out of fuel distributor
(fuel rail).
Installing
– Renew the O-rings at all opened connections.
– Lubricate the O-rings lightly with clean engine oil.
– Ensure that the injectors are installed in the correct position.
– Ensure retaining clips are properly seated.
– Position fuel distributor (fuel rail) together with secured injec‐
tors against lower part of intake manifold and press into place
evenly.
AG. Volkswagen AG d
– Install upper part of intake manifold. lksw
agen oes
not
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– Check coolant level after completion of workris⇒
ed page 89 .
b ara
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Specified torques aut ra
ss c
ce
e

nl
pt
du
an
itte
♦ ⇒ “2.2 Assembly overview - lower part of intake manifold with
y li
erm
ab
fuel rail”, page 113
ility
ot p
wit
, is n
3.2 Checking injectors
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
3. Injectors 115

equipment required
♦ Remote control - V.A.G
1348/3 A-
♦ Adapter cable - V.A.G
1348/3 - 2-
♦ Injection rate tester - V.A.G AG. Volkswagen AG d
agen oes
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♦ Auxiliary measuring set - hor eo
ut
V.A.G 1594 C- ss a ra
c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING

Test prerequisites
• The fuel pressure must be OK. Checking ⇒ page 120 .
• Fuses SD14 and SD30 -arrows- must be removed from their
sockets.
Procedure
necting hose.

- 3094- .
filter bracket.
-1- from retainer.
Note
♦ Block off intake ports in lower part of cylinder head with a clean
cloth.
♦ Do not disconnect fuel hoses.
– Pull off connector to the injectors.

– Pull hose off vent pipe for air shroud injectors
⇒ Item 8 (page 113) .
– Remove securing bolts of fuel distributoren(fuel
AG. Vrail).
olkswagen AG
ag does
lksw not
– Lift off fuel distributor (fuel rail) bwith
y V injectors.
o gu
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ed nte
ris
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
117
Prote AG.
3. Injectors
– Connect remote control - V.A.G 1348/3 A- with adapter cable

- V.A.G 1348/3-3- to terminal of fuse 30b -enlargement-.
– Insulate second free flat connector of adapter cable -
V.A.G 1348/3-3- -arrow- using commercially available insulat‐
ing tape.
– Connect battery positive terminal of remote control -
V.A.G 1348/3 A- to positive terminal -+- of battery.
Note
♦ This step serves only to have the fuel pump running when the
engine is stopped.
♦ If injectors are renewed, erase event memory ⇒ Vehicle diag‐
nostic tester.
♦ Always renew seals.
– Check injectors for leaks (visual check). No more than 1 to 2

drops per minute must escape from each valve when fuel
pump is running.
If the fuel loss is greater:
– Separate connection between fuse socket 30b and battery
positive, and renew leaking injector ⇒G.page
Volksw114
age . A n AG d
agen oes
Specified torques o lksw not
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d b ara
♦ ⇒ “2.1 rise
Assembly overview - intake manifold”, page 111 nte
tho eo
au ra
♦ ⇒ “2.2 Assembly
s overview - lower part of intake manifold with
s c
ce

e
nl
pt
du
an
itte
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erm
3.3 Checking quantity injected

ab
ility
ot p
wit
Test prerequisites
, is n
h re
hole
• The fuel pressure must be OK. Checking ⇒ page 120 .

spec
es, in part or in w
• Upper part of intake manifold removed.

t to the co
• Injectors installed in fuel distributor (fuel rail) and fuel line con‐
nected.
rrectness of i

l purpos
sockets.
Test procedure
nform
ercia
– Place the injector which is to be tested into measuring glass

m
at
om
of injection quantity tester - V.A.G 1602- .

ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lks wage es n
– Connect fuse socket 30b and battery -+- using Vocables from ot g
by ua
auxiliary measuring set - V.A.G 1594 C- r.ised ran
tee
tho or
s au ac
s
Note
ce
e
nl
pt
du
an
itte
y li
This step serves only to have the fuel pump running when the
erm
ab
engine is stopped.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
– Connect a contact of injector to be tested to engine earth using
n
c
in t
r
test leads from auxiliary measuring set - V.A.G 1594 C- .

o
his
ate
do
riv
– Connect second injector contact to remote control - V.A.G

p
cum
or
1348/3 A- using adapter cable - V.A.G 1348/3 - 2- .

f
en
ng
t.
yi Co
– Connect crocodile clip to battery (+). t. Cop py
rig
gh ht
yri
– Operate remote control - V.A.G 1348/3 A- for 30 seconds. p by
co Vo
by lksw
cted agen
– Repeat check on other injectors. Use new measuring beakers. Prote AG.
– After all injectors have been activated, place measuring beak‐

ers on a level surface and compare the quantity injected.
Specifications: 85 ... 105 ml per valve
When checking the quantity injected, check the spray pattern as
well. The spray patterns must be the same for all injectors.
If the measured values of one or more injectors are above or be‐
low the prescribed specifications:
– Renew defective injector ⇒ page 114 .
– Check coolant level after completing work.
Note
♦ If injectors are renewed, clear event memory ⇒ Vehicle diag‐

nostic tester.
♦ Always renew seals.
Specified torques
♦ ⇒ “2.2 Assembly overview - lower part of intake manifold with
3. Injectors 119
4 Senders and sensors

⇒ “4.1 Checking fuel pressure regulator and holding pressure”,
page 120
4.1 Checking fuel pressure regulator and holding pressure

equipment required
♦ Pressure gauge - V.A.G
1318-
♦ Adapter - V.A.G 1318/9-
♦ Adapter set - V.A.G
1318/17-
♦ Connector - V.A.G
1318/23-
♦ Remote control - V.A.G
1348/3 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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f
Note
en
ng
t.
yi Co
Cop py
t.
♦ The fuel pressure regulator regulates the fuel pressure to ap‐
rig
gh ht
yri by
prox. 3 bar. cop Vo
by lksw
cted agen
Prote
♦ Observe safety precautions ⇒ page 4 .
AG.

Test prerequisites
sockets.
WARNING

Test procedure
– Separate fuel supply line -3- plug-in connector. Collect escap‐

ing fuel with a cleaning cloth.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
le
un
pt
an
d
itte
y li
erm
– Connect pressure tester - V.A.G 1318- with adapter - V.A.G

ab
ility
1318/9- , double union - 1318/23- and adapter set - V.A.G

ot p
wit
1318/17- as shown.
is n
h re
ole,
– Open shut-off tap of pressure tester. The handle points in di‐

spec
rection of flow.
t to the co
– Start engine and run at idling speed.

– Measure fuel pressure. Specification: approx. 2.5 bar.
rrectness o
cial p
f inform
mer
atio
– Pull vacuum hose -arrow- off fuel pressure regulator.

om
n
c
– The fuel pressure must increase to approx. 3 bar.

or
n thi
te
sd
a
If the specification is not attained:

iv
o
pr
cum
r
fo
– Switch off ignition.

en
ng
t.
yi Co
op
– Check fuel delivery rate of fuel pump ⇒ Rep. gr. 20 ; Fuel
C py
t. rig
gh
pump; Checking fuel system pressurisation pump - G6- .
ht
pyri by
Vo
co lksw
by
If specification is attained:
cted agen
Prote AG.
– Switch off ignition.

– Now check for leaks and check retention pressure (entire sys‐
tem). Observe pressure drop on pressure gauge for this. After
10 minutes, there must be a residual pressure of at least 2.0
bar.
If the holding pressure drops below 2 bar:
– Start engine and run at idling speed.
4. Senders and sensors 121

– After pressure has built up, switch off the ignition. At the same
time, close shut-off tap of pressure tester (handle perpendic‐
ular to direction of flow) -arrow-.
– Observe pressure drop on pressure gauge.
If the pressure does not drop:
– Check non-return valve of fuel pump ⇒ Rep. gr. 20 ; Fuel
pump; Checking fuel system pressurisation pump - G6- .
If the pressure drops again:
– Check pressure tester for leaks.
– Check line connections, O-rings on fuel distributor (fuel rail)
and injectors for leaks. ⇒ page 115
– Check pressure tester for leaks.
If no leak is detected:
– Renew fuel pressure regulator.
Note
Before removing pressure tester, place cleaning cloths again

around the connections to be loosened.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5 Engine control unit

⇒ “5.1 Removing and installing engine control unit J623 ”,
page 123
5.1 Removing and installing engine control

unit - J623-
♦ Vehicle diagnostic tester
Removing
– If engine control unit - J623- was renewed, learnt values must
be reset ⇒ Vehicle diagnostic tester, 01 - Systems capable
of self-diagnosis , 01 - Diesel direction injection
and preglow system EDC 17 , 01 - Engine electronics
functions , Bringing into operation .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
Note rised ara
nte
ho eo
aut ra
If the adaption values of the injectors
ss cannot be read from the old c
(defective) engine control unit - J623- , the adaption values must
ce
le
un
pt
be entered in the new engine control unit - J623- manually and
an
d
itte
y li
adjusted.
rm
ab
pe
ility
ot
wit
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
, is n
h re
Removing and installing battery tray .
hole
spec
– Remove electronics box cover ⇒ Electrical system; Rep. gr.
es, in part or in w
t to the co
97 ; Relay carrier, fuse carrier, electronics boxes; Removing
and installing electronics box .
– Separate electrical connectors -2- and -3- from engine control
rrectness of i
unit - J623- -1-.
l purpos
– Pull out engine control unit - J623- -1- in direction of -arrow-

from E-box -2-.
nform
ercia
Installing
m
a
com
tion in
Install in reverse order.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5. Engine control unit 123

26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 124
⇒ “1.2 Separating exhaust pipes, silencers”, page 124
1.1 Assembly overview - silencers
1 - From front exhaust pipe

2 - Mounting
❑ With retaining ring.
3 - Bolt
❑ 25 Nm
4 - Front silencer
5 - Coupling point
❑ During production, front
and rear silencers are
AG. Volkswagen AG d
installed as a single ksw
agen oes
not
l
component. For repairs, by Vo gu
ara
front and rear silencers
rise
d
nte
are supplied separately.
autho eo
ra
s c
❑ The connection s is made
ce
le
with a clamp.
un
pt
an
d
itte
❑ Evenly tighten threaded

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erm
ab
connections of clamping
ility
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sleeve
wit
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❑ Separating front and

h re
ole,
rear silencers
spec
⇒ page 124 .
t to the co
6 - Mounting
rrectne
7 - Bolt
❑ 60 Nm
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
1.2 Separating exhaust pipes, silencers

t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
124 Rep. gr.26 - Exhaust system

♦ Pneumatic sabre saw - V.A.G 1523/A-
Procedure
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
♦ Renew seals, gaskets and self-locking nuts.
– Separate front silencer -1- at right anglesAGat

. Vocoupling
lkswagen Apoint
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point marked all round with point agen
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point on silencers with no emarked coupling point). ua
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– Align exhaust system free of stress.
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For vehicles having silencers with no marking indentations, the

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– Measure distance -A- (144 mm) from folded seam of front si‐
lencer. Mark exhaust pipe at measured point.
rrectness o
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1. Exhaust pipes, silencers 125

– Centre repair double clamp -2- when installing.

– Align exhaust system free of stress.
Specified torque
Repair double clamp 52 Nm
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2 Emission control
⇒ “2.1 Assembly overview - emission control”, page 127
2.1 Assembly overview - emission control
1 - Gasket
2 - Connecting pipe
❑ For exhaust gas recircu‐
lation.
3 - Union nut
❑ 40 Nm
4 - Connector
❑ 6-pin
5 - Lambda probe before cata‐
lytic converter - G39-
❑ Grease only the thread
with high-temperature
paste - G 052 112 A3- ; wagen AG. Volkswagen AG does
high-temperature paste ks not
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must not get into risedthe ara
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slots of probeut body.
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❑ 55 Nm s s c
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7 - Connecting pipe
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❑ For secondary air sys‐

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8 - Union nut
es, in part or in w
❑ 40 Nm
t to the co
9 - Threaded union
❑ 35 Nm
rrectness of i
10 - Gasket
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11 - Front exhaust pipe with

catalytic converter
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12 - Nut
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❑ 25 Nm
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13 - Connector
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14 - Lambda probe after catalytic converter - G130-
AG.
❑ Grease only the threads with high-temperature paste - G 052 112 A3- ; high-temperature paste must not
get into the slots of probe body.
❑ 55 Nm
15 - Double clamp
❑ 52 Nm
2. Emission control 127

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16 - To front silencer ris
ed
b ran
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17 - Bolt au ac
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❑ 25 Nm
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18 - Mounting for front exhaust pipe
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19 - Catalytic converter
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20 - Nut
spec
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❑ 25 Nm
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3 Exhaust gas recirculation

⇒ “3.1 Assembly overview - exhaust gas recirculation”,
page 129
3.1 Assembly overview - exhaust gas recirculation
1 - Upper part of intake mani‐

fold
2 - Threaded union
❑ Insert with locking fluid -
D 000 600 A2- .
❑ 45 Nm
3 - Union nut
❑ 40 Nm
4 - Connecting pipe
5 - Union nut
❑ 40 Nm
7 - To pressure line for secon‐
dary air system.
8 - Connector
9 - Bolt
❑ 20 Nm
10 - Exhaust gas recirculation
valve - N18- with exhaust gas
recirculation potentiometer -
G212-
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11 - Gasket ut
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129
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3. Exhaust gas recirculation
4 Secondary air system

⇒ “4.1 Function”, page 130
⇒ “4.2 Assembly overview - secondary air system”, page 130
⇒ “4.3 Checking combination valve”, page 131
4.1 Function
During a cold start, air is temporarily blown from the secondary
air system into the exhaust ports. This produces an Aoxygen
G. Volkswrich
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exhaust gas, causing afterburning and reducing agen
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does
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4.2 Assembly overview - secondary air system
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1 - Combination valve
itte
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2 - Union nut
ility
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❑ 40 Nm
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3 - Connecting pipe
spec
es, in part or in w
4 - Threaded union
t to the co
❑ 45 Nm
5 - O-ring
rrectness of i
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6 - to Exhaust gas recirculation

valve - N18- with exhaust gas
nf
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recirculation potentiometer -
orm
G212-
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7 - Pressure hose n in
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8 - Bracket yi
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10 - Secondary air pump motor
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11 - Bracket
12 - Bolt
❑ 10 Nm
13 - Washer
14 - Nut
❑ 10 Nm
15 - Subframe
16 - Bolt
❑ 25 Nm
17 - Union
❑ For combination valve.
18 - Bolt
❑ 20 Nm
19 - Gasket

4.3 Checking combination valve

• Hose connections must be leak-free.
Note
Do not use compressed air during the following check!

Volkswa
– Pull pressure hose -arrow- off combination
swa
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– Slide auxiliary hose onto icombination
sedb valve. ara
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– Blow into auxiliary hoseaut using light pressure. Combination ra
c
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valve must be closed.s
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– Blow into auxiliary hose using strong pressure. Combination
an
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valve must open.
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If the combination valve does not open, or is constantly open:
ot
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– Renew combination valve.
hole
spec
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4. Secondary air system 131

28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 132
⇒ “1.2 Removing and installing spark plugs”, page 133
⇒ “1.3 Test data, spark plugs”, page 134
1.1 Assembly overview - ignition system
1 - Ignition cable
❑ 4 ... 8 kΩ
❑ With suppression con‐
nector and spark plug
connector.
❑ Check for continuity.
❑ Pull off spark plug con‐
nector using assemblywagen AG. Volkswagen AG doe
tool - T10029- . y Volks s no
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2 - Ignition transformer
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❑ With markings
ss
a for H.T. ac
cables: A = Cylinder 1, B
ce
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= Cylinder 2, C = Cylin‐
an
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3 - Bolt
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❑ 10 Nm
h re
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spec
4 - Connector
❑ For ignition transformer

t to the co
- N152- .
5 - Knock sensor I - G61-
rrectne
6 - Connector
s
❑ 2-pin
s o
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❑ For knock sensor I -

inform
G61- .
mer
atio
7 - Bolt
om
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c
❑ 20 Nm
or
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8 - Knock sensor II - G66-

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9 - Connector
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10 - Spark plug
❑ To remove and install, pull off connectors for outer injectors.
❑ 25 Nm
❑ Type and electrode gap ⇒ page 134 .
11 - Connector
❑ 3-pin
❑ For Hall sender - G40- .
132 Rep. gr.28 - Ignition system

12 - Bolt
❑ 10 Nm
13 - Bolt
❑ 100 Nm
14 - Camshaft pulley
❑ With rotor for Hall sender.
❑ Assembly overview ⇒ page 58 .
15 - Hall sender - G40-
16 - Bracket lkswage es n
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1.2 Removing and installing spark plugs ss
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♦ Torque wrench - V.A.G 1331-

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Not illustrated:
♦ Spark plug connector pliers - Hazet 1849-
1. Ignition system 133

Removing
Observe safety precautions ⇒ page 5 .
– Detach connectors of injection valves -2-.
– Pull off spark plug cable -1- using assembly tool - T10029- .
For the 3rd cylinder, use the spark plug connector pliers - Ha‐
zet 1849- if necessary.
– Fit spark plug socket - 3122 B- onto spark plugs and unscrew
them.
– Remove spark plugs with spark plug socket - 3122 B- .
Installing
– Carefully screw in and tighten spark plugs using spark plug
socket - 3122 B- .
– Connect spark plug cables in accordance with the firing order
⇒ page 134 .
– Connect injector connectors together.
Specified torques
♦ ⇒ “1.1 Assembly overview - ignition system”, page 132
AG. Volkswagen AG d
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1.3 Test data, spark plugs ol not
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Engine codes s aut ra
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AXA
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Firing order 1-3-4-2
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Spark plugs5)
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VW/Audi 101 000 033 AA

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Manufacturer's designation BKUR 6 ET-10

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Electrode gap 0.9 ... 1.1 mm

hole
spec
Specified torque 25 Nm
es, in part or in w
t to the co
5) For current specifications plus spark plug change intervals: ⇒ Data sheets for
rrectness of i
exhaust emissions test

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134 Rep. gr.28 - Ignition system

VW-4-Cylinder Injection Engine (2 0 L Engine)

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VW-4-Cylinder Injection Engine (2 0 L Engine)

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg K0058982120

3.2 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.3 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . en

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.2 Assembly overview - Y thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.5 Testing Y-thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.1 Assembly overview - radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.2 Assembly overview - radiator, radiator fan, 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

2 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

2.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1.1 Engine number, engine data

Engine codes AXA AXA

Compression ratio 10.5 10.5

Injection system Motronic ME 7.5 Motronic ME 7.5

Ignition system Motronic ME 7.5 Motronic ME 7.5

RON 95 unleaded 95 unleaded

Firing order 1-3-4-2 1-3-4-2

Catalytic converter yes yes

Exhaust gas recirculation yes yes

Lambda control yes yes

Electronic power control yes yes

Valves per cylinder 2 2

Leakage diagnosis system no no

1) Dependent on vapour pressure

2.1 Safety precautions when working on

When the engine is warm, the cooling system is under pres‐

Observe the following during all assembly work, particularly in

♦ When the engine is warm, the cooling system is under pres‐

♦ Hose connections are secured with couplings or spring-type

♦ Always renew clamp-type clips with spring-type clips.

♦ Fuel hoses on engine must be secured with spring-type clips

only. The use of clamp or screw-type clips is not permissible.

♦ Spring-type clip pliers - VAS 5024 A- or pliers - V.A.G 1921-

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

ment, pay attention to the following due to the cramped condi‐

vated charcoal filter system, coolant and refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

When removing and installing fuel gauge sender or fuel pump

Fuel supply lines are under pressure! Before loosening hose

Fuel system is under pressure! Before opening the system

carefully loosening the connection.

4 Rep. gr.00 - Technical data

♦ Do not touch or disconnect ignition cables when the engine is

fluid and vacuum) and electrical wiring in their original po‐

Note the following if testers and measuring instruments have to