Workshop Manual Transporter 2016 2-29

Service
Workshop Manual
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
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28 - Ignition system agen
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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 © 2018 Volkswagen AG, Wolfsburg D4B805652C1

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 06.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . g.e.n.A.G.. V. o.lk.s.w.a.ge. n.A.G. . . . . . . . . . . . . . . . . . . . . . . . 5
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3.2 General information . . . . . . . . . . . y.V.o.lks. w. . . . . . . . . . . . . . . . . .e.s .no.t .g . . . . . . . . . . . . . . . . . 5
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3.3 General repair instructions . . .ris.e.d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . . . . 6
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3.4 Foreign objects in engine .a.uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a. . . . . . . . . . . 6
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3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.2 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in 30

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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.1 Assembly overview - flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.5 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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3.6 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4 Balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.1 Assembly overview - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.4 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.1 Assembly overview - cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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2.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.1 Assembly overview - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.2 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.4 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.5 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . . . 133
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4.6 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1.1 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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1.2 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 154
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2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

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3.1 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

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4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.1 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.2 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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ii Contents
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.1 Fitting location overview - cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.4 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.5 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 182
2.6 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 183
2.7 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.3 Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.1 Assembly overview
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au Assembly overview - charge air system . r.a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

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2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

spec
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
s
3.2 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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3.3 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

inform
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4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

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4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

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4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

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5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

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5.1 Assembly overview - lower part of intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . 218
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5.2 Removing and installing intake manifold upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

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5.3 Removing and installing lower part of intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
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5.4 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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5.5 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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Prote AG.
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

6.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
6.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 228
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
8.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Contents iii
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
9.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
9.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.1 Removing and installing centre silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.2 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.3 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.4 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.5 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.1 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 248
satelettronica
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . w.a.ge. n. A. G. ..V.ol.ks.w.a.ge. n. A. G. d.o.e. . . . . . 249
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1.4 Removing and installing Hall sender G40 . . . . . . . . .by. V.o.l . . . . . . . . . . . . . . . . . . . . . n.o.t g.u.a . 250
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1.5 Removing and installing engine speed sender G28 ris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n250
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1.6 Test data, spark plugs . . . . . . . . . . . . . . . . . s.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251r ac
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iv Contents
00 – Technical data
1 Safety information
(VRL011702; Edition 06.2018)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
⇒ “1.4 Safety precautions when working on the cooling system”,
page 2
⇒ “1.5 Safety precautions when working on ignition system”, page
2
⇒ “1.6 Safety precautions when working on exhaust system”,
page 3
1.1 Safety regulations for working on fuelAsupply
satelettronica
G. Volkswagen n AG do
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Risk of injury from highly pressurised fuel. Volks ot g
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The fuel system is pressurised. Injury from fuel
thorisspray possible. tee
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Before opening the fuel system: ss
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– Wear protective goggles.
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– Wear protective gloves.
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– To release pressure, wrap a clean cloth around the connection
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and carefully loosen the connection.
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Danger of fire caused by escaping fuel
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When the battery is connected and the driver door opens, the door
l purpos
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire. nform
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– Disconnect voltage supply to fuel pump before opening the

fuel system.
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1.2 Safety measures when working on vehicles with a start/stop system
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Risk of injury due to unexpected motor start p by
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If the vehicle’s start/stop system is activated, the engine can start Prote AG.
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
Transporter 2016 ➤ en AG. Volkswagen AG
ag does
4-cylinder injection
Vol engine (2.0 l direct injection
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1.3 Safety precautions when using testers and measuring instruments during
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Risk of injury caused by unsecured testing and measuring instru‐

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When the front passenger airbag is triggered in an accident, in‐
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dangerous projectiles.
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– Secure testing and measuring instruments on the rear seat.
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– Have a second person operate the test and measuring equip‐
rrectness of i
ment on the rear seat.
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1.4 Safety precautions when working on the cooling system
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Danger of scalding by hot coolant
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On a warm engine, the cooling system is under high pressure.

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Danger of scalding by steam and hot coolant. en

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– Wear protective gloves. C py
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– Reduce excess pressure by covering cap of coolant expan‐
AG.
sion tank with cloths and opening it carefully.
1.5 Safety precautions when working on ignition system

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

Connecting or disconnecting electric cables or washing the en‐
gine while it is running may damage components.
– Switch off the ignition before connecting or disconnecting elec‐
tric cables.
– Switch off the ignition before washing the engine.
2 Rep. gr.00 - Technical data

1.6 Safety precautions when working on exhaust system

Risk of poisoning due to chemical substances
Exhaust gas temperature senders may contain chemical sub‐
stances. There is a risk of poisoning or injuries to respiratory
system.
– Never open an exhaust gas temperature sender by cutting,
sawing or any other means.
Risk of injury due to hot condensate and particles in the exhaust
system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation.
satelettronica
AG. Volkswagen AG d
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1. Safety information 3
2 Identification
⇒ “2.1 Engine number/engine data”, page 4
2.1 Engine number/engine data

The engine number (engine code and serial number) is located
at the front on the joint -arrow- between engine and gearbox.
In addition, a sticker is attached to the top of the toothed belt guard
-arrow- showing the engine code.
The engine codes have four characters.
olkswagen AG
en AG. V
The first 3 characters stand for the engine's cubic capacity and olkswag does
not
mechanical structure. They are stamped into the cylinder block db
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together with the serial number. rise nte
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The fourth character denotes the engine's performance
ss and tor‐ c
que rating and depends on the engine control unit.
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Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet
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20.1 ; General; Vehicle data sticker .
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Codes CJKA CJKB
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Displacement l 2.0 2.0
Power kW at rpm 150 kW at 4200 to 6000 rpm 110 kW at 3750 to 6000 rpm
l purpos
Torque Nm at rpm 350 Nm at 1500 to 4000 rpm 280 Nm at 1500 to 3750 rpm
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Displacement cm3 1984 1984

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Bore ∅ mm 82.5 82.5
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Stroke mm 92.8 92.8
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Valves per cylinder 4 4
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Compression ratio 9.6:1 9.8:1
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Fuel: acc. to DIN EN 228 Cop
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DIN EN 228 Co
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Firing order 1-3-4-2 1-3-4-2
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Catalytic converter Yes Yes
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Exhaust gas recir‐ No No
culation
Charging Yes Yes
Knock control Yes Yes
Camshaft timing Yes Yes
adjustment
Secondary air injec‐ No No
tion
1) If petrol with a RON rating of less than 95 is used, reduced power output and
torque must be expected.

3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 General information”, page 5
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Foreign objects in engine”, page 6
⇒ “3.5 Contact corrosion”, page 6
⇒ “3.6 Routing and attachment of lines”, page 7
⇒ “3.7 Fitting radiator and condensers”, page 7
⇒ “3.8 Checking vacuum system”, page 7
3.1 Rules for cleanliness

Even slight soiling can cause faults. You must therefore comply
with the following cleanliness rules when working on the fuel sup‐
ply system, injectors or the turbocharger:
♦ Carefully clean connection points and the surrounding area,
satelettronica
and dry thoroughly before opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components. . Volkswage n AG n AG d
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♦ Install only clean parts; do not remove new ypartsVol
ks from pack‐ not
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have been stored outside of their packaging
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(e.g. in tool box‐ eo
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♦ If system is open, do not work with compressed air. Do not

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♦ Protect disconnected electrical connectors from dirt and water,
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and reconnect them only when dry.

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♦ The components must be clean and dry.

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3.2 General information

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♦ The engine control unit has a self-diagnosis capability. Before

carrying out repairs and for fault finding, first read event mem‐
rrectne
ory. Also the vacuum hoses and connections must be checked

(unmetered air).
ss
♦ For trouble-free operation of electrical components, a voltage

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of at least 11.5 volts is necessary.

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♦ Do not use sealants containing silicone. Particles of silicone

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drawn into the engine will not be burnt in the engine and dam‐
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age the Lambda probe.

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♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces

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the danger of a fire in a crash as the fuel pump is switched off

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via the fuel pump relay.

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♦ The system also improves the starting characteristics of the
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engine. When the driver door is opened, the fuel pump is ac‐ py by
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system, observe safety precautions ⇒ page 1 .
Prote AG.
3. Repair instructions 5
3.3 General repair instructions

♦ Clean tools and workbench etc. before working on injection
system.
♦ The injectors and locations are to be checked before installa‐
tion by means of a visual inspection for damage and dirt. It
must be ensured that theeinjector
AG. Volkbore
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n Aclean. If necessary,
clean the injector shaft ag n G do
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♦ If high-pressure
au
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on removal.
ss High-pressure fuel lines must always be re-instal‐
c
led in their original positions (i.e. on the same cylinder).
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♦ Take care not to damage the injectors when removing the old
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♦ Check all new O-rings for damage before installing. Lubricate
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O-rings with engine oil or assembly oil before installing.
hole
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♦ Align high-pressure lines so that they are not subjected to
es, in part or in w
stress . First tighten all unions hand-tight and then tighten to
t to the co
torque.
♦ Never attempt to reshape high-pressure fuel lines.
satelettronica
rrectness of i
♦ When working on any parts of the high-pressure fuel system,
l purpos
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
nform
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♦ Press the fuel return lines onto the injectors by hand from
m
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above so that they engage audibly on each injector (do not

on
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press in the release pins when doing this). Then, press the
in t
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release pin downwards. Pull fuel return lines upwards by hand

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to check that they are firmly attached and are not leaking.
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♦ Disassembling individual common rail components is not per‐

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♦ Do not carry out any installation work on common rail system
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whilst engine is running.
AG.
♦ Never attempt to bleed the common rail system by loosening

high-pressure components after starting the engine.
♦ All cable ties which were opened or cut during removal must
be renewed at the same locations.
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
not permissible.
3.4 Foreign objects in engine

♦ To prevent the ingress of foreign bodies during work on the
engine, seal all openings.
♦ Seal openings with suitable bungs from engine bung set - VAS
6122- .
3.5 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.

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

is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .
3.6 Routing and attachment of lines

Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Ensure there is sufficient clearance to moving or hot compo‐
nents.
3.7 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does not
mean that these components have been damaged. It is not per‐
missible to renew radiators, charge airlkcoolersn AG. Volkswagen AG do
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3.8 Checking vacuum system autho or
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Special tools and workshop equipment required
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♦ Hand operated vacuum pump - VAS 6213-
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Sequence of operations
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– Check all vacuum lines throughout entire vacuum system for:

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♦ Cracks
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♦ Porous areas and other leaks p by
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– Check vacuum line to solenoid valve and from solenoid valve Prote AG.
to relevant component.
– If a fault has been entered in the event memory, make sure to
check not only all vacuum lines leading to the specified com‐
ponent, but also those leading to other components.
– If pressure cannot be built-up using hand vacuum pump - VAS
6213- or pressure immediately drops again, check hand vac‐
uum pump and connecting hoses for leaks.
3. Repair instructions 7
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 8
⇒ “1.2 Securing engine on engine and gearbox support”,
page 18
⇒ “1.3 Installing engine”, page 19
1.1 Removing engine
AG. Volkswagen AG d
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♦ Hose clamps to 25 mm - 3094-

♦ Torque wrench - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Ratchet attachment - V.A.G 1410/3-
♦ Stepladder - VAS 5085-
8 Rep. gr.10 - Removing and installing engine

Special tools and workshop

equipment required
satelettronica
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♦ Engine bung set - VAS 6122-

♦ Drip tray for workshop hoist - VAS 6208-
l purpos
♦ Hose clamp pliers - VAS 6340-

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♦ Spring-type clip pliers - VAS 6362-

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1. Removing and installing engine 9

Engine support - T50046-

Removing
Note
♦ The engine is removed downwards together with the gearbox.

♦ Seal open lines and unions with clean plugs from engine bung
set - VAS 6122- .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery tray .
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Move to service position ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Moving to and back from service
position .
– Remove left headlight ⇒ Electrical system; Rep. gr. 94 ;
Headlights; Removing and installing headlights .
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– Remove upper part of electronics kswbox ⇒ Electrical system;
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installing fuse holders, relay car‐
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– Remove wiring harness -2- and -3-.

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– Disconnect connector -4-.

– Unplug electrical connectors -2, 3, 5, 6-.
– Open retainer -1-.
– Remove wiring harness together with seal -7- from electronics
box.
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– Remove wiring harness together with seal -1- from electronics
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– Lay wiring harness on engine and secure.
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– Drain coolant ⇒ page 163 .
– Remove subframe together with steering rack ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and rrectness of i
l purpos
installing subframe with steering rack .

– Remove right and left drive shaft ⇒ Running gear, axles,
nform
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steering; Rep. gr. 40 ; Drive shaft; Removing and installing

drive shaft .
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– Remove downstream catalytic converter ⇒ page 245 .

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Vehicles with air conditioner:

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– Remove air conditioner compressor from bracket with lines

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– Remove power steering vane pump with lines still attached,

and secure it to body ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Hydraulic power steering, Removing and installing
vane pump .

– Unscrew bolt -1-.
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– Unscrew bolts -2- and -3-.
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– Remove rear engine support -1- from cylinder block -4-.
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– Remove front engine support -3- from cylinder block -2-.
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4-cylinderut injection engine (2.0 l direct injection engine,eturbocharger)
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a ac
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– Separate connector -1-.
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– Move clear wiring harness -4-.
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– Unscrew bolts -3- and move coolant expansion tank -2- to one ot p
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– Separate electrical connector in direction of -arrow-.
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– Loosen screw-type clip -3-.

– Pull off pressure hose -2- from throttle valve module - J338-
-1- to charge air cooler.

– Remove pressure hose -1-.
– Remove air filter ⇒ page 216 .
– Detach electrical connector from intake hose.

4-cylinder injection engine (2.0 l direct injection engine, turbocharger)
. Volkswage
- Edition 06.2018
AG n AG d
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– Unscrew bolt -4-. db
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– Pull off pressure hoses from turbocharger -3-.
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– Pull pressure hose on right -2- towards the rear and off the
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charge air cooler.

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– Remove pressure hoses.

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– Loosen hose clips -2- and -3- and pull off coolant hoses from
radiator -1-.
– Open hose clips -1- and -2-.

– Pull coolant hoses -3- and -4- off heat exchanger.

Note
Bolts -2- are only loosened. They are unscrewed later.
– Loosen bolts -2- a maximum of 2 turns.
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– Detach electrical connectorise-3-
d of Lambda probe - G39- .
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– Unclip wiring harness s-2-
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The fuel system is pressurised.
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– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
rrectne
– Disconnect fuel lines -1- and -2- in engine compartment.

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– Pull the vacuum line off the brake servo.

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mer
Vehicles with dual clutch gearbox:

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– Remove selector lever cable from gearbox ⇒ Rep. gr. 34 ;

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Selector mechanism; Removing and installing selector lever

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– Clamp off coolant hoses -1- and -2- using hose clamps to 25
mm - 3094- and disconnect hoses from gear oil cooler.
Vehicles with manual gearbox:
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Detach gear selector cable.

– Pull out clip -arrow-.

– Separate slave cylinder of hydraulic clutch at electrical con‐
nector.
– Seal line at slave cylinder with clean plugs from engine bung
set - VAS 6122- .
Vehicles with all-wheel drive:
– Remove transfer box ⇒ Rep. gr. 39 ; Transfer box; Removing
and installing transfer box .
Note
Depending on equipment, it can be necessary to detach or dis‐

connect other connection, coolant, vacuum and intake hoses.
Note
satelettronica
Stud - T50046/1- is required to separate engine and gearbox after
removing.
– Attach stud - T50046/1- -1- with recess -arrow- to engine in

such a way that bolt -2- connecting engine and gearbox can
be unscrewed.
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– Introduce engine bracket - T50046- with mounting bolt placed ss
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in the holes -arrows- in the cylinder block.

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– Tighten stud - T50046/1- on engine bracket - T50046- . y li

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– Tighten bolt -1-. wit

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Prote AG.
Rep. gr.10 - Removing and installing engine
– Tighten engine bracket - T50046- to front of cylinder block with

bolt -arrow- and spacer sleeve - T50046/4- .
– Insert engine bracket - T50046- in engine and gearbox jack -
V.A.G 1383 A- and raise engine and gearbox slightly.
– Unscrew bolts -2-.
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– Only unscrewisbolts
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– Carefully lower engine and gearbox using engine and gearbox

jack - V.A.G 1383 A- in direction of -arrow-.
ss
– Carefully lower engine with gearbox, making sure that none of

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the connecting, coolant, vacuum and intake hoses are dam‐

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aged when doing so.

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– Check needle bearing -arrow- in crankshaft. If it is damaged

or has turned blue, it must be renewed ⇒ page 55 .
– Lightly lubricate needle bearings with high-temperature
grease - G 052 133 A2- .
– End of gearbox shaft (but not splines) also must be lightly
greased.
Specified torques
AG. Volkswagen AG d
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Component Specified torque
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Bolt securing spacer sleeve - T50046/4- 50 Nm
ab
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Stud - T50046/1- on engine bracket 50 Nm
wit
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Bolt securing engine bracket to cylinder block 50 Nm
hole
spec
es, in part or in w
t to the co
satelettronica
1.2 Securing engine on engine and gearbox support
rrectness of i
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equipment required
nform
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♦ Lifting tackle - 2024 A-

♦ Workshop hoist - VAS 6100-
♦ Engine and gearbox support - VAS 6095-
• Engine removed and mounted on engine support - T10359- .
• Gearbox detached from engine
– Attach lifting tackle - 2024 A- as follows and lift out using work‐
shop hoist - VAS 6100- .
Note
Use securing pins arrows on hooks and locking pins to avoid

damage to engine.
– Using workshop hoist - VAS 6100- , lift engine off engine and
gearbox jack - V.A.G 1383 A- .
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– Firmly bolt gearbox end of engine to the engine and gearbox
ce
le
un
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bracket - VAS 6095- as shown in the picture.

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1.3 Installing engine

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♦ Engine and gearbox jack - V.A.G 1383 A-
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♦ Stepladder - VAS 5085- cted agen
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♦ Spring-type clip pliers - VAS 6362-
Engine support - T50046-
♦ Vehicle diagnostic tester

Installing
Install in reverse order of removal, observing the following:

– Check clutch release bearing for wear and, if necessary, re‐

place (gearbox removed).
– Lightly grease input shaft splines with grease - G 000 100-
(gearbox removed).
– Check whether dowel sleeves for centring engine and gearbox
are in cylinder block; install if necessary (gearbox removed).
– Install engine with engine bracket - T50046- .
– Tighten new bolts -2-.
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orm
m
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or c
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– Tighten new bolts -arrows A- to body.

– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Install catalytic converter ⇒ page 243 .
Vehicles with manual gearbox:
– Join line with electrical connector to hydraulic clutch slave cyl‐
inder ⇒ Rep. gr. 30 ; Clutch mechanism; Removing and
installing clutch master cylinder .
– Install selector mechanism ⇒ Rep. gr. 34 ; Selector mecha‐
nism; Removing and installing selector mechanism .
– Install gear selector cable.
– Adjust selector mechanism ⇒ Rep. gr. 34 ; Selector mecha‐
nism; Adjusting selector mechanism .
– Mount and adjust selector lever cable of gearbox ⇒ Rep. gr.
34 ; Selector mechanism; Removing and installing selector
mechanism .
satelettronica
– If fitted, install air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor .
– Install front engine support ⇒ page 46 . n AG. Volkswagen AG do
lkswage es n
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– If present, install noise insulation ⇒ General body by V repairs, ex‐ ua
ed ran
terior; Rep. gr. 66 ; Noise insulation; Removingoris and installing tee
noise insulation . auth or
ac
ss
– Add coolant ⇒ page 163 .
ce
e
nl
pt
du
an
– Carry out road test and read all event memories ⇒ Vehicle
itte
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diagnostic tester.
ab
ility
ot p
Specified torques
wit
, is n
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 24
hole
spec
es, in part or in w
♦ ⇒ “4.1 Assembly overview - air filter housing”, page 215

t to the co
Component Specified torque rrectness of i
Nuts and M6 10 Nm
bolts
l purpos
M8 20 Nm
M10 45 Nm
nform
ercia
M12 60 Nm
m
at
om
Bolts for 3.5 Nm

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coolant ex‐
in t
or
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e
pansion tank
at
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AG. Volkswagen n AG do
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2 Assembly mountings ed ran
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⇒ “2.1 Assembly overview - assembly
s mountings”, page 24
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⇒ “2.2 Removing and installing engine mounting”, page 26
an
itte
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⇒ “2.3 Removing and installing engine mounting”, page 28
ility
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⇒ “2.4 Removing and installing gearbox mounting”, page 29
wit
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hole
⇒ “2.5 Supporting engine in installation position”, page 30
spec
es, in part or in w
2.1 Assembly overview - assembly mountings
t to the co
1 - engine mounts
rrectness of i
❑ Right
l purpos
❑ Removing and installing

⇒ page 28
nform
ercia
2 - Bolt
m
at
om
❑ Renew after removal
ion
c
in t
r
❑ 90 Nm +90°
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satelettronica
his
ate
do
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3 - Bolts
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❑ Qty. 3
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❑ Renew after removal Cop py
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❑ 50 Nm +90°
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4 - Bolts
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Prote AG.
❑ Qty. 3
❑ 40 Nm +180°
5 - Bolt
❑ 50 Nm +90°
6 - Bolts
❑ Qty. 3
❑ 50 Nm +90°
7 - Bolts
❑ Qty. 4
❑ 20 Nm +180°
8 - Engine mounting
⇒ page 26
9 - Bolt
❑ 50 Nm +90°
10 - Engine support
❑ Removing and installing ⇒ page 47
11 - Subframe
12 - Nuts
❑ Qty. 4

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13 - Bolts s au ra
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❑ Qty. 2
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❑ 20 Nm +90°
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14 - Engine mounting
wit
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❑ 20 Nm +90°
hole
spec
es, in part or in w
t to the co
15 - Engine support
rrectness of i
16 - Bolt
l purpos
❑ 90 Nm +120°
nform
ercia
17 - Bolts
m
a
❑ Qty. 3
com
tion in
r
te o
thi
s
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❑ 50 Nm +90°
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18 - Bolts
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❑ 50 Nm +90°
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19 - Engine support
20 - Bolt
❑ Qty. 2
❑ 50 Nm +90°
21 - Bolt
❑ Qty. 1
❑ 50 Nm +90°
Gearbox mounting
– Bolt gearbox mounting to longitudinal member using bolts
-A-.
– Bolt gearbox mounting to gearbox using bolts -B-.
Specified torques
Bolts -A- and -B- 50 Nm +90°
2. Assembly mountings 25
2.2 Removing and installing engine mount‐

ing
⇒ “2.2.1 Removing and installing front engine mountings”,
page 26
⇒ “2.2.2 Removing and installing rear engine mountings”,
page 26
⇒ “2.2.3 Removing and installing right engine mounting”,
page 27
2.2.1 Removing and installing front engine

mountings
satelettronica
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Removing
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noise insulation .
ot p
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– Unscrew bolt -3- from bracket -2-.

h re
ole,
spec

t to the co
– Remove engine mounting -1-.

Installing
rrectne

ss o
cial p
Note
inform
mer
Bolt -3- is the last to be tightened for all work, as this is used to
atio
m
achieve vertical tolerance compensation.

o
n
c
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Specified torques
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2.2.2 Removing and installing rear engine
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Removing
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noise insulation .
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– Remove engine support ⇒ page 47 .
– Remove nut -3-.
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satelettronica
– Remove bolts -1-.
s
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Installing
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Specified torques
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2.2.3 Removing and installing right engine

mounting
Removing
– Remove engine mounting ⇒ page 28 .
– If fitted, unscrew earth wire.

Installing
Specified torques
2.3 Removing and installing engine mount‐ AG. Volkswagen AG d

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Removing
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– Remove air filter housing ⇒ page 216 .

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ion
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do
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– Remove engine carrier -4-. cted agen
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Installing
Specified torques

2.4 Removing and installing gearbox

mounting G. Volkswage nA n AG d
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⇒ “2.4.1 Removing and installing gearbox mounting,
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⇒ “2.4.2 Removing and installing gearbox
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2.4.1 Removing and installing gearbox
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terior; Rep. gr. 66 ; Noise insulation; Removing and installing by c lksw
cted agen
noise insulation . Prote AG.
Note
To gain access to the upper bolts, lower the engine slightly if nec‐
essary.

– Remove gearbox mounting -1-.
Installing
Specified torques
2.4.2 Removing and installing gearbox

mounting, vehicles with dual clutch
gearbox
AG. Volkswagen AG d
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Removing
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noise insulation .
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Note
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To gain access to the upper bolt, lower the engine slightly if nec‐
o
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– Remove gearbox mounting -1-.

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Installing
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Specified torques
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2.5 Supporting engine in installation position


equipment required
satelettronica
AG. Volkswagen AG d
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♦ Support - 10 - 222 A-
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♦ Adapter - 10 - 222 A /3-

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♦ Adapter - 10 - 222 A /16-

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♦ Adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-

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– If necessary, equip adapter - 10 - 222 A /23- with adapter - 10
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– Remove cap -1-.

– Remove cap -2-, and unscrew support bolt -3- located beneath
it.
– Insert adapter - 10 - 222 A /23-1- -4- into adapter - 10 - 222
A /23- -5-.
– Insert bolt -6- from underneath in adapter - 10 - 222 A /23- and
tighten.
– Fit support bracket - 10 - 222 A- with adapter - 10 - 222 A /23-
satelettronica
and adapter - 10 - 222 A /23-1- as shown and take up weight
of engine in installation position.
Specified torques
AG. Volkswagen AG d
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Component ss Specifiedctorque
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Bolt -6- 40 Nm
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4-cylinder injection engine (2.0 l direct injection engine,
agen AG.turbocharger)
Volkswagen AG - Edition 06.2018
do w es n
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13 – Crankshaft group
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⇒ “1.1 Assembly overview - poly V-belt drive”, page 33
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⇒ “1.2 Removing and installing poly-V belt”, page 35
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⇒ “1.3 Removing and installing tensioner for poly V-belt”,
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⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,

page 45
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⇒ “1.7 Removing and installing engine support”, page 46
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1.1 Assembly overview - poly V-belt drive

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1 - Poly V-belt
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on belt pulleys.
❑ Poly V-belt routing
⇒ page 35
2 - Idler roller
❑ 20 Nm
3 - Bolt
❑ 150 Nm +90°
4 - O-ring
5 - Vibration damper
❑ With poly V-belt pulley
⇒ page 37
6 - Bolt
❑ 40 Nm
7 - Tensioning device for poly
V-belt
⇒ page 36
8 - Ancillary bracket
❑ With oil filter and engine
oil cooler
❑ Removing and installing ancillary bracket ⇒ page 43 .
❑ Removing and installing engine oil cooler ⇒ page 156
1. Cylinder block (pulley end) 33

9 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
10 - Bolts
❑ Qty. 4
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
11 - Bolts
❑ Qty. 5
❑ Observe tightening sequence ⇒ page 34
❑ 20 Nm +90°
12 - Bolt
❑ Specified torque ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted steering;
Assembly overview - vane pump
13 - Sleeve
14 - Vane pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted steer‐
ing; Removing and installing vane
wage
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Volkswagen AG
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15 - Air conditioner compressor
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or gr. 87 ; Air conditioner compressor;
Removing andss a installing air conditioner compressor from and to acbracket
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17 - Dowel sleeves
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❑ For air conditioner compressor.

18 - Bolts
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❑ Qty. 2
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Assembly overview - vane pump
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Bracket for ancillaries - tightening sequence

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34 Rep. gr.13 - Crankshaft group

Poly V-belt route with air conditioning system

1- Vibration damper
2- Idler roller
3- Poly V-belt tensioning element
4- Alternator
5- Vane pump
6- Air conditioner compressor
Poly V-belt route without air conditioner

1- Vibration damper
2- Idler roller
3- Poly V-belt tensioning element
4- Alternator
satelettronica
5- Vane pump
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♦ Locking tool - T40098-

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– Remove poly V-belt.
Installing
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Alternator and airssconditioner compressor must be firmly mounted
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– Fit poly V-belt as shown in figure.
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Vehicles without air conditioning system

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– Turn tensioning device in -direction of arrow- and withdraw

locking tool - T40098- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
1.3 Removing and installing tensioner for

poly V-belt

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– To slacken poly V-belt turn tensioning device in direction of
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rig ht
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Prote AG.
– Remove poly V-belt from tensioning device.

– Remove bolt -1- and take off tensioning device for poly V-belt
from bracket for ancillaries.
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 33
1.4 Removing and installing vibration damp‐

er
♦ Counter-hold tool - T10355-

♦ Assembly tool - T10531-
Components of assembly tool - T10531- :

♦ Support - T10531/1-
♦ Clamping pin - T10531/2- AG. Volkswagen AG d
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fore unscrewing the bolt, lock the timing sprocket in position
hole
spec
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Removing
– Remove poly V-belt ⇒ page 35 .
rrectness of i
– Relieve tension from tensioning device, and pull out locking
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– Turn vibration damper to TDC position -arrow- using counter-

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m
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• Notch on vibration damper must align with arrow marking on

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lower cover for timing chains

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– Use counterhold tool - T10355- to loosen bolt for vibration

damper by approx. half a turn.
– If vibration damper was turned while loosening bolt, reset TDC
position.

– Unscrew bolts -arrows-.
– Fit support - T10531/1- to vibration damper and tighten knurled

screws -arrows- by hand.
– Unscrew vibration damper bolt completely.
satelettronica
– Check if turning over tool - T10531/3- -A- slides easily over
clamping pieces -B-.
– If necessary, turn tensioning bolt -arrow-.
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– Tighten tensioning bolt -A- hand-tight.
– Unscrew knurled screws -arrows-.

– Remove support - T10531/1- and vibration damper -A-.
Turning crankshaft without vibration damper
satelettronica
AG. Volkswagen AG d
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– Fit turning over tool s-a T10531/3- -A- on clamping pin. Note
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T10531/4- -B-.
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– Turn crankshaft at hexagon -arrow-.

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– Fit turning over tool - T10531/3- -A- on clamping pin.
Note
The hexagon faces the vibration damper.
– Screw on flange nut - T10531/4- -B-, moving vibration damper

back and forth slightly when doing so.
Note
To check whether the vibration damper is correctly located in the

teeth: Tighten the flange nut until the vibration damper can no
longer be turned.
– Fit support - T10531/1- to vibration damper and tighten knurled

screws -arrows- by hand.

– Unscrew flange nut - T10531/4- -A-.

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– Unscrew knurled screws -arrows-, and remove support -
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– Tighten bolt for vibration damper using counter-hold tool -

T10355- .

– Screw in new bolts -arrows-.

Specified torques
1.5 Removing and installing bracket for an‐

cillaries
satelettronica
Removing
– Remove poly V-belt ⇒ page 35 . n AG. Volkswagen AG do
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Air conditioner compressor; Removing and installing air con‐

ditioner compressor from/on bracket .
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– Remove vane pump and tie up on longitudinal member with

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– Remove bolt -arrow- for dipstick
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♦ Renew O-rings and seals.
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– Coat O-ring -4- with coolant and install on connection -2-.

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– Push ancillary bracket -1- on connection. C py
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– Start bolts and tighten ⇒ page 34 .
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– Install vane pump ⇒ Running gear, axles, steering; Rep. gr.
AG.
48 ; Hydraulic power-assisted steering; Removing and instal‐

ling vane pump .
– If fitted, install air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Removing and installing air conditioner
compressor .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install poly V-belt ⇒ page 35 .
– If present, install noise insulation ⇒ General body repairs, ex‐
noise insulation .
Specified torques

1.6 Renewing crankshaft oil seal - belt pul‐

ley end n AG. Volkswagen A ge G do
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♦ Thrust piece - T10354- oris tee
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♦ Thrust piece - T10368-
nform
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satelettronica
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♦ Extractor hook - T40274-

Removing
– Remove vibration damper ⇒ page 37 .
– Pull out oil seal using puller hooks - T40274- .
Installing
– Clean contact surface and sealing surface.
– Fit oil seal -arrow- with press piece - T10354- .
satelettronica
– Attach additional thrust piece - T10368- and tighten flange nut
-A-.
– Install oil seal onto stop using thrust piece - T10182- .
– Install vibration damper ⇒ page 37 .
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1.7 Removing and installing engine support

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⇒ “1.7.1 Removing and installing front engine support”,

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⇒ “1.7.2 Removing and installing rear engine support”,

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page 47
⇒ “1.7.3 Removing and installing right engine support”,
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page 48
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1.7.1 Removing and installing front engine

support
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Removing
position .
– Remove front engine mounting ⇒ page 26 .
satelettronica
– Remove engine support -1-.
Installing . Volkswagen AG
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Specified
thotorques
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♦ ⇒ s“2.1
s
Assembly overview - assembly mountings”, page 24
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1.7.2 Removing and installing rear engine

support
nform
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Removing
– Remove rear engine mounting ⇒ page 26 .
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– Remove engine support -1-. y Vo lk ot g
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Installing ir se tee
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Install in reverse order of removal, observing the following: ss
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Specified torques
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satelettronica
1.7.3 Removing and installing right engine
nf
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Removing
– Remove engine mounting ⇒ page 28 .
noise insulation .

satelettronica
Installing
AG. Volkswagen AG d
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Engine support tightening sequence
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– Then tighten bolts as per tightening sequence. spec

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– Install engine mounting ⇒ page 28 .

t to the co
Specified torques
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AG. Volkswagen
Transporter 2016 ➤ ksw
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4-cylinder injection engine
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ara - Edition 06.2018
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⇒ “2.1 Assembly overview - flywheel”, page 50 itte
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⇒ “2.2 Removing and installing flywheel”, page 51
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⇒ “2.4 Renewing needle bearing in drive plate”, page 55
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2.1 Assembly overview - flywheel
rrectness of i
1 - Cylinder block
l purpos
2 - Dowel pin
nform
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❑ Not installed
m
3 - Sealing flange on gearbox
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❑ With seal
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❑ Renew only as com‐

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❑ Qty. 8
❑ Observe tightening se‐
quence ⇒ page 51
❑ 9 Nm
5 - Adapter
❑ Must seat on dowel
sleeves.
❑ Do not damage or bend
when assembling.
❑ Is fitted onto sealing
flange ⇒ page 51
6 - Bolts
❑ Qty. 8
❑ 60 Nm +90°
7 - Flywheel
❑ Can only be installed in
one position, holes are
offset.
⇒ page 51
8 - Dowel pin
❑ Not installed

Sealing flange at gearbox end - tightening sequence

– Tighten bolts -1 … 8- in the sequence shown:
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Install intermediate plate. rise
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– Engage intermediate plate s a on sealing flange, and press onto
u ra
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2.2 Removing and installing flywheel
l purpos
nform
♦ Counter-hold tool - 3067-
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Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
2. Cylinder block, gearbox end 51

Note
To avoid damaging the flywheel when removing, the bolts -B-

must not be removed with an impact driver or similar. It is only
permissible to remove the bolts by hand.
– Mark position of flywheel in relation to engine.

– Rotate dual-mass flywheel -A- so that bolts -B- align centrally
with the holes -arrows-.
– When unscrewing bolts -B-, ensure that bolt heads do not
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged when turning further.
AG. Volkswagen AG d
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– Insert counterhold - 3067- in hole on cylinder block -B-.
an
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– Unscrew flywheel.
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– Insert counter hold - 3067- in hole on cylinder block -A-. t. Cop py
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Specified torques yri
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♦ ⇒ “2.1 Assembly overview - flywheel”, page 50
agen
Prote AG.

2.3 Removing and installing sealing flange

on gearbox side
♦ Guide piece - T10122/6- or guide piece - T10122/6A- from fit‐
ting tool - T10122B- or fitting tool - T10122C-
AG. Volkswagen AG d
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♦ Assembly aid - T10122/1- from fitting
aut tool - T10122B- or fitting
h eo
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tool - T10122C- ss c
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♦ Hand drill with plastic brush attachment

♦ Safety goggles
nform
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♦ Sealant ⇒ Electronic parts catalogue (ETKA)

m
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com
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Removing
n in
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– Remove flywheel or drive plate ⇒ page 51 .

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– Detach intermediate plate from sealing flange and dowel pins

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-arrows-.
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– Unscrew bolts -1 to 8-.

– Remove sealing flange.
Installing
– In order to prevent the lubrication system from being soiled,
cover the open section of the sump with a clean cloth.
CAUTION
Risk of eye injury caused by sealant residue.
satelettronica
– Remove sealant residue.

– Clean sealing surfaces.
Note agen
AG. Volkswagen AG d
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Observe use-by date of silicone sealant.
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– Cut off nozzle on tube at front
s marking (∅ of nozzle approx.
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– Apply silicone sealant -arrow- to clean sealing surface of seal‐

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ing flange.
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• Thickness of sealant bead: 2 to 3 mm

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Note
♦ Check sealing flange; it must be free of kinks and damage.

♦ The sealing lip must face engine following installation. Other‐
wise, oil leaks may occur.
♦ Install the sealing flange within 5 minutes after application of
the silicone sealant.
AG. Volkswagen AG d
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V gu
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– Check guide - T10122/6- -B-; it must be ut clean and free of sharp
ho eo
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satelettronica
a
edges. ss c
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– Attach assembly aid - T10122/1- -A- to guide - T10122/6-
an
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– Push sealing flange -C-, with outer side leading, onto guide
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– Remove assembly aid -A-.
spec
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nform
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– Put guide -A- with sealing flange -B- onto crankshaft journal.
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It is not necessary to tighten the bolts -arrows-.
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Prote AG.
– Push sealing flange -B- over guide -A- onto crankshaft journal.
– Remove guide -A-.
– Tighten bolts; observe tightening sequence ⇒ page 51 .
• After installing the sealing flange, wait about 30 minutes for
the sealant to dry. Only then fill with engine oil.
Specified torques
♦ ⇒ “2.1 Assembly overview - flywheel”, page 50
2.4 Renewing needle bearing in drive plate


equipment required
AG. Volkswagen AG d
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satelettronica
au ra
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nl
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♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-

om
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♦ Internal puller e.g. KUKKO 21-2 - VAS 251 605-

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♦ Centring mandrel - 3176-

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♦ Drift - VW 207 C-
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Removing
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• Gearbox is separated from engine.
co lksw
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– Pull out needle bearing using internal puller, e.g. KUKKO 21-2
- VAS 251 605- and counter support e.g. KUKKO 22-1 - VAS
251 621- -A-.

Installing
Note
The lettering on the needle bearing must be visible when installed.
– Drive in needle bearing using drift - VW 207 C- or centring

mandrel - 3176- .
– Drive needle bearing in carefully.
– Constantly measure insertion depth when driving in.
– Renew bearing if driven in too deep.
Installation depth dimension a = 1.5 to 1.8 mm.

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3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 58
⇒ “3.2 Crankshaft dimensions”, page 59
⇒ “3.3 Measuring axial clearance of crankshaft”, page 59
⇒ “3.4 Measuring radial clearance of crankshaft”, page 60
⇒ “3.5 Allocation of main bearing shells”, page 61
⇒ “3.6 Removing and installing sender wheel”, page 62
3.1 Assembly overview - crankshaft
1 - Cylinder block
2 - Bearing shells for cylinder lkswage es n
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❑ Qty. 5 utho
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❑ With oil groove. ss
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❑ Do not interchange
pt
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used bearing shells
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bearing shells
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⇒ page 61
hole
spec
es, in part or in w
3 - Crankshaft
t to the co
❑ After removing, place
down in such a way that
sender wheel does not
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rest on surface and be‐
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come damaged
❑ If crankshaft is renewed,
bearing shells must be nform
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reassigned to bearing
m
cap ⇒ page 61
at
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ion
❑ Axial clearance
c
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⇒ page 59
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❑ Radial clearance
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⇒ page 60
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❑ Crankshaft dimensions
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Prote AG.
⇒ page 59 .
4 - Bearing bushes
❑ Qty. 5
❑ Without oil groove.
used bearing shells (mark).
❑ Marking of crankshaft bearing shells (classification) ⇒ page 61
5 - Bolts
❑ Qty. 10
❑ Tightening sequence ⇒ page 59
6 - Bearing cap
❑ Qty. 5

❑ Bearing cap 1: belt pulley end.
❑ The bearing shell retaining lugs in cylinder block and bearing caps must be aligned with each other
7 - Bolt
❑ Qty. 3
❑ Sender wheel must be renewed if bolts are loosened ⇒ page 62
❑ 10 Nm +90°
8 - Sender wheel
❑ For engine speed sender - G28-
❑ Can only be installed in one position (holes are offset).
❑ Sender wheel must be renewed if bolts are loosened
9 - Thrust washers
❑ Qty. 2
❑ For bearing 3
10 - Bolt
satelettronica
Crankshaft tightening sequence

– Tighten crankshaft bolts in the sequence -1 … 5- as follows.
1. Tighten bolts -1 to 10- and -arrows- by hand.
2. Pre-tighten bolts -1 to 10- to 65 Nm.
3. Turn bolts -1 to 10- 90° further using a rigid wrench.
4. Pre-tighten bolts -arrows- to 20 Nm. AG. Volkswagen AG d
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5. Turn bolts -arrows- 90° further using a rigid wrench. by Vol not
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3.2 Crankshaft dimensions

(Dimensions in mm)
rrectness of i
Honing dimension Main journal ∅ Conrod journal ∅

l purpos
1)
Basic dimension 58.00 47.80

nf
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orm
1)
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No provision has yet been made to recondition worn crank‐

atio
m
shafts.
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3.3 Measuring axial clearance of crankshaft

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3. Crankshaft 59
♦ Universal dial gauge holder - VW 387-
. Volkswagen AG
♦ Dial gauge - VAS 6079- kswagen AG does
not
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– Screw dial gauge - VAS 6079- with universal dial gauge holder
l purpos
- VW 387- onto cylinder block and set against crank web.

– Press crankshaft against dial gauge by hand and set gauge to
nform
ercia
“0”.
m
– Push crankshaft away from dial gauge and read off value.
com
tion in
Axial clearance:
r
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• New: 0.07 … 0.23 mm

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• Wear limit: 0.30 mm

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3.4 Measuring radial clearance of crank‐
ht
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♦ Plastigage
Note
♦ Mark used bearings for re-installation but not on bearing sur‐

face.
♦ If the bearing shells have worn down to the nickel layer, they
must be renewed.
– Remove bearing cap and clean crankshaft journal.

– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
• The Plastigage must be in the middle of the bearing shell

– Fit bearing cap and tighten.

– Do not rotate crankshaft.
– Remove bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.017 … 0.037 mm agen
AG. Volkswagen AG d
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• Wear limit: 0.15 mm d by gu
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3.5 Allocation of main bearing shells th
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Bearing shells of the correct thickness are allocated to the cylin‐
nl
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thickness of the bearing shells.
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Which bearing shell is to be inserted at each place in the cylinder
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block (upper bearing shell) is marked by letters on the lower seal‐
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ing surface or on the front side of cylinder block.
hole
spec
es, in part or in w
Which bearing shell is to be inserted at each place in bearing cap
t to the co
(lower bearing shell) is marked by letters on the crankshaft.
satelettronica
The first letter is allocated to bearing cap 1, the second to bearing
rrectness of i
cap 2, etc.
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Marking on bearing shell for cylinder block:
nform
ercia
Note
m
at
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io
The marking on the cylinder block can be found engraved either
n
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in the sump sealing surface or in the front end (gearbox side) of

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the cylinder block.

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Identification on cylinder block is allocated to upper bearing shell
(bearing shell for cylinder block).
– Note letters and identify colour code to be installed based on
table.
3. Crankshaft 61
Marking on bearing shell for bearing cap:

Identification on crankshaft is allocated to lower bearing shell
(bearing shell for bearing cap).
– Note letters and identify colour code to be installed based on
table.
S = black
R = red
G = yellow
B = blue
AG. Volkswagen AG d
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W = white Volksw
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3.6 Removing and installing sender wheel
h re
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hole
spec
Removing
es, in part or in w
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– Remove engine ⇒ page 8 .
– Remove sealing flange on gearbox side ⇒ page 53 .
rrectness of i
– Remove upper part of sump ⇒ page 147 .
l purpos
– Remove balancer shaft timing chain ⇒ page 116 .

– Unscrew conrod bearing cap.
nform
mercia
– Remove crankshaft bearing cap.
at
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ion
c
– Remove crankshaft and unscrew sender wheel.
in t
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ate
– Always renew sender wheel -2- each time bolts -1- are loos‐
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♦ The second time the bolts are tightened, the contact points in
cted agen
Prote AG.
the sender wheel for the countersunk heads are deformed so
much that the bolt heads seat on the crankshaft -3-, -arrows-
and the sender wheel is loose under the bolts.
♦ Sender wheel can only be installed in one position. The holes
are offset.
Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 58

4 Balancer shaft
⇒ “4.1 Assembly overview - balance shaft”, page 63
⇒ “4.2 Removing and installing balance shaft”, page 64
4.1 Assembly overview - balance shaft
1 - Bolt
❑ 9 Nm
2 - Balancer shaft
❑ Inlet side
❑ Lubricate bearing with
engine oil
⇒ page 64
satelettronica
3 - Balancer shaft
❑ Exhaust side
❑ Must always be re‐
newed if removed
engine oil
⇒ page 67
4 - Bolt
❑ 9 Nm
5 - Tube for balancer shaft AG. Volkswagen AG d
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❑ Fitting position ed by
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⇒ page 63 horis nte
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6 - Seal for balance shaft, inlet ss c
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Tube for balancer shaft - installation position

• Lug on tube for balance shaft must engage in slot -arrow-.
rrectness o
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63
AG.
4. Balancer shaft
4.2 Removing and installing balance shaft

⇒ “4.2.1 Renewing balancer shaft for inlet camshaft”, page 64
⇒ “4.2.2 Renewing balancer shaft for exhaust
AG. Vocamshaft”,
lkswagen AG
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⇒ “4.2.3 Renewing oil seal risfor balance shaft (inlet side)”,
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4.2.1 Renewing balancer shaft for inlet cam‐
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Removing
Note
The balancer shaft for the inlet camshaft must always be renewed
after removing.
– Remove drive sprocket and toothed belt for coolant pump

⇒ page 180 .
– Remove camshaft timing chain ⇒ page 104 .
– Lower engine with support bracket - 10 - 222 A- slightly until
balance shaft is accessible.

– Remove intermediate shaft sprocket -1-.
– Unscrew bolt -2- for balance shaft of inlet camshaft.
satelettronica
– Insert shell half - T10394/1- from puller - T10394- and turns
upwards in direction of arrow. agen
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– Insert puller - T10394- and push locking collar in

-direction of arrow-.
rrectness of i
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4. Balancer shaft 65
– Screw puller - T10055- into puller - T10394- and force out bal‐
ance shaft in -direction of arrow-.
Installing
Note
Due to the small amount of play between the balancer shaft and
cylinder block, the balancer shaft may need to be installed chilled.
Check whether the balancer shaft can be fitted into the cylinder
block without exerting force. If this is not the case, the balancer
shaft must be chilled before installing.
– If necessary, place new balance shaft in freezer compartment

for 30 minutes or spray with commercially available cooling
spray.
– Lubricate balancer shaft bearing with engine oil.
– Install new balance shaft for inlet camshaft and tighten bolt
-2-.
satelettronica
AG. Volkswagen AG d
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– Renew O-ring -1- and lubricate with engine oil.
hole
spec
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Note
Dowel pin -arrow- for bearing mounting must engage in bore in

rrectness of i
cylinder block.
l purpos
– Coat bearing mounting with engine oil and insert.

nform
mercia
Note
at
om
ion
c
in t
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♦ The intermediate shaft sprocket must be replaced. Otherwise

o
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te
no tooth backlash is set, engine damage.

a
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♦ The new intermediate shaft sprocket is coated with a solid film

f
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lubricant that wears off after a short period and thus automat‐
t.
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ically sets the tooth backlash.
C py
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– Mark faces of gear teeth of intermediate shaft sprocket with

paint -arrows-. wage
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– Insert intermediate shaft sprocket;
d b marking on balancer shaft
y ara
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must be positioned betweenthomarkings on faces of gear teeth.
ri
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es, in part or in w
t to the co
– Tighten bolt -1- for intermediate shaft sprocket: tightening se‐
quence ⇒ page 102 .
rrectness of i
– Check markings on intermediate shaft sprocket/balancer shaft
-arrow-.
l purpos
– Install balance shaft timing chain ⇒ page 116 .
nform
ercia
– Install camshaft timing chain ⇒ page 104 .
satelettronica
m
a
– Install timing chain cover (bottom) ⇒ page 96 .
com
tion in
r
– Install timing chain cover (top) ⇒ page 96 .

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– Install plenum chamber bulkhead on left and right ⇒ General
en
ng
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body repairs, exterior; Rep. gr. 50 ; Plenum chamber bulk‐ Cop py
head; Removing and installing plenum chamber bulkhead .
t. rig
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– Install tensioner for poly V-belt ⇒ page 36 .
c by lksw
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Prote AG.
– Renew oil seal for coolant pump drive ⇒ page 175 .
– Install drive sprocket and toothed belt for coolant pump
⇒ page 180 .
noise insulation .
Specified torques
♦ ⇒ “3.1 Assembly overview - drive chain for balance shaft”,
page 100
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 171
♦ ⇒ “2.1 Assembly overview - cover for timing chain”,
page 94
4.2.2 Renewing balancer shaft for exhaust

camshaft
♦ Puller - T10394- AG. Volkswagen AG d

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Removing
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Note
The balancer shaft for the inlet camshaft must always be renewed
after removing.

– Lower the engine with the support bracket - 10 - 222 A- slightly
until the balance shaft is accessible.
– Unscrew bolt -1- for balance shaft of exhaust camshaft.

– Insert shell half -T10394/1- from puller - T10394- .
– Insert puller - T10394- and push locking collar in

-direction of arrow-. wage
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es, in part or in w
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– Screw puller - T10055- into puller - T10394- and force out bal‐
ance shaft.
rrectness of i
Installing
l purpos

nform
ercia
Note
m
at
om
io
Due to the small amount of play between the balancer shaft and
n
c
in t
or
cylinder block, the balancer shaft may need to be installed chilled.

his
te
Check whether the balancer shaft can be fitted into the cylinder
a
do
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block without exerting force. If this is not the case, the balancer
p
cum
or
shaft must be chilled before installing.

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– Install tube for balance shaft in direction of -arrow-.
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Prote AG.
Note
Lug -arrow- must engage in slot.
– If necessary, place new balance shaft in freezer compartment

for 30 minutes or spray with commercially available cooling
spray.
– Lubricate balancer shaft bearing with engine oil.
– Install balancer shaft for exhaust camshaft.

– Before tightening bolt -1-, check that balance shaft rests flat
against crankcase.
Note
If the balancer shaft does not rest flat, the pipe for balancer shaft
must be inserted again.
– Install balance shaft timing chain ⇒ page 116 .

– Install timing chain cover (bottom) ⇒ page 96 .
– Install plenum chamber bulkhead on left and right ⇒ General
body repairs, exterior; Rep. gr. 50 ; Plenum chamber bulk‐
head; Removing and installing plenum chamber bulkhead .
satelettronica
noise insulation .
Specified torques
♦ ⇒ “3.1 Assembly overview - drive chain for balance shaft”, agen
AG. Volkswagen AG d
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♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 33 ris
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4.2.3 Renewing oil seal for balance shaft (inlet

ab
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Special tools and workshop equipment required spec

es, in part or in w

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Removing
Co
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– Remove toothed belt for coolant pump ⇒ page 180 .
gh ht
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– Detach drive sprocket -1- for toothed belt for coolant pump.
AG. Volkswagen AG d
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– Press screwdriver -1- firmly onto section -2- ed byof oil seal
V gu
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-arrow B-. horis nte
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– Lever out seal using screwdriver -1-s in direction of -arrow A-.
s c
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spec
es, in part or in w
t to the co
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– Lubricate sealing surface of balance shaft -2- with gear oil.
l purpos
– Fit seal -1- onto balance shaft.
nf
ercia
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Note
rm
m
atio
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Inscription -arrow- must be readable from above.

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AG. Volkswagen AG d
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V
Transporter 2016 ➤ d by gu
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ise nte
4-cylinder injection engine (2.0thol direct injection engine, turbocharger) - Edition
r e o 06.2018
au ra
ss c
– Apply thrust piece - T10353- to oil seal -1- and press into cyl‐
ce
le
un
pt
inder block as far as possible using bolt -2- (take care not to
an
d
itte
cant oil seal).
y li
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ab
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ility
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Note
h re
hole
spec
♦ Risk of damage to thread.
es, in part or in w
t to the co
♦ The drive sprocket bolt has a left-hand thread.
rrectness of i
Installing
l purpos

– Fit toothed belt for coolant pump ⇒ page 180 .
nform
ercia
– Install small coolant pipe.

m
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tion in
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Note
te o
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Never reuse old coolant.
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satelettronica
t.
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– Add coolant ⇒ page 163 . C py
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Specified torques cop Vo
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AG.
page 171

AG. Volkswagen
lkswagenturbocharger) A- GEdition
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5 Pistons and conrods ss
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⇒ “5.1 Assembly overview - pistons and conrods”, page 73
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⇒ “5.2 Removing and installing pistons”, page 74
erm
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ility
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⇒ “5.3 Checking pistons and cylinder bores”, page 76
wit
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⇒ “5.4 Separating new conrod”, page 77
hole
spec
⇒ “5.5 Checking radial clearance of conrods”, page 78
es, in part or in w
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5.1 Assembly overview - pistons and conrods
rrectness of i
1 - Conrod bolts
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❑ Qty. 2
nf
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❑ Oil threads and contact
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❑ Use old bolt for measur‐
or c
ing radial clearance.
thi
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❑ To measure radial clear‐
o
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ance, tighten to 30 Nm
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but not further.

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❑ 45 Nm +90°
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2 - Conrod bearing cap
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❑ Observe installation po‐
AG.
sition
❑ Due to industrial crack‐
ing, the caps only fit in
one position and only on
the appropriate conrod
❑ Mark with cylinder num‐
ber -A-.
❑ Installation position:
Marking -B- faces to‐
wards pulley end.
3 - Bearing bushes
❑ Qty. 2
❑ Fitting position
⇒ page 74
used bearing shells
(mark).
❑ Axial clearance, new:
0.10 … 0.35 mm, wear
limit: 0.40 mm
❑ Measure radial clear‐
ance using Plastigage; new: 0.02 … 0.06 mm; wear limit: 0.09 mm. Do not rotate crankshaft when
checking radial clearance.
4 - Pressure relief valve
❑ 27 Nm
5 - Oil spray jet
❑ For piston cooling
6 - Retaining rings
❑ Qty. 2
5. Pistons and conrods 73

7 - Piston pin
❑ If difficult to move, heat piston to approx. 60°C
❑ Remove and install using drift - VW 222 A- .
8 - Piston
❑ Checking ⇒ page 76
❑ Mark installation position and cylinder number.
❑ Arrow on piston crown points to belt pulley end. agen
AG. Volkswagen AG d
oes
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❑ Install using piston ring clamp. d by
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❑ Piston and cylinder dimensions ⇒ h opage
r 76 . eo
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❑ Checking cylinder bores ⇒ page ss 77 . c
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9 - Compression rings
pt
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❑ Qty. 2
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❑ Offset gaps by 120°
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❑ Use piston ring pliers to remove and install.
h re
hole
❑ “TOP” or “R” marking must face upwards towards piston crown.
spec
es, in part or in w
❑ Checking ring gap ⇒ page 76 .
t to the co
❑ Checking ring-to-groove clearance ⇒ page 77 .
satelettronica
10 - Oil scraper ring
rrectness of i
❑ Two-piece design.
l purpos
❑ Offset gap of top steel element of piston ring by 120° to next compression ring
❑ Offset gaps of individual parts of oil scraper ring
nform
ercia
❑ Checking ring gap ⇒ page 76 .

m
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❑ Ring-to-groove clearance not measurable.
com
tion in
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11 - Connecting rod
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❑ Renew as set only.

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❑ Mark with cylinder number -A-.
fo
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❑ Installation position: Marking -B- faces towards pulley end.
Co
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❑ Separate new conrod ⇒ page 77
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Prote AG.
Bearing shells - installation position

– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Distance -a- must be identical on both sides.
5.2 Removing and installing pistons


♦ Drift - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
– Secured engine on engine and gearbox support - VAS 6095-
⇒ page 18
– Remove cylinder head ⇒ page 82 .
– Remove upper part of sump ⇒ page 147 .
satelettronica
– Mark piston installation position and corresponding cylinder
number.
– Mark conrod installation
wage
n AGposition
. Volkswagand corresponding
en AG
does cylinder
number ⇒ Item
y Vo 11 (page 74) .
lks not
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ed
– Remove tho
risconrod bearing cap and withdraw piston nand
tee conrod
or
upwards.
s au ac
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If the piston pin is difficult to move, heat the piston to approx. 60°
wit
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C.
h re
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spec
– Remove retaining ring from piston pin eye.

t to the co
– Drive out piston pin using drift - VW 222 A- .

Installing
rrectne

ss o
cial p
f i
Note
nform
mer
atio

om
angle.
c
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♦ Arrow on piston crown points to belt pulley end.

t
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♦ Offset piston ring gaps by 120°.

fo
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ng
t.
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– Oil running surfaces of bearing shells.
t. C rig
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– Install piston with commercially available piston ring clamp,
co lksw
by
cted agen
noting installation position ⇒ Item 8 (page 74) .
Prote AG.
– Install conrod bearing cap, noting installation position

⇒ Item 2 (page 73) .
– Install cylinder head ⇒ page 82 .
– Install upper part of sump ⇒ page 147 .

Specified torques
♦ ⇒ “5.1 Assembly overview - pistons and conrods”, page 73
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 79
5.3 Checking pistons and cylinder bores

♦ External micrometre 75 - 100 mm - VAS 6071-
satelettronica
♦ Feeler gauge, commercially available
Checking piston
– Measure approx. 15 mm from lower edge, offset 90° from
piston pin axis with a 75 … 100 mm external micrometer.
♦ Difference between actual and nominal diameter max.
0.04 mm.
Piston ∅ Cylinder bore ∅
Basic dimension mm 82.4651) 82.51
• 1)
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear
agen
down.
AG. Volkswagen AG d
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Checking piston ring gap utho eo
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– Push piston ring at right angles to cylinder wall from above
ce
le
down to approx. 15 mm from bottom end of cylinder. Push in

un
pt
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using a piston without rings.

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ility
Piston ring New Wear limit

ot
dimensions in mm
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hole
compression ring 0.20 … 0.40 0.80

spec
es, in part or in w
Oil scraper ring 0.25 … 0.50 0.80

t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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co lksw
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Prote
76
AG.
Rep. gr.13 - Crankshaft group
Checking ring-to-groove clearance

– Clean annular groove of piston before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 … 0.09 0.20
2nd compression ring 0.03 … 0.06 0.15
Oil scraper rings Cannot be measured
Checking cylinder bores
olks
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– Using cylinder
ir se
d gauge - VAS 6078- take measurements ran
tee at 3
positions
uth diagonally in lateral direction -A- and longitudinal
o
or
ac
di‐
a
rection
ss -B-.
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un
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NOTICE
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ab
Risk of damage to the surface of the cylinder bore caused by
ility
ot p
satelettronica
incorrect machining.
wit
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– Do not machine cylinder bore (reboring, honing, grinding)
h re
ole,
with workshop equipment.
spec
– Using a cylinder gauge - VAS 6078- , take measurements at t to the co

3 positions diagonally in the lateral direction -A- and in the
longitudinal direction -B-.
rrectne
♦ Difference between actual and nominal diameter max.

0.08 mm.
ss o
cial p
f i
Cylinder bore ∅
nform
mer
Basic dimension m
82.51
atio
m
m
o
n
c
i
or
n thi
te
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Note
p
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fo
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ng
t.
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Do not measure cylinder bores when cylinder block is mounted
Co
Cop py
on engine and gearbox support - VAS 6095- , as measurements
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may be incorrect.
p by
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by lksw
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Prote AG.
5.4 Separating new conrod

Note
♦ To avoid damage, only clamp the conrod lightly in a vice and

use protective jaw covers.
♦ On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:

– Clamp conrod -1- below dashed line.

– Unscrew bolts -2- approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -1- in direction of -arrow- until it is loose.
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• New: 0.02 … 0.06 mm
• Wear limit: 0.09 mm
– Renew conrod bolts.
Specified torques
Conrod bearing cap bolts 45 Nm +90°

15 – Cylinder head, valve gear

1 Cylinder head
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2 - Bolt
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3 - Engine lifting eye
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❑ Check for distortion
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⇒ page 81 .
⇒ page 82
6 - Cylinder head bolts
❑ Qty. 10
❑ Observe specified tor‐
ques and tightening se‐
quence ⇒ page 82
7 - O-ring
❑ Moisten with engine oil.
❑ Check for damage
❑ Not a replacement part,
provided together with
actuator for camshaft adjustment
8 - Actuator for camshaft adjustment -F366- / -F373-
❑ Qty. 8
9 - Bolts
❑ Qty. 8
❑ 5 Nm
1. Cylinder head 79
10 - O-rings
❑ Qty. 2
❑ Lubricate with engine oil
11 - Plug
❑ Qty. 2
❑ With ball head for engine cover panel
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15 - Bracket
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16 - Bolts
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❑ 9 Nm
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17 - Heat shield
18 - Bolt
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23 - Seal
24 - Bolts
❑ Qty. 10
❑ 11 Nm
25 - Crankcase ventilation
26 - To intake manifold
27 - Seal
28 - Seal
❑ Renew if damaged
29 - Vacuum pump
80 Rep. gr.15 - Cylinder head, valve gear

30 - Bolt
❑ 9 Nm
31 - Retaining plate
32 - Bolt AG. Volkswagen AG d
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37 - Bolt
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38 - Hall sender - G40-
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♦ The bolts are self-tapping. When renewing cylinder head, only
genuine bolts may be used since cylinder head is supplied
without thread to attach crankcase breather system.
♦ It is not permissible to tap threads with a thread tap.
– Tighten bolts for crankcase breather in the sequence

-1 … 10-.
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
♦ Max. permissible distortion: 0.05 mm
1. Cylinder head 81
Loosening cylinder head bolts

– Slacken cylinder head bolts in the sequence -1 to 10-.
Tightening sequence for cylinder head

– Tighten cylinder head bolts in the sequence -1 … 10- as fol‐
lows.
1. Using a torque wrench, pre-tighten bolts with strength rating
of 10.9 to 40 Nm, pre-tighten bolts with strength rating of
12.9 to 50 Nm.
2. Use fixed wrench to turn 90° further.
satelettronica
3. Use fixed wrench to turn 90° further.
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4. Pre-tighten bolts -arrows-swtoag8enNm.
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♦ Removal tool - T10352- and removal tool - T10352/1-
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♦ Contour blade set - VAS 852 005- (not illustrated) or commer‐
cially available CERAN surface scraper
Removing
Note
♦ Fit the cable ties in the original position when installing.

♦ Always seal open channels of the intake connecting pipe and
exhaust system with suitable plugs, for example from the en‐
gine bung set - VAS 6122- .
1. Cylinder head 83
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spec
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– Remove turbocharger ⇒ page 196 .
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– Release brake servo vacuum line.
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– Remove coolant hose on cylinder head.

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– Completely remove pressure hose from the throttle valve con‐

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Note
Disregard positions -1- and -2-.
– Remove ignition coils ⇒ page 248 .

– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Remove oil separator ⇒ page 157 .
– Detach hose clip -2- for fuel supply line -3-.

– Pull fuel supply line -3- off high-pressure pump -1-.
– Detach fuel lines for activated charcoal filter solenoid valve 1
- N80- .
– Unclip fuel lines from guide and lay aside.
– Detach electrical connectors from intake air temperature send‐
er - G42- , solenoid valve 1 for activated charcoal filter - N80- ,
throttle valve control module - J338- and Hall sender - G40- .
– Unclip wiring harness from intake manifold and place to one
side.
– Unscrew bolt -arrow- on intake manifold support.

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– Unscrew bolts -arrows- from intake manifold.
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– Release and separate electrical connector -arrow- from fuel
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pressure sender - G247- using assembly tool - T10118- .
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– Remove timing chain cover (top) ⇒ page 96 .
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– Turn vibration damper to TDC position -arrow- using counter‐

hold - T10355- .
bottom cover for timing chains
• Markings -1- on camshafts must face upwards.
– Depending on model, remove regulating valve using removal

tool - T10352- or removal tool - T10352/1- in
-direction of arrow-.
Note
The timing valve has a left-hand thread.
1. Cylinder head 85

– Remove bearing saddle.
– Remove right engine support ⇒ page 48 .

hold - T10355- .
lower cover for timing chains
satelettronica
– Use a waterproof pen to mark drive chain/chain sprockets
-arrows-.
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– Insert scriber or suitable screwdriver in hole of chain tensioner

in direction of -arrow 1- and lift locking element for chain ten‐
sioner.
– Turn crankshaft in opposite direction to normal rotation
-arrow 2- and lock in place using locking pin - T40011- .
Note
Inlet camshaft will move in direction of engine rotation.

– Guide tensioning rail -2- downwards.
– Remove upper guide rail -3-. Release catch with a screwdriver
and push guide rail off towards the front of vehicle.
– Remove camshaft timing chain from camshaft sprockets.
satelettronica
Note
♦ Avoid damage to valves and piston crowns.

♦ Do not turn the crankshaft after the camshaft timing chain has
been removed from the cylinder head.
– Install right engine support ⇒ page 48 .

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– Unscrew ball head -1- and -2-.

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– Remove filler cap.

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To be able to unscrew the cylinder head bolts, turn camshafts

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using spanner, if necessary.

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1. Cylinder head 87

– Unscrew cylinder head bolts in the sequence -1 … 5- with
special wrench, long reach - T10070- with exception of 2 bolts.
Cylinder head cover version 2
Note
On cylinder head cover version 2, not all cylinder head bolts are
accessible.
– Remove cylinder head cover ⇒ page 122 .

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♦ Make sure all hoses/pipes
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– Remove cylinder head. spec

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– Place cylinder head onto soft surface (foam plastic).

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Installing
Note
♦ Do not use sandpaper, grinding wheels, abrasive or scour

pads or any other sanding or abrasive media.
♦ Sealing surface (see photo) must not project.
♦ Discolouration (dark spots, see photo) need not be removed.
♦ When removing the sealant residue, make sure no loose par‐
ticles get into the open
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CAUTION
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– Do not use any other means rather than the contour blade set
- VAS 852 005- or a commercially available CERAN surface
rrectness of i
scraper to remove the sealant residue from the cylinder head

and cylinder block.
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• The sealing surfaces must not be damaged.

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• There must be no oil or coolant in the bolt pockets.

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• Do not remove new cylinder head gasket from packaging until

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• If a new cylinder head is installed, contact surfaces between

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roller rocker fingers and running surface of cam must be oiled.

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– Remove any loose remains using a lint-free cloth.

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♦ Handle the cylinder head gasket very carefully to prevent

damage to the silicone coating or the indented area of the
gasket.
♦ After fitting a new cylinder head or cylinder head gasket, the
engine oil and coolant must be changed.
1. Cylinder head 89
– Position cylinder head gasket.

♦ Note centring pins in cylinder block -arrows-.
♦ Check installation position of cylinder head gasket. Charac‐
teristic: the part number should be legible from the inlet side.
Note
When turning crankshaft, make sure that no components are

damaged by timing chain.
– If crankshaft has been turned in the meantime, set piston of

No. 1 cylinder to TDC, and turn crankshaft back slightly.
– Fit cylinder head.
Note
To enable insertion of the cylinder head bolts, the inlet camshaft

must be turned with a wrench.
satelettronica
– Tighten cylinder head bolts in prescribed sequence
⇒ page 82 .

hold - T10355- .
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The timing chain links with markings must be positioned at the

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– Fit camshaft timing chain.

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– Drive chain/sprocket markings must align -arrows-.

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– Use open-jaw spanner to turn inlet camshaft in direction of

-arrow- and fit timing chain.
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– Attach bearing saddle and screw in bolts -arrows- hand-tight.

– Remove locking pin - T40011- .
– Tighten bolts -arrows- for bearing saddle.
– Install regulating valve.
– Reset service position ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Moving to and back from service position .
– Install turbocharger ⇒ page 196 .
noise insulation .
Specified torques AG. Volkswagen AG d
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♦ ⇒ “4.1 Assembly overview - valve gear”,ut page 120
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♦ ⇒ “1.1 Assembly overview - turbocharger”, page 193
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1.3 Checking compression
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1. Cylinder head 91

equipment required
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♦ Spark plug socket - 3122 B-

♦ Puller - T40039-
♦ Compression tester - V.A.G 1763-
Test sequence
Note
♦ Engine oil temperature: at least 30°C

♦ Battery voltage: at least 12.7 V
– Removing ignition coils with output stages ⇒ page 248 .

3122 B- .
– Check compression using compression tester - V.A.G 1763-
and adapter - V.A.G 1763/6- .
Note
Using compression tester ⇒ operating instructions .

– Operate starter until tester shows no further pressure
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– Install spark plugs ⇒ Maintenance ; Booklet 20.1 .
hole
spec
– Install ignition coils with output stages ⇒ page 248 .
es, in part or in w
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Note
rrectness of i
Faults will have been stored in the memory owing to connectors
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after the test.
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– Read engine control unit event memory using ⇒ Vehicle diag‐

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Specified torques
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♦ ⇒ “1.1 Assembly overview - ignition system”, page 247
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⇒ page 231 .
– Unscrew earth wire -1-.
– Remove vacuum hose -3- from vacuum pump -2.-
– Detach bracket from vacuum pump -2- and place aside.

– Remove vacuum pump.
Note
Dismantling of the vacuum pump is not permitted.
Installing
– Clean sealing surfaces.
Specified torques
1. Cylinder head 93
2 Cover for timing chain

⇒ “2.1 Assembly overview - cover for timing chain”, page 94
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⇒ “2.2 Removing and installing timing chain cover”, Vpage
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❑ Lubricate before as‐
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2 - Dipstick guide tube
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3 - Bolt
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❑ 9 Nm
4 - Bolt
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❑ 9 Nm
8 - Timing chain cover (top)
⇒ page 96
9 - Seal
10 - O-ring
❑ Lubricate before assembling.
11 - Dowel pins
❑ Qty. 2
❑ For centring cover
12 - Lower timing chain cover
❑ If the cover was bent, renew it
13 - Bolts
❑ Qty. 8
14 - Oil seal
❑ For vibration damper

15 - Plug
Timing chain cover (top), tightening sequence

– Tighten bolts -1 … 5- in the sequence shown.
Timing chain cover (bottom), tightening sequence
satelettronica
Note
Do not tighten bolts -1- and -4- with turning further angle until after
the vibration damper has been installed. The bolts must be un‐
screwed again for installing the vibration damper. Note the differ‐
ent torques for steel bolts and aluminium bolts!
Stage Steel bolts Specified torque/turning further angle

for steel bolts
1. -1 … 8- 8 Nm
2. -1 … 8- 45°
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2. Cover for timing chain 95

2.2 Removing and installing timing chain

cover
⇒ “2.2.1 Removing and installing upper timing chain cover”, page
96
⇒ “2.2.2 Removing and installing timing chain cover (bottom)”,
page 96
2.2.1 Removing and installing upper timing

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– Remove bolts -1 … 5-.
– Remove upper timing chain cover.
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♦ ⇒ “2.1 Assembly overview - cover for timing chain”, page 94
2.2.2 Removing and installing timing chain

cover (bottom)

Removing
– Remove tensioner for poly V-belt ⇒ page 36 .
– Remove vibration damper ⇒ page 37 .
– Remove guide roller ⇒ Item 2 (page 33) .
– Pull dipstick guide tube out of the timing chain cover.
satelettronica
– Lever off lower timing chain cover, starting at points -1- and
-2-.
Note
To avoid deformation, do not lever between the bolt holes.
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spec
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♦ Danger of soiling lubrication system. Cover open parts of en‐

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CAUTION
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– Check that both dowel pins for centring the cover -arrows- are
fitted.
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wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
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– Install cover immediately and tighten bolts ⇒ page 95 .
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– Installing engine support ⇒ page 46 .
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– Install air filter housing ⇒ page 216 .

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3 Chain drive
⇒ “3.1 Assembly overview - drive chain for balance shaft”,
page 100
⇒ “3.2 Assembly overview - camshaft timing chains”, page 102
⇒ “3.3 Removing and installing camshaft timing chain”,
page 104
⇒ “3.4 Removing and installing drive chain for balance shaft”,
page 116
⇒ “3.5 Checking valve timing”, page 119
3.1 Assembly overview - drive chain for balance shaft
1 - Bolt
❑ 9 Nm
2 - Balancer shaft
satelettronica
❑ Exhaust side
newed if removed
engine oil
3 - Tube for balancer shaft
⇒ page 101
4 - Chain tensioner
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8 - Bearing mounting
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⇒ page 101
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9 - Intermediate shaft sprocket

❑ For balancer shaft.
nform
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❑ If bolt
m
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⇒ Item 12 (page 100) has been loosened, intermediate shaft sprocket will need to be renewed.
ion
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10 - Bolt
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❑ If bolt has been loosened, intermediate shaft sprocket ⇒ Item 9 (page 100) will need to be renewed.
Prote AG.

13 - Slide rail
❑ For timing chain
14 - Guide pin
❑ 20 Nm
15 - Tensioning rail
❑ For timing chain
16 - Guide pin
❑ 20 Nm
17 - Timing chain
18 - Sprocket
❑ Fitting position ⇒ page 102
19 - Slide rail
❑ For balancer shaft timing chain AG. Volkswagen AG d
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❑ 20 Nm ise nte
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Tube for balancer shaft - installation position
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• Lubricate bearing mounting.

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3. Chain drive 101

Intermediate shaft sprocket - tightening sequence
Note
♦ The intermediate shaft sprocket must be replaced. Otherwise

no tooth backlash is set.
♦ The new intermediate shaft sprocket is coated with a solid film
lubricant that wears off after a short period and thus the tooth
backlash is automatically set.
– Tighten as follows using new bolt.

1. Pre-tighten to 10 Nm using torque wrench.
2. Turn intermediate shaft sprocket.
There must be no play in intermediate shaft sprocket; otherwise
loosen bolt and tighten again.
3. Tighten to 25 Nm using torque wrench.
4. Use fixed wrench to turn 90° nfurther.
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3.2 Assembly overview - camshaft timing chains
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1 - Bolts
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secure with locking pin -

T40011- or locking tool -
T40267- .
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3 - Tensioning rail for timing

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⇒ page 104
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4 - Guide pin
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remove using removal

tool - T10352- or remov‐
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❑ 35 Nm
7 - Bolt
❑ 20 Nm +90°

8 - Washer
9 - Bearing saddle
10 - Guide rail for camshaft timing chain
11 - Camshaft case
12 - Camshaft timing chain
❑ Before removing, mark running direction with paint
13 - Guide rail for camshaft timing chain
14 - Guide pin
❑ 20 Nm
15 - Sprocket
❑ Crankshaft
❑ Fitting position ⇒ page 103
satelettronica
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3. Chain drive 103

3.3 Removing and installing camshaft timing chain

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♦ Assembly tool - T10352/2-

♦ Pin - T40011-
♦ Assembly lever - T40243-
♦ Camshaft clamp - T40271-

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♦ Assemblystool
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Components of assembly tool - T10531- :

♦ Support - T10531/1-
♦ Clamping pin - T10531/2-
♦ Turning over tool - T10531/3-
♦ Flange nut - T10531/4-
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove front part of right wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
3. Chain drive 105

– Turn vibration damper to “TDC position” using counter-hold -

T10355- .
• The markings -1- on the camshaft sprockets must be aligned
with markings -2- and -3-.
• The notch on the vibration damper must align with the marking
on the lower timing chain cover -arrow-
– Remove lower timing chain cover ⇒ page 96 .
Note
The timing valves have left-hand threads.

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– Screw in lever - T40243- -arrows-.

– Press together retaining ring -1- of chain tensioner and hold it
in that position.
– Slowly push lever - T40243- in -direction of arrow-, and hold it
in that position.
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insert it in teeth of chain sprocket (direction of arrow -2-).
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– If necessary, turn inlet camshaft using assembly tool - T40266-

-arrow 1-.
– Bolt camshaft clamp - T40271/1- to cylinder head.

A second mechanic is required for the following work step.
– Using assembly tool - T40266- , locate exhaust camshaft in
direction of arrow -A-.
– Remove bolt -1- and guide tensioning rail -2- downwards.
– Turn exhaust camshaft clockwise -A- until camshaft clamp -
T40271/1- can be inserted in teeth of chain sprocket -C-.
3. Chain drive 107

– Remove guide rail -1-. Release catch -arrow- using a screw‐

driver, and push guide rail off forwards.
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– Press tensioning bar of oil pump chain tensioner in direction
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– Remove guide rail -2-.

– Remove camshaft timing chain from camshaft sprockets and

fit onto journals -arrows- of camshafts.
– Remove chain tensioner -1- for balance shaft timing chain.
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– Remove tensioning rail -2-.
– Remove guide rails -3- and -4-.
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– Loosen tensioning bolt -A-.

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– Remove camshaft timing chain and drive chain for balance
shaft.
3. Chain drive 109

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spec
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– Mark tooth -1- of triple chain sprocket which is aligned with
inform
marking -2- using a permanent felt tip marker.
mer
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– Turn idler gear and balance shaft to markings -arrow-.
Note
Do not loosen bolt -1-.
– Fit drive chain for balance shafts and position coloured chain
links -arrows- at markings on chain sprockets.

– Install guide rail -1-.

– Tighten bolts -arrows-.
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– Fit camshaft timing chain onto camshaft journals with coloured
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– Fit timing chain for oil pump drive onto triple chain sprocket.
inform
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– Swing triple sprocket towards engine (-direction of arrow-),

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and fit it onto crankshaft.

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3. Chain drive 111

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

by hand.
II - Fit turning over tool - T10531/3- . Screw on flange nut -
T10531/4- by hand. Slightly move turning over tool back and forth
with a 32 mm open-end spanner. While doing so, retighten flange
nut until the chain sprocket is securely seated on the crankshaft
splines. Now tighten tensioning bolt -A-.
– Position link of drive chain for balance shafts with coloured
satelettronica
marking -arrow- at marking of triple sprocket.
– Install tensioning rail -1-.
– Tighten bolts -3-. agen
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– Install chain tensioner -1-.

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– Make sure that adjustment has been carried out correctly:

n in
chain links with coloured markings -arrows- must be posi‐

r
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tioned at markings on chain sprockets.

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– Fit camshaft timing chain on inlet camshaft, exhaust camshaft

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and crankshaft.
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– Position chain links with coloured markings -arrows- at the

markings on chain sprockets.
satelettronica
AG. Volkswagen AG d
agen
– Tighten bolts -1-. Volksw
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– Install upper guide rail -1-.

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3. Chain drive 113

A second mechanic is required for the following work step.

I - Turn exhaust camshaft in -direction of arrow A- using assembly
tool - T40266- , and remove camshaft clamp - T40271/1- from
between teeth of chain sprocket -B-.
Volkswagen AG
II - Release tension from camshaft in -direction of arrowswC- ageuntil
n AG. does
timing chain rests against guide rail -1-. Hold camshaft by
Volkin this po‐ not
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– Install chain tensioner -1-.
satelettronica
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– Install chain tensioner -2-. Prote AG.
– The retaining clip -arrow- must be seated in recess in top sec‐

tion of sump.
– Tighten bolt -1-.
– Using assembly tool - T40266- , turn inlet camshaft in

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

– Make sure that adjustment has been carried out correctly:

chain links with coloured markings -arrows- must be posi‐
tioned at markings on chain sprockets.
– Tighten bolts -arrows-. n AG. Volkswagen AG do

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– Moisten holes -arrows- with engine oil.
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Clamping sleeve -1- is not fitted on all bearing saddles.

inform
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– Screw in bolts -1 to 6- by hand.
c by lksw
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Prote AG.
Note
If a spring pin is installed, it is pulled into the cylinder head to‐

gether with bolt -1-.
3. Chain drive 115

– Remove locking tool - T40267- .

– Install control valve.
– Turn engine two times in engine direction of rotation.
Note
satelettronica
Due to the ratio, the coloured chain links no longer align with the
markings after the engine has been turned.
– Remove turning over tool, and install lower timing chain cover
⇒ page 96 .
AG. Volkswagen AG d
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Note Volksw not
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Do not tighten bolts -1- and -4- with turningut further angle until after
ho eo
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the vibration damper has been installed. ss a The bolts must be un‐ c
screwed again for installing the vibration damper.
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– After working on the chain drive, adapt learnt values in engine

control unit ⇒ Vehicle diagnostic tester.
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Specified torques
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♦ ⇒ “3.2 Assembly overview - camshaft timing chains”,
nform
ercia
page 102
m
♦ Assembly overview - noise insulation ⇒ General body repairs,

com
tion in
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -

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noise insulation
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3.4 Removing and installing drive chain for

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noise insulation .
– Remove guide rail for camshaft timing chain -1-.
– Remove chain tensioner for camshaft timing chain -3-.
satelettronica
– Remove chain tensioner for balancer shaft timing chain -1-.
– Remove tensioning rail -2-.
AG. Volkswagen AG d
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– Remove timing chain. Volksw
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Install in reverse order
ss a of removal, observing the following: c
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-arrows-.
h re
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spec
es, in part or in w
Note
t to the co
Timing chain links with coloured markings must be positioned at

markings on chain sprockets.
rrectness of i
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mercia
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tion in
r
te o
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Prote AG.
3. Chain drive 117

– Fit timing chain. The timing chain links with coloured markings
must be positioned at the markings on the chain sprockets.
– Fit guide rail for timing chain and tighten bolts -4-.
– Fit guide rail for timing chain and tighten bolts -3-.
– Fit tensioning rail for timing chain and tighten bolt -2-.
– Install chain tensioner of timing chain -1- with locking fluid ⇒
Electronic parts catalogue (ETKA) .
satelettronica
– Check adjustment again.
– Install timing chain cover (bottom) ⇒ page 96 . AG. Volkswagen AG d
agen oes
ksw
– Install timing chain cover (top) ⇒ page 96 . by Vol not
gu
d ara
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– Install tensioner for poly V-belt ⇒ page 36 . thor eo
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– Install poly V-belt ⇒ page 35 . ss c
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noise insulation .
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♦ ⇒ “3.2 Assembly overview - camshaft timing chains”,

spec
page 102
es, in part or in w
t to the co
♦ ⇒ “3.1 Assembly overview - drive chain for balance shaft”,

page 100
rrectness of i

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3.5 Checking valve timing

Note
Use a ratchet spanner with a 24 mm socket to turn the vibration

damper. Always turn the vibration damper in the engine's direc‐
tion of rotation to the “TDC” position. Do not correct TDC position
by turning the damper in the other direction.

bottom cover for timing chains (use a mirror)
• Markings -1- on camshafts must face upwards.
satelettronica
– Measure the distance from the outer edge of web -A- to mark‐
ing -B- on the inlet camshaft.
• Specification: 61 to 64 mm
AG. Volkswagen AG d
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– If the specified value is achieved, measure the distance be‐ s
ce
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nl
tween the marking on the inlet camshaft -B- and the marking
pt
du
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on the exhaust camshaft -C-.

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• Specification: 124 to 126 mm

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Note
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An offset of one tooth results in a deviation of approx. 6 mm from

the specified value. If an offset is found, the timing chain must be
re-fitted.
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3. Chain drive 119

4 Valve gear
⇒ “4.1 Assembly overview - valve gear”, page 120
⇒ “4.2 Removing and installing camshaft”, page 122
⇒ “4.3 Removing and installing camshaft adjuster”, page 133
⇒ “4.4 Removing and installing camshaft control valve 1 N205 ”,
page 133
⇒ “4.5 Removing and installing valve stem seals”, page 133
⇒ “4.6 Measuring axial play of camshaft”, page 141
4.1 Assembly overview - valve gear

AG. Volkswagen AG d
1 - Exhaust valves agen oes
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❑ Qty. 8 ed b ara
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❑ Do not rework; only lap‐ aut
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❑ Valve dimensions
nl
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⇒ page 144
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2 - Cylinder head
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⇒ page 82
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3 - Valve guides
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❑ Qty. 16
❑ Checking valve guides
⇒ page 143
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4 - Valve stem seal
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❑ Qty. 16
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5 - Valve springs
❑ Qty. 16
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6 - Valve spring plate

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❑ Qty. 16
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❑ Qty. 32
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8 - Hydraulic compensation el‐ rig ht
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❑ Qty. 8
Prote AG.
❑ Oil contact surface
9 - Exhaust camshaft
❑ Check radial clearance
with Plastigage (roller
rocker fingers re‐
moved).
❑ Radial clearance: 0.024 to 0.066 mm.
❑ Runout: max. 0.04 mm
10 - Cylinder head cover
❑ With integrated camshaft bearings.
❑ Clean sealing surface; reworking not permitted.

❑ Completely remove sealant residue
11 - Bolts
❑ Qty. 22
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12 - O-rings
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❑ Moisten with engine oil.
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13 - Actuator for camshaft adjustment -F366- / -F373-
t to the co
❑ Qty. 8
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14 - Bolts
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❑ Qty. 8
satelettronica
❑ 5 Nm
nform
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15 - O-rings
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❑ Qty. 3
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17 - Inlet camshaft p by
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❑ Check radial clearance with Plastigage (roller rocker fingers removed).
agen
Prote AG.
❑ Radial clearance: 0.024 to 0.066 mm.

❑ Runout: max. 0.04 mm
18 - Cap
❑ Removing: with cylinder head cover installed, pierce one side of cap with awl and lever cap off
19 - Inlet valve
❑ Qty. 8
❑ Do not rework; only lapping in is permitted
❑ Valve dimensions ⇒ page 144
Cylinder head cover - release

– Loosen cylinder head cover bolts in the sequence -1 … 6-.
4. Valve gear 121

Tightening sequence for cylinder head cover

– Tighten bolts in the sequence -1 … 6-.
4.2 Removing and installing camshaft
satelettronica
AG. Volkswagen AG d
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♦ Puller - T40039-
atio
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n in
c
♦ Pin - T40011-
or
thi
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♦ Removal tool - T10352/1-

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122
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Rep. gr.15 - Cylinder head, valve gear
AG. Volkswagen AG d
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♦ Assembly pin - T40196-

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♦ Spacers - T40191-
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Prote AG.
4. Valve gear 123

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

cylinder head must not be machined.
♦ Camshaft bearings are integrated into cylinder head and cyl‐
inder head cover. Camshaft timing chain must be relieved of
tension before you remove cylinder head cover.
♦ Renew sealing cap if cylinder head cover has been detached.
♦ Fit the cable ties in the original position when installing.

– Remove pressure hose leading from charge air cooler to tur‐
bocharger.
– Separate electrical connectors -arrows-.
– Remove ignition coils ⇒ page 248 .
satelettronica
– Remove actuators -F366- / -F373- ⇒ page 133 .
– Loosen clamp -3-.

agen AG olksw
– Pull hose -2- off throttle
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– Loosen clip on edother
by side where hose is and remove
ua hose.
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– Disconnect crankcase breather hose -1-.

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– Pull off hose -2- in direction of -arrow-.

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– Remove crankcase breather.

nform
mercia
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tion in
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– Disconnect line -arrows-.

– Remove regulating valve using removal tool - T10352/1- in di‐

rection of -arrow-.
satelettronica
noise insulation .
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Notch on vibration damper must align with arrow marking on cover

t to the co
for timing chains (bottom).

rrectness of i
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4. Valve gear
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– Insert drifts - T40196- . au
tho e or
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Only insert drifts - T40196- in points marked in illustration.
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– Turn crankshaft 2 times in direction of engine's rotation.
hole
spec
es, in part or in w
t to the co
Note
Engine must be at “TDC” again.
rrectness of i
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– Remove drifts - T40196- .
nform
ercia
– Use a waterproof pen to mark drive chain at marks on chain

sprockets -arrows-.
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Prote AG.
Up to 29/04/2013
– Remove sealing plug -arrow-.
– Insert scriber or suitable screwdriver in hole of chain tensioner

in direction of -arrow 1- and lift locking element for chain ten‐
sioner.
– Turn crankshaft in opposite direction to normal rotation
-arrow 2- and lock in place using locking pin - T40011- .
Note
Inlet camshaft will move in direction of engine rotation.

As of 29/04/2013
AG. Volkswagen AG d
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– Screw in lever - T40243- -arrows-.
wit
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– Press together retaining ring -1- of chain tensioner and hold it
hole
spec
in that position.
es, in part or in w
t to the co
– Slowly push lever - T40243- in -direction of arrow-, and hold it
in that position.
satelettronica
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ion
c
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– Secure chain tensioner with locking pin - T40267- . opyri
gh by
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– Remove lever - T40243- .
lksw
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Prote AG.
4. Valve gear 127


AG. Volkswagen AG d
– Unscrew bolt -1-. ksw
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– Guide tensioning rail -2- downwards. ised b ara
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– Remove upper guide rail -3-. Releases acatch
ut with a screwdriver ra
c
and push guide rail off towards the front of vehicle.
s
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– Remove camshaft timing chain from camshaft sprockets.
an
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Note
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♦ Risk of damage to valves and piston crowns!
spec
es, in part or in w
t to the co
♦ Do not turn the crankshaft after the camshaft timing chain has
been removed from the cylinder head.
rrectness of i
– Remove high-pressure pump ⇒ page 231 .
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– Remove vacuum pump ⇒ page 93 .
nform
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satelettronica
m
– Unscrew cylinder head cover bolts in the sequence -1 … 6-.
at
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– Unscrew cylinder head cover bolts in the sequence -1 … 6-.
– Remove cylinder head cover.
– Detach camshafts.
Installing
Note
♦ The sealing surfaces must be free of oil and grease.

♦ Pistons must not be positioned at TDC.
AG. Volkswagen AG d
agen
♦ Ensure that all rollerVorocker
lksw fingers are properly
oes
seated
not on
valve stem ends.
se
db
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– Remove ssealant
s remaining on cylinder head with flat scraper.
ac
satelettronica
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CAUTION
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es, in part or in w
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Note
♦ Danger of lubrication system and bearings becoming soiled!

rrectness of i
♦ Cover open parts of engine.

l purpos
– Remove sealant left in groove of cylinder head cover and on

nform
ercia
sealing surfaces, e.g. using a rotating plastic brush.

m
at
om
– Clean sealing surfaces. They must be free of oil and grease.

ion
c
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or
– Oil running surfaces of both camshafts.

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Prote AG.
– Lock camshaft using spacers - T40191- , pushing sliding

pieces into correct position as necessary.
Note
If available, use second set of spacers - T40191/2- or reuse -

T40191/1- .
4. Valve gear 129

– Insert camshafts into cylinder head.

– Markings -arrows- must be located as shown in illustration.
AG. Volkswagen n AG do
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– Check alignment -arrows- of camshafts.
es, in part or in w
t to the co
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l purpos
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ercia
satelettronica
m
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tion in
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2 mm).
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Prote AG.

– Apply silicone sealant -arrows- onto clean sealing surface of

cylinder head cover.
♦ Thickness of sealant bead: 2 to 3 mm.
Note
♦ The cylinder head cover must be installed within 5 minutes

after applying the silicone sealant.
♦ Observe use-by-date of sealant.
– Fit cylinder head cover onto cylinder head.

– Renew bolts for cylinder head cover.
– Tighten bolts in several stages, tightening sequence
⇒ page 120 .
satelettronica
Note
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gen AG
Install cylinder head cover, making
Vol
ksw sure not to cant it.
a does
not
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– Use thrust piece s-auT10174- to drive in sealing cap -1- without ra
c
sealant. s
ce
le
un
pt
-a-: 1 … 2 mm
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bottom cover for timing chains

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4. Valve gear 131

– Fit camshaft timing chain.
Note
The drive chain/sprocket markings must align -arrows-.
– Use open-jaw spanner to turn inlet camshaft in direction of

-arrow- and fit timing chain.
– Attach bearing saddle and screw in bolts -arrows- hand-tight.

– Install regulating valve.
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spec
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– Install vacuum pump ⇒ page 93 .

– Installing high-pressure pump ⇒ page 231 .
rrectness of i
– Install air filter housing ⇒ page 216 .

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noise insulation .
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Specified torques
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♦ ⇒ “4.1 Assembly overview - valve gear”, page 120

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4.3 Removing and installing camshaft ad‐

juster
⇒ “4.3.1 Removing and installing actuator for camshaft adjust‐
ment F366 / F373 ”, page 133
4.3.1 Removing and installing actuator for

camshaft adjustment -F366- / -F373-
Removing AG. Volkswagen AG d
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– Disconnect connector -arrow- frombyrespective
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4.4 Removing and installing camshaft con‐
rrectness of i
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Removing
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– Separate electrical connector from camshaft control valve 1 -

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N205- -1-.
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– Remove camshaft control valve 1 - N205- .

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♦ Renew O-ring after each removal.

♦ Lubricate seal and O-ring with engine oil.
Specified torques
4.5 Removing and installing valve stem

seals
⇒ “4.5.1 Renewing valve stem seals with cylinder head installed”,
page 133
⇒ “4.5.2 Renewing valve stem seals with cylinder head removed”,
page 137
4.5.1 Renewing valve stem seals with cylinder head installed
4. Valve gear 133


equipment required
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♦ Spark plug socket - 3122 B-

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Adapter - T40012-
♦ Dismantling and assembling device for valve cotters - VAS
5161-
♦ Guide plate for 2.0 l and 3.0 l FSI engine - VAS 5161/19B-
Removing
– Remove camshafts ⇒ page 122 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
3122 B- .

– Secure guide plate for 2.0 l and 3.0 l FSI engine - VAS
5161/19B- with knurled screws - VAS 5161/12- on cylinder
head.
– Set piston of respective cylinder to “bottom dead centre”.
– Screw adapter - T40012- into spark plug thread.

– Connect compressed air with pressure rating of at least 6 bar.
– Strike tight valve cotters with drift - VAS 5161/3- and a plastic
hammer.
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For inlet side
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– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
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- VAS 5161/19B- .
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– Insert assembly cartridge - VAS 5161/8- into guide plate for
hole
2.0 l and 3.0 l FSI engine - VAS 5161/19B- . spec

es, in part or in w
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– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .
rrectness of i
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For exhaust side

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into outer threads of guide plate for 2.0 l and 3.0 l FSI engine
com
tion in
- VAS 5161/19B- .
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– Press installation cartridge - VAS 5161/8- down and turn

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knurled screw of installation cartridge - VAS 5161/8- to right

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until tips engage in valve cotters.

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– Move knurled screw back and forth slightly to press apart valve C py
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– Release pressure fork - VAS 5161/2- . cted agen
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– Remove installation cartridge - VAS 5161/8- .
4. Valve gear 135

– Pull off valve stem seals using valve stem seal puller - 3364- .
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– If valve stem seal puller - 3364- cannot be used on account of
t to the co
satelettronica
restricted space, knock out pin -arrow- with a punch and re‐
move the impact extractor attachment.
rrectness of i
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– Place lower part of valve stem seal puller - 3364- onto valve
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stem seal. t. Cop py
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– Place installation lever on puller and pull out valve stem seal
agen
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-arrow-.
Installing
– To prevent damage to new valve stem seals -B-, attach plastic

sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem seal -B-, place it in the valve
stem seal fitting tool - 3365- and push carefully onto valve
guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Install removal and installation device for valve cotters - VAS
5161- as shown.

Inlet side
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- VAS 5161/18- .
AG.
♦ Press assembly cartridge -VAS 5161/8- onto insertion device

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

fork - VAS 5161/2- , and turn installation cartridge knurled
screw back and forth whilst pulling upwards.
– Relieve pressure fork - VAS 5161/2- whilst pulling on knurled
screw.
– Remove removal and installation device - VAS 5161- .
– Install camshafts.
4.5.2 Renewing valve stem seals with cylinder

head removed
4. Valve gear 137

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365- n AG. Volkswagen AG do

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♦ Dismantling and assembling device for valve cotters - VAS
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♦ Cylinder head tensioning device - VAS 6419-
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Removing
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– Remove cylinder head ⇒ page 82 .
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– Remove camshafts ⇒ page 122 .
h re
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– Mark allocation of roller rocker fingers and hydraulic compen‐
spec
sation elements for reinstallation.
es, in part or in w
t to the co
– Remove roller rocker fingers together with hydraulic compen‐
satelettronica
sation elements and place down on a clean surface.
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– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095A- .
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– Secure cylinder head on cylinder head clamping device.
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– Connect cylinder head tensioning device to compressed air.
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– Use lever -arrow- to slide air cushion under combustion cham‐

o
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– Secure guide plate for 2.0 l and 3.0 l FSI engine - VAS cted agen
Prote AG.
5161/19B- with knurled screws - VAS 5161/12- to cylinder
head as shown.
– Set piston of respective cylinder to “bottom dead centre”.
– Insert drift -VAS 5161/3- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
4. Valve gear 139

AG. Volkswagen
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For inlet side d by V ua
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– Screw retainer
autho
- VAS 5161/6- with guide fork - VAS 5161/5- or
ac
into centre
ss thread of guide plate for 2.0 l and 3.0 l FSI engine
- VAS 5161/19B- .
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– Insert assembly cartridge - VAS 5161/8- into guide plate for
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2.0 l and 3.0 l FSI engine - VAS 5161/19B- .
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For exhaust side
s
into outer threads of guide plate for 2.0 l and 3.0 l FSI engine
s o
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- VAS 5161/19B- .
inform
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– Press installation cartridge - VAS 5161/8- down and turn
atio
knurled screw of installation cartridge - VAS 5161/8- to right
om
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until tips engage in valve cotters.
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– Move knurled screw back and forth slightly to press apart valve
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– Release pressure fork - VAS 5161/2- .

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– Pull off valve stem seals using valve stem seal puller - 3364- . Prote AG.
Installing
Note
♦ Risk of damage when valve stem seals are being installed!

♦ Place plastic sleeve -A-, enclosed with new valve stem seals
-B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal -B-.

– Push valve stem seal -B- onto plastic sleeve -A-.
– Carefully press valve stem seal -B- onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Assemble removal and installation device for valve cotters -
VAS 5161- .

Inlet side
Exhaust side AG. Volkswagen AG d

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Note
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s
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f inform
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♦ Press assembly cartridge -VAS 5161/8- onto insertion device
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screw back and forth whilst pulling upwards.

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– Remove removal and installation device for valve cotters -
lksw
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VAS 5161- .
Prote AG.
– Install camshafts ⇒ page 122 .

– Install cylinder head ⇒ page 82 .
4.6 Measuring axial play of camshaft

4. Valve gear 141

AG. Volkswagen
Transporter 2016 ➤ ksw
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4-cylinder injection engined(2.0
by l direct injection engine, turbocharger)
ua
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♦ Universal dial gauge holderau - VW 387- ra
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♦ Dial gauge - VAS 6079-
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Test sequence
– Take measurements with retaining frame removed.
– Fit camshaft to be tested in retaining frame.
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: 0.05 to 0.17 mm

AG. Volkswagen AG d
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Inlet and exhaust valves
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⇒ “5.1 Checking valve
ut
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⇒ “5.2 Checking valves”, page 144
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⇒ “5.3 Valve dimensions”, page 144
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pyri by
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Test sequence
– Insert valve in guide. Valve stem end must be flush with guide.
On account of differing stem diameters, only use inlet valve in
inlet guide and exhaust valve in exhaust guide.
– Determine rock.
Wear limit
Inlet valve guide Exhaust valve guide
0.80 mm 0.80 mm
Note
♦ If the wear limit is exceeded, repeat the measurement with

new valves. If the wear limit is exceeded again, renew the cyl‐
inder head.
♦ If the valve is to be renewed as part of a repair, use a new
valve for the calculation.
5. Inlet and exhaust valves 143

5.2 Checking valves

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

Valve dimensions
Note
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
Dimension Inlet valve Outletagvalve

en AG. V
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∅a mm 33.85 ± 0.10 db
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Diameter mm 5.98 ± 0.01
ss 5.96 ± 0.01
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17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Removing and installing sump”, page 145
⇒ “1.2 Removing and installing upper part of sump”, page 147
⇒ “1.3 Removing and installing oil pump”, page 152
⇒ “1.4 Engine oil:”, page 153
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 154
1.1 Removing and installing sump

♦ Used oil collector and extractor - eV.A.G
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♦ Hand drill with plastic brush

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♦ Safety goggles
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♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)

Removing
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noise insulation .
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– Drain engine oil ⇒ Maintenance ; Booklet 20.1 .

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1. Sump, oil pump 145

swage es
– Separate electricalbconnector
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-1 … 19-. ac
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– Remove sump; if necessary, loosen using light blows with a

un
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Installing
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♦ Observe use-by date of silicone sealant.
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♦ The sump must be installed within 5 minutes of applying sili‐
nform
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mer
atio
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♦ Let sealing compound dry for approx. 30 minutes after instal‐

o
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ling oil sump. Only then fill with engine oil.
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CAUTION
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Risk of eye injury caused by sealant residue. t. Cop py
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– Remove sealant residues from sump upper part with a flat
scraper.
– Remove sealant residue from sump (bottom section) using a

rotating plastic brush, for example.
146 Rep. gr.17 - Lubrication


3 mm).
Note
Thickness of sealant bead: 2 to 3 mm.
– Apply silicone sealant ⇒ Electronic parts catalogue (ETKA) to
satelettronica
clean sealing surface of sump (bottom section).
– Fit bottom section of sump immediately and tighten bolts
-1 … 19- in 3 stages as follows:
1- Tighten bolts by hand.
2- Tighten bolts to 8 Nm.
3- Turn bolts 45° further.
Volkswagen AG
– Fill with engine oil ⇒ Maintenance ; Booklet 20.1sw. agen AG. does
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Specified torques edb ara
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Bolt 8 Nm +45°
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equipment required
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♦ Brake lining wear gauge - VW 136-

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♦ Silicone sealant - D 174 003 A2-
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Removing
agen
Prote AG.
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing

gearbox; Removing gearbox .
– Remove oil pump ⇒ page 152 .
– Remove sealing flange on gearbox side ⇒ page 53 .

Note
♦ Danger of injury! When removing upper part of sump, spring

of chain tensioner for oil pump drive jumps from upper part of
sump to lower timing chain cover.
n AG. Volkswagen A
♦ When removing upper part of sump,
olks
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not grip between
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upper
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part of sump and lower timing
db
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– Detach bracket of continued coolant circulation pump - V51-
ility
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-1- from sump upper part -2-.
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rrectness of i
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nform
ercia
– Remove bolts -arrows- from the upper part -1- of the gearbox
sump.
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– Undo and remove bolts -arrows- from the outside of the oil
sump upper part -1-.

– Unscrew bolts -arrows- securing top section of sump -1-.

– Carefully remove top section of sump.
Note
Lever off upper part of sump on gearbox side first. When levering
off, exercise caution to ensure the timing chain cover is not bent
in the process.
Installing
Note
♦ Observe use-by date of silicone sealant.

♦ The sump upper part must be installed within 5 minutes of ap‐
plying silicone sealing compound.
satelettronica
– Use assembly tool - T10118- to pull spring of chain tensioner
for oil pump drive in direction of guide rail -arrow-.
– Insert brake lining wear gauge - VW 136- in hole of guide rail.
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The spring is secured in this way. aut or
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– Remove sealant residues from cylinder block with a flat scra‐
du
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– Remove remaining sealant on sump (top section) and lower
rrectness of i
timing chain cover e.g. using rotating plastic brush.
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Note
nf
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Check timing chain cover for deformation. To do this, fit sump

m
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atio
upper part first without sealant and check gap between cover and
om
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sump upper part. Renew cover if deformation is found which can‐

or c
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not be corrected. Renew cover once sump upper part has been
te
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installed.
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3 mm).
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– Apply silicone sealant - D 174 003 A2- -arrow- to clean sealing
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surface of sump (top section).
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• Thickness of sealant bead: 2 to 3 mm
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Note
t to the co
♦ The sump upper part must be installed within 5 minutes of ap‐
rrectness of i
plying silicone sealing compound.
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nform
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• Top section of sump and crankcase must be flush on gearbox

at
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side
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– Fit sump upper part immediately and tighten bolts in 3 stages

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– Tighten bolts -arrows- in 2 stages:
– 1. Tighten bolts to 8 Nm.
– 2. Turn bolts 45° further.

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4-cylinder injection engineor is (2.0 l direct injection engine, turbocharger)
e nte - Edition 06.2018
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– Pull brake lining wear gauge
ss - VW 136- out of guide rail
ce
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-arrow-.
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Spring now jumps back to installation position.
hole
spec
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Specified torques
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Bolt securing top section of sump 15 Nm +90°
orm
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Bolts -arrows- 8 Nm +45°
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1.3 Removing and installing oil pump

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♦ Assembly tool - T10118- yri
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Prote AG.
Removing
– Remove sump (bottom section) ⇒ page 145 .
– Remove baffle plate -arrows-.
Note
The following procedure must be carried out in a single operation.

This requires a second mechanic.


– Remove oil pump.
– Pull back chain tensioner using assembly tool - T10118- in

direction of -arrow- and have oil pump removed by a second
mechanic.
Installing
– Before installing oil pump, check strainer in oil suction pipe and
oil galleries in upper part of sump for soiling.
satelettronica
– Check that both centring sleeves for centring oil pump are
present. en AG. V
olkswagen AG
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On the baffle plate are plastic ribs that are permanently deformed
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during tightening. The plastic rips ensure that the baffle plate rests
erm
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without play and does not rattle. For this reason, the baffle plate
ot p
should always be replaced.

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Specified torques
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Bolts for oil pump 9 Nm
rrectness of i
Bolts for baffle plate 9 Nm

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1.4 Engine oil:

nform
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Engine oil specification and oil capacities

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Capacities and specifications ⇒ Maintenance ; Booklet 20.1 ;

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Descriptions of work; Engine oil: capacities and specifications .

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damage to catalytic converter!
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♦ Check oil level ⇒ Maintenance ; Booklet 20.1 ; Descriptions
Prote AG.
of work; Oil level: check .

1.5 Removing and installing oil level and oil

temperature sender - G266-
Removing
noise insulation .
– Drain engine oil ⇒ Maintenance ; Booklet 20.1 .
– Separate electrical connector from oil level and oil tempera‐
ture sender - G266- -1- in direction of -arrow-.
– Unscrew nuts -arrows-.
– Remove oil level and oil temperature sender - G266- -1-.
Installing
Specified torques
satelettronica
Nuts 9 Nm
AG. Volkswagen AG d
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2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 155
⇒ “2.2 Removing and installing engine oil cooler”, page 156
2.1 Assembly overview - engine oil cooler

lksw
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1 - Ancillary bracket aut
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❑ Removing and installing ss
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⇒ page 43
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❑ Not replacement part.
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plied with valve unit
4 - O-ring
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❑ Not replacement part.
Include in items sup‐
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5 - Valve unit
nf
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❑ With O-rings
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6 - Oil filter
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❑ Remove and install with
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oil filter tool - 3417- .

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⇒ Maintenance ; Book‐
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let 20.1
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8 - Oil pressure switch - F22-

⇒ page 158
❑ Checking ⇒ Vehicle di‐
agnostic tester
❑ 20 Nm
9 - Bolts
❑ Qty. 4
❑ 23 Nm
10 - Union
11 - Seal
❑ Moisten with coolant additive.
12 - Engine oil cooler
❑ Ensure clearance to adjacent components.
❑ Observe notes ⇒ page 156
13 - Seal
2. Engine oil cooler 155

14 - Bolts
❑ Qty. 5
2.2 Removing and installing engine oil cool‐

er
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♦ Drip tray for workshop
orise hoist - VAS 6208- nte
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Removing
– Drain coolant ⇒ page 163 . ss o
cial p
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– Remove bracket for ancillaries ⇒ page 43 .

mer
atio

om
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– Remove engine oil cooler -3- with seal -2-.

thi
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Installing
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Prote AG.
♦ Renew gaskets and seals after each removal.
♦ Restore the factory standard by securing all of the hose con‐
nections with hose clips appropriately ⇒ Electronic parts
catalogue (ETKA) .
– Install engine oil cooler -3- with new seal -2-.

– Install bracket for ancillaries ⇒ page 43 .
– Replenish engine oil and check oil level ⇒ Maintenance ;
Booklet 20.1 ; Descriptions of work; Engine oil: draining or
extracting; Renewing oil filter and replenishing engine oil .
Specified torques
♦ ⇒ “2.1 Assembly overview - engine oil cooler”, page 155

3 Crankcase ventilation
⇒ “3.1 Removing and installing oil separator”, page 157
3.1 Removing and installing oil separator

Removing
– Detach clamp from pressure hose for throttle valve module -
J338- . Pull off pressure hose from throttle valve module -
J338- and lay aside.
– Separate electrical connectors -arrows-, detaching them all
from the ignition coils at the same time.
Note
Only the ignition coils of the third and fourth cylinders have to be
pulled out.
satelettronica
– Pull out ignition coils using puller - T40039- in direction of
-arrow-. n AG. Volkswagen AG
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– Pull off hose -1-.
rrectness of i
– Remove oil separator and pull off from hose -2- for crankcase
breather in direction of -arrow-.
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Installing
nf
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f
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♦ Renew gaskets, oil seals and self-locking nuts. C py
t. rig
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Vo
co
Specified torques
by lksw
cted agen
Prote AG.
3. Crankcase ventilation 157

4 Oil filter, oil pressure switch

⇒ “4.1 Removing and installing oil pressure switch F22 ”,
page 158
⇒ “4.2 Checking oil pressure”, page 158
4.1 Removing and installing oil pressure

switch - F22-
Removing
Note
Place a cloth underneath bracket for ancillaries to catch any es‐

caping engine oil.
– Separate electrical connector -2- on oil pressure switch - F22-

-1-.
– Unscrew oil pressure switch - F22- -2-.
satelettronica
Installing
Note
♦ Renew seal.
G. Volkswagen AG d
♦ Insert new oil pressure switch - F22- immediately
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avoid loss of oil. o not
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Specified torques aut ra
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4.2 Checking oil pressure

ab
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♦ Oil pressure tester - V.A.G 1342-

spec
es, in part or in w
t to the co
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nform
mercia
at
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Conditions for testing

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• Oil level OK.
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• Engine oil temperature at least 80°C (radiator fan must have
ht
pyri by
Vo
run once)
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Prote AG.

Test sequence
Note
Place a cloth underneath bracket for ancillaries to catch any es‐

caping engine oil.

– Unscrew oil pressure switch - F22- -1-.
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of oil pressure switch -1-.
– Start engine.
• Oil pressure at idling speed: 1.2 … 2.1 bar
• Oil pressure at 2000 rpm: 1.6 … 2.1 bar
• Oil pressure at 3700 rpm: 3.0 … 4.0 bar
AG. Volkswagen AG d
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During the first 1000 km, the oil pressure at 2000 rpm can be ss c
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between 3.0 and 4.0 bar.

nl
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Assembling
ab
ility
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– Install oil pressure switch.
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Specified torques
hole
spec
es, in part or in w
t to the co
rrectness of i
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or c
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4. Oil filter, oil pressure switch 159

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Fitting location overview - cooling system”, page 160
⇒ “1.2 Checking cooling system for leaks”, page 161
⇒ “1.3 Draining and adding coolant”, page 163
1.1 Fitting location overview - cooling system
1 - Coolant hose
❑ Return
2 - Fastener
3 - Radiator outlet coolant tem‐
perature sender - G83-
⇒ page 183
satelettronica
4 - Seal
5 - Spring-type clip
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6 - Retaining spring yV
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7 - Coolant hose ir se tee
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❑ Return ss
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8 - Bracket for continued cool‐
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ant circulation pump - V51-
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9 - Coolant hose
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10 - Coolant pipe
h re
hole
spec
11 - Nut
es, in part or in w
❑ 8 Nm
t to the co
12 - Bolt
❑ 8 Nm
rrectness of i
13 - Coolant pump
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⇒ page 172
nform
ercia
14 - Coolant pipe
m
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15 - Oval hexagon socket head

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or
bolt
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❑ 9 Nm
p
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for
16 - Coolant hose
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t.
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17 - Coolant hose
C py
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18 - Coolant hose cop Vo
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19 - Gear oil cooler
❑ On vehicles with dual clutch gearbox only.
20 - Coolant hose
21 - Coolant hose
22 - Continued coolant circulation pump - V51-
160 Rep. gr.19 - Cooling

23 - Coolant expansion tank

24 - Coolant hose
25 - Bolt
❑ M6 x 22
26 - Bolt
❑ M6 x 12
27 - Coolant hose
AG. Volkswagen AG d
❑ Supply agen oes
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28 - Coolant hose rise
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29 - Coolant hose ss au ra
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30 - Radiator/cooler
un
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1.2 Checking cooling system for leaks
h re
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spec
es, in part or in w
satelettronica
t to the co
equipment required
rrectness of i
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nform
mercia
a
com
tion in
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te o
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Prote AG.
♦ Cooling system tester - V.A.G 1274 B-
1. Cooling system/coolant 161

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

Prerequisites for check
• Engine at operating temperature.
• Perform cooling system leak test using cooling system tester
- V.A.G 1274- , adapter for cooling system tester - V.A.G
1274/8- and adapter for cooling system tester - V.A.G 1274/9-
Test sequence
CAUTION
satelettronica
– Open filler cap on coolant expansion tank.
– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.
– Using hand pump of tester, build up a pressure of approx.wagen AG. Volkswagen AG doe
1.0 bar. yV
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Before the cooling system tester - V.A.G 1274 B- is disconnected

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from the connecting hose or the connector - V.A.G 1274 B/1- ,

erm
ab
reduction of the pressure is essential. To do this, press pressure

ility
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relief valve on cooling system tester - V.A.G 1274 B- until pres‐

wit
is n
sure gauge displays value of »0«.

h re
ole,
spec
If the pressure drops:

t to the co
– Find leaks and rectify.

rrectne
Check pressure relief valve in cap.

– Fit cooling system tester - V.A.G 1274 B- with adapter -
ss
V.A.G 1274/9- to filler cap -1-.

o
cial p
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– Build up pressure using hand pump of cooling system tester.

form
mer
atio
• The pressure relief valve must open at a pressure of 1.4 to

om
1.6 bar.
c
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– Renew filler cap, if pressure relief valve does not open as de‐
t
sd
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scribed.
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1.3 Draining and adding coolant

⇒ “1.3.1 Draining and adding coolant”, page 163
⇒ “1.3.2 Charging the cooling system in the case of emergency”,
page 168
1.3.1 Draining and adding coolant

equipment required
satelettronica
AG. Volkswagen AG d
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♦ Cooling system tester - V.A.G 1274 B-
C py
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♦ Coolant system charge unit - VAS 6096-
op Vo
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♦ Refractometer - T10007 A-

Draining
CAUTION
G. Volkswagen AG d
– Reduce excess pressure ksw
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not
expan‐
sion tank with cloths
by
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– Open filler
ss
cap on coolant expansion tank. au ac
ce
le
– Remove spring-type clip -1- and pull coolant hose downwards

un
pt
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off radiator -2-.
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Note
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spec
Please observe disposal instructions!
es, in part or in w
satelettronica
t to the co
Filling
rrectness of i
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nform
mercia
a
com
tion in
r
te o
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AG. Volkswagen AG d
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Note horis nte
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♦ Use only distilled water for mixing coolant additives. The use
ce
le
un
of distilled water ensures optimum protection against corro‐
pt
an
d
sion.
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ab
pe
♦ The water used for mixing has a major influence on the effec‐
ility
ot
tiveness of the coolant. Since water quality differs from country
wit
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to country and even region to region, it is necessary to set a
h re
hole
standard for the quality of water to be used. Distilled water
spec
fulfils all requirements. Therefore, always use only distilled
es, in part or in w
t to the co
water when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
rrectness of i
reduce corrosion protection substantially. The resulting dam‐
l purpos
age could lead to loss of coolant and subsequent severe

damage to the engine.
nform
ercia
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐

rosion damage as well as scaling. Such additives also raise
m
a
the boiling point of the coolant. For this reason, the cooling
com
tion in
system must be filled all-year-round with coolant additives.
r
satelettronica
te o
thi
♦ Because of its high boiling point, the coolant improves engine
s
iva
do
reliability under heavy loads, particularly in countries with trop‐
r
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ical climates.
en
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♦ The refractometer - T10007A- must be used to determine the C py
ht. rig
current anti-freeze value. rig ht
py by
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by lksw
♦ Frost protection must be guaranteed down to -25°C as a min‐ cted agen
Prote AG.
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Coolant mixture ratio

• Coolant additive (40 %) and distilled water (60 %) for frost
protection to -25 °C
• Coolant additive (50%) and distilled water (50%) for frost pro‐
tection to -36 °C
• Coolant additive ⇒ Electronic parts catalogue (ETKA)
– Reconnect coolant hoses, and secure them with clamps.

– Fill tank of cooling system charge unit - VAS 6096- with at least
8 litres of pre-mixed coolant in correct mixture ratio.
Note
The quantity may vary depending on the equipment level.
– Screw adapter for cooling system tester - V.A.G 1274/8- onto

coolant expansion tank -1-.
– Install 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
satelettronica
flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 to 10 bar.
AG. Volkswagen AG d
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ility
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es, in part or in w
t to the co
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l purpos
nform
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a
com
tion in
r
te o
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Cop py
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gh ht
pyri by
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co lksw
by
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Prote AG.

– Open valve -B-; turn lever in direction of flow to do this.

• In cooling system, vacuum is generated by suction jet pump;
needle of gauge must move into green area.
– In addition, open valve -A- briefly by turning lever in direction
of flow until expansion tank hose of cooling system charge unit
- VAS 6096- fills with coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• Vacuum continues to be generated in the cooling system by
the suction jet pump; the needle of gauge must remain in green
range.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
satelettronica
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
AG. Volkswagen AG d
agen
♦ If vacuum drops, cooling system
Vomust
lksw be checked for leaks.
oes
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– Pull off compressed airuhose.
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– Open valve -A-. ce
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• The vacuum in the cooling system causes coolant to be ex‐ an

itte
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tracted from coolant expansion tank of cooling system charge
erm
ab
unit - VAS 6096- and the cooling system to be filled.
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– Remove cooling system charge unit - VAS 6096- from coolant

h re
expansion tank.
hole
spec
es, in part or in w
– Fill coolant up to max. mark.

t to the co
– Close coolant expansion tank.

– If fitted, switch off air conditioning system.
rrectness of i
– Start engine and maintain engine speed at approx. 2000 rpm

l purpos
for about 3 minutes.

– Then run engine at idling speed until radiator fan cuts in.
nform
mercia
at
CAUTION
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Cop py
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agen
Prote AG.
– Check coolant level and top up as needed.

• The coolant level must be at the max. marking when the en‐
gine is warm.
• When the engine is cold, the coolant level must be between
min. and max. marking.

enturbocharger)
AG. Volkswagen A-GEdition 06.2018
ag does
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1.3.2 Charging the cooling system in the case
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♦ The following steps only apply in the case of a breakdown.
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♦ Here, the cooling system is charged without using the cooling
ole,
spec
system charge unit - VAS 6096- . urposes, in part or in wh
t to the co
♦ Charging in the case of an emergency is only permissible to
keep the vehicle mobile and does not replace the proper
charging procedure according to the repair manual.
rrectne
♦ After an emergency charging, the vehicle should be brought
to a workshop as soon as possible where the cooling system
s
should be filled properly in accordance with the repair manual.
s o
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CAUTION
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C py
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– Wear protective goggles. p by
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by lksw
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Prote AG.
– Open filler cap on coolant expansion tank.

Note
♦ Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. 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. Therefore, always use only distilled
water when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
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reduce corrosion protection substantially.
wagen AGThe resulting dam‐
does
age could lead to loss of coolant olks
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♦ Mixed in the proper proportions,
ss
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c
rosion damage as well as scaling. Such additives also raise
ce
le
the boiling point of the coolant. For this reason, the cooling
un
pt
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system must be filled all-year-round with coolant additives.

itte
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erm
ab
♦ Because of its high boiling point, the coolant improves engine
ility
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reliability under heavy loads, particularly in countries with trop‐
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h re
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spec
♦ The refractometer - T10007A- must be used to determine the
current anti-freeze value.
t to the co
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
rrectne
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired. ss o
cial p
f inform
♦ Do not reduce the coolant concentration by adding water even

mer
in warmer seasons and in warmer countries. Frost protection

atio
m
must be guaranteed down to at least -25°C.

o
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♦ Read off anti-freeze figures for respective replenished coolant

te
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additives.
i
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♦ The temperature read off the refractometer - T10007A- corre‐

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sponds the ice flocculation point. Flakes of ice may start
Co
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forming in the coolant below this temperature. ht. rig
rig ht
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♦ Never reuse old coolant.
by c lksw
cted agen
Prote AG.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Coolant mixture ratio

• Coolant additive (40 %) and distilled water (60 %) for frost
protection to -25 °C
• Coolant additive (50%) and distilled water (50%) for frost pro‐
tection to -36 °C
• Coolant additive ⇒ Electronic parts catalogue (ETKA)
– Fill a suitable container with pre-mixed coolant observing the
correct mixing ratio.
– Fill the cooling system via the coolant expansion tank up to
max. marking.
– Close coolant expansion tank.
– If fitted, switch off air conditioning system.

– Start engine and maintain engine speed at approx. 2000 rpm

for about 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
CAUTION
– Check coolant level and top up as needed.

• The coolant level must be at the max. marking when the en‐
gine is warm.
• When the engine is cold, the coolant level must be between
min. and max. marking.
AG. Volkswagen AG d
satelettronica
agen oes
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AG. Volkswagen AG d
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not Transporter 2016 ➤
o
4-cylinder
d by
V
injection engine (2.0 l direct gu injection
ara engine, turbocharger) - Edition 06.2018
ise nte
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2 Coolant pump, regulation of cooling
ss c
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⇒ “2.1 Assembly overview - coolant pump, thermostat”,
ility
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page 171
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⇒ “2.2 Removing and installing coolant pump”, page 172
ole,
spec
⇒ “2.3 Removing and installing thermostat”, page 179
t to the co
⇒ “2.4 Removing and installing toothed belt for coolant pump”,
page 180
rrectne
⇒ “2.5 Removing and installing coolant temperature sender G62
”, page 182
ss o
⇒ “2.6 Removing and installing radiator outlet coolant tempera‐
cial p
f i
ture sender G83 ”, page 183
nform
mer
⇒ “2.7 Removing and installing coolant valves”, page 184
atio
om
n
c
2.1 Assembly overview - coolant pump, thermostat
i
or
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1 - Bolts
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t.
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❑ Qty. 5 t. Cop py
rig
❑ Observe tightening se‐
gh ht
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quence ⇒ page 172
o Vo
by c lksw
cted agen
Prote
❑ 9 Nm
AG.
2 - O-rings
❑ Qty. 2
3 - Union
4 - Retaining clip
❑ Only for inserted ver‐
sion.
❑ Ensure firm seating
5 - Bolt
❑ Only for screwed ver‐
sion.
❑ 4 Nm
6 - Support plate
❑ Only for screwed ver‐
sion.
7 - Radiator outlet coolant -
G62-
⇒ page 182
8 - O-ring
9 - Coolant pump
❑ New coolant pump: re‐
move protective cap
⇒ page 172
10 - Seal
2. Coolant pump, regulation of cooling system 171

11 - Centring pins
❑ Qty. 2
12 - Toothed belt
13 - Toothed belt guard
14 - Bolt agen
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❑ 9 Nm d by
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15 - Bolt ut
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❑ Renew after removal ss
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❑ Left-hand thread
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❑ 10 Nm +90°
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16 - Toothed belt drive sprocket
wit
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❑ Observe installation position
h re
hole
spec
17 - Oil seal
es, in part or in w
t to the co
satelettronica
rrectness of i
18 - Balancer shaft
l purpos
19 - Thermostat
nform
ercia

m
at
20 - Centring pin
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21 - O-ring
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22 - Union
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23 - Bolt C py
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❑ 9 Nm yri
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Prote AG.
Coolant pump - tightening sequence

– Tighten bolts for coolant pump in the sequence -1 … 5-.
2.2 Removing and installing coolant pump

⇒ “2.2.1 Removing and installing coolant pump”, page 172
⇒ “2.2.2 Renewing oil seal for coolant pump drive”, page 175
⇒ “2.2.3 Removing and installing continued coolant circulation
pump V51 ”, page 177
2.2.1 Removing and installing coolant pump


♦ Hose clamp pliers - V.A.G 1921-
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
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aut ra
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pt
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ab
ility
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spec
es, in part or in w
CAUTION
t to the co
rrectness of i
l purpos

satelettronica
nform
ercia

m
at
om
ion
c
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Removing
his
ate
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priv
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for
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noise insulation .
Co
Cop py
ht. rig
rig ht
py by
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Rep. gr. 50 ; Lock carrier; Moving to and back from service by c lksw
cted agen
position . Prote AG.

– Loosen clamp -arrow-.
– Pull off hose.
– Unscrew bolt -arrow-.
– Remove coolant pipe -1-.
– Lift up clip -1- and pull off water hose from water pipe in di‐
rection of arrow.

– Unscrew bolt -arrow- from water pipe -1-.

– Remove water pipe -1-.
– Disconnect electrical connector -1- at coolant temperature

sender - G62- .
Note
Disregard -2- and -arrows-.
satelettronica
– Lift retaining clips -1- and -2-. agen
AG. Volkswagen AG d
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– Pull off coolant hoses and lay aside. d by V gu
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ility
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, is n
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es, in part or in w
t to the co
rrectness of i
– Detach coolant pump from centring pin and pull off engine oil
cooler.
l purpos
Note
nf
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orm
m
atio
Disregard -arrow-.
om
n in
or c
thi
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Installing
t
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f
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ng
t.
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Cop py
t. rig
Note opyri
gh by
Vo
ht
c by lksw
cted
Renew seals and O-rings.
agen
Prote AG.

– Coat O-rings -4- with coolant; coolants ⇒ Electronic parts

catalogue (ETKA) .
– Check whether the two centring pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push coolant pump -3- onto connecting piece and centring pin
into cylinder block.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Tighten bolts for coolant
s autpump. ra
c
s
ce
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un
pt
an
d
Note
itte
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rm
ab
pe
ility
Remove protective cap -arrow- if a new coolant pump has been
ot
wit
fitted.
, is n
h re
hole
spec
satelettronica
– Fit toothed belt for coolant pump ⇒ page 180 .
es, in part or in w
t to the co
– Install coolant pipe.
rrectness of i
Specified torques
l purpos

page 171
nform
mercia
2.2.2 Renewing oil seal for coolant pump drive

a
com
tion in
r

te o
thi
s
iva
do

r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.
Removing


– Detach drive sprocket -1- for toothed belt for coolant pump.
G. Volkswagen AG d
– Press screwdriver -1- firmly onto section -2- of oillksseal
wage
nA oes
not
-arrow B-. db
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– Lever out seal using screwdriver -1- inutdirection
ho of -arrow A-. eo
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ab
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wit
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spec
t to the co
– Lubricate sealing surface of balance shaft -2- with gear oil.
rrectne
– Fit seal -1- onto balance shaft.
ss o
cial p
Note
f inform
mer
Inscription -arrow- must be readable from above.

atio
om
n
c
i
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fo
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Apply thrust piece - T10353- to oil seal -1- and press into cyl‐
inder block as far as possible using bolt -2- (take care not to
cant oil seal).
Note
♦ Risk of damage to thread.

♦ The drive sprocket bolt has a left-hand thread.
Installing n AG. Volkswagen AG do

lkswage es n
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– Fit toothed belt for coolant pump ⇒ page 180 s.au or
ac
s
ce
– Install small coolant pipe.
le
un
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an
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itte
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erm
ab
Note
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Never reuse old coolant.
ole,
spec
satelettronica
t to the co
Specified torques
rrectne
page 171
ss o
2.2.3 Removing and installing continued cool‐
cial p
f inform
ant circulation pump - V51-
mer
atio
m

o
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c
i
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t
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Cop py
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olks
wage engine, turbocharger)es n - Edition 06.2018
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♦ Drip tray for workshop hoist - VAS 6208- rise nte
tho eo
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ab
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wit
is n
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spec
t to the co
rrectne
Removing
ss o
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Note
form
mer
atio
m
To collect the escaping coolant, place drip tray for workshop hoist
o
n
c
i
- VAS 6208- underneath.
or
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te
sd
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satelettronica
iv
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pr
cum
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fo
en
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t.
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noise insulation .
Co
Cop py
t. rig
gh
– Clamp off coolant hoses -arrows- using hose clamps to 25 mm
ht
pyri by
Vo
o
- 3094- and remove.
c by lksw
cted agen
Prote AG.
– Undo bolt -arrow- and remove coolant circulation pump - V51-

-1-.
Installing
Note
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
– Check coolant level ⇒ page 163 .

Specified torques

Bolt 8 Nm

2.3 Removing and installing thermostat

Removing
AG. Volkswagen
terior; Rep. gr. 66 ; Noise insulation; Removing
kswagen and installingAG does
not
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noise insulation . db
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– Move to service position ⇒ Generaltho body repairs, exterior; or
s au
Rep. gr. 50 ; Lock carrier; Moving to and back from service ac
s
position .
ce
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nl
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du
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wit
Note
, is n
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hole
spec
Only the lower water hose has to be removed.
es, in part or in w
t to the co
– Lift retaining clip -2- and pull off coolant hose.
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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C py
t. rig
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– Remove connection. cop Vo
by lksw
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Prote
– Detach thermostat.
AG.
Installing
Note
Renew seals and O-rings.
– Clean sealing surface for O-ring.

– Coat O-ring with coolant; coolants ⇒ Electronic parts cata‐
logue (ETKA) .

– Insert thermostat -4- in coolant pump housing -5- and swivel

forwards slightly -arrow-.
– Fit connection -3- carefully (insert centralising pin -2- in guide
-1-).
Specified torques
page 171
2.4 Removing and installing toothed belt for
satelettronica
coolant pump
♦ Insert tool - T10360-
AG. Volkswagen AG d
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olksw not
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Removing
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t.
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Co
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noise insulation .
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– Move to service position ⇒ General body repairs, exterior; by c lksw
cted agen
Rep. gr. 50 ; Lock carrier; Moving to and back from service Prote AG.
position .

– Loosen clamp -arrow-.

– Pull off hose.
– Remove coolant pipe -1-.
– Lift up clip -1- and pull off water hose from water pipe in di‐
rection of arrow.
satelettronica
– Unscrew bolt -arrow- from water pipe -1-.
– Remove water pipe -1-. AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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un
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an
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
– Unscrew bolts -arrows- and remove toothed belt guard.

rrectne
Note
The drive sprocket bolt has a left-hand thread.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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t.
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Cop py
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pyri by
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Prote AG.

– Use torque wrench - V.A.G 1331- and socket - T10360- to re‐

move bolt on coolant pump drive sprocket -1- (counterhold at
vibration damper.
– Detach drive sprocket -1- and toothed belt -2-.
Installing
Note
♦ Replace bolt for drive sprocket. AG. Volkswagen AG d

agen oes
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♦ Renew seals and O-rings. by
Vol not
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ara
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♦ Note installation position of V-belt
hor pulley ⇒ page 171 . eo
aut ra
ss c
– Install coolant pipe.
ce
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un
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erm
ab
ility
Specified torques
ot p
wit
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satelettronica
h re
ole,
page 171
spec
t to the co
2.5 Removing and installing coolant temper‐
ature sender - G62-
rrectne
s
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

Removing
• Engine cold
position . wage
es
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– Disconnect econnector
db
y -2-. ara
nte
is
or eo
– Place drip
au tray for workshop hoist - VAS
th 6208- underneath.ra
ss c
ce
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– Detach retaining plate -1-.

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ab
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– Remove coolant temperature sender - G62- .
ility
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Installing
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Renew O-rings after removal.
satelettronica
l purpos
♦ Insert new coolant temperature sender - G62- immediately in‐

to connection to avoid loss of coolant.
nform
ercia

m
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tion in
Specified torques
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page 171
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op
2.6 Removing and installing radiator outlet
C py
t. rig
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coolant temperature sender - G83-
pyri by
Vo
co lksw
by
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Prote
AG.
Removing
• Engine cold
noise insulation .

Note
♦ To collect the escaping coolant, place drip tray for workshop

hoist - VAS 6208- underneath.
♦ Fit new radiator outlet coolant temperature sender - G83- im‐
mediately into union to avoid loss of coolant.
– Separate electrical connector on radiator outlet coolant tem‐

perature sender - G83- in direction of -arrow-.
– Pull out securing clip in direction of -arrow-.
– Remove radiator outlet coolant temperature sender - G83-
-arrow-.
Installing
Note
AG. Volkswagen AG d
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satelettronica
oes
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♦ Renew O-rings after removal. o l not
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♦ Hose connections and coolant pipes/hoses must beutfree
hor
of oil eo
and grease before installing them. ss a ra
c
ce
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un
pt
an
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catalogue (ETKA) .
rm
ab
pe
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, is n
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hole
spec
noise insulation .
es, in part or in w
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2.7 Removing and installing coolant valves
rrectness of i
l purpos
⇒ “2.7.1 Removing and installing 3/2-way valve”, page 184
2.7.1 Removing and installing 3/2-way valve

nform
ercia

m
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com
tion in

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s
iva
do
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fo
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
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Place a cloth under water hoses to absorb aescaping
ut
h coolant. eo
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nl
– Release clips -3-.
satelettronica
pt
du
an
itte
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– Pull off water hoses from 3/2-way valve -2-.
erm
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ility
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– Separate connector -1-.
wit
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hole
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– Remove 3/2-way valve.
es, in part or in w
t to the co
Installing
rrectness of i
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Note
nform
ercia
m
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c
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priv
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Specified torques ht. Cop py
rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Nut 8 Nm

3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator/radiator fan”, page 186
⇒ “3.2 Removing and installing radiator”, page 186
⇒ “3.3 Removing and installing radiator cowl with radiator fan”,
page 191
3.1 Assembly overview - radiator/radiator fan
1 - Radiator/cooler
⇒ page 186
2 - Radiator fan
⇒ page 191
3 - Bolts
❑ Qty. 3
satelettronica
❑ 5 Nm
AG. Volkswagen AG d
4 - Bolts agen oes
olksw not
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❑ Qty. 4 rise
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❑ 5 Nm auth
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5 - Retainer tab
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an
❑ Must be engaged in ra‐
itte
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diator.
erm
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ility
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6 - Radiator cowl
wit
, is n
h re
hole
⇒ page 191
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
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n in
or c
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te
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t.
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Cop py
t. rig
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3.2 Removing and installing radiator pyri by
Vo
co lksw
by
cted agen
Prote
AG.


AG. Volkswagen AG d
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olksw not
V gu
d by ara
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or eo
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aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
noise insulation .
l purpos
nform
ercia
– Remove front bumper cover ⇒ General body repairs, exterior;
satelettronica
Rep. gr. 63 ; Front bumper; Removing and installing bumper
m
at
cover .
om
ion
c
in t
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– Remove charge air cooler ⇒ page 202 .

o
his
ate
do
riv
– Unscrew bolt -arrow- from radiator mounting on right and left.

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for
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Pull back securing lever -1- onto stop

– Press down locking lever -2- and separate electrical connec‐
tor.
3. Radiator, radiator fan 187

– Remove spreader rivets -1- and remove air duct -2- upwards.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
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ility
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es, in part or in w
– Open spring-type clips -arrows-.
t to the co
– Pull off coolant hoses -1- and -2- from radiator.
rrectness of i
l purpos
nform
ercia
satelettronica
m
at
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ion
c
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his
ate
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priv
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– Pull out power steering pipes -1- from mountings -2 … 4-.

f
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Cop py
t. rig
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Note p by
co Vo
by lksw
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Prote AG.
Remove the two holders for the servo steering pipe only if the
radiator is to be replaced.


– Squeeze catch -arrow- and pull condenser forwards a little.
AG. Volkswagen AG d
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olksw not
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– Squeeze catch -arrow- and pull condenser -2- off radiator
erm
ab
satelettronica
-1-.
ility
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Note
spec
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♦ Do not bend or stretch the refrigerant lines.
♦ The condenser must be held in the “2 o'clock position” when
rrectne
the radiator is being removed.
♦ A second mechanic is needed to remove the radiator.
ss o
cial p
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mer
atio
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n
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Cop py
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– Lift condenser -1- out of the left holder -2- and right holder py
rig by
ht
-3- and place it on the bumper. co Vo
by lksw
cted agen
Prote AG.

– Unscrew bolt -2- from upper left and right radiator mounting.
– Press right and left catches -1- together.
– Press the two radiator mountings downwards into the radiator.
NOTICE
Risk of damage to refrigerant lines from rupture of inner foil.
– Never bend refrigerant lines to a radius tighter than
r = 100 mm.
– Hold condenser -1- in “2 o'clock position” with aid of second

mechanic.
– Carefully remove radiator -2- in left-hand direction, while guid‐
ing radiator -2- past refrigerant lines and bumper carrier.
If radiator is to be renewed, remove radiator cowl together with
radiator fan - V7- ⇒ page 191 .
Installing
satelettronica
Note
Use only distilled water for mixing coolant additives. The use of
distilled water ensures optimum protection against corrosion.
– Insert lower radiator mounting -1- into lock carrier -2- trans‐
verse to direction of travel, and then turn it 90°.
AG. Volkswagen AG d
agen oes
olksw not
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ara
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wit
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es, in part or in w
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Fasteners -1- of upper left and right radiator mountings must

be completely engaged in lock carrier.
noise insulation .
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 186
3.3 Removing and installing radiator cowl

with radiator fan
Removing
– Removing radiator ⇒ page 186 .
– Unscrew bolts -arrows- and remove radiator cowl with radiator
fan - V7- from radiator. wage
satelettronica
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olks o t gu
yV
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au ra
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erm
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ility
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spec
es, in part or in w
t to the co
– Push back locking lug -arrow-, and remove radiator cowl to‐
gether with radiator fan - V7- from radiator.
rrectness of i
Installing
l purpos

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op
– Insert radiator cowl with radiator fan - V7- into radiator with C py
t. rig
locking lug first -arrow-.
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.


– Installing radiator ⇒ page 186 .
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 186
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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un
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an
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erm
ab
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wit
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spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes Transporter 2016 ➤
olksw not
V
4-cylinder injectioned b engine (2.0 l direct injection engine,
y gu
ara turbocharger) - Edition 06.2018
ris nte
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21 – Turbocharging/supercharging
ss
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rm
ab
1 Exhaust turbocharger
pe
ility
ot
wit
, is n
⇒ “1.1 Assembly overview - turbocharger”, page 193
h re
hole
spec
⇒ “1.2 Removing and installing turbocharger”, page 196
es, in part or in w
t to the co
1.1 Assembly overview - turbocharger
rrectness of i
Note
l purpos
♦ Sealed bolts and nuts must not be loosened.
nform
ercia
♦ All hose connections are secured.

m
a
♦ Charge air system must be free of leaks.
com
tion in
♦ Renew self-locking nuts and bolts.
r
te o
thi
s
iva
do
♦ Before screwing on oil pressure line, fill turbocharger at union with engine oil.
r
rp
cum
satelettronica
fo
♦ After installing turbocharger, allow engine to run at idling speed for about 1 minute to ensure that oil is
en
ng
t.
yi
supplied to turbocharger.
Co
Cop py
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pyri by
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by
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1 - Exhaust manifold with tur‐ Prote AG.
bocharger
❑ Renew only as com‐
plete unit
❑ Renewed together with
vacuum unit, exhaust
manifold and regulating
flap potentiometer -
G584-
❑ When turbocharger and
connecting pipes are
being assembled, it is
essential that the cor‐
rect repair set ⇒ Elec‐
tronic parts catalogue
(ETKA) is used
⇒ page 196
2 - Seal
3 - Retaining clip
4 - Bolt
❑ M5 x 12
❑ 7 Nm
5 - Turbocharger air recircula‐
tion valve - N249-
6 - Hose
7 - Clip
8 - Bolt
❑ M5 x 12
❑ 3 Nm
1. Exhaust turbocharger 193

9 - Hose
10 - Hose
11 - Banjo bolt
❑ Not available as replacement part
12 - Seal
13 - Connection piece
14 - Charge pressure control solenoid valve - N75-
15 - Bracket for cover
16 - Pressure capsule with attachments
17 - Splash plate
18 - Bolt
❑ M6 x 16
satelettronica
19 - Plug
20 - Banjo bolt AG. Volkswagen AG d
agen oes
ksw
❑ 32 Nm byV
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ara
ed
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21 - Seal hor eo
aut ra
❑ Renew after removal ss c
ce
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nl
22 - Thermal protection for oil pipe
pt
du
an
itte
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23 - Bolt
erm
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ility
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❑ M6 x 15
wit
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❑ 9 Nm
h re
hole
spec
24 - Oil pipe
es, in part or in w
t to the co
Note
rrectness of i
♦ Risk of damage when removing
and installing turbocharger.
l purpos
♦ Check oil pressure line for dam‐

age after removing (kinks in
nf
ercia
hose). Oil pressure line must be

orm
renewed if damaged.
m
atio
om
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c
25 - Banjo bolt
or
thi
te
sd
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❑ 32 Nm
iv
o
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26 - Seal
f
en
ng
t.
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❑ Renew after removal . Cop py
rig
ht ht
27 - Securing nut
rig by
copy Vo
by lksw
❑ Renew after removal cted agen
Prote AG.
❑ Observe tightening sequence and specified torque ⇒ page 200
28 - Coolant pipe
❑ Supply line
29 - Seal
30 - Bolt
❑ M8 x 35
194 Rep. gr.21 - Turbocharging/supercharging

❑ 30 Nm
AG. Volkswagen AG d
agen oes
31 - Support Volksw not
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32 - Bolt rise nte
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❑ M8 x 16 ss a ra
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❑ 30 Nm
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33 - Nut itte
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ility
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34 - Stud
h re
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❑ M10 x 32
spec
❑ 24 Nm
t to the co
35 - Coolant pipe
❑ Return
rrectne
36 - Tensioner
ss
37 - Bolt
o
cial p
f i
❑ M6 x 15
nform
mer
❑ 9 Nm
atio
satelettronica
om
38 - Oil pipe
n
c
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39 - Seal
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um
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40 - Bolt
Co
Cop py
t.
❑ M6 x 15
rig
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pyri by
Vo
❑ 9 Nm
co lksw
by
cted agen
Prote AG.
41 - Seal
Installation location of turbocharger air recirculation valve - N249-

– Note installation position -arrows-.

olkswagen AG
wag en AG. V
Transporter 2016 ➤ olks
does
not
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4-cylinder injection engine (2.0
sedl direct injection engine, turbocharger)
b ara - Edition 06.2018
n ri tee
ho
ut or
1.2 Removing and installing turbocharger
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
equipment required
ility
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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
or
satelettronica
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Note
♦ If a mechanical fault is found on the turbocharger, e.g. a de‐

stroyed compressor impeller, just renewing the turbocharger
is not enough. To avoid subsequent damage, the following
work must be carried out:
♦ Check air filter housing, air filter element and intake hoses for
dirt/soiling.
♦ Check the whole charge air path and charge air cooler for for‐
eign objects.
♦ If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Removing
Note
satelettronica
♦ After lines and hoses have been removed, the open connec‐
tions are to be sealed immediately with a plug from the engine
bung set - VAS 6122- .
♦ Only use clean plugs.
wage
– If fitted, remove noisey insulation
Volks ⇒ General body erepairs,
s no
t gu ex‐
terior; Rep. gr. 66ise;dNoise insulation; Removing and installing
b ara
nte
noise insulationtho.r eo
u ra
sa c
s
ce
le
un
pt

an
d
itte
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erm
ab
– Detach electrical connector from intake hose.

ility
ot p

wit
is n
h re
ole,
– Loosen clamps -1- and -2- and pull off hoses from turbocharg‐
spec
er -3-.
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
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew bolt -1- from support mounting -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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un
pt
an
d
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erm
ab
ility
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wit
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spec
t to the co
rrectne
satelettronica
ss o
cial p
f in
Note
form
mer
Note different bolt lengths. atio

om
n
c
i
or
n thi
e

t
sd
iva
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pr
cum
– Remove front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing

r
fo
en
ng
and installing propshaft .

t.
yi Co
Cop py
– Remove bevel box ⇒ Rep. gr. 39 ; Components of bevel box;
t. rig
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Removing and installing bevel box . p by
o Vo
by c lksw
cted agen
Vehicles with front-wheel drive: Prote AG.
– Unscrew bolts -arrows- and swivel drive shaft support down‐

wards.
Continued for all vehicles:
– Remove starter catalytic converter ⇒ page 243 .

– Detach electrical connectors -3- from turbocharger.

– Detach vacuum hoses from turbocharger.

– Remove pendulum support -1-.
– Loosen clip -2- and pull water hose off.
Note
satelettronica
Avoid damage to oil pressure line and coolant line.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
– Unscrew boltsut -2- and -3-.
ho eo
ra
s a c
s
– Release coolant line bracket -4- from turbocharger -1-.
ce
e
nl
pt
du
an
– Remove coolant line from turbocharger and swing aside.

itte
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erm
ab
– Detach oil supply line from turbocharger.

ility
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– Unscrew oil return line from turbocharger and also swing

h re
aside.
hole
spec
– Remove heat shield on turbocharger .

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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sd
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Cover anti-roll bar with a cloth or similar to avoid damage to
paintwork.
– Remove turbocharger, tilt to rear and remove via subframe
and anti-roll bar.
Installing
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts after re‐

moval.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. AG. Volkswagen AG d
agen oes
lksw not
♦ Restore the factory standard by securing all of the hose con‐d by Vo gu
ara
nections with hose clips appropriately ⇒ Electronic parts orise nte
catalogue (ETKA) . h eo
satelettronica
aut ra
ss c
♦ After installing turbocharger, run engine for about 1 minute at
ce
le
un
pt
idling speed to ensure that oil is supplied to turbocharger.
an
d
itte
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erm
ab
ility
ot p
Tightening sequence - turbocharger
wit
is n
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– Tighten bolts in sequence -1 … 5- in 4 stages as follows:
ole,
spec
1. Tighten screws to 5 Nm.
t to the co
rrectne
ss
o
cial p
f in
– Install front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing
form
mer
atio
m
– Install bevel box ⇒ Rep. gr. 39 ; Components of bevel box;

o
n
c
i
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Removing and installing bevel box .
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terior; Rep. gr. 66 ; Noise insulation; Removing and installing . Cop py
noise insulation .
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– Check oil level; replenish engine oil if necessary ⇒ Mainte‐
nance ; Booklet 20.1 ; Descriptions of work; Engine oil:
draining or extracting; Renewing oil filter and replenishing en‐
gine oil .
Specified torques

2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 201
⇒ “2.2 Removing and installing charge air cooler”, page 202
⇒ “2.3 Removing and installing charge pressure sender G31 ”,
page 203
⇒ “2.4 Checking charge air system for leaks”, page 204
2.1 Assembly overview - charge air system
1 - Charge air cooler

⇒ page 202
2 - Bolts
❑ Qty. 2
❑ 5 Nm
3 - Clamps
satelettronica
❑ Qty. 6
4 - Connection hose
❑ Note installation posi‐
tion ⇒ page 202
5 - Connection hose
tion ⇒ page 202
6 - Connection hose
tion ⇒ page 202 AG. Volkswagen AG d
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7 - Union d byV gu
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8 - O-ring ut
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❑ Renew if damaged or ss
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9 - Charge air pressure sender

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- G31-
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⇒ page 203
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10 - Bolt
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❑ 2 Nm
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2. Charge air system 201

Installation position of connecting hoses

– Install connecting hose in such a way that marking -1- on con‐
necting hose aligns with marking -2- on respective connecting
piece.
2.2 Removing and installing charge air cool‐

er
AG. Volkswagen AG d
♦ Engine bung set - VAS 6122- agen oes
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– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .


– Pull pressure hose on left -1- towards the rear and off the
charge air cooler.

– Pull pressure hose on right -2- towards the rear and off the
charge air cooler.
satelettronica
AG. Volkswagen AG d
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– Remove charge air cooler -1- from mounting on left and right.
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Specified torques t to the co
♦ ⇒ “2.1 Assembly overview - charge air system”, page 201

rrectness of i
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2.3 Removing and installing charge pres‐

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Removing
– Separate connector -1-. n AG. Volkswagen AG do
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– Move clear wiring harness -4-. d byV
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– Unscrew bolts -3- and move coolant expansion tank -2-utto
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– Separate electrical connector in direction of -arrow-.
nform
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satelettronica
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– Remove charge pressure sender - G31- .
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Bolts for coolant expansion tank ⇒ page 23
2.4 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
Note
Items 2 and 4 can be disregarded.

– Release hose clip -1- and pull pressure hose off turbocharger
-3-.
– Depending on hose diameter, insert adapter - 1687/10- ,
satelettronica
-1687/11- or -1687/12- in air duct -1- and secure with hose clip.
– Connect charge air system tester - V.A.G 1687- as shown in
figure.
AG. Volkswagen AG d
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Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Close valves -3- and -4-.

– Apply compressed air -1- to charge air system tester - V.A.G
1687- .
– If there is water in inspection glass, drain via drain screw -6-.
– Open valve -3-.
Note
♦ Risk of damage if pressure is set too high!
satelettronica
♦ The pressure must not exceed 0.5 bar.
– Adjust pressure to 0.5 bar with pressure control valve -2-.

– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.5 bar.
– Check charge air system for leaks by hearing, touching, with
commercially available leak detector spray or using ultrasonic
AG. Volkswagen AG d
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tester - V.A.G 1842- . Volksw
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♦ A small amount of air escapes through the valves and enters
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♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
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instructions
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♦ Before removing the adapters, depressurise the test circuit by

spec
detaching coupling.
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24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 207
1.1 Overview of fitting locations - injection system
1 - Air mass meter - G70-

⇒ page 226
2 - Turbocharger air recircula‐
tion valve - N249-
3 - Inlet camshaft control valve
1 - N205-
⇒ page 133
satelettronica
4 - Charge pressure control
solenoid valve - N75-
⇒ page 226
5 - Ignition coils with output
stages
⇒ page 248
AG. Volkswagen AG d
6 - Lambda probe - G39- and agen oes
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Lambda probe heater - Z19- d by V gu
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❑ Removing and installing thor eo
⇒ page 235 ss au ra
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7 - High-pressure pump
nl
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⇒ page 231
ility
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8 - Intake air temperature
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sender - G42- with charge air
hole
pressure sender - G31-

spec
es, in part or in w
❑ Removing and installing t to the co

⇒ page 203
9 - Engine control unit - J623-
rrectness of i

⇒ page 228
l purpos
10 - Fuel pressure regulating valve - N276-

nform
ercia
11 - Intake manifold flap potentiometer - G336-

m
at
om
12 - Activated charcoal filter solenoid valve 1 - N80-

ion
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or
13 - Engine speed sender - G28-

his
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14 - Knock sensor 1 - G61-

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❑ Removing and installing ⇒ page 249 C py
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❑ Throttle valve drive angle sender - G187- and throttle valve drive angle sender 2 - G188- Prote AG.
1. Injection system 207

❑ After each removal and installation procedure or after renewing throttle valve module - J338- , it must be
re-adapted to engine control
agen unit - J623- . AG does
AG. Volkswagen
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16 - Radiator outletthocoolant - G62- or
au ac
❑ Removing s and installing ⇒ page 182
s
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17 - Fuel pressure sender - G247-
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208 Rep. gr.24 - Mixture preparation - injection

2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 209
2.1 Connection diagram - vacuum system
1 - Vacuum hose
2 - Air filter
3 - Silencer
4 - Fuel lines
5 - Hose
❑ With non-return valve
6 - Intake manifold
7 - Vacuum hose
8 - Vacuum unit for fuel rail
❑ Removing and installing AG. Volkswagen AG d
satelettronica
fuel rail ⇒ page agen.
w221 oes
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9 - Intake manifold
ris
ed flap air flow nte
control valve
ut - N316-
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10 - Vacuum hose
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2. Vacuum system 209

3 Injectors
⇒ “3.1 Removing and installing injectors”, page 210
⇒ “3.2 Renewing seals on injectors”, page 211
⇒ “3.3 Cleaning injectors”, page 213
wage es n
3.1 Removing and installing injectors olks ot g
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♦ Tool kit with puller - T10133-
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Removing
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– Remove intake manifold with fuel rail ⇒ page 219 .
mer
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♦ Remove injectors if these remain in fuel rail.
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♦ Remove injectors if these remain in cylinder head.
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1 - Replace intermediate ring
2 - Support bearing
3 - Combustion chamber ring seal (Teflon ring seal), renew; when
fitting, do not grease ring or use any other lubricant.
4 - Injection valve
5 - Spacer (renew if damaged)
6 - O-ring (renew; to install, lightly lubricate with clean engine oil).
7 - Support ring (via this support ring, the fuel rail exerts force
which secures injector in cylinder head)
– Cover open intake ports with a clean cloth.
– Separate electrical connector from injector to be removed.

– Insert puller -T10133/2A- into groove in injector.

– Then position removal tool -T10133/16- and pull injector out
by turning bolt -1-.
Note
The combustion chamber seal must always be renewed prior to

reinstallation of the injector ⇒ page 211 .
Installing
Install in reverse order of removal.
3.2 Renewing seals on injectors

♦ Tool kit with puller - T10133-
satelettronica
lkswage es n
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Note
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♦ The combustion chamber seal must always be renewed prior

pe
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to reinstallation of the injector

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♦ Injector must be renewed if groove is damaged.

hole
spec
es, in part or in w
– Carefully remove old Teflon ring using a suitable tool (e.g. cut
t to the co
open ring using razor blade, or prise open ring with small
screwdriver and then pull off forwards).
rrectness of i
– Before fitting new Teflon ring, clean any combustion residue

from annular groove and injector shaft using a clean cloth.
l purpos
nform
ercia
Note
m
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com
♦ The figure shows an injector with an angled connector.

ion in
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♦ This can be ignored in the subsequent procedure since it is

s
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not important when renewing the combustion chamber ring

do
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seal.
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3. Injectors 211
– Fit assembly cone -T10133/5- with new Teflon ring -1- on in‐
jector -2-. agen
AG. Volkswagen AG d
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– Push Teflon ring with assembly sleeve -T10133/6- further on
to assembly cone -T10133/5- until Teflon ring engages in seal
ring.
rrectne
Note
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♦ Pushing Teflon ring onto injector stretches Teflon ring.
form
mer
satelettronica
♦ The Teflon ring must therefore be compressed again after it
atio
om
has been fitted.
n
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Perform step 1 of calibration (adaption) of Teflon ring using cali‐

iv
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bration sleeve -T10133/7- .
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– Using a twisting movement (approx. 180°) and applying slight
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pressure, slide calibration sleeve -T10133/7- over injector as
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– Twist calibration sleeve -T10133/7- in opposite direction and
pull it off.
Perform step 2 of calibration (adaption) of Teflon ring using cali‐
bration sleeve -T10133/8- .
– Using a twisting movement (approx. 180°) and applying slight

pressure, slide calibration sleeve -T10133/8- over injector as
far as it will go.
– Twist calibration sleeve -T10133/8- in opposite direction and
pull it off.
– Renew O-ring on injector.
– Before installing O-ring, lightly moisten it with clean engine oil.
Note
Teflon ring must not be oiled.

– Before installing injectors, thoroughly clean injector bores in

cylinder head with nylon brush provided -T10133/4- .
Note
♦ Do not oil or grease the Teflon seal on the injector.

♦ There must be no cleaning fluid or oil in the bores in the cyl‐
inder head when installing the injector.
– Push injector by hand as far as it will go into the hole of the

cylinder head (free of oil and grease). Ensure injectors are
positioned correctly in cylinder head.
Note
♦ It should be possible to insert the injector easily. If necessary,

wait until the combustion chamber ring seal has contracted
sufficiently.
♦ Ensure injectors are correctly seated and positioned in cylin‐
satelettronica
der head.
♦ If it is not possible to insert the injector by hand, use the puller
- T10133/2A- -2- with a hammer - T10133/3- to insert the in‐
jector.
Important: It is essential to comply with the following points:G. Volkswage

nA n AG d
wage oes
• Moisten O-rings of high-pressure injectors with
y V clean engine
olks not
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oil to aid insertion into fuel rail isedb ara
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• Renew all gaskets aut ra
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• Fuel rail must be placed on injectors and evenly pressed in
le
un
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• Install intake manifold with fuel rail

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3.3 Cleaning injectors wit

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spec
es, in part or in w
♦ Ultrasonic cleaning device - VAS 6418-

t to the co
♦ Mounting plate for injection modules - VAS 6418/1-

rrectness of i
♦ Cleaning fluid ⇒ Electronic parts catalogue (ETKA)

l purpos
– Remove injectors ⇒ page 210 .
nform
ercia
– Insert injectors -1- to stop into mounting plate for injection

m
modules - VAS 6418/1- .

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Prote AG.
3. Injectors 213
Note
♦ The ultrasonic cleaner - VAS 6418- must be filled with cleaning

agent to the upper edge of the holes -2-.
♦ Adhere to the safety precautions and the instructions for use
of the ultrasonic cleaner - VAS 6418- .
– Immerse injectors together with mounting plate for injection

modules - VAS 6418/1- into cleaning fluid .
– Set rotary knob -2- to a temperature of 50°C.
– Set a cleaning time of 30 minutes with the rotating knob -4-.
– Switch on ultrasonic unit with button -3-.
satelettronica
Note
The time set starts to elapse as soon as a cleaning temperature

of 50°C has been attained. wage
e
ks s no
Vol t gu
d by ara
– Each time after cleaning injector, renew combustion
or
ise chamber nte
eo
ring seal (Teflon ring seal) ⇒ page 211 . auth ra
ss c
– Then reinstall injectors ⇒ page 210 .
ce
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un
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4 Air filter
⇒ “4.1 Assembly overview - air filter housing”, page 215
⇒ “4.2 Removing and installing air filter housing”, page 216
4.1 Assembly overview - air filter housing

wage es n
1 - Air filter lower part yV
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❑ Removing and installingo
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ran
tee
⇒ page 216 au th or
ac
ss
2 - Air filter element
ce
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un
pt
❑ Renew air filter ⇒ Main‐
an
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itte
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tenance ; Booklet 20.1 ;
erm
ab
Descriptions of work; Air
ility
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filter: cleaning housing
wit
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and renewing filter ele‐
h re
ole,
ment
spec
3 - Grommet
t to the co
satelettronica
4 - Plug
rrectne
5 - Air filter upper part
s
⇒ page 216
s o
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f
6 - Air filter - maintenance indi‐
inform
cator
mer
atio
❑ Only for countries with
om
high dust content in the n

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7 - Buffer stop
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8 - Pop rivet
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❑ Use blind-rivet gun -
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VAS 5072- to renew. p by
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9 - Bracket Prote AG.
❑ Fitted onto wheel hous‐

ing
10 - O-ring
11 - Bolt
❑ M6 x 22
❑ 3.5 Nm
12 - Air mass meter - G70-
13 - Clip
14 - Intake hose
❑ Markings on intake hose must be flush with webs on turbocharger (very important)
❑ Clean oil from ends of hoses before installing
❑ Do not use oil-based lubricants
❑ To turbocharger
15 - Clip
16 - Water drain hose
❑ Clipped onto lower part of air filter
4. Air filter 215

❑ Make sure it is mounted in correct position on longitudinal member
❑ Clean if soiled
17 - Grille
18 - Pop rivet
❑ Use blind-rivet gun - VAS 5072- to renew.
19 - Bracket
❑ Fitted onto longitudinal member
20 - Bolt
❑ M6 x 35
21 - Spreader rivet
22 - Air duct
❑ Ensure proper engagement.
23 - Sealing clip
4.2 Removing and installing air filter hous‐
satelettronica
ing
Special tools and workshop equipment required lkswage es n
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♦ Torque wrench - V.A.G 1410- o
ir se
ran
tee
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ility
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Prote AG.

Removing
– Unplug electrical connector -3- from air mass meter - G70- .
– Unclip vacuum hose -2- from retainer and pull it off air filter
housing -1-.
– Release clamp -4-, and pull off intake hose.

– Release water drain pipe -3-.
– Carefully pull air filter housing -2- out of guides and remove.
Installing
satelettronica
Specified torques
AG. Volkswagen AG d
agen oe
♦ ⇒ “4.1 Assembly ksw
oloverview - air filter housing”,
s no page 215
tg
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c
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4. Air filter 217

5 Intake manifold
⇒ “5.1 Assembly overview - lower part of intake manifold with fuel
rail”, page 218
⇒ “5.2 Removing and installing intake manifold upper part”, page
219
⇒ “5.3 Removing and installing lower part of intake manifold”,
page 221
⇒ “5.4 Removing and installing throttle valve module J338 ”, page
222
⇒ “5.5 Checking intake manifold change-over”, page 224
5.1 Assembly overview - lower part of intake manifold with fuel rail
1 - Fuel distributor
⇒ page 221
2 - Intake manifold flap poten‐
satelettronica
tiometer - G336-
3 - Bolts
❑ Qty. 2
4 - Seal
5 - Hose
6 - Intake manifold flap air flow
control valve - N316-
7 - Bolt n AG. Volkswagen AG do
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8 - Bracket utho tee
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9 - Bolt ss
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❑ 9 Nm
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10 - Bracket
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11 - Hose
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12 - Bolt
hole
spec
❑ 9 Nm
es, in part or in w
t to the co
13 - Throttle valve module -

J338-
rrectness of i

⇒ page 222
l purpos
14 - Seal
nf
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orm
15 - Bolt
m
atio
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❑ 9 Nm
n in
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16 - Bracket for valve

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17 - Attachment
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18 - Variable intake manifold
Co
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19 - Intake air temperature sender - G42-

20 - Bolt
❑ 9 Nm
21 - Bolt
❑ 20 Nm
22 - Support
23 - Bolt
❑ 20 Nm
24 - Nut
❑ 9 Nm agen
AG. Volkswagen AG d
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25 - Bolt ed by
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❑ 9 uNm thor eo
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26 - Seal
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27 - Stud
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❑ 9 Nm
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5.2 Removing and installing intake manifold t to the co

upper part
Removing
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Note
nform
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♦ The injectors can only be accessed after removal of the intake

m
manifold and fuel rail.

com
tion in
♦ The combustion chamber ring seal (Teflon) and O-ring must

r
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always be renewed.
s
iva
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– Remove intake manifold and fuel rail ⇒ page 218 .

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op
C py
t. rig
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pyri by
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noise insulation .
by c lksw
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position .
– Detach electrical connectors from intake air temperature send‐
er - G42- , solenoid valve 1 for activated charcoal filter - N80- ,
throttle valve control module - J338- and Hall sender - G40- .
– Unclip wiring harness from intake manifold and place to one
side.
5. Intake manifold 219

– Detach clamp -3- of pressure hose -2- at throttle valve module

- J338- .
– Pull off pressure hose from throttle valve module - J338- and
lay aside.
– Detach bracket -4- from solenoid valve 1 for activated charcoal
filter - N80- .
– Loosen activated charcoal filter line from intake manifold and
lay aside.
satelettronica
– Detach bracket.
Note
The fuel system must not be under pressure.

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– Loosen union nut of pressure pipe -1-.

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– Loosen bracket of pressure pipe at intake manifold.

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hole
spec
es, in part or in w
t to the co
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220
Prote AG.
Rep. gr.24 - Mixture preparation - injection
– Undo and remove bolts -arrows- from intake manifold -2-.

– Carefully pull upper part of intake manifold off lower part of
intake manifold.
Note
Seal intake ports with a clean cloth.
Installing
Specified torques
♦ ⇒ “5.1 Assembly overview - lower part of intake manifold with
fuel rail”, page 218
5.3 Removing and installing lower part of in‐

take manifold wage
e ks s no
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Removing d by ara
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♦ The injectors can only be accessed after removal of the intake
y li
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manifold and fuel rail.
ility
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♦ The combustion chamber ring seal (Teflon) and O-ring must
wit
, is n
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always be renewed.
hole
spec
es, in part or in w
t to the co
noise insulation .
rrectness of i
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position .
– Remove upper part of intake manifold ⇒ page 219 .
nf
ercia
orm
– Pull vacuum line -arrow- off intake manifold flap air flow control
m
atio
m
valve - N316- and detach electrical connector.

o
n in
or c
– Unclip crankcase breather hose from oil trap.

thi
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sd
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– Remove oil filter ⇒ Item 6 (page 155) .

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If present, open cable retainer -arrow-, and lay wiring harness to Prote
cted AG.
agen
one side.

– Detach electrical connector -1- from intake manifold flap po‐

tentiometer - G336- . Volkswa AG. gen AG
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spec
– Detach electrical connector -arrow- from fuel pressure sender
t to the co
- G247- -1-.
– Unscrew the two stud bolts and remove lower part of intake
rrectne
manifold.
ss o
Note
cial p
f inform
satelettronica
mer
♦ The injectors can remain in the fuel rail.
atio
om
n
♦ Seal intake ports with a clean cloth.
c
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sd
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Installing
i
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– Push lower part of intake manifold onto stud bolts (left and t. C rig
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right) on cylinder head. pyri by
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Specified torques Prote AG.

5.4 Removing and installing throttle valve

module - J338-
⇒ “5.4.1 Removing and installing throttle valve module J338 ”,
page 222
⇒ “5.4.2 Cleaning throttle valve module J338 ”, page 223
5.4.1 Removing and installing throttle valve

module - J338-
Removing
– Detach electrical connector -5- from throttle valve control mod‐
ule - J338- -1-.

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– Detach clamp -3- of pressure hose -2- at throttle valve module
an
d
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- J338- .
erm
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ility
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– Pull off pressure hose from throttle valve module - J338- .
wit
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– Unclip bracket -4- from solenoid valve 1 for activated charcoal
filter - N80- . ole,
spec
t to the co
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f inform
– Unscrew bolts -arrows- of throttle valve module - J338- .
mer
atio
– Remove throttle valve module - J338- upwards.
om
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Installing
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– Clean sealing surface for O-ring.
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– Renew seal.
satelettronica
t. C rig
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pyri by
– After throttle valve module - J338- has been renewed, it must
co Vo
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be readapted to engine control unit - J623- ⇒ Vehicle diag‐ Prote AG.
nostic tester.
Specified torques
5.4.2 Cleaning throttle valve module - J338-
Note
♦ If a new engine control unit - J623- is installed, the throttle

valve module - J338- must be adapted.
♦ When cleaning the throttle valve nozzle it must not be scratch‐
ed.
– Remove throttle valve module - J338- ⇒ page 222 .

– Open throttle valve module - J338- by hand and lock throttle
valve module - J338- in open position using a suitable object
(e.g. wood or plastic wedge) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.

– Thoroughly clean throttle valve connection, especially in area

-arrows- of closed throttle valve housing - J338- using com‐
mercially available acetone compliant with DIN 53247 and a
brush.
– Wipe the inside of the throttle valve housing with a lint-free
cloth.
– Allow acetone to flash off completely and reinstall cleaned
throttle valve module - J338- .
– Delete programmed values, and adapt engine control unit -
J623- to throttle valve module - J338- ⇒ Vehicle diagnostic
tester.
5.5 Checking intake manifold change-over

Perform check only if there is a loss of torque. This means when
there is a lack of elasticity or a lack of pulling power.
Special tools and workshop equipment AG. Volkswagen AG d
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♦ Hand operated vacuumsepump
db
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- VAS 6213- ara
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Prerequisites for check

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♦ Variable intake manifold valve - N316- checked with ⇒ Vehicle

diagnostic tester
nform
ercia
If the intake manifold flap valve - N316- is OK, perform the fol‐
m
lowing tests:
a
com
tion in
– Start engine and allow to idle.

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s
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– Get a second person to abruptly increase engine speed (burst

do
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rp
of acceleration).
um
fo
en
ng
t.
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– Observe vacuum unit for intake manifold changeover.
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• Actuator must move -arrow-
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If changeover does not operate as indicated: cted agen
Prote AG.
– Check vacuum system for leaks.

– Check changeover mechanism for ease of movement . To do
this, operate rods by hand.
– Check that vacuum lines are connected correctly.
– Check vacuum hoses for porosity.
– Remove vacuum hose -1- leading to actuator for intake mani‐
fold flap valve - N316- from intake manifold flap valve - N316-
-2-.

– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for vacuum.
– Connect hand vacuum pump - VAS 6213- to actuator for intake

manifold flap valve - N316- .
– Operate hand vacuum pump - VAS 6213- several times.
vacuum unit -arrows- must move.
– If the vacuum unit does not move, renew it.
satelettronica
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mer
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6 Senders and sensors

olkswagen AG
en AG. V
⇒ “6.1 Removing and installing air mass meter G70 ”, page 226olkswag does
not
V gu
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⇒ “6.2 Removing and installing fuel pressure sender G247ris”,edpage nte
227 au
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6.1 Removing and installing air mass meter
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nl
pt
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- G70-
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Removing
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– Unplug electrical connector -3- from air mass meter - G70- .
h re
hole
spec
– Pull off vacuum hose -2- and unclip from retainer.
es, in part or in w
t to the co
– Loosen clamp -4- and disconnect hose.
rrectness of i
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nform
ercia
satelettronica
m
at
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ion
c
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– Unscrew bolts -arrows- from air mass meter - G70- -1-.

at
do
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– Remove air mass meter - G70- from air cleaner housing.
um
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t.
Installing
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To ensure proper operation of the air mass meter - G70- it is im‐ cted agen
Prote AG.
portant to observe the following instructions and comply with the
procedures described.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter - G70- and affect the air mass value.
This would lead to loss of power, since a smaller injection
quantity is calculated.
catalogue (ETKA) .
– Check air mass meter and intake hose (engine intake side) for
salt residue, soiling and leaves.
– Check intake port for dirt as far as the air filter element.
– If contamination is found, remove salt residue, dirt and leaves
from top and bottom part of air filter housing (rinse out or use
vacuum cleaner if necessary).
– Removing and installing air filter element ⇒ Maintenance ;
Booklet 20.1 ; Descriptions of work; Air filter: cleaning housing
and renewing filter element
Specified torques

6.2 Removing and installing fuel pressure

sender - G247-
If fuel pressure sender - G247- fails, fuel pressure regulating valve
- N276- is switched off, electric fuel pump is fully actuated, and
engine is operated with available fuel pressure. This reduces the
engine torque drastically.
AG. Volkswagen AG d
agen oes
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spec
♦ Double hex socket1/2”, 27mm - VAS 5301/7- or commercially
t to the co
available 27 mm socket
rrectness o
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Removing
t.
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– Separate electrical connector -arrow- from fuel pressure send‐ yri
gh by
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er - G247- using assembly tool - T10118- . cop Vo
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– Unscrew fuel pressure sender - G247- -1- using double hex‐
AG.
agon socket Unscrew 1/2, 27mm - VAS 5301/7- .

Installing
Specified torques
Fuel pressure sender - G247- 27 Nm
6. Senders and sensors 227

7 Engine control unit

⇒ “7.1 Removing and installing engine (motor) control unit J623
”, page 228
7.1 Removing and installing engine (motor)

control unit - J623-
wage
satelettronica
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Removing au ac
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Note
itte
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ility
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Before removing engine control unit, read the identification of
wit
is n
control device and the code of the control unit used up to now
h re
⇒ Vehicle diagnostic tester.
ole,
spec
t to the co
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Remove electronics box cover ⇒ Electrical system; Rep. gr.
rrectne
97 ; Relay carrier, fuse carrier, electronics boxes; Removing
and installing electronics box .
ss o
– Disconnect connectors -2- and -3- from engine control unit -
cial p
f in
J623- -1-.
form
mer
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om
n
c
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fo
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t.
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Cop py
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cted agen
Prote AG.

– Pull engine control unit - J623- -1- in -direction of arrow- out of

electronics box -2-.
Installing
– Check previous code and code new engine control unit - J623-
⇒ Vehicle diagnostic tester.
Specified torques
. Volkswagen AG
♦ Assembly overview - battery ⇒ Electrical system; Rep.kgr. gen AG
l swa 27 ; does
not
Battery; Assembly overview - battery . by
Vo gu
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♦ Overview of fitting locations - relay carrier, fuse
ut
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r eo
tronics boxes ⇒ Electrical system; Rep. gr. ss 97 ; Relay carrier,
a ra
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fuse carrier, electronics boxes; Overview of fitting locations -
ce
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nl
relay carrier, fuse carrier, electronics boxes
pt
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at
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c
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7. Engine control unit 229

8 High-pressure pump
⇒ “8.1 Assembly overview - high-pressure pump”, page 230
⇒ “8.2 Removing and installing high-pressure pump”, page 231
8.1 Assembly overview - high-pressure pump
1 - Roller tappet
❑ Can remain inserted in
vacuum pump after re‐
moval of high-pressure
pump
2 - O-ring
3 - High-pressure pump
AG. Volkswagen AG d
❑ Fuel tank contains elec‐ agen oes
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tric fuel pump which ed by
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pumps fuel to mechani‐ horis nte
eo
cal high-pressure pump.
satelettronica
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❑ When installing the
ce
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un
high-pressure pump,
pt
an
d
itte
ensure that no dirt en‐
y li
erm
ab
ters the fuel system
ility
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❑ The fuel system must be
wit
is n
depressurised in order
h re
ole,
to install the high-pres‐
spec
sure pump; relieve fuel

pressure.
t to the co
❑ Install fuel lines free of
stress.
rrectne
⇒ page 231
ss o
4 - Fuel pressure regulating
cial p
f i
valve - N276-
nform
mer
5 - Bore in vacuum pump for

atio
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high-pressure pump
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6 - Injectors
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❑ Renew O-ring and Tef‐

pr
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lon ring
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❑ Ensure correct installa‐ t. Cop py
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tion position
8 - Inlet camshaft control valve 1 - N205-
9 - Bolts
❑ Qty. 2
❑ Do not cant high-pressure pump
❑ Tighten in diagonal sequence by hand and then to 5 Nm
❑ Final specified torque 20 Nm
10 - Connecting piece for fuel supply line from fuel tank
11 - Connection for fuel supply line
❑ Fuel supply line must be free of tension when installed.
❑ Union: 30 Nm
satelettronica
❑ Specified specified torque for union nut of fuel pressurisation line: 27 Nm
8.2 Removing and installing high-pressure

pump G. Volkswage
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Note
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♦ It is only permissible to remove high-pressure pump when en‐

an
d
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gine is cold.
erm
ab
ility
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♦ When installing the high-pressure pump, it is essential to en‐

wit
is n
sure that no dirt enters the fuel system.

h re
ole,
♦ The O-ring must always be renewed.

spec
t to the co
♦ Always ensure that high-pressure fuel line is free of tension

when installed.
rrectne
– Disconnect connector from fuel pressure regulating valve -

N276- -1-.
ss o
cial p
f inform
mer
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om
n
c
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Cop py
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Prote AG.
8. High-pressure pump 231

– Open both fuel lines -arrows-.
AG. Volkswagen AG d
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spec
– Carefully pull out high-pressure pump -2-.
t to the co
– The roller tappet can remain inserted in vacuum pump in some
cases.
Installing
rrectne
satelettronica
ss o
cial p
f in
Note
form
mer
atio
m
The fuel pressure regulating valve - N276- must be adapted if it

o
n
c
has been renewed ⇒ Vehicle diagnostic tester.
i
or
n thi
te
sd
iva
o
r
– Renew high-pressure pump O-rings.

p
cum
r
fo
en
ng
– Insert roller tappet in vacuum pump (first check roller tappet

t.
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op
for damage). C py
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pyri by
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cted agen
Note Prote AG.
♦ Roller tappet must be at bottom dead centre to enable high-

pressure pump to be installed.
♦ If same or a used high-pressure pump is installed, connection
for fuel pressurisation line (high-pressure side) must be re‐
newed. See assembly overview - high-pressure pump item 11
⇒ Item 11 (page 231)
– Turn crankshaft until roller tappet is at bottom dead centre.

– Insert high-pressure pump into vacuum pump.
– Tighten bolts by hand.
– Renew high-pressure pump connection.
– Tighten union nuts of fuel supply line by hand and align free
of stress.

. Volkswagen AG
gen AG does
– Re-attach electrical connector of fuel pressureVoregulating
lksw
a
not
valve - N276- -1-. ed
by gu
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– Put back fuse if it has been removed.auth eo
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ss c
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nl
pt
du
Note
an
itte
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ab
ility
Then check entire fuel system for leaks.
ot p
wit
, is n
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Specified torques hole
spec
es, in part or in w
♦ ⇒ “8.1 Assembly overview - high-pressure pump”, page 230
t to the co
rrectness of i
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ercia
orm
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satelettronica
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Prote AG.
8. High-pressure pump 233

9 Lambda probe
AG. Volkswagen AG d
⇒ “9.1 Assembly overview - Lambda probe”, page 234 lksw
agen oes
not
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⇒ “9.2 Removing and installing Lambda probe”, page r235 ised ara
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ut
9.1 Assembly overview - Lambda probe ss a ra
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un
Electrical plug connector -1- for the Lambda probe - G39- and
pt
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Lambda probe heater - Z19-
y li
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Lambda probe - G39- and Lambda probe heater - Z19- -1-
ss o
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atio
om
n
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Lambda probe after catalytic converter - G130- and Lambda

probe heater 1 after catalytic converter - Z29- -1-
Note
The arrow in the picture shows the direction.
Specified torques
Lambda probe 55 Nm

Electrical plug connector -arrow- for the Lambda probe after the
catalytic converter - G130- and Lambda probe heater 1 after cat‐
alytic converter - Z29-
Note
♦ New lambda probes are coated with an assembly paste. The

paste must not get into the slots on the Lambda probe body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue (ETKA)
♦ When installing, the electrical wiring of the Lambda probe must
always be re-attached at the same locations to prevent the
Lambda probe wiring from coming into contact with the ex‐
haust pipe.
– Removing and installing Lambda probe - G39- and Lambda

probe heater - Z19- before catalytic converter ⇒ page 235 .
– Removing and installing Lambda probe after catalytic convert‐
satelettronica
er - G130- ⇒ page 236 .
AG. Volkswagen AG d
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9.2 Removing and installing Lambda probe
ol not
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⇒ “9.2.1 Removing and installing
aut
h Lambda probe G39 before cat‐ ra
alytic converter”, page s235
s c
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⇒ “9.2.2 Removing and installing Lambda probe after catalytic pt

an
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converter G130 ”, page 236 y li

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9.2.1 Removing and installing Lambda probe
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- G39- before catalytic converter

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spec

t to the co
♦ Lambda probe open ring spanner set - 3337-

rrectness o
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9. Lambda probe 235

Removing
– Detach electrical connector -3- of Lambda probe - G39- .
– Unclip wiring harness -2- for Lambda probe - G39- from brack‐
et -1-.
– Unscrew Lambda probe - G39- -arrow- from catalytic convert‐

er -1-.
Installing
satelettronica
Note

AG. Volkswagen A
with high-temperature paste. This kspaste
wage must not get into
n G do
ethe
sn
slots on the Lambda probe body. y Vol High-temperature paste ⇒ ot gu
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Electronic parts catalogue
or (ETKA)
ise nte
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ut or
♦ When installing, the electrical
ss
a
wiring of the Lambda probe must ac
ce
le
un
pt
an
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haust pipe.
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ility
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9.2.2 Removing and installing Lambda probe

h re
ole,
after catalytic converter - G130-

spec
t to the co

♦ Lambda probe open ring spanner set - 3337-
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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Removing cop Vo
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– Loosen heat shield on underbody sufficiently so that the elec‐
AG.
trical plug connector of the Lambda probe after the catalytic

converter - G130- and Lambda probe heater 1 after the cata‐
lytic converter - Z29- is accessible.

– Electrical plug connector -arrow- for the Lambda probe after

the catalytic converter - G130- and Lambda probe heater 1
after catalytic converter - Z29-
AG. Volkswagen AG d
agen oes
ksw
– Unclip wiring harness for Lambdaby
Vol probe after catalytic con‐ not
gu
verter - G130- and Lambda rised probe heater 1 after catalytic ara
nte
converter - Z29- -A-. utho eo
ra
s a c
– Unscrew Lambda probe after catalytic converter - G130- and
s
ce
le
Lambda probe 1 heater after catalytic converter - Z29- -B- from

un
pt
an
d
exhaust pipe -1- using tool from Lambda probe open ring
itte
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spanner set - 3337- .
ab
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Installing
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wit
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spec
t to the co
Note
rrectne
s
s o
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f
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒ inform
mer
Electronic parts catalogue (ETKA)

atio
om
♦ When installing, the electrical wiring of the Lambda probe must

c
i
or

thi
te
sd
a
iv
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pr
haust pipe.
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9. Lambda probe 237

26 – Exhaust system
1 Exhaust pipes and silencers
agen
AG. Volkswagen AG d
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olks
⇒ “1.1 Removing and installing centreedsilencer”,
by
V
page 238 t gu
ara
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⇒ “1.2 Removing and installing rear
au
tho silencer”, page 239 eo
ra
ss c
⇒ “1.3 Aligning exhaust system free of stress”, page 240
ce
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nl
pt
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⇒ “1.4 Check exhaust system for leaks”, page 241
itte
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⇒ “1.5 Installation position of clamp”, page 241
ility
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1.1 Removing and installing centre silencer
h re
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spec
es, in part or in w
t to the co
♦ Chain-type pipe cutter - VAS 6254-
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
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or
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op
♦ or body saw - V.A.G 1523A- C py
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– Mark cutting location -a- = 144 mm on centre silencer exhaust
AG.
pipe -1-.
CAUTION
Risk of eye injury caused by flying swarf.
Eye irritation and injury possible.
– Cut through exhaust pipe at separating point at right angles

using chain-type pipe cutter - VAS 6254- .
– Loosen nuts -arrows-.

– Remove double clamp.
– Unscrew bolts -arrows- for bracket of centre silencer at front.
238 Rep. gr.26 - Exhaust system

– Unscrew bolts -arrows- for bracket of centre silencer at rear

and remove centre silencer.
Installing
– Align repair double clamp -2- between front silencer -1- and
rear silencer -3- when installing.
• The distance “a” must be approx. 5 mm.
– Tighten threaded connections -4- in this position.
satelettronica
Checking exhaust system for leaks ⇒ page 241 .
Align exhaust system free of stress ⇒ page 240 .
1.2 Removing and installing rear silencer

♦ Chain-type pipe cutter - VAS 6254- AG. Volkswagen AG d
agen oes
olksw not
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♦ or body saw - V.A.G 1523A-

rrectness of i
Removing
l purpos
– Mark cutting location -a- = 144 mm on centre silencer exhaust

pipe -1-.
nform
ercia
CAUTION
m
at
om
Risk of eye injury caused by flying swarf.

on
c
in t
or
Eye irritation and injury possible.

his
ate
do
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for
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– Cut through exhaust pipe at right angles using chain-type pipe
Co
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cutter - VAS 6254- , for example.
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1. Exhaust pipes and silencers 239

– Unscrew bolts -arrows- from bracket for rear silencer and re‐
move rear silencer -1-.
Installing
– Align repair double clamp -2- between front silencer -1- and
rear silencer -3- when installing.
• The distance “a” must be approx. 5 mm.
– Tighten threaded connections -4- in this position.
satelettronica
1.3 Aligning exhaust system free of stress. Volkswag

AG en AG
agen does
Special tools and workshop equipment required y Volksw not
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♦ Torque wrench - V.A.G 1331- oris nte
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th
au ra
c
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rrectne
• The exhaust system must be aligned when cold

ss
o
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f inform
– Loosen bolts of double clamp -3-.

mer
atio
– Tighten bolts by hand.

om
n
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or
– Align exhaust system until the marking- 4- is visible.

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– Align bolts of double clamp -3- horizontally.

– Align rubber mountings -1- for front silencer -2- and rear si‐
lencer -1- in such a way that dimension -a- is 8 mm.
Specified torques
Bolts for double clamp 31 Nm
1.4 Check exhaust system for leaks

– Start engine and run it at idling speed.
– Seal exhaust pipe with cloths or plugs, for example, for the
duration of the leakage test. gen AG
. Volkswagen AG
d wa oes
olks not
– Check (by listening) points of
y V connection between exhaust
satelettronica
gu
db ara
manifold and the cylinderrise head, between turbocharger and nte
tho
front exhaust pipe etc.
eo
au to make sure there are no leaks. ra
c
ss
– Repair any leaks found.
ce
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1.5 Installation position of clamp

itte
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es, in part or in w
t to the co
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tion in
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Specified torque and mounting dimensions of clamping sleeve.

do
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Clamp -A- has 2 individual clips.

en
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op
Clamp -B- has continuous clip.
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Specified torques
op Vo
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Prote AG.
Clamp -A- 25 Nm
Clamp -B- 35 Nm
1. Exhaust pipes and silencers 241

Installation dimension -a- applies to vehicles with marking -A- on

front exhaust pipe, 8.5 mm (only for front clamping sleeve).
1 - Clamping sleeve AG. Volkswagen AG d
agen oes
lksw not
2 - Front exhaust pipe d by V o gu
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3 - Nut ut
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4 - Nut s
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a - Installation dimension
an
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A - Marking
pe
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spec
Installation position of clamp
es, in part or in w
t to the co
– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• The threaded connection of the front clamp faces to the right.
rrectness of i
• The threaded connection of the rear clamp faces to the rear.
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
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t.
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Cop py
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Prote AG.

2 Exhaust gas cleaning

⇒ “2.1 Removing and installing catalytic converter”, page 243
2.1 Removing and installing catalytic con‐

verter
⇒ “2.1.1 Removing and installing starter catalytic converter”, page
243
⇒ “2.1.2 Removing and installing downstream catalytic convert‐
er”, page 245
2.1.1 Removing and installing starter catalytic

converter
satelettronica
Removing
– If fitted, remove noise insulation
AG. Volkswa⇒genGeneral
AG do body repairs, ex‐
agen
terior; Rep. gr.Vo66
lksw; Noise insulation; Removing
es n
ot g and installing
noise insulation
ed
by . ua
ra
is nte
or e
– Detach
au electrical connector -3- of Lambda probe - G39-
th or .
a
ss c
– Unclip wiring harness for Lambda probe - G39- and remove it
ce
e
nl
pt
from bracket.
du
an
itte
y li
erm

ab
ility
ot p

wit
, is n
h re
– Remove front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing

hole
spec

es, in part or in w
t to the co
– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing and

installing bevel box .
rrectness of i
Vehicles with front-wheel drive:

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
2. Exhaust gas cleaning 243


– Remove bracket for starter catalytic converter -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Unscrew bolts -arrows- from catalytic converter.
hole
spec
– Remove bracket on starter catalytic converter -1-.
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Unscrew nuts -arrows- of catalytic converter on turbocharger.

iv
o
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rp
cu
o
– Remove catalytic converter -1-.

m
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en
ng
t.
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Installing Cop py
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p by
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Prote AG.
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. Loosen double clamp and clamp if necessary. Align
silencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly loa‐
ded.
♦ Renew self-locking nuts.

Specified torques

AG. Volkswagen AG d
agen oes
ksw
2.1.2 Removing and installing downstream ol not
y V gu
d b ara
ise
catalytic converter r nte
tho eo
au ra
s c
Torque wrench - V.A.G 1331- s
ce
le
un
pt
Removing
an
d
itte
y li
rm
ab
– Loosen heat shield on underbody sufficiently so that the elec‐
pe
ility
trical connector of the Lambda probe after the catalytic con‐
ot
wit
, is n
verter - G130- is accessible.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Detach electrical connector -arrow- of Lambda probe after

catalytic converter - G130- .
nform
ercia
– Unclip wiring harness for Lambda probe after catalytic con‐

m
a
com
ti
verter - G130- from underbody.
on in
satelettronica
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
t.
yi
Disregard bolts -arrows- for bracket of centre silencer.
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Undo bolts -arrows- from bracket for catalytic converter -1-.
2. Exhaust gas cleaning 245


– Remove downstream catalytic converter -2-.
Installing
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. Loosen double clamp and clamp if necessary. Align
silencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly loa‐
ded. AG. Volkswagen A gen G do
swa es n
♦ Renew self-locking nuts.
by
Vol
k ot g
ua
ed ran
oris tee
Checking exhaust system
au
th
for leaks ⇒ page 241 . or
ac
ss
ce
e
nl
pt
du
an
Specified torques
itte
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satelettronica
erm
ab
♦ ⇒ “1.5 Installation position of clamp”, page 241
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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om
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Cop py
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Prote AG.

28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 247
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 248
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 249
⇒ “1.4 Removing and installing Hall sender G40 ”, page 250
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
250
⇒ “1.6 Test data, spark plugs”, page 251
1.1 Assembly overview - ignition system
1 - Knock sensor 1 - G61-
satelettronica
AG. Volkswagen AG d
agen oes
❑ On front of cylinder head Volksw not
gu
y
under intake manifold sed b ara
nte
ri
aut
ho eo
ra
⇒ page 249 ss c
ce
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un
2 - Bolt
pt
an
d
itte
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❑ The specified torque in‐
erm
ab
fluences the function of
ility
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the knock sensor.

wit
is n
❑ 20 Nm h re
ole,
spec
3 - Ignition coils
t to the co
❑ Ignition coil 1 with output

stage - N70-
rrectne
stage - N127-
ss
stage - N291-
o
cial p
f in

form
mer
stage - N292-
atio
m

o
n
c
⇒ page 248
i
or
n thi
te
sd
a
4 - Spark plug
iv
o
pr
cum
r
❑ If a spark plug is to be
fo
en
ng
renewed, regrease igni‐

t.
yi Co
op
tion coil with final output
C py
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stage rig ht
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❑ Type and electrode gap
by
cted agen
Prote
⇒ page 251 .
AG.
❑ 25 Nm
5 - O-ring
6 - Engine speed sender -
G28-
❑ In cylinder block at front on the bottom left, at an angle beneath the coolant pump ⇒ page 250
1. Ignition system 247

7 - Bolt
❑ 10 Nm
❑ In cylinder head cover at front.
1.2 Removing and installing ignition coils

with output stage
♦ Puller - T40039-
AG. Volkswagen AG d
agen oes
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s
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un
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♦ Lubricating paste - G 052 141 A2-
spec
es, in part or in w
Removing
t to the co
Note
rrectness of i
l purpos
♦ To detach spark plugs, fit puller - T40039- onto uppermost,

thick rib -arrow- of ignition coils with final output stages.
nform
ercia
♦ If the lower ribs are used, they could be damaged.

m
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com
tion in
r
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cum
fo
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ng
t.
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op py
– Release electrical connectors -1- of ignition coil with output
. C rig
ht ht
rig
stage and separate in direction of -arrow-. py by
co Vo
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cted agen
Prote AG.
248 Rep. gr.28 - Ignition system

wage es n
yV
o lks ot g Transporter 2016 ➤
b ua
ir se
d engine (2.0 l direct injection engine, ran turbocharger) - Edition 06.2018
tee
ho
aut or
ac
– Pull all ignition coils
ss out of spark plug recess using puller -
T40039- .
ce
le
un
pt
an
d
itte
Installing
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
♦ When fitting new spark plugs, the ignition coil must be re‐
greased using lubricating paste - G 052 141 A2- This will stop
the ignition coil sealing hose from »sticking« to the spark plug.
rrectness of i
♦ The lubricating paste must be distributed on the spark plug
l purpos
when inserting on the ignition coil.

♦ New ignition coils with output stage are lubricated when de‐
nform
ercia
livered.
m
a
com
tion in
r
– Apply lubricating paste - G 052 141 A2- around circumference

te o
thi
(1 … 2 mm thick) of ignition coil sealing hose -arrow-.
s
iva
do
r
rp
cum
– Insert all ignition coils loosely into spark plug hole.
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Align ignition coils to electrical connectors.

– Fit electrical connectors -arrows-.
Note
Electrical connectors must engage audibly.
– Evenly push ignition coils onto spark plugs by hand.
1.3 Removing and installing knock sensor 1

- G61-
Removing
noise insulation .

– Release electrical connector -2-.

– Detach wiring harness for knock sensor 1 - G61- -3- from re‐
tainer -1-.
Note
♦ The knock sensor I - G61- is located under the intake manifold

behind the coolant pump.
♦ To remove, the coolant pump must be removed.
– Remove coolant pump ⇒ page 172 .

AG. Volkswagen AG d
agen
– Unscrew bolt -2-. Volksw
oes
not
by gu
d ara
– Remove knock sensor 1 - G61- -1-. orise nte
th eo
u ra
Installing ss a c
ce
e
nl
pt
du
an
itte
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Specified torques
erm
ab
satelettronica
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.4 Removing and installing Hall sender -
rrectness of i
G40-
l purpos
Removing
nf
ercia
– Separate electrical connector -arrow- from Hall sender - G40- .
orm
m
– Undo bolt -arrow- and remove Hall sender - G40- -1-.
atio
om
n in
c
Installing
or
thi
te
sd
a

iv
o
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rp
cu
o
Specified torques
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.5 Removing and installing engine speed

sender - G28-
Removing
noise insulation .
250 Rep. gr.28 - Ignition system

– Separate electrical connector -2- from engine speed sender -

G28- underneath coolant pump.
– Unscrew bolt from engine speed sender - G28- .
– Remove engine speed sender - G28- -3-.
Installing
Specified torques
1.6 Test data, spark plugs n AG. Volkswagen AG do

lkswage es n
o ot g
yV
Engine code d b CJKA, CJKBua
ran
ir se tee
o
Firing order auth 1-3-4-2 or a
ss c
Spark plugs
ce
e
nl
pt
du
VW/Audi ⇒ Electronic parts catalogue (ETKA)
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Workshop Manual Transporter 2016 2-29

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Copyright:

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Workshop Manual Transporter 2016 2-29

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Service

Service Department. Technical Information

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Copyright © 2018 Volkswagen AG, Wolfsburg D4B805652C1

3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in 30

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.6 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1.2 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.1 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

3.2 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

3.3 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

5.2 Removing and installing intake manifold upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

1.1 Safety regulations for working on fuelAsupply

– Wear protective gloves.

– To release pressure, wrap a clean cloth around the connection

and carefully loosen the connection.

– Disconnect voltage supply to fuel pump before opening the

Risk of injury caused by unsecured testing and measuring instru‐

sufficiently secured testing and measuring instruments become

– Secure testing and measuring instruments on the rear seat.

Danger of scalding by hot coolant

On a warm engine, the cooling system is under high pressure.

Danger of scalding by steam and hot coolant. en

sion tank with cloths and opening it carefully.

1.5 Safety precautions when working on ignition system

Risk of damage to components

2 Rep. gr.00 - Technical data

1.6 Safety precautions when working on exhaust system

2.1 Engine number/engine data

20.1 ; General; Vehicle data sticker .