Engine Cjza CJZB CJZC CJZD Cyva Cyvb Cyvd Repair Manual Eng

Service
Workshop Manual
Golf 2013 ➤ , Golf 2017 ➤ ,
Golf Cabriolet 2012 ➤ ,
Golf Sportsvan 2015 ➤ ,
Golf Variant 2014 ➤ ,
Golf Variant 2017 ➤ , Polo 2014 ➤ ,
Touran 2016 ➤
4-cylinder direct injection engine (1.2 l engine, 4V, EA
211, turbocharger)
Engine ID CJZA CJZB CYV CYV CJZC CJZD CYV
A B D
Edition 04.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3 Removing and installing gearbox mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.7 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 82
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Contents i
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.7 Setting piston to TDC position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.1 Assembly overview - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.2 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.4 Preassembling and installing valve timing tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.7 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.8 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.3 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.4 Removing and installing toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.6 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 209
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.2 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 217
4.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
ii Contents
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.7 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 250
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 251
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 252
2.10 Removing and installing radiator fan thermal switch F18 . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.4 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 276
4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.6 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 298
1.4 Removing and installing connection for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.5 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.3 Removing and installing resonator for intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Contents iii
4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
4.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
5.1 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
5.3 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
6.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
6.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
7.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
8.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
8.2 Assembly overview - engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
1.3 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.6 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
iv Contents
00 – Technical data
1 Safety information
(VRL014138; Edition 04.2020)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with 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
1.1 Safety regulations for working on fuel supply

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

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

Risk of injury due to unexpected motor start
If the vehicle's start/stop system is activated, the engine can start
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
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
Or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
1.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
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

2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data

The engine code and the engine number can be found on the
sticker -arrow- on the upper toothed belt guard.
The engine code is also on the vehicle data sticker and on the
crankcase above the gearbox.
The engine number consists of up to 9 characters (alphanumeric).
The first part (maximum 3 characters) makes up the “engine
code”, and the second part (6 characters), the “serial number”. If
more than 999,999 engines were produced with the same code
letters, the first of the six digits is replaced by a letter.
Vehicles with four digit engine codes
Four-place engine codes are being introduced, starting with letter
“C”. The first 3 places show the mechanical design of engine and
are stamped on the engine as previously. The fourth digit denotes
the performance and torque rating of the engine and depends on
the engine control unit - J623- . The four-digit engine code can be
found on the type plate, the vehicle data label and on the engine
control unit.
Note
Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

Vehicle data sticker .
Engine code CJZA CJZB CYVA CYVB CYVD CJZD CJZC

Manufactured
from
Golf 2013► 08.12 ► 08.12 ► 05.14 ► 05.14 ► --- --- ---
Golf Estate 05.13 ► 07.13 ► 05.14 ► 05.14 ► --- --- ---
2014►
Golf SV 2015► --- --- 05.14 ► 05.14 ► --- --- ---
Touran 2016► --- --- --- 08.15 ► --- --- ---
Golf Cabriolet --- --- --- --- 04.15 ► --- ---
2012►
Polo 2014► --- --- --- --- --- 04.14 ► 04.14 ►
Exhaust emis‐ EU5 EU5 EU 6 EU 6 EU 6 EU 6 EU 6
sion standard
Displace‐ 1197 1197 1197 1197 1197 1197 1197
ment
Power kW 77/4500-5 63/4300-5 63/4300-5 81/4600-5 77/4600-5 81/4600-5 66/4400-5
at 500 300 300 600 600 600 400
rpm
Torque Nm 175/1400- 160/1400- 160/1400- 175/1400- 175/1400- 175/1400- 160/1400-
at 4000 3500 3500 4000 4000 4000 3500
rpm
Bore ∅ 71.0 71.0 71.0 71.0 71.0 71.0 71.0
mm
Stroke mm 75.6 75.6 75.6 75.6 75.6 75.6 75.6
Compression ra‐ 10.5 10.5 10.5 10.5 10.5 10.5 10.5
tio
Valves per cylin‐ 4 4 4 4 4 4 4
der
2. Identification 3
Engine code CJZA CJZB CYVA CYVB CYVD CJZD CJZC

RON min. 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐ 95 unlea‐
ded ded ded ded ded ded ded
Injection, ignition Motronic Motronic Motronic Motronic Motronic Motronic Motronic
system MED 17.5.
25
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

3 Repair notes
⇒ “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 6
⇒ “3.7 Fitting radiator and condensers”, page 6
⇒ “3.8 Checking vacuum system”, page 6
3.1 Rules for cleanliness

Even slight soiling can cause faults. When working on the fuel
supply, injection and turbocharger system, pay careful attention
to the following rules of cleanliness:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only!
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been stored outside of their packaging (e.g. in tool box‐
es).
♦ If system is open, do not work with compressed air. Try not to
move the vehicle.
♦ Make sure that no fuel gets onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned immediately.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
3.2 General information

♦ The engine control unit has a self-diagnosis capability. Inter‐
rogate the event memory first before performing repairs and
before fault finding. Also check the lines, vacuum hoses and
connections.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. The crash
fuel shut-off system reduces the risk of a vehicle fire in the
event of a crash by switching the fuel pump off via the fuel
pump relay.
♦ The system also improves the starting characteristics of the
engine. When the driver door is opened, the fuel pump is ac‐
tivated for 2 seconds in order to build up pressure in the fuel
3. Repair notes 5
system, observe safety precautions

⇒ “1.1 Safety regulations for working on fuel supply”, page 1 .
3.3 General repair instructions

♦ Clean tools and workbench etc. before working on injection
system.
♦ Align high-pressure lines so that they are not subjected to
stress . First tighten all unions hand-tight and then tighten to
torque.
♦ Never attempt to reshape high-pressure lines.
♦ When working on any parts of the high-pressure fuel system,
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.
♦ 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

♦ Use engine bung set - VAS 6122- .
Note
In the event of mechanical damage to the turbocharger, proceed

according to chapter
⇒ “1.2 Removing and installing turbocharger”, page 295 .
3.5 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
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 .
3.6 Routing and attachment of lines

♦ Make sketches or take photographs if necessary.
♦ To avoid damaging pipes and wires, ensure adequate clear‐
ance from all moving or hot components in the engine com‐
partment on account of the confined space.
3.7 Fitting radiator and condensers

Even when correctly installed, radiator and condenser may show
slight marks on plates. This does not mean that these compo‐
nents have been damaged. Minor indentations such as these are
not a reason to renew either the radiator or condenser.
3.8 Checking vacuum system

Special tools and workshop equipment required

♦ Hand operated vacuum pump - VAS 6213-
Sequence of operations
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
– If an entry is stored in the event memory, check all vacuum
lines leading to the corresponding component and also check
the remaining vacuum lines 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 notes 7
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 8
⇒ “1.2 Separating engine and gearbox”, page 37
⇒ “1.3 Securing engine on engine and gearbox support”,
page 39
⇒ “1.4 Installing engine”, page 40
1.1 Removing engine

⇒ “1.1.1 Removing engine, Golf, Golf Estate, Golf SV, Touran”,
page 8
⇒ “1.1.2 Removing engine, Golf Cabriolet”, page 18
⇒ “1.1.3 Removing engine, Polo”, page 28
1.1.1 Removing engine, Golf, Golf Estate, Golf SV, Touran
Special tools and workshop

equipment required
♦ Release lever - 80 - 200-
8 Rep. gr.10 - Removing and installing engine

♦ Extension -2024 A /1- of lifting tackle - 2024 A-

♦ Engine and gearbox jack - V.A.G 1383 A- or -VAS 6931-
♦ Engine support - T10497-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Spring-type clip pliers - VAS 6362-
♦ Protective mat - VAS 531003- (not illustrated)
♦ Locking pin - T10060 A-
♦ Commercially available stepladder

♦ Safety glasses
♦ Safety gloves
Note
♦ The engine is removed downwards together with the gearbox.

♦ Attach cable ties in all the same places when installing.
CAUTION
Skin and other parts of the body may be scalded.
1. Removing and installing engine 9

– Open cap -arrow- on coolant expansion tank.

– Open clamp -2-, and pull off coolant hose.
– Remove front wheel on left and right. ⇒ Running gear, axles,
steering; Rep. gr. 44 ; Wheels, tyres; Wheel change .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove left and right front wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 227 .
Vehicles with air conditioner compressor:
– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning system; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing air conditioner compressor from and in‐
stalling on bracket .
Continued for all vehicles:

– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
– Lift retaining clip -arrow- and disconnect coolant hose (top

right) from water radiator for charge air cooling circuit.
– Remove radiator cowl ⇒ page 285
– Cover radiator using protective mat - VAS 531003- .

– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .

Vehicles with no auxiliary heater

– Lift retaining clips -arrows- and disconnect coolant hoses from
heat exchanger for heater.
Vehicles with auxiliary heater

– Release retaining clip and hose clip and pull off both coolant
hoses -arrows-.
Continued for all vehicles

– Unscrew bolts -arrows- on camshaft housing.
– Unscrew bolts -arrows- from heat shield -1- of turbocharger,

and remove heat shield.

– Loosen bolt -1- until clamp -2- can be pushed over catalytic
converter.
– Unscrew bolt -2- and remove screw-type clip.

– Remove bolt -1- and nuts -arrows- and tie up catalytic con‐
verter.
– Undo bolts -arrow- and remove bracket.
– Release hose clip -1- and pull off coolant hose.

– Place a cloth underneath to catch any escaping coolant.

– Release and pull off fuel lines -1- and -2- ⇒ Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .
– Open retainer for coolant hose -1-.

– Free off coolant hose -2-.
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 323 .
– Remove air intake pipe
⇒ “2.5 Removing and installing air pipe”, page 308 .
Note
For the work steps below use removal lever - 80 - 200- to unclip
the binding clips.
– Disconnect upper connector -1- on engine control unit - J623- .

⇒ “8 Engine control unit”, page 360
– Remove electrical connectors -2- and -3- from retainer and
disconnect.
– Move electrical lines free.

– Disconnect connector -2-.

– Push back cover for battery positive terminal -1-, and unbolt
battery positive cable from starter solenoid switch.
– Unbolt earth wire from body.
– Release catches -arrows- and detach cover -1- for electronics

box in engine compartment.
– Release catch using a screwdriver -arrow- and detach cover

-1- for electronics box in engine compartment upwards.
– Remove nut -arrow-, detach electrical wiring and move clear.

Manual gearbox
– Disconnect connectors -1- and -2-.
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Remove clutch slave cylinder and lay aside with hydraulic line
still connected ⇒ Rep. gr. 30 ; Clutch mechanism; Removing
and installing clutch slave cylinder .
– Do not open hydraulic system when doing this. Lay clutch
slave cylinder to one side.
Dual clutch gearbox
– Remove selector lever cable, pull connector off mechatronic
unit, and remove all retainers from gearbox ⇒ Rep. gr. 34 ;
Removing and installing gearbox; Removing gearbox .

– Unscrew bolts -arrows- on engine mounting approx. 2 turns.
– Unscrew bolts -arrows- on gearbox mounting approx. 2 turns.
– Disconnect electrical connector -1- on oil level and oil temper‐

ature sender - G266- .
– Detach wire from retainer -2-.

– Unscrew nuts for coupling rod -arrow- on left and right of anti-
roll bar.
– Remove pendulum support
⇒ “2.4 Removing and installing pendulum support”,
page 60 .
– Remove drive shaft heat shield ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive
shaft heat shield .
– Unscrew nuts -arrows- for swivel joint on left and right.
– If fitted, unscrew bolt -arrow- on bracket for front left vehicle

level sender - G78- .
– Detach swivel joint from transverse link on left and right.
– Unbolt drive shafts from gearbox on left and right ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft and tie them up.
– Make sure not to damage the surface protection of the drive
shaft.
– Swivel front left suspension strut outwards and support with

extension -2024 A /1- , as shown in illustration.
– Secure locking pin and swivel joint with locating pin -arrow-
and nut -1-.

– Secure swivel joint -2- (right-side) to transverse link -1- with

nut -arrow-, as shown in illustration.
– Position clamping piece - T10497/2- on housing rib of cylinder
block as shown in illustration.
– Position engine bracket - T10497- with pin - T10497/1- on cyl‐

inder block.
– Screw in bolt -1- through hole “B” on - T10497- and tighten to
20 Nm.
– Fit adapter - T10497/3- to engine support - T10497- and tight‐

en bolt -1- to 20 Nm.
– Insert engine and gearbox jack - V.A.G 1383 A- in engine sup‐
port - T10497- and raise engine/gearbox assembly slightly.
– To unscrew bolts for assembly mounting use commercially
available stepladder.
– Remove bolts -arrows- for engine mounting.

– Remove bolts -arrows- securing gearbox mounting.
Note
♦ Danger of damage to vacuum lines or electrical wiring and to

engine compartment.
♦ Check that all vacuum lines and electrical wiring between en‐
gine, gearbox, subframe and body have been detached.
♦ When lowering, carefully guide engine/gearbox assembly with
assembly carrier out of engine compartment.
– First lower engine/gearbox assembly slightly.

– Then push gearbox end of engine/gearbox assembly forwards
and only then lower further.
1.1.2 Removing engine, Golf Cabriolet

equipment required

♦ Extension -2024 A /1- of lifting tackle - 2024 A-


♦ Engine bung set - VAS 6122-

♦ Safety glasses
♦ Safety gloves
Note


– Carefully open filler cap -1- on coolant expansion tank -2- in

direction of -arrow-.
CAUTION
– Remove activated charcoal filter ⇒ Rep. gr. 20 ; Activated

charcoal filter system; Removing and installing activated char‐
coal filter .
– Release and pull off connectors -5-.

– Unscrew bolts -arrows- and place coolant expansion tank -1-
on engine with coolant hoses connected.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
– Release catch -arrow- and disconnect vacuum hose -1-.

– Move clear vacuum hose at air pipe -2-.
– Disconnect lines -1- and -2- ⇒ Rep. gr. 20 ; Plug-in connec‐

tors; Disconnecting plug-in connectors .

Note
For the work steps below use removal lever - 80 - 200- to unclip
the binding clips.
– Release and pull off connector on engine control unit - J623-

⇒ “8.1 Removing and installing engine control unit J623 ”, page
360 .
– Open cable duct latches on longitudinal member -arrows-.
– Release and disconnect connectors -1- and -2-.

– Open locking elements -arrows- of cable guide, and place en‐
gine wiring harness -3- on engine.
– Secure cables to engine using a cable tie.

– Push back cover for battery positive terminal -1-, and unbolt
battery positive cable from starter solenoid switch.
– Unbolt earth wire from body.

– Release fasteners -1- in -direction of arrow-, and remove cover

-2- for electronics box in engine compartment.
– Remove nut -arrow-, detach electrical wiring and move clear.
– Unscrew bolts -1- from engine mounting -2- approx. 2 turns.
– Unscrew bolts -2- from gearbox mounting -1- by 2 turns.

– Remove left and right front wheel ⇒ Running gear, axles,
steering; Rep. gr. 44 ; Wheels, tyres and alignment .
sulation .
– Remove left and right front wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .
– Remove radiator cowl
⇒ “4.5 Removing and installing radiator cowl”, page 285 .

– Attach protective mat - VAS 531003- to vehicle as shown in

illustration.
– Remove poly V-belt
⇒ “1.2 Removing and installing poly-V belt”, page 88 .
– Remove air conditioner compressor with refrigerant lines con‐
nected from engine ⇒ Heating, air conditioning; Rep. gr. 87 ;
Air conditioner compressor; Removing air conditioner com‐
pressor from and installing to bracket .
– Detach air conditioner compressor from bracket (refrigerant
hoses remain connected) and tie up to right side.


converter.


verter.
– Undo bolts -arrow- and remove bracket.
Vehicles with manual gearbox:

– Disconnect connectors -1- and -2-.
anism .
– Remove clutch slave cylinder and lay aside with hydraulic line
still connected ⇒ Rep. gr. 30 ; Clutch mechanism; Removing
and installing clutch slave cylinder .
Vehicles with dual clutch gearbox:
– Remove selector lever cable, pull connector of mechatronic
off and remove all retainers from gearbox:⇒ Rep. gr. 34 ;
Removing and installing gearbox


– Disconnect electrical connector -1- on oil level and oil temper‐
– Detach wire from retainer -2-.
– Remove coupling rod on anti-roll bar ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing
coupling rod .
page 60 .
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
– If fitted, unbolt front left vehicle level sender - G78- on trans‐
verse link ⇒ Running gear, axles, steering; Rep. gr. 43 ;
Vehicle level sender; Assembly overview - front vehicle level
sender .
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft , raise
and tie.
– Swivel front left suspension strut outwards and support with

extension -2024 A /1- , as shown in illustration.
– Secure locking pin and swivel joint with locating pin -arrow-
and nut -1-.
– Secure swivel joint -2- (right-side) to transverse link -1- with

nut -arrow-, as shown in illustration.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Drain coolant

from radiator.

– Disconnect coolant hoses -1- and -2- from heat exchanger for
heater.
– To do this, lift securing clips in -direction of arrow-.
Vehicles with auxiliary heater

– Release retaining clip and hose clip and pull off both coolant
hoses -arrows-.


– Release hose clip -1- and pull off coolant hose.

inder block.
– Screw in bolt -1- through hole “B” in engine support - T10497-
and tighten to 20 Nm.

– Remove bolts -1- for engine mounting -2-.

– Unscrew bolts -2-.
Note
♦ Avoid damage to vacuum lines, electrical wiring or the engine

compartment.
♦ Depending on the gearbox, 2 or 3 bolts can be mounted.

1.1.3 Removing engine, Polo


equipment required


♦ Safety glasses
♦ Safety gloves
Removing
Note

♦ Reinstall all cable ties in the same locations when installing.
– Release connectors -2- and pull off.

– Unclip wiring harness from coolant expansion tank -1-.
– Unscrew securing bolts -3-.
– Place coolant expansion tank -1- on top of engine.
– Disconnect fuel supply line -1- and line to activated charcoal

filter solenoid valve 1 - N80- -2-. Separate plug-in connectors
⇒ Rep. gr. 20 ; Plug-in connectors .
– Disconnect connectors of lambda probe 1 after catalytic con‐

verter - GX7- and lambda probe 1 before catalytic converter -
GX10- -arrows-.
– Remove air filter
– Remove battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐
moving and installing battery .

Vehicles with manual gearbox

– Pull vacuum line -1- off brake servo -2-.
– Release and disconnect connector on vacuum sender on vac‐

uum line.
– Detach or cut open cable tie.
– Remove engine control unit - J623- from bracket
360 .
– Release and pull off lower connector -1- on engine control unit
- J623- . Separate connection -4-.
– Unscrew bolts -2- and -3- on fuse box, and pull off lines.
– Place wiring harness on engine.

converter.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .
Rep. gr. 66 ; Noise insulation .
– Remove front right and front left wheel housing liners ⇒ Rep.
gr. 66 ; Wheel housing liner; Removing and installing front
wheel housing liner .

– Release and pull off connector -1- on oil level and oil temper‐
– Move clear electrical wiring harness, and lay it to one side.
– Remove right and left drive shafts ⇒ Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .
– If fitted, unbolt front left vehicle level sender - G78- on trans‐
verse link ⇒ Running gear, axles, steering; Rep. gr. 43 ;
Vehicle level sender; Assembly overview - front vehicle level
sender .
– Remove radiator cowl.
⇒ “4.5 Removing and installing radiator cowl”, page 285
– Attach protective mat - VAS 531003- to vehicle as shown in

illustration.
– Drain coolant
air conditioning system; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing air conditioner compressor from and in‐
stalling on bracket .

– Loosen clamp -arrow-, and push it to rear.
– Unscrew nuts -arrows-, and push catalytic converter -3- to

right.
– Remove screw-type clip -1- with bolt -2-.

– Detach exhaust hangers -3- in -direction of arrow- from sub‐

frame -2-.
– Lower exhaust system -1- until it rests on subframe -2-.
– Unscrew bolts -arrows- and remove bracket -1-.
– Open spring-type clip -arrow- and pull off coolant hose down‐
wards.
– Open spring-type clips -arrows-.

– Pull coolant hoses -1- off water radiator for charge air cooling
circuit -2-.

– Release retaining clips -arrows-.

– Pull coolant hoses -1- off heat exchanger for heater unit.
– Release and pull off connector -2- on starter -1-.

– Pull off protective cap -3-.
– Unscrew nut -arrow- and remove line from starter -1-.

– Unclip connectors -2- from bracket -1-.
– Unclip wires -3- and -4- from bracket -1-.
– Unscrew nuts -arrow-.
– Remove bracket -1- from gearbox.
– Release and pull off connector -3- on alternator -2-.

– Remove nuts -4-.
– Remove wire -1- from alternator -2-.
– Lay wiring harness -1- on coolant hose to one side.

– Lay lower wiring harness on intake manifold to one side.

– Use removal lever - 80 - 200- to do this.
– Release and pull off connectors on gearbox.
anism .
– Detach clutch slave cylinder with hydraulic line still connected
⇒ Rep. gr. 30 ; Clutch mechanism; Removing and installing
clutch slave cylinder .
Vehicles with dual clutch gearbox

– Release catch -arrow- and disconnect vacuum hose -1-.
– Remove selector lever cable -1- from gearbox ⇒ Rep. gr. 34 ;
Removing and installing gearbox .
– Release and pull off connector -1- of mechatronic unit in

-direction of arrow-.
– Unscrew bolts -2- and -3-.
– Remove retainer with wiring harness and lay them to one side.
– Pull vacuum line -2- in direction of -arrow- off vacuum pump

for brakes - V192- -1-.
– Lay vacuum line -1- to one side.


– Pull coolant hose -1- off radiator -2-.
– Unscrew earth wire -1-.

– Unscrew bolts -arrows- on engine mounting approx. 2 turns.
– Unscrew securing bolts -arrows- on gearbox mounting by ap‐

prox. 2 turns.
page 60 .

inder block.
– Screw in bolt -1- through hole “B” in engine support - T10497-


– Remove bolts -arrows- for engine mounting.
– Unscrew securing bolts -arrows- from gearbox mounting.
Note
♦ Risk of damage to the vacuum lines, electrical wiring or the

engine compartment.

1.2 Separating engine and gearbox

♦ Hook - 10 - 222 A /2-

♦ Workshop hoist - VAS 6100-
♦ Shackle - 10 - 222 A /12-
• Engine/gearbox assembly removed and attached to engine
bracket - T10497- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Attach shackle - 10-222 A/12- to gearbox and screw in pin to
stop.
– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /
2- to lifting tackle.

– Remove bolts -1, 2, 3, 6, 7, 8, 9- securing gearbox to engine.

– Pull gearbox off engine.
1.3 Securing engine on engine and gearbox

support
♦ Lifting tackle - 2024B- (not illustrated)
♦ Engine and gearbox support - VAS 6095-
♦ Lifting tackle - 2024B-

♦ Workshop hoist - VAS 6100-
• Gearbox detached from engine
⇒ “1.2 Separating engine and gearbox”, page 37 .

– Secure lifting tackle - 2024 B- on engine, and attach it to work‐

shop hoist - VAS 6100- as shown in illustration.
Note
♦ In order to match the lifting tackle to the centre of gravity of the

engine, the holes in the hook rail must be allocated as shown
in the illustration.
♦ The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
♦ The illustration shows the predecessor version 2024 A of the
lifting tackle, which, meanwhile, has been substituted by the
lifting tackle - 2024B- . The old version must not any longer be
used.
– Using workshop hoist - VAS 6100- , lift engine off engine

bracket - T10497- .
– Secure engine to engine and gearbox bracket - VAS 6095-

using pins -arrows- as shown in illustration.
1.4 Installing engine

• Engine/gearbox assembly secured to engine bracket -
T10497- .
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Secure all hose connections with hose clips comparable to
production standard ⇒ Electronic parts catalogue
– Install intermediate plate

⇒ Fig. ““Install intermediate plate:”“ , page 99 .

– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
– Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.
– Install gearbox support.
– Take up engine/gearbox assembly with engine support -
T10497- .
– Guide engine/gearbox assembly into body.
– Bring engine/gearbox assembly into position on mountings.
– Install engine mounting
⇒ “2.2 Removing and installing engine mounting”, page 52 .
– First screw in bolts for mountings to stop by hand.
– The bolts are tightened to final torque only after adjusting the
assembly mountings
⇒ “2.6 Adjusting assembly mountings”, page 80 .
– Tighten bolts
⇒ “2.1 Assembly overview - assembly mountings”,
page 44 .
– Remove - T10497- from engine.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐
sembly overview - starter .
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;
Removing and installing clutch slave cylinder .
– Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐
lector mechanism; Assembly overview - selector cables .
Vehicles with dual clutch gearbox
– Install selector lever cable, fit connector of mechatronic and
install all retainers on gearbox:⇒ Rep. gr. 34 ; Removing and
installing gearbox
– Install catalytic converter
⇒ “2.2 Removing and installing catalytic converter”,
page 400 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Assembly overview - drive shaft .
– Install transverse link, swivel joint and coupling rod ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Lower transverse link,
swivel joint; Assembly overview - lower transverse link, swivel
joint .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Install poly V-belt
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, electron‐
ics boxes and ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Install engine control unit - J623-
⇒ “8 Engine control unit”, page 360 .
– Connect coolant hoses with plug-in connector ⇒ page 264 .

– Install pendulum support

page 60 .
– Install front left and right wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Install front wheels ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres; Changing wheel .
– Adjust assembly mountings
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Assembly overview - battery .
– Install air pipe
– Install air filter housing
Note
♦ Risk of damage to control units caused by overvoltage.

♦ Never use battery charging equipment for boost starting.
– Fill with coolant. ⇒ page 230
Note
♦ Drained-off coolant may only be used again if the cylinder

head and cylinder block have not been renewed.
♦ Soiled coolant must not be reused.
If a new base engine has been installed:

• Depending on the version and the variant of the engine control
unit, there may be differences in the availability of functions.
• Only the functions that are supported by the respective engine
control unit must be performed.
– Perform the function 0001 - Adaption after sender re-
placement ⇒ Vehicle diagnostic tester.
– Perform the function 0001 - Reset learnt injector val-

ues ⇒ Vehicle diagnostic tester.
– Perform the function 0001 - Adapt / adjust charge

pressure positioner -V465- ⇒ Vehicle diagnostic tester.
– Perform the function 0001 - Adaption of lambda probes

⇒ Vehicle diagnostic tester.

Specified torques
Note
♦ The specified torques are only valid for nuts and bolts which
have been slightly greased, oiled, phosphate-treated or black-
oxided.
♦ Additional lubricant such as engine oil or gear oil may be used,
but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ The tolerance for specified torques varies by ± 15%.
Component Nm
Bolts and nuts 9
15
20
M10 40
M12 65
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”,
page 44 .
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
page 265
♦ ⇒ “2.1 Assembly overview - emission control”, page 397
♦ ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Assembly
overview - vacuum pump
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower sus‐
pension link, swivel joint; Assembly overview - lower suspen‐
sion link, swivel joint .
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Assembly overview - drive shaft
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Installing
gearbox
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified
torques for gearbox
♦ ⇒ Electrical system; Rep. gr. 27 ; Starter; Assembly overview
- starter
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Assembly overview - drive unit of air conditioner
compressor

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 44
⇒ “2.2 Removing and installing engine mounting”, page 52
⇒ “2.3 Removing and installing gearbox mountings”, page 56
⇒ “2.4 Removing and installing pendulum support”, page 60
⇒ “2.5 Supporting engine in installation position”, page 63
⇒ “2.6 Adjusting assembly mountings”, page 80
⇒ “2.7 Checking adjustment of assembly mountings (engine and
gearbox mountings)”, page 82
2.1 Assembly overview - assembly mount‐

ings
⇒ “2.1.1 Assembly overview - assembly mountings, Golf, Golf
Estate, Golf SV, Touran”, page 44
⇒ “2.1.2 Assembly overview – assembly mountings, Golf Cabrio‐
let”, page 46
⇒ “2.1.3 Assembly overview - assembly mountings, Polo with dual
clutch gearbox”, page 48
⇒ “2.1.4 Assembly overview - assembly mountings, Polo with
manual gearbox”, page 50
2.1.1 Assembly overview - assembly mountings, Golf, Golf Estate, Golf SV, Tour‐
an

1 - Bolt
❑ Renew
❑ Tightening sequence
⇒ Fig. ““Engine support
- specified torque and
installation sequence”“ ,
page 95
2 - Engine support
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling engine support”,
page 92
❑ Specified torque and
tightening sequence
page 95
3 - Engine mounting
❑ With support arm
⇒ “2.2.1 Removing and
installing engine mount‐
ing, Golf, Golf Estate,
Golf SV, Touran”,
page 52
4 - Bolt
❑ Renew
❑ 40 Nm +90°
5 - Bolt
❑ Renew
❑ 23 Nm +90°
6 - Bolt
❑ 8 Nm
7 - Bracket
8 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
9 - Pendulum support
⇒ “2.4.1 Removing and installing pendulum support, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet”,
page 60
10 - Bolt
❑ Specified torque and tightening sequence
⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
11 - Bolt
12 - Bolts
2. Assembly mountings 45
13 - Bolt
❑ 60 Nm +90°
14 - Bolt
❑ Renew
❑ 60 Nm +90°
15 - Bolt
❑ Renew
❑ 50 Nm +90°
16 - Gearbox mounting
❑ With support arm
⇒ “2.3.1 Removing and installing gearbox mounting, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet”,
page 56
2.1.2 Assembly overview – assembly mountings, Golf Cabriolet
1 - Connection
2 - Bolt
❑ Connection to engine
mounting and body
❑ 20 Nm +90°
3 - Bolt
❑ Connection to engine
mounting and body
❑ 20 Nm +90°
4 - Bolts
❑ Engine mounting to en‐
gine support
❑ 60 Nm +90°
5 - Bolt
❑ For bracket for activated
charcoal filter
❑ 20 Nm +90°
6 - Centre hex stud
❑ Engine mounting to
body
❑ 40 Nm +90°
7 - Bolt
❑ Engine mounting to
body
❑ 40 Nm +90°

8 - Engine mounting
❑ Removing and installing ⇒ “2.2.2 Removing and installing engine mounting, Golf Cabriolet”, page 52
9 - Bracket
❑ For activated charcoal filter
10 - Bolt
❑ Engine support to engine
⇒ Fig. ““Engine support - specified torque and installation sequence”“ , page 95
11 - Engine support
❑ Removing and installing ⇒ “1.5 Removing and installing engine support”, page 92
⇒ Fig. ““Engine support - specified torque and installation sequence”“ , page 95
12 - Bolt
❑ Gearbox mounting to gearbox support
❑ 60 Nm +90°
13 - Bolt
❑ Gearbox mounting to body
❑ 40 Nm +90°
❑ Illustration shows version for dual clutch gearbox.
15 - Bolt
❑ Gearbox support to gearbox
Specified torques:
❑ Vehicles with manual gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques for
gearbox
❑ Vehicles with dual clutch gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques
for gearbox
16 - Centre hex stud
❑ Gearbox support to gearbox
Specified torques:
❑ Vehicles with manual gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques for
gearbox
❑ Vehicles with dual clutch gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques
for gearbox
17 - Gearbox support
⇒ “2.4.1 Removing and installing pendulum support, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet”,
page 60
❑ Bolt pendulum support to gearbox and then to subframe.
19 - Bolt
❑ Pendulum support to subframe
❑ Specified torque: ⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
20 - Bolts
❑ Pendulum support to gearbox
❑ Specified torque: ⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
2.1.3 Assembly overview - assembly mountings, Polo with dual clutch gearbox
1 - Engine support
page 92
tightening sequence
page 95
2 - Bolt
tightening sequence
page 95
3 - Engine mounting
ing, Polo”, page 54
❑ Aligning engine mount‐
ing
⇒ Fig. ““Aligning engine
mountings:”“ ,
page 55
4 - Bolt
❑ 20 Nm +90°
❑ Qty. 4
5 - Nut
❑ The securing nut must
not be loosened.
6 - Centre hex stud
❑ With mounting for earth wire; specified torque ⇒ Fig. ““Earth strap on engine mounting”“ , page 49
❑ 30 Nm +90°
7 - Bolt
❑ Qty. 2
❑ 30 Nm +90°
8 - Bolt
❑ 40 Nm +90°
❑ Tightening sequence
⇒ Fig. ““Tightening sequence - gearbox mounting, dual clutch gearbox”“ , page 49

❑ Tightening sequence - gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, dual clutch gearbox”“ , page 49 .
10 - Bolt
❑ 50 Nm +90°
11 - Bolt
❑ 50 Nm +90°
❑ Qty. 2
❑ Removing and installing ⇒ “2.4.2 Removing and installing pendulum support, Polo”, page 61
13 - Bolt
❑ 40 Nm +90°
14 - Bolt
❑ 30 Nm +90°
❑ Qty. 2
Earth strap on engine mounting

– Earth strap -1- is secured to stud with a nut -2-.
Nut Specified torque
-2- 20 Nm
Tightening sequence - gearbox mounting, dual clutch gearbox

Ite Procedure Specified torque
m
B Start bolts before tightening hand-tight
an them
dC
B Tighten bolts 50 Nm +90°
C Tighten bolt. 50 Nm +90°
A Start bolts before tightening hand-tight
them
A Bolts 40 Nm +90°
2.1.4 Assembly overview - assembly mountings, Polo with manual gearbox
1 - Engine support
page 92
tightening sequence
page 95
2 - Bolt
tightening sequence
page 95
3 - Engine mounting
ing, Polo”, page 54
❑ Aligning engine mount‐
ing
⇒ Fig. ““Aligning engine
mountings:”“ ,
page 55
4 - Bolt
❑ 20 Nm +90°
❑ Qty. 4
5 - Nut
❑ The securing nut must
not be loosened.
6 - Centre hex stud
❑ With mounting for earth wire ⇒ Fig. ““Earth strap on engine mounting”“ , page 52
❑ 30 Nm +90°
7 - Bolt
❑ Qty. 2
❑ 30 Nm +90°
8 - Bolt
❑ 40 Nm +90°
❑ Tightening sequence ⇒ Fig. ““Tightening sequence - gearbox mounting, manual gearbox”“ , page 51
❑ Removing and installing ⇒ “2.3 Removing and installing gearbox mountings”, page 56
⇒ Fig. ““Tightening sequence - gearbox mounting, manual gearbox”“ , page 51 .

10 - Bolt
❑ 50 Nm +90°
11 - Bolt
❑ 50 Nm +90°
❑ Qty. 2
❑ Removing and installing ⇒ “2.4.2 Removing and installing pendulum support, Polo”, page 61
13 - Bolt
❑ 40 Nm +90°
14 - Bolt
❑ 30 Nm +90°
❑ Qty. 3
15 - Bolt
❑ 50 Nm +90°
Tightening sequence - gearbox mounting, manual gearbox
Note
Risk of damage to threads by starting bolts at an angle.
Ite Procedure Specified torque

m
B Start bolts before tightening hand-tight
an them
dC
B Tighten bolts 50 Nm +90°
C Tighten bolt. 50 Nm +90°
A Start bolts before tightening hand-tight
them
A Bolts 40 Nm +90°
Earth strap on engine mounting

– Earth strap -1- is secured to stud with a nut -2-.
Nut Specified torque
-2- 20 Nm
2.2 Removing and installing engine mount‐

ing
⇒ “2.2.1 Removing and installing engine mounting, Golf, Golf Es‐
tate, Golf SV, Touran”, page 52
⇒ “2.2.2 Removing and installing engine mounting, Golf Cabrio‐
let”, page 52
⇒ “2.2.3 Removing and installing engine mounting, Polo”,
page 54
2.2.1 Removing and installing engine mount‐

ing, Golf, Golf Estate, Golf SV, Touran
Removing
– Pull off connector -1-.
– Open locking element -3-, and move hoses -2- to one side.
– Using a screwdriver, release fasteners -arrow- and lay coolant
expansion tank to one side.
– Support engine in its installation position
⇒ “2.5 Supporting engine in installation position”, page 63 .
– Unscrew bolts -arrows- and remove engine mounting -1-.

Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings
⇒ “2.7 Checking adjustment of assembly mountings (engine
and gearbox mountings)”, page 82 .
Specified torques
♦ ⇒ “2.1.1 Assembly overview - assembly mountings, Golf, Golf

ing, Golf Cabriolet

♦ Torque wrench - V.A.G 1331-
♦ Socket - T40055-
Removing
– Support engine in its installation position
⇒ “2.5 Supporting engine in installation position”, page 63 .
– Pull off breather line -arrow- ⇒ Rep. gr. 20 ; Plug-in connec‐
tors .
– Release locking lug -3- in direction of arrow, and remove ac‐
tivated charcoal filter -1- upwards.
– Place activated charcoal filter -1- on engine with line -2- con‐
nected.
– Unscrew bolt -4- and turn filler neck for washer fluid reservoir
-2- towards front.
– Open clip -3- and pull connector -5- off coolant expansion tank
-1-.
– Unscrew bolts -arrows- and place coolant expansion tank -1-
on engine with coolant hoses connected.
– If fitted, unscrew jump-start connection point -3- at front of en‐

gine mounting -2- using socket - T40055- .
– Unscrew bolts -5- and remove bracket -4-.

– Unscrew bolts -1- and -3-, and remove engine mounting up‐
wards.
Installing
Installation is performed in the reverse order of removal. Observe
the following:
Specified torques
♦ ⇒ “2.1.2 Assembly overview – assembly mountings, Golf Cab‐
riolet”, page 46

ing, Polo

Removing
– Release connectors -2- and pull off.
– Unscrew securing bolts -3-.
– Place coolant expansion tank -1- on top of engine.
– Support engine in installation position
⇒ “2.5.4 Supporting engine in installation position, Polo”, page
78 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew nut -3-.

– Remove earth wire.
Note
The securing nut -4- must not be loosened.
– Unscrew bolts -2- between engine mounting and engine.

– Unscrew bolts -arrows- and remove engine mounting.
Installing
Install in reverse order. Observe the following:
Aligning engine mountings:

– Fit engine mounting on longitudinal member.
Note
Risk of damage to threads by starting bolts at an angle.
• The positioning holes -arrows- must be in line; check with ap‐

propriate drill if necessary.
– First, screw in securing bolts between engine mounting and
engine bracket 2 to 3 turns. This ensures that the engine will
not be twisted.
– Remove support bracket - 10 - 222 A- from engine. Do not
remove support bracket - 10 - 222 A- until the bolts securing
the assembly mounting have been tightened to specified tor‐
que.
Specified torques
Component Specified torque

Securing bolts for coolant expansion tank 1.8 Nm
♦ ⇒ “2.1.3 Assembly overview - assembly mountings, Polo with

dual clutch gearbox”, page 48
2.3 Removing and installing gearbox

mountings
⇒ “2.3.1 Removing and installing gearbox mounting, Golf, Golf
Estate, Golf SV, Touran, Golf Cabriolet”, page 56
⇒ “2.3.2 Removing and installing gearbox mountings, Polo”, page
58
2.3.1 Removing and installing gearbox

mounting, Golf, Golf Estate, Golf SV,
Touran, Golf Cabriolet
Removing
Golf, Golf Estate, Golf SV, Touran:
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Remove engine control unit
360 .
– Unscrew nuts -arrows- and remove bracket -1-.
Note
Different types of brackets are fitted depending on version.
Golf Cabriolet:
– Remove resonator for intake air
⇒ “2.3 Removing and installing resonator for intake air”, page
324 .

– Unclip wire guide -1- upwards -arrows-, and push it slightly to

one side.
– Support engine in installation position.
Vehicles with 2 bolts between gearbox mounting and gearbox

bracket:
– Remove bolts -arrows- and detach gearbox mounting -1-.
Vehicles with 3 bolts between gearbox mounting and gearbox

bracket:
– Remove bolts -arrows- and detach gearbox mounting -1-.
Installing
Note
♦ Renew bolts that are tightened with specified further tightening

angle.
♦ Gearbox support and support arm of gearbox mounting must
be perfectly parallel to each other before screwing in bolts
-arrows 1-. If necessary, lift gearbox at rear using trolley jack.
♦ Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.
– Lift gearbox with spindle of support bracket until gearbox sup‐

port makes contact with support arm of gearbox mounting.
– Remove support bracket - 10 - 222 A- from engine.
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 44
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 320
- battery
♦ ⇒ “8.1 Removing and installing engine control unit J623 ”, page
360
2.3.2 Removing and installing gearbox

mountings, Polo

Removing
324 .
– Release fastener, detach engine control unit - J623- , and
place it to one side.
– Release and pull off lower connector -1- on engine control unit
- J623- . Separate connection -4-.
– Unscrew bolts -2- and -3- on fuse box, and pull off lines.
– Support engine in installation position
⇒ “2.5.4 Supporting engine in installation position, Polo”, page
78 .
– Unscrew securing bolts -arrows- from gearbox mounting.

Installing
– Remove support bracket - 10 - 222 A- from engine.
Specified torques
♦ Tightening sequence for gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, dual clutch
gearbox”“ , page 49 .
♦ ⇒ Fig. ““Tightening sequence - gearbox mounting, manual
gearbox”“ , page 51
- battery
2.4 Removing and installing pendulum sup‐

port
⇒ “2.4.1 Removing and installing pendulum support, Golf, Golf
⇒ “2.4.2 Removing and installing pendulum support, Polo”, page
61
2.4.1 Removing and installing pendulum sup‐

port, Golf, Golf Estate, Golf SV, Touran,
Golf Cabriolet

sulation .
– First unscrew bolt -1-.
– Then remove bolts -2- and -3-.
– Remove pendulum support -4- from subframe -5-.
Installing

Note
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

for the pendulum support.
♦ Identification: shoulder along beginning of thread -arrow-.
Pendulum support - specified torque and tightening sequence

– Renew bolts that are tightened with specified tightening angle.
– Tighten bolts in stages in the sequence shown.
Stage Bolts Specified torque/turning further angle
1. -2, 3- 50 Nm
2. -1- 130 Nm
3. -1 … 3- Turn 90° further
2.4.2 Removing and installing pendulum sup‐

port, Polo
Removing
sulation .
Vehicles with dual clutch gearbox:
– Unscrew bolts -arrows- for pendulum support.
Note
Bolt -1- must not be loosened.
– Pull pendulum support out of subframe.
Vehicles with manual gearbox:

– Unscrew bolts -arrows- for pendulum support -1-.
Note
Bolt -3- must not be loosened.
– Pull pendulum support -1- out of assembly carrier -2-.

Installing
– Insert pendulum support in subframe.
– Tighten securing bolts on gearbox by hand (do not use any
tools).
– Tighten fitted bolt for subframe.
– Tighten securing bolts on gearbox to final torque.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
Note
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

for the pendulum support.
♦ Identification: shoulder along beginning of thread -arrow-.
Specified torques
dual clutch gearbox”, page 48

2.5 Supporting engine in installation posi‐

tion
⇒ “2.5.1 Supporting engine in installation position, Golf, Golf Es‐
tate, Golf SV”, page 63
⇒ “2.5.2 Supporting engine in installation position, Touran”, page
68
⇒ “2.5.3 Supporting engine in installation position, Golf Cabriolet”,
page 74
⇒ “2.5.4 Supporting engine in installation position, Polo”,
page 78
2.5.1 Supporting engine in installation posi‐

tion, Golf, Golf Estate, Golf SV
♦ Support bracket - 10 - 222 A-
♦ Shackle - 10 - 222 A /12-

♦ Adapter - 10 - 222 A /18-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - T40091/1-
♦ Adapter - T40091/3-
♦ Adapter - T40093/3-
♦ Adapter - T40093/3-6-
♦ Adapter - 10-222A/29-
♦ Spindle - 10 - 222 A /10-

♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /18-
Preparing support bracket - 10 - 222 A- :

– If support bracket - 10 - 222 A- does not yet have a hole
(marked with -arrow-), drill it into support bracket accordingly.
• Dimension -a- = 225 mm.
• Hole ∅ = 12.5 mm.
Check adapters - T40093/3-6- and modify as necessary

– If necessary, cut off the marked area.
– Round off front edges.
– Protect adapter against corrosion.
– Then, mark adapters - T40093/3-6- as -T40093/3-6A- .
At a later point, support bracket - 10-222 A- will be fitted onto
longitudinal members with adapters - T40093/3-6A- .
• To prevent damage to the longitudinal members, wrap the
front section of the adapters - T40093/3-6A- with textile-rein‐
forced adhesive tape ⇒ Electronic parts catalogue (ETKA
chemical substances) .
Setting up support bracket:
324 .
– Fit adapter -T40093/3-6A- with support - T40093/3- onto right

longitudinal member.
– If fitted, pull off electrical lines in front area of web on right
longitudinal member -arrow-. Do not disconnect pipe/hose
system.
– Unclip refrigerant line from retainer.
– Place adapter -T40093/3-6A- onto right longitudinal member.
• The adapter -T40093/3-6A- is locked with the pin -A- behind
the flange of the longitudinal member -arrow-.
– Unclip wires -arrows- in front area of longitudinal member on

left side. Use release tool - T10236- for this.

– Release and pull off connectors -1- and -2-.

– Release connector on retainer and unclip.
– Open locking element on retainer -arrow- on longitudinal
member.
– Expose wiring harness for engine control unit on bracket.
– Expose positive wire for fuse carrier on bracket.
– Unclip wiring harness leading to engine control unit from
bracket and on battery tray. Use release tool - T10236- for this.
– If necessary, release and pull off wiring harness on engine
control unit
360 .
– Lay wiring harnesses aside.
– Use release tool - T10236- to unclip bracket on longitudinal
member and swivel to right.
– Remove filler neck -1- at top on lock carrier -2-.

– To do this, release locking lug -3- in direction of -arrow-.
– Pull filler neck -1- upwards out of mounting.
– Fit adapter -T40093/3-6A- -A- to left longitudinal member.

– Guide adapter - T40093/3-6A- below filler pipe of washer fluid
reservoir.
– Place adapter - T40093/3-6A- onto left longitudinal member.
– Adapter - T40093/3-6A- must engage with pin -A- behind web
of longitudinal member -arrow-.
– If necessary, push adapter - T40093/3-6A- into correct posi‐
tion.
– Note lines and retainers.
Installation position of adapters - 10 - 222 A /29- :

♦ “L” = -1- adapter is used on “right-hand” side of vehicle.
♦ “R” adapter is inserted on “left” side of vehicle.
♦ On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐
tween wing mounting flange and sheet metal for mounting
wing underneath it.
– Push adapter - 10 - 222 A /18- and two connecting pieces -

T40091/3- onto support bracket - 10-222 A- as shown.
– Short side of adapter - 10 - 222 A /18- must point in direction
of travel.
– Securing bolts for connecting piece - T40091/3- must face in
direction of travel.
– Place support bracket - 10 - - 222 A /29- on longitudinal mem‐
bers.
– Screw together square tube - 10 - 222 A- and adapter - 10 -
222 A /29- as described ⇒ page 68 .
– Push square tube - T40091/1- on right side into support -
T40093/3- .
– Push spindle - 10-222A- on right side onto square tube -
T40091/1- as shown.
– Push square tube - T40091/1- on right side into connecting
piece - T40091/3- .
– Push square tube - T40091/1- on left side into support -
T40093/3- .
– Push square tube - T40091/1- on left side into connecting
piece - T40091/3- .
– Bolt one shackle - 10 - 222 A /12- to each of the two engine
lifting eyes.
– Attach one spindle - 10-222A- to adapter - 10 - 222 A /18- as
shown in illustration.
– Hook spindle - 10-222A- onto shackle - 10 - 222 A /12- on right
side.
– Attach spindle - 10-222A- to shackle - 10 - 222 A /12- on left
side.
– Align support bracket.
– Tighten all threaded connections of support bracket.

tion, Touran

♦ Shackle - 10 - 222 A /12-

♦ Adapter - 10 - 222 A /18-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - T40091/1-
♦ Adapter - T40091/3-
♦ Adapter - T40093/3-
♦ Adapter - T40093/3-6-
♦ Adapter - 10-222A/29-
♦ Spindle - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /18-

Preparing support bracket - 10 - 222 A- :

– If support bracket - 10 - 222 A- does not yet have a hole
(marked with -arrow-), drill it into support bracket accordingly.
• Dimension -a- = 225 mm.
• Hole ∅ = 12.5 mm.
Check adapters - T40093/3-6- and modify as necessary

– If necessary, cut off the marked area.
– Round off front edges.
– Protect adapter against corrosion.
– Then, mark adapters - T40093/3-6- as -T40093/3-6A- .
At a later point, support bracket - 10-222 A- will be fitted onto
longitudinal members with adapters - T40093/3-6A- .
• To prevent damage to the longitudinal members, wrap the
front section of the adapters - T40093/3-6A- with textile-rein‐
forced adhesive tape ⇒ Electronic parts catalogue (ETKA
chemical substances) .
Setting up support bracket:
324 .
– Remove air filter housing.
⇒ “2.2 Removing and installing air filter housing”, page 323
– On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐
wing underneath it.
– Fit adapter -T40093/3-6A- with support - T40093/3- onto right

longitudinal member.
– If fitted, pull off electrical lines in front area of web on right
longitudinal member -arrow-. Do not disconnect pipe/hose
system.
– Unclip refrigerant line from retainer.
– Place adapter -T40093/3-6A- onto right longitudinal member.
• The adapter -T40093/3-6A- is locked with the pin -A- behind
the flange of the longitudinal member -arrow-.
– Unclip wires -arrows- in front area of longitudinal member on

left side. Use release tool - T10236- for this.
– Release and pull off connectors -1- and -2-.

– Release connector on retainer and unclip.
– Open locking element on retainer -arrow- on longitudinal
member.
– Expose wiring harness for engine control unit on bracket.
– Expose positive wire for fuse carrier on bracket.
– Unclip wiring harness leading to engine control unit from
bracket and on battery tray. Use release tool - T10236- for this.
– If necessary, release and pull off wiring harness on engine
control unit
360 .
– Lay wiring harnesses aside.
– Use release tool - T10236- to unclip bracket on longitudinal
member and swivel to right.
– Remove filler neck -1- at top on lock carrier -2-.

– To do this, release locking lug -3- in direction of -arrow-.
– Pull filler neck -1- upwards out of mounting.

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

– Guide adapter - T40093/3-6A- below filler pipe of washer fluid
reservoir.
– Place adapter - T40093/3-6A- onto left longitudinal member.
– Adapter - T40093/3-6A- must engage with pin -A- behind web
of longitudinal member -arrow-.
– If necessary, push adapter - T40093/3-6A- into correct posi‐
tion.
– Note lines and retainers.
Installation position of adapters - 10 - 222 A /29- :

♦ “L” adapter is installed on “right” side of vehicle.
♦ “R” adapter is inserted on “left” side of vehicle.
♦ On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐
wing underneath it.
• Arrow -2- on adapter - 10 - 222 A /29- always points in direction

of travel.
• Fit adapter - 10 - 222 A /29- onto the load-bearing part of upper
wheel housing longitudinal member.
– Slide connecting piece - T40091/3- onto support bracket -

10-222 A- .
– Slide spindle - 10-222A- onto engine support bracket - 10-222
A- as shown.
– Slide additional connecting piece - T40091/3- onto support
bracket - 10-222 A- .
– Securing bolts for connecting piece - T40091/3- point in direc‐
tion of travel.
– Place support bracket - 10 - - 222 A /29- on longitudinal mem‐
bers.
– Screw together square tube - 10 - 222 A- and adapter - 10 -
222 A /29- as described ⇒ page 73 .
– Push square tube - T40091/1- on right side into support -
T40093/3- .
– Push spindle - 10-222A- on right side onto square tube -
T40091/1- as shown.
– Push square tube - T40091/1- on right side into connecting
piece - T40091/3- .
– Push square tube - T40091/1- on left side into support -
T40093/3- .
– Push square tube - T40091/1- on left side into connecting
piece - T40091/3- .
– Bolt one shackle - 10 - 222 A /12- to each of the two engine
lifting eyes.
side.
side.

tion, Golf Cabriolet
♦ Square tube and 2 wing bolts from support bracket - 10 - 222
A-
♦ Spindles - 10-222A-

♦ Square tube - T40091/1-
♦ Joints - T40091/3-
♦ Adapter - 10-222A/13-
♦ Adapter - 10-222A/28-
♦ Adapter - 10-222A/28-2-
♦ Shackle - 10 - 222 A /12-
♦ Spacer tube - 10-222A/17-

324 .
– Remove foam sections or seals from edge of left and right
wings ⇒ General body repairs, exterior; Rep. gr. 50 ; Wings;
Assembly overview - wings .
– Unscrew bolts -arrows- for retaining brackets on left and right
of lock carrier.
– Unscrew lower mounting from adapter - 10 - 222 A /28- .

– Screw in adapter - 10-222 A /28-2- .
– Unscrew one securing bolt -arrow- from adapter -10-222 A /
28-2- .

– Bolt adapter - 10-222 A /28-2- to lock carrier using securing

bolt -1-.
– The adapter - 10-222A/13- must be positioned as shown in the

illustration. The panel edge -arrow- must not be bent.
– Insert spacer tube - 10-222A/17- between handle and spindle

- 10-222A- support as shown.
– Slide adapter - T40091/3- and spindle - 10-222A- onto square
section tube of support bracket - 10 - 222 A- as shown.
– Bolt square section tube of support bracket - 10 - 222 A- to
adapter - 10-222A/13-
– Push square section tube - T40091/1- into adapter - 10 - 222
A /28- on left side.
– Push square section tube - T40091/1- into adapter - T40091/3-
on left side.
– Push square section tube - T40091/1- into adapter - 10 - 222
A /28- on right side.
– Push square section tube - T40091/1- into adapter - T40091/3-
on right side.
– Screw shackles - 10 - 222 A /12- onto support eyes on left and
right sides.
side.
side.
– Tighten all threaded connections of support bracket hand-
tight.

tion, Polo
♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10 - 222 A /32-
♦ Tensioning strap - T10038-

To prevent damage to edges of wings, cover lower areas of both

adapters - 10 - 222 A /8- with woven adhesive tape -arrow- ⇒
Electronic Parts Catalogue (ETKA) .
– Remove air filter housing.
– Remove seals from edge of wing.

– Slide adapter - 10 - - 222 A- .
– Fit adapter - 10 - - 222 A- .
– Lift up plenum chamber cover at sides.
– Position engine support bracket - 10 - 222 A- on left and right
onto longitudinal members as shown in illustration.
Note
Do not position engine support bracket - 10 - 222 A- on edges of wings.
– Fit adapter - 10 - 222 A /8- behind the hole -arrow- and align
it.
– Mount adapter - 10 - 222 A /32- to mountings on engine as
– Secure with tensioning strap - T10038- on both sides of bonnet
hinges.
2.6 Adjusting assembly mountings

– Unscrew bolts -arrows- for engine mounting one after other,
and renew them. This is only necessary if not already done
during the installation of the engine.
– First screw bolts in loosely.

– Unscrew bolts -arrows- for gearbox mounting -1- one after

other, and renew them. This is only necessary if not already
done during the installation of the engine.
– First screw bolts in loosely.
– Using assembly lever, adjust engine/gearbox assembly so

that specifications listed below are attained:
There must be a distance of -a- = 10 mm between engine support
-2- and engine mounting -1-.
Side surface of engine support -2- must be located parallel to
support arm of engine mounting -1-.
Distance -b- = distance -b-.
Note
Distance -a- = 10 mm can be checked with a metal rod of suitable

size, or similar.
– Tighten bolts for engine mounting.
– On the gearbox side, ensure that the edges of the support arm
-2- and gearbox support -1- are parallel.
• Distance -x- = distance -x-.
– Tighten bolts for gearbox mounting.
Install in reverse order.
Specified torques
♦ ⇒ “2.1 Assembly overview - charge air system”, page 302
- battery
2.7 Checking adjustment of assembly

mountings (engine and gearbox mount‐
ings)
⇒ “2.7.1 Checking adjustment of assembly mountings, Golf, Golf
⇒ “2.7.2 Checking assembly mounting settings, Golf Cabriolet”,
page 82
⇒ “2.7.3 Checking assembly mounting settings, Polo”,
page 83
2.7.1 Checking adjustment of assembly

mountings, Golf, Golf Estate, Golf SV,
Touran
The following specifications must be obtained:
• There must be a distance of -a- = 10 mm between engine
support -2- and engine mounting -1-.
• Side surface of engine support -2- must be located parallel to
support arm of engine mounting -1-.
• Distance -b- = distance -b-.
Note
Distance -a- = 10 mm can be checked with a metal rod of suitable

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

mountings ⇒ “2.6 Adjusting assembly mountings”, page 80 .
2.7.2 Checking assembly mounting settings,

Golf Cabriolet
• There must be a distance -a- of 10 to 13 mm between engine
support and right longitudinal member.
• The cast edge on the engine support -a- must be aligned par‐
allel to support arm.
• Dimension -b- must be identical at front and rear.
– If there is a noise problem and dimension -a- is outside the
tolerance range, adjust assembly mountings

2.7.3 Checking assembly mounting settings,

Polo
– The positioning holes -arrows- must be in line; check with ap‐
propriate drill if necessary.
– If there is an acoustic complaint or the positioning holes do not
line up, loosen engine mounting and align
⇒ “2.2.3 Removing and installing engine mounting, Polo”,
page 54 .
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 84
⇒ “1.2 Removing and installing poly-V belt”, page 88
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 90
⇒ “1.4 Removing and installing vibration damper”, page 91
⇒ “1.5 Removing and installing engine support”, page 92
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 95
1.1 Assembly overview - poly V-belt drive

⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles without
air conditioner compressor”, page 84
⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles with air
conditioner compressor”, page 86
1.1.1 Assembly overview - poly V-belt drive, vehicles without air conditioner com‐
pressor
84 Rep. gr.13 - Crankshaft group

1 - Bolt
❑ Renew
❑ Use counter-hold tool -
T10475- to loosen and
tighten
❑ 150 Nm +180°
2 - Vibration damper
stalling vibration damp‐
er”, page 91
3 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen
❑ For allocation, refer to ⇒
Electronic parts cata‐
logue .
❑ Do not kink
❑ Poly V-belt routing
⇒ page 89
stalling poly-V belt”,
page 88
❑ When installing, make
sure it is properly seated
on pulleys.
4 - Bolt
❑ Renew
❑ 20 Nm +90°
5 - Tensioning device for poly
V-belt
❑ Pivot with socket to slacken poly V-belt
❑ Lock with locking pin - T10060 A- .
❑ Removing and installing ⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 90
6 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
❑ With freewheel
❑ Various versions of the overrunning alternator pulley, -A- or -B-, may be fitted depending on the type and
version of alternator. Allocation ⇒ Fig. ““Allocation of overrunning alternator pulley”“ , page 86 .
❑ Determine length of poly V-belt according to ⇒ Electronic parts catalogue depending on version of over‐
running alternator pulley
1. Cylinder block (pulley end) 85

Allocation of overrunning alternator pulley
1.1.2 Assembly overview - poly V-belt drive, vehicles with air conditioner com‐
pressor
1 - Poly V-belt
❑ Check for wear
chalk or felt-tipped pen
❑ Determine length of poly
V-belt according to ⇒
logue depending on ver‐
sion of overrunning al‐
ternator pulley
❑ Do not kink
❑ Poly V-belt routing
⇒ Fig. ““Fit poly V-belt as
shown in illustration.”“ ,
page 90
installing poly V-belt, ve‐
hicles without air condi‐
tioner compressor”,
page 88
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Specified torque
⇒ Item 1 (page 85)
3 - Vibration damper
stalling vibration damp‐
er”, page 91
4 - Tensioning device for poly
V-belt
❑ Pivot with socket to slacken poly V-belt

❑ Lock with locking pin - T10060 A- .
❑ Removing and installing ⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 90
5 - Bolt
❑ Renew
❑ 20 Nm +90°
6 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
❑ With freewheel
❑ Various versions of the overrunning alternator pulley, -A- or -B-, may be fitted depending on the type and
version of alternator. Allocation ⇒ Fig. ““Allocation of overrunning alternator pulley”“ , page 87 .
❑ Determine length of poly V-belt according to ⇒ Electronic parts catalogue depending on version of over‐
running alternator pulley
8 - Dowel sleeve
❑ For air conditioner compressor.
9 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing air conditioner compressor from and to bracket
10 - Bolt
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor .
Allocation of overrunning alternator pulley

1.2 Removing and installing poly-V belt

⇒ “1.2.1 Removing and installing poly V-belt, vehicles without air
⇒ “1.2.2 Removing and installing poly V-belt, vehicles with air
1.2.1 Removing and installing poly V-belt, ve‐

hicles without air conditioner compres‐
sor
Removing
– To slacken poly V-belt, turn tensioner anti-clockwise -arrow-.
– Lock tensioning device in place with locking pin - T10060 A- .
Note
♦ If a used poly V-belt runs in the opposite direction when it is

refitted, this can cause breakage.
♦ Before removing the poly V-belt, use a piece of chalk or a felt
pen to mark the running direction.
– Remove poly V-belt.

Installing
Note
♦ Various versions of the overrunning alternator pulley, -A-

or-B-, may be fitted depending on the type and version of
alternator. Allocation
⇒ Fig. ““Allocation of overrunning alternator pulley”“ ,
page 86 .
♦ Determine length of poly V-belt according to ⇒ Electronic parts
catalogue depending on version of overrunning pulley.

– Fit poly V-belt as shown in illustration.

1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
– Turn tensioning device in -direction of arrow-, and pull out

locking pin - T10060 A- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
1.2.2 Removing and installing poly V-belt, ve‐

hicles with air conditioner compressor
Removing
– If poly V-belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen before removing.
– Fit tool -3- onto hexagon of tensioner -1-.
– To slacken poly V-belt push tool -3- in -direction of arrow-.
– Lock tensioner -1- in place with locking pin - T10060 A- -2-.
– Remove poly V-belt -4-.
Installing

Various versions of the overrunning alternator pulley, -A- or -B-,

may be fitted depending on the type and version of alternator.
The length of the poly V-belt must be determined according to the
⇒ Electronic parts catalogue depending on the version of over‐
running alternator pulley.
Fit poly V-belt as shown in illustration.

1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
– Push tool -3- in -direction of arrow-, and pull out locking pin -
T10060 A- -2-.
– Release tension from tensioner -1-.
– Check that poly V-belt -4- is properly seated.
– Start engine and check that poly V-belt runs properly.
1.3 Removing and installing tensioner for

poly V-belt
Removing
– Remove poly V-belt from tensioner

– Remove bolts -arrows- and detach poly V-belt tensioner -1-.

Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 84
1.4 Removing and installing vibration damp‐

er
♦ Counter-hold tool - T10475-
Preparing counterhold tool - T10475-
Note
♦ Different types of vibration damper can be installed.

♦ For this reason, the counterhold tool - T10475- must be adap‐
ted to the holes of the respective vibration damper.
Version 1
– Convert counterhold tool - T10475- -1- with inserts -T10475/2-
-2-.

Version 2
– Convert counterhold tool - T10475- with inserts -T10475/1-
and -T10475/2- as shown in illustration.
• To do this, use hole -A- or -B- of counterhold tool - T10475-
-1- depending on type of vibration damper.
Removing
sulation .
– Set piston in cylinder no. 1 to »TDC« position
⇒ “4.7 Setting piston to TDC position”, page 119 .
– Loosen bolt -arrow- for vibration damper using counterhold -

T10475- .
– Unscrew bolt and remove vibration damper.
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
Installing
Note

♦ All contact surfaces between bolt, vibration damper and crank‐
shaft toothed belt pulley must be free of oil and grease.
– Fit vibration damper, oil threads of bolt for vibration damper

and screw it in to stop by hand.
– Tighten bolt -arrow- for vibration damper using counterhold -
T10475- .
Specified torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Assembly overview- front wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation
1.5 Removing and installing engine support

Removing
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery

– Drain coolant
324 .
– Remove tensioner for poly V-belt.
⇒ “1.3 Removing and installing tensioner for poly V-belt”, page
90
– Remove upper part of toothed belt guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”,
page 139 .
– Unscrew bolt -1-.
– Loosen hose clip -2- and pull off coolant hose.
– Unscrew bolts -1- and remove bracket -2- for catalytic con‐
verter.
– Pull off connector -1-.
– Open retaining clips on pipes of air conditioning system.
– Loosen bolt -1- but do not remove.

– Swivel alternator -3- in -direction of arrow- towards front.

– Unscrew bolts -arrows- from bracket for front exhaust pipe.

⇒ “2.4 Removing and installing pendulum support”, page 60 .
– Removing engine mounting
⇒ “2.2 Removing and installing engine mounting”, page 52 .
– Remove lower toothed belt guard
⇒ “2.3.2 Removing and installing lower toothed belt guard”,
page 139 .
– Unscrew bolts -1, 2, 3-.
– Unscrew bolts -arrows-.

– Push engine/gearbox assembly slightly towards left, and de‐
tach engine support.
Installing

Engine support - specified torque and installation sequence
Note
Renew bolts that are tightened with turning further angle.

1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
3. -1 … 3- Turn 90° further
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 136
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 254
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly over‐
view - alternator
- battery
1.6 Renewing crankshaft oil seal - belt pul‐

ley end
♦ Assembly tool - T10485A-
♦ Thrust piece - T10485/4-

♦ Extractor hook - T20143-
– Remove toothed belt
⇒ “2.5 Removing and installing toothed belt”, page 148 .
– Detach crankshaft pulley -1- -arrow-.
NOTICE
– Pry out seal using extractor hook -T20143/2- -arrow-.

– Clean contact surface and sealing surface.
Note
Do not lubricate new seal.
– Fit new seal in -direction of arrow- over assembly sleeve -

T10485/3- onto assembly sleeve - T10485/2- .

– Pull off assembly sleeve - T10485/3- in -direction of arrow-.

• Installation position: closed end of seal faces fitting sleeve.
– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
– Draw in seal -3- to stop using thrust piece - T10485/4- -2- and
pulley bolt -1-.
– Fit crankshaft sprocket onto crankshaft.

• The contact surface between vibration damper and crankshaft
toothed belt pulley must be free of oil and grease.
• The machined surface -arrow- of crankshaft pulley must be
positioned over the machined surface of the crankshaft jour‐
nal.
– Install toothed belt and adjust the valve timing

2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 98
⇒ “2.2 Removing and installing flywheel”, page 99
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 100
2.1 Assembly overview - cylinder block, gearbox end
Note
For assembly work, secure engine to engine and gearbox support

⇒ “1.3 Securing engine on engine and gearbox support”, page 39 .
1 - Bolt
❑ Renew
❑ 60 Nm +90°
2 - Flywheel
stalling flywheel”,
page 99
❑ Can only be fitted in one
position
3 - Engine speed sender -
G28-
stalling engine speed
sender G28 ”,
page 412
4 - Bolt
❑ Specified torque
⇒ “1.1 Assembly over‐
view - ignition system”,
page 408
5 - Dowel pin
❑ Qty. 2
6 - Intermediate plate
❑ Do not damage or bend
when assembling.
❑ Installing
⇒ Fig. ““Install inter‐
mediate plate:”“ ,
page 99
7 - Bolt
tightening sequence
⇒ Fig. ““Sealing flange on gearbox side - specified torque and tightening sequence”“ , page 99
8 - Sealing flange with sender wheel and oil seal
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 100

Sealing flange on gearbox side - specified torque and tightening

sequence
– Tighten bolts in stages as follows:
Stage Bolts Specified torque
1. -1 … 6- Screw onto stop by hand
2. -1 … 6- In diagonal sequence and in stages;
final torque 10 Nm
Install intermediate plate:

– Engage intermediate plate on sealing flange -top arrow- and
push onto dowel sleeves -bottom arrows-.
2.2 Removing and installing flywheel

♦ Counter-hold tool - 3067-
Removing
• Gearbox removed
2. Cylinder block, gearbox end 99

– Insert counterhold tool - 3067- into hole in cylinder block

-item B-.
– Loosen and remove flywheel bolts.
Installing
Note

♦ Flywheel with sender wheel can only be fitted in one position.
– Insert counterhold - 3067- in hole in cylinder block -item A-.

Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
98
2.3 Removing and installing sealing flange

on gearbox side
♦ Ring spanner insert - V.A.G 1332/11-
♦ Depth gauge - VAS 6082-

♦ Assembly tool - T10134-
♦ Locating bolt - T10340-
♦ Three M6 × 35 bolts
♦ Spark plug socket , e.g. -3122 B-
♦ Screwdriver with a shaft length of at least 250 mm
♦ Hexagon key
Note
For reasons of clarity, illustrations show work procedure with en‐

gine removed.

sulation .
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox .
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
clutch .

– Remove flywheel
⇒ “2.2 Removing and installing flywheel”, page 99 .
– Remove intermediate plate -1- from dowel sleeves
-arrows A-.
– Guide intermediate plate -1- upwards.
– While doing so, pull retaining lug -arrow B- of intermediate
plate -1- out of recess behind sealing flange.
– Turn crankshaft to “TDC” position
– Remove sump
⇒ “1.3 Removing and installing sump”, page 201 .
– Remove engine speed sender - G28- -arrow-
⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 412 .
– Unscrew bolts -arrows- for sealing flange -1-.
– To press off, screw qty. 3 M6 x 35 bolts -arrows- into sealing

flange -1-.
Note
The sealing flange -1- is pressed off crankshaft -3- together with
the sender wheel -2-.
– Screw bolts alternately into sealing flange not more than 1/2
turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
Pressing in sealing flange with sender wheel

Note
♦ Do not re-use old sealing flange.

♦ The sealing flange with a PTFE seal is equipped with a sealing
lip support ring -2-.
♦ This support ring serves as a fitting sleeve and must not be
removed prior to installation.
♦ Sealing flange and sender wheel -1- must not be separated
after removal from packaging.
♦ The sender wheel -1- is held in its installation position on the
locating pin of the assembly tool - T10134- ⇒ page 103 .
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly tool - T10134- is held in its position relative to
the crankshaft by a guide pin inserted into a hole in the crank‐
shaft ⇒ page 103 .
Set-up of assembly tool - T10134- :

A - Clamping surface
B - Nut
C - Assembly housing
D-
Locating pin
E - Hexagon socket head bolt (qty. 2)
F-
Guide pin for petrol engines (red knob)
G - Guide pin for diesel engines (black knob)
H - Knurled screws (qty. 3)
I - Inner part
Fitting sealing flange with sender wheel on assembly tool -

T10134- :
– Screw on nut -B- until just before it touches the clamping sur‐
face -A- of the threaded spindle.

– Clamp assembly device - T10134- at clamping surface -A- of

threaded spindle in a vice -1-.
– Press assembly housing -C- downwards until it rests against
nut -B-.
• Inner part of assembly tool and assembly housing must be at
same height.
– If fitted, remove securing clip -arrow- from new sealing flange

-1-.
Note
Do not take the sender wheel out of the sealing flange.
– Place sealing flange with front side facing down on a clean

level surface.
– Push sealing lip support ring -1- downwards in
-direction of arrow- until it rests against the flat surface.
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.

– Place sealing flange -1- with front side facing downwards onto
assembly tool - T10134- so that locating pin -D- is seated in
hole -3- in sender wheel hole -2-.
– If necessary, rotate sender wheel with support ring so that lo‐
cating pin and hole align.
• The sealing flange must rest flat against the assembly tool.
– Screw knurled screws -H- into sealing flange -1-.

– Press sealing flange -1- and sealing lip support ring -2- against
surface of assembly tool - T10134- whilst tightening knurled
screws.
– This prevents the locating pin from slipping out of the sender
wheel hole.
– When installing sealing flange, ensure that sender wheel re‐
mains fixed in assembly tool.
Mounting assembly tool - T10134- with sealing flange -1- on

crankshaft flange:
• The crankshaft flange must be free of grease and oil.
• Engine is at “TDC” position.
– Screw on nut -B- until it reaches end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in
-direction of arrow-, until nut -B- rests against assembly hous‐
ing -C-.
– Align flat side of assembly housing to sealing surface of cyl‐
inder block on sump side.
– Attach assembly tool - T10134- together with sealing flange

-1- to crankshaft flange -2-.
– To do this, screw hexagon socket head bolts -E- into crank‐
shaft flange (approx. 5 full turns) using a hexagon key.
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.

– To guide sealing flange -1-, screw two M6 × 35 mm bolts -2-

into cylinder block.
Bolting assembly tool - T10134- onto crankshaft flange:

– Push assembly housing -C- by hand in -direction of arrow- until
sealing lip support ring -1- rests against crankshaft flange
-2-.
– Make sure that guide pin for petrol engines (red knob) -F- is
properly seated in hole in crankshaft. This ensures that the
sender wheel reaches its final installation position.
Note
The guide pin for diesel engines (black knob) must not be inserted
in threaded hole of crankshaft.
– Tighten the two hexagon socket head bolts of assembly tool

hand-tight.
– Screw nut -B- onto threaded spindle by hand until nut rests
against assembly housing -C-.
Pressing sender wheel onto crankshaft flange using assembly

tool - T10134- :
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.
• After the nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block and sealing flange -1-.
Checking sender wheel installation position on crankshaft:

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

– Position depth gauge - VAS 6082- on crankshaft flange -2-.

– Measure distance between crankshaft flange -2- and sender
wheel -1-.
– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: dimension -a- = 0.5 mm
– If specification is not achieved, press sender wheel further in
⇒ page 107 .
– If specification is achieved, proceed with subsequent work
steps ⇒ page 108 .
Re-pressing sender wheel:

– Secure assembly tool - T10134- on crankshaft flange.
– Make sure that locating pin of assembly tool - T10134- is prop‐
erly seated in sender wheel hole.
– Tighten hexagon socket head bolts -E- by hand.
– Push assembly tool - T10134- by hand against sealing flange
-1-.
– Screw nut -B- by hand onto threaded spindle until nut rests
against assembly tool - T10134- .
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
– Screw knurled screws -H- into sealing flange -1-.
– Screw two M6 × 35 mm bolts -2- into cylinder block to guide
sealing flange.

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

– Check sender wheel installation position on the crankshaft
again ⇒ page 106 .
– If the specification is not achieved, tighten nut of assembly tool
- T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 106 .
Installing
– Tighten bolts for sealing flange (vehicles with manual gearbox)
⇒ Fig. ““Sealing flange on gearbox side - specified torque and
tightening sequence”“ , page 99 .
– Install sump
– Install intermediate plate (vehicles with manual gearbox)
⇒ Fig. ““Install intermediate plate:”“ , page 99 .
– Install flywheel (vehicles with manual gearbox)
⇒ “2.2 Removing and installing flywheel”, page 99 .
Specified torques
♦ ⇒ Fig. ““Sealing flange on gearbox side - specified torque and
tightening sequence”“ , page 99
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
98
♦ ⇒ “1.1 Assembly overview - ignition system”, page 408
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 196
torques for gearbox

3 Crankshaft
⇒ “3.1 Crankshaft dimensions”, page 109
⇒ “3.2 Measuring axial clearance of crankshaft”, page 109
⇒ “3.3 Renewing needle bearing in crankshaft”, page 110
3.1 Crankshaft dimensions

NOTICE
Risk of damage to bearing pedestals when the crankshaft is
removed.
If the bolts of the crankshaft bearing cap are loosened, the
bearing pedestals of the cylinder block will be deformed, and
damage to the bearings will result.
– Never remove the crankshaft.
• Measuring the crankshaft bearing clearance is not possible

with normal workshop equipment.
Honing dimension Crankshaft bearing journal diameter
mm
Basic dimension 42.00 -0.022
-0.042
3.2 Measuring axial clearance of crankshaft

NOTICE
Risk of damage to bearing pedestals when the crankshaft is
removed.
If the bolts of the crankshaft bearing cap are loosened, the
bearing pedestals of the cylinder block will be deformed, and
damage to the bearings will result.
– Never remove the crankshaft.
Note
♦ If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
♦ Measuring the crankshaft bearing clearance is not possible
with normal workshop equipment.

♦ Universal dial gauge holder - VW 387-
3. Crankshaft 109
♦ Dial gauge - VAS 6079-
– Screw dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder block as shown in the illustration.
– Position dial gauge against crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off measured
value.
• Axial clearance: 0.066 to 0.233 mm
3.3 Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-

♦ Pin - VW 207 C-
Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Condition:
• The front edges of the inner puller must be free of chips.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .
3. Crankshaft 111
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing has been accidentally driven in too far, the
bearing must be renewed because it will be damaged when it is
pulled out.
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐

box; Removing gearbox .

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 113
⇒ “4.2 Removing and installing pistons”, page 115
⇒ “4.3 Checking pistons and cylinder bores”, page 116
⇒ “4.4 Separating new conrod”, page 117
⇒ “4.5 Checking radial clearance of conrods”, page 118
⇒ “4.6 Removing and installing oil spray jets”, page 118
⇒ “4.7 Setting piston to TDC position”, page 119
4.1 Assembly overview - pistons and conrods
1 - Bolts
❑ Renew
❑ Oil threads and contact
surface
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ The conrod bearing cap
only fits in one position
and only on the appro‐
priate conrod due to the
breaking procedure
(cracking) separating
the cap from the conrod.
❑ Mark allocation to cylin‐
der and conrod in colour
-B-.
❑ Installation position: Lug
-A- on conrod bearing
cap faces towards pul‐
ley end
3 - Bearing bushes
❑ Fitting position
⇒ Fig. ““Bearing shells -
installation position”“ ,
page 115
❑ Renew worn bearing
shells
❑ Ensure firm seating
4 - Connecting rod
❑ With industrially
cracked conrod bearing
cap
❑ Renew as set only.
❑ Mark allocation to cylin‐
der and conrod bearing cap in colour -B-.
❑ Measuring radial clearance ⇒ “4.5 Checking radial clearance of conrods”, page 118
❑ Separate new conrod ⇒ “4.4 Separating new conrod”, page 117 .
❑ Installation position: Lug -A- on conrod bearing cap faces towards pulley end
5 - Retaining ring
❑ Qty. 2
❑ Renew
4. Pistons and conrods 113

6 - Piston pin
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 115
7 - Piston
❑ With combustion chamber.
❑ Mark installation position and cylinder number
⇒ Fig. ““Installation position and allocation of piston to cylinder”“ , page 114 .
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 115
❑ Checking piston and cylinder bore ⇒ “4.3 Checking pistons and cylinder bores”, page 116
8 - Piston rings
❑ Compression rings
❑ Measuring ring gap ⇒ page 116
❑ Measuring ring-to-groove clearance ⇒ page 117
❑ Use commercially available piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gaps by 120°
9 - Piston ring
❑ Oil scraper ring
❑ Measuring ring gap ⇒ page 116
❑ Measuring ring-to-groove clearance ⇒ page 117
❑ Use piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gap 120° relative to lower compression ring
Installation position and allocation of piston to cylinder

• Arrow on piston crown points to pulley end -arrow-.

Bearing shells - installation position

– Centre bearing shells on conrod and on conrod bearing cap.
• Distance -a- = distance -a-.
4.2 Removing and installing pistons

♦ Pin - VW 222 A-
♦ Commercially available
Removing
– Removing cylinder head.
⇒ “1.3 Removing and installing cylinder head”, page 126
– Remove sump
⇒ “1.3 Removing and installing sump”, page 201 and baffle
plate.
– Mark piston installation position and corresponding cylinder
number.
– Mark installation position and matching of cylinder and conrod
bearing cap to conrod ⇒ Item 4 (page 113) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
Note
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installing

Note
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position
⇒ Fig. ““Installation position and allocation of piston to cylin‐
der”“ , page 114 .
– Install conrod bearing cap, noting installation position
⇒ Item 2 (page 113) .
– Install cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 126 .
– Install sump
Specified torques
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 113
4.3 Checking pistons and cylinder bores

Checking piston
♦ - 75 mm - VAS 6070-
– Using an external micrometre, measure approx. 10 mm from
lower edge, offset 90° from piston pin axis.
• Maximum deviation from nominal dimension: -0.04 mm.
Piston diameter, mm
Specification 70.921)
• 1) Dimension (thickness 0.015 mm on each side)
Measuring piston ring gap

– Push piston ring squarely from above down into cylinder bore
to approx. 15 mm from bottom end of cylinder.
– To check piston ring gap insert a commercially available feeler
gauge into the gap.
– Push in using a piston without piston rings.
Piston ring New Wear limit
mm mm
compression ring 0.20 + 0.15 0.7
Oil scraper ring 0.20 + 0.20 1.2

Measuring ring-to-groove clearance

– Clean annular groove of piston before check.
Piston ring New Wear limit
mm mm
1st compression ring 0.05 … 0.09 0.15
2nd compression ring 0.03 … 0.07 0.15
Oil scraper rings (2 parts) 0.04 to 0.08 0.15
Oil scraper rings (3 parts) Cannot be measured
Measuring cylinder bore

♦ Cylinder gauge - VAS 6078-
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Using cylinder gauge - VAS 6078- take measurements at 3

positions diagonally in lateral direction -A- and longitudinal di‐
rection -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore diameter, mm
Specification 71.0 + 0.015
+0.005
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
4.4 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– To avoid damage, gently clamp conrod in a vice with protection
jaws, as shown in illustration.
• Clamp conrod below dashed line.
– Unscrew bolts -arrows- around 5 turns.

– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -arrow- until conrod bearing cap is loose.
4.5 Checking radial clearance of conrods

♦ Plastigage
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm (without turning
further angle). Do not rotate crankshaft while doing so.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
• Radial clearance: 0.028 to 0.065 mm.
– Renew conrod bolts.
4.6 Removing and installing oil spray jets

♦ Multi-point bit - T10545-
Removing
sulation .
– Remove sump
– Turn crankshaft via vibration damper securing bolt in direction
of engine rotation until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using Torx bit T40 -
T10545- .
– Remove oil spray jets -2-.
Installing

1- Pressure relief valve - 27 Nm

2- Oil spray jet
NOTICE
Risk of damage to oil spray jets.
– Do not bend oil spray jets.
– Check clearance of oil jets after reinstallation of pistons.
– Bent oil spray jets must be renewed.
• Installation position: align leading edge of oil spray jet arrow

with machined surface of cylinder block.
– Install sump
tion .
4.7 Setting piston to TDC position

Setting piston from cylinder no. 1 to TDC position ⇒ page 119
Setting piston from cylinder no. 1 to TDC position for repair work
on toothed belt drive and for setting valve timing ⇒ page 120
Setting piston from cylinder no. 1 to TDC position
Rotate crankshaft to “TDC” as follows:
– Remove ignition coil 1 with output stage - N70- and the spark
plug cylinder 1
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 409 .
Note
♦ Risk of damage to engine!

♦ Locking pin - T10340- can be inserted to stop at 2 positions.
♦ It is essential that the “TDC” position is checked as described.
– Carefully insert a screwdriver with a shaft length of at least

250 mm into spark plug hole so that it contacts piston crown.
– Turn crankshaft in direction of engine rotation until piston in
cylinder 1 is at “BDC”.

The screwdriver moves in the -direction of the arrow-.
– Turn crankshaft further in direction of engine rotation until

screwdriver has moved -30 mm- in -direction of arrow-.
sulation .
– Unscrew plug for “TDC” hole in cylinder block.

– Screw locking pin - T10340- into cylinder block as far as stop
– Rotate crankshaft in normal direction of rotation as far as stop.
• The locking pin now rests against the crank web.
Note
Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation only.
Setting piston from cylinder no. 1 to TDC position for repair work
on toothed belt drive and for setting valve timing
324 .
– Remove air intake pipe

– Press release tabs and disconnect hose -1- for activated char‐
coal filter.
– Unscrew bolts -arrows- and pull off crankcase breather hose.
Note
Risk of chemical damage to the coolant pump gasket caused by

oil entering between the coolant pump and the cylinder head.
– Cover coolant pump with a cloth.

– Remove connection for turbocharger
⇒ “1.4 Removing and installing connection for turbocharger”,
page 299 .
– Lay wiring harness to one side -arrows-.

– Unscrew bolts -1, 3- and remove cover -2- for toothed belt for
coolant pump.
– Unscrew bolts -arrows- and detach sealing cap -1-.
• The asymmetrically positioned grooves on gearbox end of

both camshafts -top arrows- must now be above the horizontal
centre line.
• Grooves -arrows- on exhaust camshaft -A- can be accessed
through recesses in drive wheel for coolant pump.
• On inlet camshaft -E-, grooves -arrows- are above horizontal
camshaft centre line.
A - Exhaust camshaft
E - Inlet camshaft

Plug for “TDC” drilling in cylinder block - specified torque

♦ Renew O-ring if damaged.
♦ Tighten bolt -arrow- to 30 Nm.
Specified torques
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 293
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 235
♦ ⇒ “1.2 Assembly overview - camshaft housing”, page 125

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 123
⇒ “1.2 Assembly overview - camshaft housing”, page 125
⇒ “1.3 Removing and installing cylinder head”, page 126
⇒ “1.4 Removing and installing camshaft housing”, page 131
⇒ “1.5 Checking compression”, page 133
1.1 Assembly overview - cylinder head
Note
♦ The camshafts must not be removed individually.

♦ In the event of repair, the camshaft housing must be renewed completely.
1 - Cylinder head gasket

❑ Renewing
stalling cylinder head”,
page 126
❑ Observe installation po‐
sition: Part number to
cylinder head
2 - Dowel sleeve
❑ Qty. 2
3 - Cylinder head
stalling cylinder head”,
page 126
❑ Check for distortion
⇒ page 124 .
4 - Dowel pins
5 - Seal
❑ With oil strainer
❑ Inserted into cylinder
head
6 - Seal
❑ Renew
7 - Camshaft case
stalling camshaft hous‐
ing”, page 131
8 - Bolt
tightening sequence
⇒ Fig. ““Camshaft housing - specified torque and tightening sequence”“ , page 126
1. Cylinder head 123

9 - Bolt
❑ Renew
❑ Sequence when loosening ⇒ page 129 .
⇒ Fig. ““Cylinder head - specified torque and sequence”“ , page 124
Cylinder head - specified torque and sequence
Note

1. -1 … 10- 40 Nm
2. -1 … 10- Turn 90° further
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
Checking cylinder head for distortion

♦ Straight edge 500 mm - VAS 6075-
– 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
124 Rep. gr.15 - Cylinder head, valve gear

1.2 Assembly overview - camshaft housing
1 - Bolt
tightening sequence
⇒ Fig. ““Camshaft hous‐
ing - specified torque
and tightening se‐
quence”“ , page 126
2 - Inlet camshaft control valve
1 - N205-
stalling camshaft control
valve 1 N205 ”,
page 185
❑ Check O-ring for dam‐
age.
❑ O-ring not available as a
separate part; renew to‐
gether with camshaft
control valve 1 - N205- if
damaged.
3 - Bolt
❑ 8 Nm
4 - Camshaft case
stalling camshaft hous‐
ing”, page 131
5 - Hall sender - G40-
stalling Hall sender”,
page 411
6 - Bolt
❑ 8 Nm
7 - Seal
❑ For exhaust camshaft, gearbox end
❑ Renewing ⇒ “3.5.3 Removing and installing exhaust camshaft oil seal, gearbox end”, page 182
8 - Crankshaft
❑ For coolant pump
⇒ “2.7 Removing and installing toothed belt pulley for coolant pump”, page 250
9 - Bolt
❑ Specified torque ⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 235
10 - Bolt
❑ 8 Nm
11 - Cap
12 - O-ring
❑ Renew
13 - Seal
❑ Renew

14 - Dowel pin
15 - Seal
❑ With oil strainer
❑ Inserted into cylinder head
Note
♦ Versions with or without oil

strainers are used depending on
production date.
♦ If no strainer was installed at the
factory, a strainer is instead inte‐
grated in camshaft control valve
1 - N205- .
♦ Damage may result if the strainer
is installed in both locations!
16 - Seal
❑ For inlet camshaft
❑ Renewing
⇒ “3.5.1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end”, page 178
17 - Seal
❑ For exhaust camshaft (pulley end)
❑ Renewing ⇒ “3.5.2 Removing and installing exhaust camshaft oil seal, pulley end”, page 180
18 - Cap
Camshaft housing - specified torque and tightening sequence
Note

1. -1 … 15- 10 Nm
2. -1 … 15- Turn 180° further
1.3 Removing and installing cylinder head


♦ Commercially available razor blade scraper (blade width:

40 mm)
Removing
Note
♦ Seal open channels/ports using suitable plugs from engine

bung set - VAS 6122- .
♦ Cover the openings in the gearbox with a cloth to prevent any
coolant or other liquids from getting into the clutch housing.
♦ Fit the cable ties in the original position when installing.
♦ Attach all heat-shielding sleeves in the same places when in‐
stalling.
– Remove camshaft housing

⇒ “1.4 Removing and installing camshaft housing”,
page 131 .
– Remove intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 327 .
– Disconnect connectors:
1- On oil pressure switch for reduced oil pressure - F378-
2- On fuel pressure sender - G247-
3- On injectors -N30- to -N33-

verter.

– Unscrew bolts -arrows- and detach oil supply pipe -1- and oil
return pipe -2-.
1 - For coolant temperature sender - G62-
2 - For charge pressure positioner - V465-
– Unscrew bolt -1- from engine support.

– Loosen cylinder head bolts in the sequence -1 to 10- and un‐

screw.
– Take off cylinder head and set it down on a soft surface (foam
plastic).
Installing
Note
♦ Using unauthorised sanding or abrasive media may lead to

secondary damage such as, for example, damage to the tur‐
bocharger or the conrod bearings.
♦ Do not use sandpaper, grinding wheels, abrasive or scour
pads or any other sanding or abrasive media.
♦ When removing the sealant residue, make sure no loose par‐
ticles get into the open channels of the engine.
Note
♦ Do not use any other means rather than a standard blade

scraper to remove the sealant residue from the cylinder head
and cylinder block. Take care not to damage the sealing sur‐
faces.
♦ Remove any loose remains using a lint-free cloth.
♦ Remove oil or coolant from blind holes of cylinder head bolts.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Make sure to prevent damage to the silicone coating or the
indented area of the gasket.

– Fit cylinder head gasket -1-.

♦ 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

♦ Renew self-locking nuts as well as gaskets, seals and O-rings.
♦ When installing a replacement cylinder head, the contact sur‐
faces between hydraulic compensation elements, roller rocker
fingers and running surface of cams must be oiled before in‐
stalling the camshaft housing.
♦ Secure all hose connections with hose clips corresponding to
the series equipment ⇒ Electronic parts catalogue .
♦ When cylinder head or cylinder head gasket is renewed, the
entire coolant and the engine oil must be changed.
– If the crankshaft has been turned in the meantime, set piston

of no. 1 cylinder to TDC. Turn crankshaft back slightly.
– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
– Tighten bolts for cylinder head
⇒ Fig. ““Cylinder head - specified torque and sequence”“ ,
page 124 .
Note
After repair work it is not necessary to retighten the cylinder head

bolts.
Further installation is carried out in reverse order of removal, ob‐

serving the following:
– Install camshaft housing
page 131 .
– Change engine oil. ⇒ Maintenance ; Booklet
– Fill cooling system with fresh coolant
Specified torques
♦ ⇒ Fig. ““Engine support - specified torque and installation se‐
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 123
♦ ⇒ “3.1 Assembly overview - intake manifold”, page 325
♦ ⇒ Fig. ““Installing catalytic converter - specified torque and
sequence”“ , page 398

1.4 Removing and installing camshaft hous‐

ing
Removing
– Remove coolant pump
⇒ “2.5 Removing and installing coolant pump”, page 243 .
– Remove ignition coils
page 409 .
– Remove toothed belt from camshafts
⇒ “2.8 Removing toothed belt from camshaft”, page 165 .
– Remove high-pressure pipe -3-
⇒ “6.3 Removing and installing high-pressure pipe”,
page 353 .
– Release hose clip -2- and disconnect hose.
page 299 .
– Release hose clip -2- and detach coolant hose.

– Remove bolts -arrows- and pivot coolant lines -1- to right side.
– Unscrew bolts -arrows- and remove bracket with heat shield

-1-.

– Disconnect connector -arrow- from intake manifold sender -

GX9- .
2 - For camshaft adjuster valve 1 - N205-
4 - for Hall sender - G40-
– Remove bolt -3-, move wiring harness clear and place to left
side.
– Pull out dipstick -1-.
– Loosen bolts for camshaft housing in the sequence -15 to 1-

and unscrew.
– Carefully detach camshaft housing from adhesive bond and
remove it.
– Mark allocation of roller rocker fingers and compensation ele‐
ments for reinstallation.
– Remove roller rocker fingers together with compensation ele‐
ments and place them on a clean surface.
Installing
Note

♦ Renew seals.
– Check, if all roller rocker fingers are seated properly on valve

stem end and if their clipped into the respective compensation
element.
Note
♦ Versions with or without oil strainers are used depending on

production date.
♦ If no strainer was installed at the factory, a strainer is instead
integrated in camshaft control valve 1 - N205- .
♦ Damage may result if the strainer is installed in both locations!

– Fit seal with oil strainer -2- into cylinder head -1-.
– Fit gasket onto dowel pins -arrows-.
– Screw 2 studs -items 2, 4- (e.g. -T10288/4- ) into cylinder head.

– Carefully lower camshaft housing -3- vertically onto studs in
cylinder head.
Note
Ensure that camshaft housing is not canted.
– Tighten bolts for camshaft housing

⇒ Fig. ““Camshaft housing - specified torque and tightening
sequence”“ , page 126 .
– Install high-pressure pipe
page 353 .
– Install toothed belt (adjust valve timing)
– Install ignition coils
page 409 .
– Install coolant pump
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Note
Risk of damage to valves and piston crowns after working on

valve gear.
– Turn the engine carefully at least 2 rotations to ensure that

none of the valves make contact when the starter is operated.
Specified torques
♦ ⇒ “3.1 Assembly overview - valve gear”, page 169
1.5 Checking compression


♦ Spark plug socket - 3122 B-
♦ Compression tester - V.A.G 1763-
♦ Puller - T10530-
• Engine oil temperature at least 30 °C.
• Battery voltage at least 12.5 V.
– Remove fuse for fuel pump control unit from fuse holder. Fuse
assignment ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
– Start engine and run until it stalls.

– Switch off ignition.
324 .

– Pull off connector -2- and unscrew bolt -1-.

– Pull out ignition coils with output stages
page 409 .
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Check compression pressure using compression tester -
V.A.G 1763- ; refer to ⇒ Operating instructions .
– Have a second mechanic press down accelerator completely
and simultaneously operate starter until pressure no longer
increases on tester display.
– Repeat procedure on each cylinder.
Compression pressures bar
New 10.0 … 15.0
Wear limit 7.0
Maximum difference between cylinders 3.0
Installing
Assembly is carried out in reverse sequence; note the following:
– Install spark plugs. Specified torque 22 Nm.
– Install ignition coils with output stages
page 409 .
Note
Entries will have been made in the event memory of the engine
control unit because connectors were separated and the engine
was started.
– Generate readiness code using ⇒ Vehicle diagnostic tester

with button 0001 - Generating readiness code .

2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt cover”, page 136
⇒ “2.2 Assembly overview - toothed belt”, page 137
⇒ “2.3 Removing and installing toothed belt guard”, page 139
⇒ “2.4 Preassembling and installing valve timing tool”,
page 139
⇒ “2.5 Removing and installing toothed belt”, page 148
⇒ “2.6 Checking valve timing”, page 154
⇒ “2.7 Adjusting valve timing”, page 156
⇒ “2.8 Removing toothed belt from camshaft”, page 165
2.1 Assembly overview - toothed belt cover
1 - Lower toothed belt guard

2 - Bolt
❑ 8 Nm
3 - Engine support
tightening sequence
page 95
4 - Bolt
tightening sequence
page 95
5 - Upper toothed belt guard
6 - Bolt
❑ 8 Nm

2.2 Assembly overview - toothed belt
1 - Toothed belt
chalk or felt-tipped
marker pen.
❑ Check for wear
stalling toothed belt”,
page 148
2 - Bolt
❑ 25 Nm
❑ When setting specified
torque on torque wrench
- VAS 6583- , length
must be entered in tor‐
que wrench.
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
page 92 .
4 - Bolt
❑ Renew
❑ 50 Nm +90°
5 - Exhaust camshaft toothed
belt pulley
stalling toothed belt pul‐
ley”, page 176
6 - Inlet camshaft toothed belt
pulley
❑ With camshaft adjuster
❑ Removing and installing camshaft adjuster
⇒ “3.3 Removing and installing camshaft adjuster”, page 172
7 - Guide sleeve
8 - Bolt
❑ Renew
❑ 50 Nm +135°
9 - O-ring
❑ Renew
10 - Plug
❑ 20 Nm
11 - O-ring
❑ Captive, supplied with “item 13”.
12 - Spacer sleeve
❑ Supplied with item “13”.
2. Toothed belt drive 137

13 - Idler roller
14 - Bolt
❑ 40 Nm
15 - Crankshaft pulley
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
Bend radius of toothed belt
Plug for “TDC” drilling in cylinder block - specified torque
Note
Renew O-ring or bolt if damaged. ⇒ Electronic Parts Catalogue
– Tighten bolt -arrow- to 30 Nm.

2.3 Removing and installing toothed belt

guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”, page
139
⇒ “2.3.2 Removing and installing lower toothed belt guard”, page
139
2.3.1 Removing and installing upper toothed

belt guard
Removing:
– Detach hoses from retainer -3-.
– Release clips -arrows- and remove upper toothed belt guard
-1-.
Installing:
Specified torques:
2.3.2 Removing and installing lower toothed

belt guard
Removing:
– Remove vibration damper
⇒ “1.4 Removing and installing vibration damper”, page 91 .
– Remove lower part of toothed belt guard.
Installing:
– Install vibration damper
Specified torques:
2.4 Preassembling and installing valve tim‐

ing tool
⇒ “2.4.1 Preassembling test tool VAS 611 007 ”, page 139
⇒ “2.4.2 Installing test tool VAS 611 007 ”, page 143
⇒ “2.4.3 Teaching-in test tool VAS 611 007 electronically and
performing basic setting”, page 147
2.4.1 Preassembling test tool - VAS 611 007-


♦ Tester for checking elongation of chain links - VAS 611 007-
Test tool - VAS 611 007-
A - Angle sensor - VAS 611

007/1-
❑ Specified torque brake:
11 Nm
B - Lock ring - VAS 611 007/2-
C - Clamping ring - VAS 611
007/3-
D - Adapter for camshaft hous‐
ing - VAS 611 007/8-
E - Adapter for angle sensor -
VAS 611 007/9- and adapter
for angle sensor - VAS 611
007/10-
❑ Adapter for angle sen‐
sor - VAS 611 007/9-
blue
❑ Adapter for angle sen‐
sor - VAS 611 007/10-
red

Preassembling test tool - VAS 611 007-

– Before inserting adapter for angle sensor - VAS 611 007/9-
and adapter for angle sensor - VAS 611 007/10- -E- in angle
sensor - VAS 611 007/1- -A-, verify correct allocation in ac‐
cordance with colour coding -a-.
– Insert adapter for angle sensor - VAS 611 007/9- and adapter
for angle sensor - VAS 611 007/10- -E- in angle sensor - VAS
611 007/1- -A-.
– Note position of dowel pins -a- when installing.

– Adapter for angle sensor - VAS 611 007/9- and adapter for
angle sensor - VAS 611 007/10- -E- only fit in one position.
– Make sure that brake -b- is released. Do not apply force.
– Insert adapter for angle sensor - VAS 611 007/9- and adapter
for angle sensor - VAS 611 007/10- -E- as far as stop in angle
sensor - VAS 611 007/1- -A-.
– Secure clamping ring - VAS 611 007/3- -C- in groove -a- from
adapter for angle sensor - VAS 611 007/9- and adapter for
angle sensor - VAS 611 007/10- -E-.
– Insert angle sensor - VAS 611 007/1- -A- with red colour cod‐
ing on side marked red -arrows a- of adapter for camshaft
housing - VAS 611 007/8- -D-. To do this, release locking pins
-c- by pulling them upwards.
– Insert angle sensor - VAS 611 007/1- -A-, and push it in until
locking pin can be heard to engage.
– Repeat procedure with angle sensor - VAS 611 007/1- -A- with
blue colour coding -arrows b-.

– Screw in locking ring - VAS 611 007/2- red and blue -B- ap‐
prox. 2 turns. Note colour coding -arrows a- and -arrows b-
when doing this.
– Screw in lock ring - VAS 611 007/2- -B- max. 2 turns by hand.
– Make sure that the shaft is free to move.
• Adapter for angle sensor - VAS 611 007/9- and adapter for
angle sensor - VAS 611 007/10- should turn easily.

2.4.2 Installing test tool - VAS 611 007-

Special tools and work‐
shop equipment re‐
quired
♦ Tester for checking
elongation of chain
links - VAS 611 007-
Sealing plugs from repair

kit, part number 1H0 698
311 A
The transportation pro‐
tection for the contact
pins must be fitted to the
hydraulic unit after the
control unit has been dis‐
connected from the hy‐
draulic unit.
No warranty can be as‐
sumed for hydraulic units
without transportation
protection.
1 - Transport protection
for valve contact pin
(foam)
2 - Sealing plug M10
3 - Sealing plug M12
– Preassemble test tool
- VAS 611 007-
⇒ “2.4.1 Preassem‐
bling test tool VAS
611 007 ”, page 139 .
– Teach-in test tool -
VAS 611 007- elec‐
tronically and perform
basic setting
⇒ “2.4.3 Teaching-in
test tool VAS 611 007
electronically and
performing basic set‐
ting”, page 147
– Turn adapter for an‐
gle sensor - VAS 611
007/9- and adapter
for angle sensor -
VAS 611 007/10- until
display is set to ap‐
prox. 0°.

– Remove resonator
for intake air
⇒ “2.3 Removing and
installing resonator
for intake air”,
page 324 .
– Remove air pipe
installing air pipe”,
page 308 .
– Remove connection
for turbocharger
installing connection
for turbocharger”,
page 299 .
– Set piston for cylinder
no. 1 to TDC position
⇒ “4.7 Setting piston
to TDC position”,
page 119 .
– Drain coolant
⇒ “1.3 Draining and
adding coolant”, page
227 .

– Remove cover for thermostat housing -1-.

– Unclip wiring harness -3- and place to one side.

– Place a cloth underneath to catch any oil which may drain out.
– Take off cap -5-.
– Pull off pipe -2-.
– Remove toothed belt cover -4-.
Polo 2014 LHD vehicles:
– Remove brake master cylinder ⇒ Brake system; Rep. gr. 47 ;
Brake servo/brake master cylinder; Removing and installing
brake master cylinder .
– Make sure that the piston in cylinder no. 1 is at TDC position
– Make sure that brakes on angle sensor - VAS 611 007/1- are
released on both sides ⇒ page 141 .
Note
Before positioning the test tool - VAS 611 007- against the cam‐
shaft housing, the grooves of the camshafts must be checked for
damage.
– Align adapter for angle sensor -E- by hand with grooves of

camshafts -arrows-.
– Check proper alignment through recess, and adapt position by
turning.

– Fit adapter for camshaft housing - VAS 611 007/8- -D- to cam‐
shaft housing, and slide it on.
– Tighten knurled screws -arrows a- alternately by hand.
– Make sure that adapter for camshaft housing - VAS 611 007/8-
-D- is properly seated.
Note
♦ If camshaft housing adapter - VAS 611 007/8- -D- touches the

housing of the coolant pump, the basic setting of the coolant
pump is incorrect.
♦ In this case, correct adjustment or testing of the valve timing
is not possible.
♦ The coolant pump must be removed and readjusted
• Test tool - VAS 611 007- must rest flush against camshaft
housing.
– Make sure that brakes on angle sensor - VAS 611 007/1- are
released on both sides ⇒ page 141 .
– Tighten locking ring - VAS 611 007/2- -B- on both sides evenly
by hand. When doing this, ensure that camshaft housing
adapter - VAS 611 007/8- -D- always lies flat against camshaft
housing -1-.
• Camshaft housing adapter - VAS 611 007/8- -D- should not lift
off of camshaft housing -1-.
Note
The correct preload is achieved when the camshaft housing

adapter - VAS 611 007/8- lies flat -a- against the camshaft hous‐
ing.

– Make sure that brakes -a- are released on both sides.
2.4.3 Teaching-in test tool - VAS 611 007-

electronically and performing basic set‐
ting
– Connect electronic measuring equipment of test tool - VAS
611 007- ⇒ Operating manual .
– Perform software installation of test tool - VAS 611 007- ⇒
Operating manual .
– Start test program ⇒ Operating manual .
If angle sensors are not connected, message shown in illustration
is displayed.
– Connect test tool - VAS 611 007- , and press CONNECT .
If test tool - VAS 611 007- is connected, display is as shown:

ANW - Exhaust camshaft, red
ENW - Inlet camshaft, blue

– Turn adapter for angle sensor - VAS 611 007/10- red -E- for
exhaust camshaft.
If »OK« is displayed, teach-in of exhaust camshaft is successful.
– Turn adapter for angle sensor - VAS 611 007/9- blue -E- for
inlet camshaft.
If display is as shown in illustration, exhaust camshaft has been

taught-in.
– Select function MEASURE .
If display is as follows:
– Check valve timing
⇒ “2.6 Checking valve timing”, page 154 .
– Make sure that brake indicator on display is green.

• It must not be yellow or red.
A - Green, brake is released
B - Yellow, brake is applied
C - Red, brake has been tightened to torque


equipment required
♦ Torque wrench - VAS 6583-

♦ Counterhold - T10172- with adapter -T10172/1-
♦ Special wrench - T10499-
♦ Insert tool - T10500-
Removing
– Set piston in cylinder no. 1 to TDC position
– Remove vibration damper
– Remove front toothed belt guard
page 139 .
– Remove lower toothed belt guard
page 139 .
– Remove plug, and loosen securing bolt of camshaft adjuster
on inlet side by approx. one turn

⇒ “3.3 Removing and installing camshaft adjuster”,

page 172 .
– Loosen securing bolt of toothed belt pulley on exhaust side by
approx. one turn
⇒ “3.4 Removing and installing toothed belt pulley”,
page 176 .
– Loosen securing bolt of tensioning roller -1- using insert tool,
13 mm - T10500- .
– Release tension on tensioning roller at eccentric -2- using
wrench - T10499- .
– Remove toothed belt.
– Detach crankshaft pulley -1- -arrow-.

NOTICE
Risk of damage to toothed belt by bending it excessively. The
toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
– Never bend toothed belt to a radius less than r = 25 mm.
– Fit toothed belt -1- together with crankshaft pulley -2- onto
crankshaft journal.
• Milled surface of crankshaft sprocket -arrow- must be posi‐

tioned on milled surface of crankshaft stub.
• Contact surface between poly V-belt pulley and crankshaft
toothed belt pulley must be free of oil and grease.
– Renew bolt -1- for camshaft adjuster on inlet side, and screw
it in to stop by hand.
– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in to stop by hand.
• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.

• Metal tab -arrow- of tensioning roller must engage in recess in

cylinder head.
Fit toothed belt in prescribed sequence:

– Pull toothed belt upwards and fit on idler pulley -1-, tensioning
roller -2- and camshaft toothed belt pulleys -3- and -4-.

– Rotate eccentric -2- of tensioning roller using special wrench,

30mm -T10499- in -direction of arrow- until adjustment pointer
-3- is located approx. 10 mm to the right from adjustment win‐
dow.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ When setting specified torque on torque wrench - VAS 6583- ,
length must be entered in torque wrench.
– Hold eccentric in that position, and tighten bolt -1- to 25 Nm

using insert tool - T10500- and torque wrench - VAS 6583-
⇒ “2.2 Assembly overview - toothed belt”, page 137 .
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviations do not affect the
toothed belt tension or the timing.
– Install lower toothed belt guard

page 139 .
– Install vibration damper
– Tighten camshaft adjuster on inlet camshaft to specified initial
torque
⇒ Fig. ““Tightening camshaft adjuster of inlet camshaft to
specified initial torque”“ , page 175 .
– Tighten toothed belt sprocket of exhaust camshaft to specified
initial torque
⇒ Fig. ““Tightening toothed belt pulley for exhaust camshaft to
specified initial torque:”“ , page 178 .
– Check valve timing
⇒ “2.6 Checking valve timing”, page 154 .
– Adjust valve timing ⇒ “2.7 Adjusting valve timing”, page 156 .
– Tighten camshaft adjuster on inlet camshaft to specified final
torque
specified final torque”“ , page 175 .
final torque
specified final torque:”“ , page 178 .
Further assembly is carried out in the reverse order of removal.
Specified torques:
• ⇒ “1.1 Assembly overview - poly V-belt drive”, page 84
• ⇒ “2.1 Assembly overview - toothed belt cover”, page 136
• ⇒ “2.2 Assembly overview - toothed belt”, page 137
• ⇒ Fig. ““Plug for TDC drilling in cylinder block - specified tor‐
que”“ , page 138

• ⇒ “1.2 Assembly overview - camshaft housing”, page 125

• ⇒ “3.1 Assembly overview - crankcase breather system”, page
212
• ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 235
• ⇒ “1.1 Assembly overview - turbocharger”, page 293
• ⇒ “2.1 Assembly overview - charge air system”, page 302
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
2.6 Checking valve timing

– Preassemble test tool - VAS 611 007-
⇒ “2.4.1 Preassembling test tool VAS 611 007 ”, page 139 .
– Install test tool - VAS 611 007-
⇒ “2.4.2 Installing test tool VAS 611 007 ”, page 143 .
– Make sure that brakes -a- are released on both sides.

– Make sure that brake indicator on display is green -A-.

• It must not be yellow or red.
– Unscrew locking pin - T10340- -A-.

– Turn crankshaft 2 turns in direction of rotation of engine.
– Screw in locking pin - T10340- -A-.
– Set piston for cylinder no. 1 to TDC position
– Read valve timing angles on display, and compare values with

specifications.
Specifications
Inlet camshaft Exhaust camshaft
-1.5° ±1.5° +1.0° ±1.5°
NOTICE
Adjust valve timing as precisely as possible. The settings must
be as close to the specifications as possible.
The valve timing must not be outside the tolerance limits.
– If necessary, adjust timing

⇒ “2.7 Adjusting valve timing”, page 156 .


– Add coolant ⇒ “1.3 Draining and adding coolant”, page 227 .
Polo 2014:
– Moisten sealing plugs with brake fluid before pressing brake
fluid reservoir into brake master cylinder.
– Bleed brake system ⇒ Brake system; Rep. gr. 47 ; Hydraulic
system .
Specified torques
page 235
♦ ⇒ Brake system; Rep. gr. 45 ; Control unit and hydraulic unit;
Assembly overview - control unit and hydraulic unit
♦ ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder, Assembly overview - brake servo/brake master cylinder
Bolt for TDC hole 30 Nm
in cylinder block
2.7 Adjusting valve timing

• Toothed belt installed.
– Check valve timing ⇒ “2.6 Checking valve timing”, page 154 .

– Do not relieve tension from toothed belt, and do not remove

toothed belt from camshafts when adjusting valve timing. Only
loosen camshaft adjuster.
– Loosen camshaft adjuster on inlet side
⇒ Fig. ““Loosening camshaft adjuster on inlet side:”“ ,
page 173 .
– Loosen toothed belt sprocket on exhaust side
⇒ Fig. ““Loosen toothed belt pulley for exhaust camshaft”“ ,
page 177 .
NOTICE
– Place a cloth under the camshaft adjusters and over tension‐

ing roller to catch the engine oil which runs out.
• The contact points between the toothed belt and components
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.
• Catch any engine oil which runs out immediately, and remove
it.
• Remove engine oil at camshaft adjusters.
– Renew bolt -1-, and screw it in loosely
page 172 .
– Renew bolt -2-, and screw it in loosely
page 176 .
• It should still be possible to turn the camshaft adjuster and
toothed belt sprocket on the camshafts.
Setting camshafts to »0°«:

– Make sure that bolts -a- for brakes are released on both sides.

– Make sure that the brake indicator on the display is »green«

-A-.
– Display must not be »yellow« or »red«.
– Set both camshafts to »0.0°«.
– To do this, turn camshafts with adapter for angle sensor - VAS

611 007/5- -E-.
– Hold camshafts via adapter for angle sensor - VAS 611 007/9-
and adapter for angle sensor - VAS 611 007/10- -E- in »0.0°«
position with a wrench.
Note
♦ The camshafts tend to turn.

♦ Use a hexagon key to hold the camshafts in 0.0° position.
♦ Always remove the hexagon key after the camshafts have
been tightened.
– Tighten brakes after adjustment has been completed.

– Tighten bolts -a- for brakes to 11 Nm on both sides.

– Make sure that the brake indicator on the display is »red«

-C-.
– Display must not be »yellow« or »green«.

torque
initial torque
– Make sure that bolts -a- for brakes are released on both sides.


-A-.
– Seal camshaft adjuster -2- using suitable plugs -A- from en‐
gine bung set - VAS 6122- .
– Fit a piece of paper -A- into plugs to catch the engine oil.
– Insert plugs into camshaft adjusters with the open side facing
towards front, as shown in illustration.
Determining correction angle
– Screw in locking pin - T10340- .
– Read valve timing on display and write down values.
1st measurement example: value read-off display
Note
♦ The correction angle is determined for each individual vehicle.

♦ The value read after the engine has been cranked is used for
determining the correction angle.
♦ Note the algebraic signs of the values.
♦ The correction angle results from the difference between the
specification and the value which has been read after the
crankshaft has been cranked twice.
♦ The correction angle is used to adjust the valve timing.
♦ The difference between the actual value (read after 2 full rev‐
olutions of the engine) and the specification is calculated.
♦ The result is the correction angle to be set, with the corre‐
sponding algebraic sign/direction of rotation.

Example
Index Explanation
e Inlet camshaft - actual value (after 2 full revolutions
of the engine)
f Inlet camshaft - specification (+/- tolerance)
c Direction of correction (+/-)
d Correction value - correction angle
a Exhaust camshaft - actual value (after 2 full revolu‐
tions of the engine)
b Exhaust camshaft - specification (+/- tolerance)
Angle in ° Inlet camshaft Exhaust camshaft

Specified angle -1.5°±1.5° +1.0°±1.5°
– Set determined correction angle for camshafts.

Setting valve timing with correction angle
– Place a cloth underneath camshaft adjuster to catch any en‐
gine oil which runs out.
– Remove plug taken from engine bung set - VAS 6122- from
camshaft adjuster.
– Remove paper from plugs and camshaft adjusters.
– Clean camshaft adjusters with a cleaning cloth and remove as
much engine oil as possible.
– Loosen camshaft adjuster on inlet side
page 173 .
– Loosen camshaft sprocket on exhaust side
⇒ Fig. ““Loosen toothed belt pulley for exhaust camshaft”“ ,
page 177 .
NOTICE

– Make sure that bolts -a- for brakes on test tool - VAS 611 007-
are released on both sides.


-A-.
– Set the two camshafts to the determined correction angle

⇒ page 160 .
– To do this, turn camshafts with adapter for angle sensor - VAS
611 007/9- and adapter for angle sensor - VAS 611 007/10-
-E-.
If the valve timing has been set:

– Tighten bolts -a- for brakes on test tool - VAS 611 007- to
11 Nm on both sides.

– Make sure that brake indicator on display is red -C-.

– Display must not be »yellow« or »green«.

torque
initial torque
– Release brakes -a- on both sides.


-A-.
– Seal camshaft adjusters -1- and -2- using suitable plugs -A-
from engine bung set - VAS 6122- .
– Fit a new piece of paper into plugs -A- to catch the engine oil.
– The plug for the camshaft adjuster -1- on exhaust side must
be pushed in slightly.
– Screw in locking pin - T10340- .
NOTICE
Adjust valve timing as precisely as possible. The settings must
be as close to the specifications as possible.
The valve timing must not be outside the tolerance limits.
– Read valve timing, and compare it with specifications.
Specified angle in °
Inlet camshaft Exhaust camshaft
-1.5° ±1.5° +1.0° ±1.5°
– If the valve timing is not OK, adjust valve timing again

⇒ “2.7 Adjusting valve timing”, page 156 .
– Unscrew locking pin - T10340- .
– Make sure that brakes on test tool - VAS 611 007- are released
on both sides.
torque
final torque


Specified torques
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 137
page 235
♦ ⇒ Brake system; Rep. gr. 45 ; Control unit and hydraulic unit;
Assembly overview - control unit and hydraulic unit
♦ ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder, Assembly overview - brake servo/brake master cylinder
2.8 Removing toothed belt from camshaft

equipment required

♦ Counterhold - T10172- with adapter -T10172/1-


– Loosen securing bolt of camshaft adjuster on inlet side by ap‐
prox. one turn
page 172 .
– Loosen securing bolt of toothed belt pulley on exhaust side by
approx. one turn
page 176 .
– Loosen securing bolt of tensioning roller -1- using insert tool,
13 mm - T10500- .
– Release tension on tensioner at eccentric -2- using wrench -
T10499- .
– Remove toothed belt from camshaft pulleys.
Installing
NOTICE
If the radius/diameter is not reached, the toothed belt could be‐
come damaged.
– The toothed belt is made of glass fibre fabric.
– Never kink any toothed belts, regardless of whether they are
used or new.
– The bend radius -r- of the toothed belt -2- may therefore
never exceed 25 mm. Approx. half of pulley diameter -1- on
crankshaft ⇒ page 166 .
Note

♦ Renew O-ring or plug if damaged ⇒ Electronic parts cata‐
logue .

• Metal tab -arrow- of tensioning roller must engage in recess in

cylinder head.
Fit toothed belt in prescribed sequence:
– Pull toothed belt upwards and fit on idler pulley -1-, tensioning
roller -2- and camshaft toothed belt pulleys -3- and -4-.

– Using special wrench 30 mm - T10499- , turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to the right
of adjustment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ When setting specified torque on torque wrench - VAS 6583- ,
length must be entered in torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm.

To do this, use insert tool, 13 mm - T10500- with torque wrench
- VAS 6583-
⇒ “2.2 Assembly overview - toothed belt”, page 137 .
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviation does not affect the
toothed belt tension or the timing.

torque
initial torque
torque
final torque
Further assembly is carried out in the reverse order of removal.
Specified torques
page 235

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 169
⇒ “3.2 Measuring axial play of camshaft”, page 171
⇒ “3.4 Removing and installing toothed belt pulley”, page 176
⇒ “3.5 Removing and installing camshaft oil seal”, page 178
⇒ “3.6 Removing and installing camshaft control valve 1 N205 ”,
page 185
⇒ “3.7 Removing and installing valve stem seals”, page 185
3.1 Assembly overview - valve gear
1 - Inlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 195
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 194
2 - Outlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 195
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 194
3 - Cylinder head
4 - Valve stem seal
❑ Renewing
stalling valve stem
seals”, page 185
5 - Valve springs
⇒ Fig. ““Installation po‐
sition of valve spring”“ ,
page 170
6 - Valve spring plate
7 - Valve cotters
8 - Roller rocker fingers
⇒ “1.4 Removing and installing camshaft housing”, page 131
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.
9 - Retaining clip
❑ For hydraulic compensation element.
3. Valve gear 169

10 - Hydraulic compensation element

❑ Do not interchange
❑ Oil contact surface
Installation position of valve spring

• -a- points to valve spring plate.
• -b- points to cylinder head.

3.2 Measuring axial play of camshaft

quired
♦ Universal dial gauge
holder - VW 387-
♦ Dial gauge - VAS

6079-
Checking camshaft axial

clearance
– Remove camshaft
housing
installing camshaft
housing”, page 131 .
– Secure dial gauge -
VAS 6079- with uni‐
versal dial gauge
bracket - VW 387- to
camshaft housing as
– Press camshaft
against dial gauge by
hand.
– Set dial gauge to “0”.
– Press camshaft away
from dial gauge and
read off value:
Axial clearance:
• Wear limit: 0.25 mm.
3. Valve gear 171

3.3 Removing and installing camshaft ad‐

juster
Camshaft adjuster for inlet camshaft
♦ Counter-hold tool - T10554/1-
♦ Knurled screws - T10554/2- (not illustrated)

♦ Counter-hold tool - T10172A-
Preparing tools
– Bolt on counter-hold tool - T10172- and counter-hold tool -
T10554/1- using knurled screws - T10554/2- -arrows-.

Fitting counter-hold tool - T10554-

• The contours of pins -1- and -2- of counter-hold tool -
T10554/1- are not distributed evenly on the bolt circle.
• They correspond to the contour of the bolt circle in the cam‐
shaft adjuster.
– Remove upper toothed belt guard
page 139 .
Note
♦ Place a cloth under the camshaft adjuster and tensioning roller

to catch the engine oil which runs out.
♦ The contact points between the toothed belt and components
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.
Loosening camshaft adjuster on inlet side:

– Fit counter-hold tool - T10554- with counter-hold tool -
T10172- to camshaft pulley -1- as shown in illustration.
– The pins must be inserted properly into holes -arrows-.
– Fit counter-hold tool - T10554- so that it rests flat against cam‐
shaft adjuster -1-.
– Hold inlet camshaft in position using counter-hold tool -
T10554- and counter-hold tool - T10172- .
– Loosen plug -1-, and unscrew it.

– Place a cloth underneath to catch engine oil.
3. Valve gear 173

– Fit counter-hold tool - T10554- with counter-hold tool -

T10172- again, to loosen securing bolt -1- of camshaft adjust‐
er.
– Loosen bolt -1- of camshaft adjuster -2-.
– Loosen securing bolt of toothed belt pulley on exhaust side
page 176 .
Removing camshaft adjuster of inlet camshaft:
– Detach toothed belt from camshafts.
– Unscrew securing bolt -1- of camshaft adjuster, and remove
camshaft adjuster -2-.
– Use a cleaning cloth to remove engine oil from camshaft and
camshaft housing.
Installing
• Set piston in cylinder no. 1 to TDC position
Note
♦ Before installing the camshaft adjuster, ensure that the guide

sleeve is inserted in the camshaft.
♦ Check O-ring of plug for damage, and renew if necessary; see
⇒ Electronic parts catalogue (ETKA) .
screw it in loosely to stop by hand.
– Fit toothed belt onto camshafts ⇒ page 166 .

Tightening camshaft adjuster of inlet camshaft to specified initial

torque
– Before pre-tightening, unscrew locking pin - T10340- .
– Hold inlet camshaft in position using counter-hold tool -
T10554- and counter-hold tool - T10172- .
– Pre-tighten bolt -1- to specified pre-tightening torque in two
stages.
Stage Securing bolt for camshaft Specified torque and
adjuster turning further angle
1. -1- 18 Nm
2. -1- 50 Nm
– Tighten toothed belt sprocket for exhaust camshaft in 2 stages
to specified initial torque
Tightening camshaft adjuster of inlet camshaft to specified final

torque
– Screw locking pin - T10340- back in.
– Tighten bolt -1- for camshaft adjuster.
Stage Securing bolt for camshaft Specified torque and
adjuster turning further angle
3. -1- 50 Nm +135°
– Tighten toothed belt sprocket for exhaust camshaft to speci‐
fied final torque
– Screw in plug -1-, and tighten it to specified torque.

– When doing this, hold inlet camshaft in position using counter-
hold tool - T10172A- and counter-hold tool - T10554- .
Stage Plug for camshaft adjuster Specified torque
1. -1- 20 Nm
Installing
Further assembly is performed in the reverse order of removal.
Specified torques
♦ ⇒ “3.1 Assembly overview - crankcase breather system”, page
212
page 235
3. Valve gear 175


pulley
Toothed belt pulley for exhaust camshaft
♦ Counter-hold tool - T10172A-
– Remove upper toothed belt guard
page 139 .


Loosen toothed belt pulley for exhaust camshaft
– Loosen bolt -1- approx. one turn using counter-hold tool -
T10172- with adapter -T10172/2- and -T10172/1- .
Remove toothed belt pulley for exhaust camshaft:
– Loosen camshaft adjuster of inlet camshaft
page 173 .
– Detach toothed belt from camshafts.
⇒ “2.8 Removing toothed belt from camshaft”, page 165
– Unscrew bolt for toothed belt pulley on exhaust side, and re‐
move toothed belt pulley.
Installing
• Set piston in cylinder no. 1 to TDC position
Note
♦ Before installing the camshaft adjuster, ensure that the guide

sleeve is inserted in the camshaft.
♦ Check O-ring of plug for damage, renew if necessary; see ⇒
Electronic parts catalogue (ETKA) .
– Fit toothed belt onto camshafts ⇒ page 166 .
3. Valve gear 177

Tightening toothed belt pulley for exhaust camshaft to specified

initial torque:
– Tighten inlet camshaft -2- to specified initial torque
– Hold exhaust camshaft -1- in position using counter-hold -
T10172- and adapter - T10172/1- .
– Pre-tighten bolt -1- to specified pre-tightening torque in two
stages.
Stage Securing bolt for toothed Specified torque
belt pulley
1. -1- 18 Nm
2. -1- 50 Nm
Tightening toothed belt pulley for exhaust camshaft to specified

final torque:
– Tighten inlet camshaft -2- to specified final torque
– Tighten securing bolt -1- for toothed belt pulley on exhaust side
to specified final torque.
Stage Securing bolt for toothed Angle to turn bolts
belt pulley
1. -1- 50 Nm +90°
Further assembly is performed in the reverse order of removal.
Specified torques:
• ⇒ “2.1 Assembly overview - toothed belt cover”, page 136
• ⇒ “2.2 Assembly overview - toothed belt”, page 137
• ⇒ “1.2 Assembly overview - camshaft housing”, page 125
• ⇒ “3.1 Assembly overview - crankcase breather system”, page
212
• ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 235
• ⇒ “2.1 Assembly overview - charge air system”, page 302
3.5 Removing and installing camshaft oil

seal
⇒ “3.5.1 Removing and installing camshaft oil seal for inlet cam‐
shaft, belt pulley end”, page 178
⇒ “3.5.2 Removing and installing exhaust camshaft oil seal, pulley
end”, page 180
⇒ “3.5.3 Removing and installing exhaust camshaft oil seal, gear‐
box end”, page 182
3.5.1 Removing and installing camshaft oil

seal for inlet camshaft, belt pulley end

♦ Assembly tool - T10478 B-
Removing
Note
♦ The illustrations may show the exhaust side.

♦ However, perform the procedure in the same way on the inlet
side.
– Remove camshaft adjuster on inlet side

page 172 .
– Remove seal -1- using extractor hook -T20143/1- .
Installing
Note
3. Valve gear 179

– Fit seal -1- over fitting sleeve -T10478/3- onto guide sleeve -
T10478/2- .
– Separate fitting sleeve and guide sleeve.
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
– Draw in seal to stop using thrust piece -T10478/1A- and »old«

bolt -1- for camshaft pulley.
– Install camshaft adjuster.
3.5.2 Removing and installing exhaust cam‐

shaft oil seal, pulley end

♦ Assembly tool - T10478 B-
Removing
– Remove toothed belt pulley.
page 176
– Remove seal -1- using extractor hook -T20143/1- .
Installing
Note
3. Valve gear 181

T10478/2- .
– Fit guide sleeve -T10478/2- with oil seal -1- to camshaft.
– Pull in thrust piece -T10478/1A- with bolt -T10478/5- as far as

stop.
– Install toothed belt (adjust valve timing)
3.5.3 Removing and installing exhaust cam‐

shaft oil seal, gearbox end

♦ Assembly tool - T10479 A-
Removing
– Remove toothed belt pulley for coolant pump
⇒ “2.7 Removing and installing toothed belt pulley for coolant
pump”, page 250 .
Note


– Carefully fit extractor hook -T20143/1- between camshaft and
seal -1-.
– Lever out seal.
Installing
Note
3. Valve gear 183

T10479/2- .
– Fit guide sleeve -T10479/2- with oil seal -2- centrally to cam‐
shaft.
– Secure guide sleeve onto camshaft using bolt -1- for coolant
pump drive sprocket.
– Push seal onto camshaft and unbolt guide sleeve.
– Draw in seal -2- to stop using thrust piece -T10479/1- and bolt
-1- for toothed belt pulley for coolant pump.
– Install toothed belt pulley for coolant pump
pump”, page 250 .

3.6 Removing and installing camshaft con‐

trol valve 1 - N205-
Removing
– Unscrew bolt -2- and remove camshaft control valve 1 -
N205- .
Installing
Note
♦ Check O-ring for damage.

♦ If it is damaged, renew it together with camshaft control valve
1 - N205- .
♦ The O-ring cannot be renewed individually.
Specified torques
♦ Specified torque
⇒ “1.2 Assembly overview - camshaft housing”, page 125
3.7 Removing and installing valve stem

seals
⇒ “3.7.1 Removing and installing valve stem seals (cylinder head
installed)”, page 185
⇒ “3.7.2 Removing and installing valve stem seals (cylinder head
removed)”, page 189
3.7.1 Removing and installing valve stem

seals (cylinder head installed)
♦ Spark plug socket - 3122 B-
3. Valve gear 185

♦ Removal and installation device for valve cotters - VAS 5161A-

with guide plate - VAS 5161A/32- .
♦ Valve stem seal fitting tool - 3365-
♦ Valve stem pliers - VAS 6770-
♦ Adapter - VAS 5161A/35- (not shown)

Golf SV
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Removing and installing
bulkhead .

– Unscrew bolts -arrows-, and remove oil supply line -1-.

– Remove camshaft housing
page 131 .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐

sation element -4- and valves -3- for reinstallation.
– Unscrew spark plugs with spark plug socket - 3122 B- .
– Unscrew locking pin - T10340- .

– Set piston of respective cylinder to “bottom dead centre”.
Note
♦ The pistons of cylinders no. 1 and no. 4 are at »TDC« position

after the camshaft housing has been removed.
♦ The pistons of cylinders no. 2 and no. 3 are at »bottom dead
centre« position after the camshaft housing has been re‐
moved.
♦ Crank engine via crankshaft half a turn in direction of engine
rotation. The pistons for cylinders no. 1 and no. 4 are at »bot‐
tom dead centre« position.
♦ When cranking the engine, hold and guide the toothed belt by
hand to prevent it from being damaged.
3. Valve gear 187

– Fit guide plate -VAS 5161A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Screw adapter - VAS 5161A/35- into the respective spark plug
thread hand-tight.
– Connect adapter to compressed air supply using a commer‐
cially available union and apply pressure continuously.
• Minimum pressure: 6 bar.
– Insert punch -VAS 5161/3A- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and
insert cartridge into guide plate -VAS 5161A/32-3- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and move to side.
• The compressed air hose remains connected.
– Remove valve spring and valve spring plate.
– Pull off valve stem seal using valve stem pliers - VAS 6770- .

– Lightly oil sealing lip of valve stem seal -A-.

– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Insert valve spring and valve spring plate. For installation po‐
sition of valve spring refer to
⇒ Fig. ““Installation position of valve spring”“ , page 170 .
If valve cotters have been removed from assembly cartridge:

– First, insert valve cotters into insertion device - VAS 5161 A/
32-3- .
– Press down spring washer until 3 grooves are visible.
– Fit valve cotters into grooves.
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge - VAS 5161A/32-2- onto insert tool
- VAS 5161A/32-3- from above, and pick up valve cotters.
– Bolt guide plate -VAS 5161A/32- onto cylinder head again.

– Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS
5161A/32-3- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Installing
Assemble in the reverse order, observing the following.
– Install camshaft housing
page 131 .
Specified torques
3.7.2 Removing and installing valve stem

seals (cylinder head removed)
3. Valve gear 189

♦ Removal and installation device for valve cotters - VAS 5161A-

with guide plate - VAS 5161A/32- .
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Valve stem pliers - VAS 6770-

♦ Valve stem seal fitting tool - 3365-
– Remove cylinder head
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.

– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
– Fit guide plate -VAS 5161A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Insert punch -VAS 5161/3A- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
3. Valve gear 191

– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and
insert cartridge into guide plate -VAS 5161/32-3- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and move to side.
– Remove valve spring and valve spring plate.
– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Note
Risk of damage when installing valve stem seals.
– Lightly oil sealing lip of valve stem seal -A-.

– Carefully press valve stem oil seal -A- onto valve guide using
valve stem seal fitting tool - 3365- .
– Insert valve spring and valve spring plate. For installation po‐
sition of valve spring refer to
⇒ Fig. ““Installation position of valve spring”“ , page 170 .

If valve cotters have been removed from assembly cartridge:

– First, insert valve cotters into insertion device - VAS 5161 A/
32-3- .
– Press down spring washer until 3 grooves are visible.
– Fit valve cotters into grooves.
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge - VAS 5161A/32-3- onto insert tool
from above and pick up valve cotters.
– Bolt guide plate -VAS 5161A/32- onto cylinder head again.

– Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS
5161A/32-3- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
– Install cylinder head
3. Valve gear 193

4 Inlet and exhaust valves

⇒ “4.1 Checking valve guides”, page 194
⇒ “4.2 Checking valves”, page 194
⇒ “4.3 Valve dimensions”, page 195
4.1 Checking valve guides

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
Test sequence
– Insert valve in guide. Valve stem end must be flush with guide.
On account of differing stem diameters, only use inlet valve in
inlet valve guide and exhaust valve in exhaust valve guide.
– Determine rock.
• Wear limit: 0.5 mm.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be exchanged.
4.2 Checking valves

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

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

∅a mm 26.5 23.5
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30
4. Inlet and exhaust valves 195

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 196
⇒ “1.2 Engine oil:”, page 200
⇒ “1.3 Removing and installing sump”, page 201
⇒ “1.4 Removing and installing oil pump”, page 206
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 209
1.1 Assembly overview - sump/oil pump
Note
♦ Large quantities of swarf or metal particles found when per‐

forming repairs to the engine could indicate that the crankshaft
bearings or conrod bearings are damaged. To avoid any sub‐
sequent damage, the following work must be carried out fol‐
lowing the repair: Carefully clean oil channels and renew oil
spray jets, engine oil cooler and oil filter.
♦ Oil spray jet and pressure relief valve
⇒ “4.6 Removing and installing oil spray jets”, page 118 .
196 Rep. gr.17 - Lubrication

1 - Dipstick
❑ Oil capacities
⇒ “1.2 Engine oil:”, page
200
❑ Minimum and
⇒ Fig. ““Markings on oil
dipstick”“ , page 199
2 - Cap
3 - Breather valve
❑ Observe installation po‐
sition
4 - O-ring
❑ Renew
❑ Moisten with oil before
installing
5 - Shield
❑ For oil separator
6 - Oil pressure switch for re‐
duced oil pressure
❑ Screw in by hand 3 full
turns
❑ 20 Nm
❑ Checking
⇒ “4.3 Checking oil
pressure and oil pres‐
sure switch”, page 218
stalling oil pressure
switch for reduced oil
pressure F378 ”,
page 217
7 - Sump
❑ Removing and installing ⇒ “1.3 Removing and installing sump”, page 201
8 - Oil filter
❑ 20 Nm
❑ Moisten seal with oil before installing
❑ Renew oil filter if outer surface is damaged
❑ If connecting union for oil filter in sump became loose
⇒ Fig. ““Tightening connecting union for oil filter”“ , page 200
9 - Seal
❑ Renew
10 - Oil level and oil temperature sender - G266-
⇒ “1.5 Removing and installing oil level and oil temperature sender G266 ”, page 209
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ Specified torques and tightening sequence
⇒ Fig. ““Sump (one-piece design) – specified torque and tightening sequence”“ , page 199
13 - Seal
❑ Renew
1. Sump, oil pump 197

Note
New procedure for all other service

types
⇒ Fig. ““Oil drain plug with renewa‐
ble seal (all future oil change serv‐
ices)”“ , page 200 .
14 - Oil drain plug

❑ Renew
Note
Needs to be renewed only on 1st oil

change after assembly in factory
⇒ Fig. ““Oil drain plug with captive
seal (factory-installed)”“ ,
page 199 .
❑ 30 Nm
15 - Suction line
16 - Bolt
❑ 8 Nm
17 - Bolt
❑ For tensioning device.
❑ Renew
❑ 20 Nm +90°
18 - Seal
❑ Renewing ⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”, page 95
❑ For oil pump drive.
19 - Bolt
❑ Renew
❑ Specified torques ⇒ page 208
20 - Oil pump
❑ Removing and installing ⇒ “1.4 Removing and installing oil pump”, page 206
21 - Seal
❑ Renew
❑ Note guide pins for proper positioning

Sump (one-piece design) – specified torque and tightening se‐

quence
1. -1 … 19- Screw onto stop by hand
2. -1 … 19- 8 Nm +90° further
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: Can be topped up with engine
oil.
c - Area from min. mark up to hatched field: top up, max. 0.5 l of
engine oil!
Oil drain plug with captive seal (factory-installed)

– On first oil change, oil drain plug with captive seal -1- is dis‐
posed of.
– Install new oil drain plug -3- with renewable seal -2-.

Oil drain plug with renewable seal (all future oil change services)
– Unscrew oil drain plug -2-, and dispose of old seal -3-.
– New oil seal -1- can be renewed individually when oil is
changed in the future.
Tightening connecting union for oil filter

• If the connecting union -2- in the top section of sump -1- is
loose, retighten it as described below.
Use only the two nuts -3 and 4- for this procedure.
• Hexagon nuts - 068 115 723- , qty. 2 ⇒ Electronic Parts Cata‐
logue
– Screw nuts -3- and -4- onto connecting union -2-, and coun‐
terlock them.
– Tighten connecting union -2- using nut -3-.
– Loosen the two nuts and remove them, taking care not to
loosen the connecting union.
Specified torque
Connecting union Specified torque
-2- 50 Nm
1.2 Engine oil:

Engine oil specification and oil capacities
Oil capacities ⇒ Maintenance ; Booklet “Capacities and specifi‐
cations”
Engine oil specifications ⇒ Maintenance ; Booklet “Capacities
and specifications”
Changing engine oil: ⇒ Maintenance ; Booklet “Engine oil: drain”.
Note
♦ After adding oil, always check correct oil level on oil dipstick
⇒ Fig. ““Markings on oil dipstick”“ , page 199 .
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter! Markings
⇒ Fig. ““Markings on oil dipstick”“ , page 199 .

1.3 Removing and installing sump

quired
♦ Oil filter tool - 3417-
♦ Multi-point bit -
T10058-
♦ Torque wrench -
V.A.G 1331-
♦ Wedges - T10383/2-

♦ Applicator gun - VAS

6966-
♦ Hand drill with plastic

brush
♦ Flat scraper (not illus‐
trated)
♦ Silicone sealant ⇒
logue
Cutting tool - T10561-
1- Bolt
2- Washer
3- Bracket
4- Knife
5- Guide
6- Handle
7- Inserts for support
(rod) for conver‐
sion of handle
8- Bolt
9- Support
Removing
– Drain engine oil.
– Remove oil filter with
oil filter tool - 3417- .
Only vehicles with air
conditioner
Note
♦ The air conditioning

system lines must not
be opened.
♦ Prevent damage to
condenser and refrig‐
erant lines and ho‐
ses.
♦ Do NOT stretch, kink
or bend lines and ho‐
ses.


installing poly-V belt”,
page 88 .
– Remove air condi‐
tioner compressor: ⇒
Heating, air condi‐
tioning; Rep. gr. 87 ;
Air conditioner com‐
pressor; Removing
and installing air con‐
ditioner compressor .
– Secure air condition‐
er compressor to lock
carrier.
Make sure lines are not
kinked.
– Remove securing bolts -arrows- for gearbox.
– Unscrew sump securing bolts on gearbox side -arrows- using

Allen key, long reach 5 mm - T10058- .
– Pull off connector for oil level and oil temperature sender -
G266-
⇒ “1.5 Removing and installing oil level and oil temperature
sender G266 ”, page 209 .
– Unscrew sump securing bolts -arrows-.

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

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

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

– Position cutting tool - T10561- on seal -arrows- without it cant‐
ing.
– Drive in cutting tool - T10561- -3- using a rubber hammer as

far as it will go -arrow-.
– Do not cant cutting tool - T10561- when doing this.
– Do not cutting tool - T10561- sideways.
– Do not lever with cutting tool - T10561- .
– Perform procedure at other points as described until sump is
detached.
– Use wedge - T10383/2- to detach further.
– Insert wedge - T10383/2- at detached points where possible.
– Using a plastic hammer carefully drive in wedge.
– Carefully detach sump (bottom section) from adhesive bond.
– Fit wedge - T10383/2- at another position and detach the bon‐
ded joint in the same way.
– Carefully lever off sump from cylinder block at recess -arrow-

using assembly lever.
– Remove sump. Loosen sump with light blows of a rubber
headed hammer if necessary.
– Remove sealant residues from cylinder block with a flat scra‐
per.

– Remove sealant residues on sump with a rotating brush, e.g.

an electric drill with plastic brush attachment (wear eye pro‐
tection).
– The sealing surfaces must be free of oil and grease.
Installing
Note
♦ Observe use-by-date of sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ The sump can be positioned more easily and more securely if
M6 studs are screwed into the cylinder block flange at two po‐
sitions as guides.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

3 mm).

– Use applicator gun - VAS 6966- to apply bead of sealant

-arrow- to clean sealing surface of bottom section of sump.
– Apply silicone sealant to clean sealing surface of sump as
shown.
Sealant bead must be:
♦ 2 to 3 mm thick
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealing compound bead cannot be thicker, or excessive seal‐

ing compound will enter the sump and may block the oil suction
pipe strainer.
– Fit sump immediately and lightly tighten all sump securing

bolts.
– Tighten new sump bolts to specified torque
⇒ Fig. ““Sump (one-piece design) – specified torque and tight‐
ening sequence”“ , page 199 .
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.
– Fill oil filter with engine oil and tighten it with oil filter tool -
3417- .
– Replenish engine oil.
Engine oil capacity ⇒ “1.2 Engine oil:”, page 200 .
– Install air conditioner compressor: ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
Install poly V-belt
Further assembly is basically a reverse of the dismantling se‐
quence.
Specified torques
♦ ⇒ Fig. ““Sump (one-piece design) – specified torque and tight‐
ening sequence”“ , page 199
torques for gearbox
1.4 Removing and installing oil pump

Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
– Remove toothed belt
– Remove sump

– Unscrew securing bolts -arrows- and remove tensioning ele‐

ment.
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove crankshaft oil seal on belt pulley end
page 95 .
– Unscrew oil pump securing bolts -1- and -2-.

– Pull oil pump in a straight line off dowel pins on cylinder block.
– Remove gasket -1- from dowel pins -arrows-.

Installing
– Fit new gasket -1- onto dowel pins -arrows-.

– Rotate oil pump gear to a position where 2 opposing notches

-arrows- are aligned vertically.
– Fit oil pump onto dowel pins.
Specified torques
– Tighten new securing bolts -1- to 8 Nm + turn 90° further.
– Tighten securing bolts -2- to 20 Nm.

– Install new crankshaft oil seal on belt pulley end
page 95 .
– Install sump
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Mount tensioning element using new securing bolts -arrows-

and tighten to 20 Nm + turn 90° further.
– Install toothed belt

1.5 Removing and installing oil level and oil

temperature sender - G266-
Removing
Removing
• Engine oil drained ⇒ Maintenance ; Booklet .
– Unscrew bolts -1- and remove oil level and oil temperature
sender - G266- -item 4-.
Installing
Note
Renew oil seal -2-. Moisten seal with oil before installing.
– Replenish engine oil, and check oil level ⇒ Maintenance ;

Booklet .
Specified torques

2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 210
⇒ “2.2 Removing and installing engine oil cooler”, page 210
2.1 Assembly overview - engine oil cooler
1 - Engine oil cooler

❑ Observe notes
view - sump/oil pump”,
page 196
stalling engine oil cool‐
er”, page 210
❑ Renew coolant after re‐
placing
2 - Bolt
❑ Renew
❑ 8 Nm +90°
3 - Oil seals
❑ Renew
2.2 Removing and installing engine oil cool‐

er
Removing
– Drain coolant

– Unscrew bolts -arrows- and detach engine oil cooler -1-.

Installing
– Insert new O-rings.
– Install intake manifold
– Add coolant ⇒ page 233 .
Specified torques:
♦ ⇒ “2.1 Assembly overview - engine oil cooler”, page 210
2. Engine oil cooler 211

3 Crankcase ventilation
⇒ “3.1 Assembly overview - crankcase breather system”,
page 212
⇒ “3.2 Removing and installing oil separator”, page 213
3.1 Assembly overview - crankcase breather system
1 - Hose
❑ For crankcase ventila‐
tion.
2 - Cover
❑ For oil separator
3 - Oil separator
stalling oil separator”,
page 213
❑ Renew if damaged
4 - O-ring
❑ Renew
❑ Moisten with oil before
installing
5 - Union
❑ Check for correct posi‐
tioning
6 - Hose
tion.
7 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
Oil separator - specified torque and sequence

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

3.2 Removing and installing oil separator

♦ Applicator gun - VAS 6966-
♦ Commercially available sealant remover

♦ Sealant ⇒ Electronic Parts Catalogue
Removing
– Unscrew bolts -arrow- and push charge air cooling pump -
V188- to one side.
– Pull off crankcase breather hose -3-.

– Release fasteners -2- -arrow- on cover -1- for oil separator and
detach cover.
3. Crankcase ventilation 213

– Loosen and unscrew bolts in the sequence -9 to 1-.

– Carefully release oil separator from bonded joint.
Installing
Note
♦ Danger of soiling lubrication system.

♦ Cover open parts of engine.
– Thoroughly clean sealing surfaces on cylinder block and on oil

separator using commercially available sealant remover.
– Remove any oil and grease from sealing surfaces.
– Screw 2 studs a few turns into holes -arrows-.
Note
Observe use-by date of sealant.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

1.5 mm).
Note
♦ Risk of blocking lubrication system with excess sealant.

♦ Do not apply sealant bead thicker than specified.
– Apply bead of sealant -arrow- onto clean sealing surface of oil

separator using applicator gun - VAS 6966- as illustrated.
• Width of sealant bead: 2 mm.
The oil separator must be installed within 5 minutes after applying
the sealant.

– Fit oil separator onto studs, and position it on crankcase.

– Unscrew studs.
– Tighten bolts to specified torque observing specified tightening
sequence.
⇒ Fig. ““Oil separator - specified torque and sequence”“ , page
212
tion .
Specified torques:
♦ ⇒ Fig. ““Oil separator - specified torque and sequence”“ , page
212
♦ ⇒ “2.2 Assembly overview - electric coolant pump”,
page 238
3. Crankcase ventilation 215

4 Oil filter, oil pressure switch

⇒ “4.1 Assembly overview - oil filter/oil pressure switch”,
page 216
⇒ “4.2 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 217
⇒ “4.3 Checking oil pressure and oil pressure switch”,
page 218
⇒ “4.4 Removing and installing oil filter housing”, page 219
4.1 Assembly overview - oil filter/oil pressure switch
1 - Oil filter
❑ Observe notes
⇒ Maintenance ; Book‐
let
❑ 20 Nm
❑ If connecting union for
oil filter in sump became
loose
⇒ Fig. ““Tightening con‐
necting union for oil fil‐
ter”“ , page 217
duced oil pressure - F378-
❑ Switch pressure 0.3 to
0.6 bar
❑ Insulation, green
❑ Checking
⇒ “4.3 Checking oil
pressure and oil pres‐
sure switch”, page 218
pressure F378 ”,
page 217
❑ 20 Nm
3 - Seal
❑ Must be renewed after
removal of oil pressure
switch ⇒ Electronic
parts catalogue
Note
♦ The oil pressure switch is fitted

with a captive seal.
♦ The seal is not designed for re‐
peated use.

Tightening connecting union for oil filter

• If the connecting union -2- in the top section of sump -1- is
loose, retighten it as described below.
Use only the two nuts -3 and 4- for this procedure.
• Hexagon nuts - 068 115 723- , qty. 2 ⇒ Electronic Parts Cata‐
logue
– Screw nuts -3- and -4- onto connecting union -2-, and coun‐
terlock them.
– Tighten connecting union -2- using nut -3-.
– Loosen the two nuts and remove them, taking care not to
loosen the connecting union.
Specified torque
Connecting union Specified torque
-2- 50 Nm
4.2 Removing and installing oil pressure

switch for reduced oil pressure - F378-
♦ Articulated wrench, 24 mm - T40175-
4. Oil filter, oil pressure switch 217

Removing
– Pull activated charcoal filter solenoid valve 1 - N80- -3- off in‐
take manifold and push it downwards slightly.
– Place a cloth underneath to catch escaping engine oil.
– Unscrew oil pressure switch for reduced oil pressure - F378-
-1-.
– Snip off encapsulated seal, renew seal.
Installing
Note
To prevent larger quantities of oil from escaping, screw the new

oil pressure switch for reduced oil pressure - F378- immediately
into the hole.
– Check oil level ⇒ Maintenance ; Booklet .

Specified torque
♦ Tighten oil pressure switch for reduced oil pressure - F378-
⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page
216 .
4.3 Checking oil pressure and oil pressure

switch
♦ Oil pressure tester - V.A.G 1342-
• Oil level OK. Checking ⇒ Maintenance ; Booklet .
• Engine oil temperature at least 80°C (radiator fan must have
run once)
– Remove oil pressure switch for reduced oil pressure - F378-
⇒ “4.2 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 217 .

Note
♦ The oil pressure switch is fitted with a captive seal.

♦ The seal is not designed for repeated use. The seal must be
renewed after each removal.
oil pressure F378 ”, page 217
– Screw oil pressure tester - V.A.G 1342- into hole for oil pres‐
sure switch.
– Screw oil pressure switch for reduced oil pressure - F378- into
hole in oil pressure tester - V.A.G 1342- in order to seal hole.
– Start engine.
• Oil pressure at idling speed: at least 0.6 bar.
• Oil pressure at 2000 rpm: at least 1.5 bar.
• Minimum oil pressure at 4,500 rpm: 2.8 bar.
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
If no fault is found:
– Renew oil pump
⇒ “1.4 Removing and installing oil pump”, page 206 .
Check oil pressure switch for reduced oil pressure - F378-
(brown):
– Switch off engine.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive and
oil pressure switch for reduced oil pressure - F378- using ca‐
bles from auxiliary test set - V.A.G 1594C- .
• LED must not light up.
– If LED lights up, renew oil pressure switch for reduced oil
pressure - F378- .
If LED does not light up:
– Start engine. At 0.3 to 0.6 bar the LED must light up. Other‐
wise, renew oil pressure switch
oil pressure F378 ”, page 217 .
4.4 Removing and installing oil filter housing

4. Oil filter, oil pressure switch 219

♦ Oil filter tool - 3417-
Removing
– Drain engine oil.
– Remove oil filter -arrow- with oil filter tool - 3417- .
Installing
– Fill oil filter with engine oil and moisten seal with oil.
– Tighten oil filter to specified torque of 20 Nm using oil filter tool
- 3417- .
• If connecting union for oil filter in sump became loose
⇒ Fig. ““Tightening connecting union for oil filter”“ , page 217
– Fill engine oil ⇒ “1.2 Engine oil:”, page 200 .

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 221
⇒ “1.2 Checking cooling system for leaks”, page 225
⇒ “1.3 Draining and adding coolant”, page 227
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses”, page 221
⇒ “1.1.2 Connection diagram - coolant hoses, vehicles with en‐
gine preheating element Z97 ”, page 224
1.1.1 Connection diagram - coolant hoses

Vehicles up to June 2013
Note
♦ Small coolant circuit: »blue«

♦ Large coolant circuit: »red«
♦ Charge air coolant circuit: »green«
♦ Coolant circuit for auxiliary heater (only for vehicles with auxiliary heater): »brown«
♦ The arrows point in the direction of coolant flow.
♦ Vehicles manufactured as of June 2013 are fitted with a modified coolant pump. Observe amended con‐
nection diagram ⇒ page 222 .
1. Cooling system/coolant 221

1 - Coolant expansion tank

2 - Cap
❑ For coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 227
3 - Cylinder head/cylinder
block
placing
4 - Turbocharger
5 - Integrated exhaust manifold
6 - Heat exchanger for heater
placing
7 - Radiator outlet coolant -
G62-
8 - Coolant pump
❑ With thermostat hous‐
ing
10 - Radiator outlet coolant
11 - Radiator for engine cool‐
ant
placing
12 - Charge air cooling pump -
V188-
13 - Radiator for charge air
cooling circuit
❑ Renew coolant after replacing
14 - Charge air cooler in intake manifold
15 - Auxiliary heater
❑ Optional equipment
Vehicles from June 2013 ►
222 Rep. gr.19 - Cooling


2 - Cap
tank
valve ⇒ page 227
block
placing
4 - Turbocharger
placing
G62-
8 - Coolant pump
ing
11 - Radiator for engine cool‐
ant
placing
V188-
13 - Radiator for charge air
cooling circuit

1.1.2 Connection diagram - coolant hoses, vehicles with engine preheating ele‐
ment - Z97-
Note
♦ Small coolant circuit: »blue«

♦ Large coolant circuit: »red«
♦ Charge air coolant circuit: »green«
♦ Coolant circuit for auxiliary heater (only for vehicles with auxiliary heater): »brown«
♦ The arrow on the coolant pipes and coolant hoses must align.

2 - Cap
tank
valve ⇒ page 227
block
placing
4 - Engine preheating element
- Z97-
❑ If fitted
5 - Turbocharger
placing
G62-
stalling coolant temper‐
ature sender G62 ”,
page 251
9 - Coolant pump
ing
12 - Radiator for engine coolant
13 - Charge air cooling pump - V188-
❑ Removing and installing ⇒ “2.4 Removing and installing electric coolant pump”, page 241

14 - Radiator for charge air cooling circuit

1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
Note
To perform the leakage test correctly, first run a self-test on the

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

Self-test of cooling system tester - V.A.G 1274 B-

– Operate cooling system tester - V.A.G 1274 B- several times.
– Build up a pressure of 3.0 bar on cooling system tester .

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

– Open sealing cap of coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Place cooling system tester - V.A.G 1274 B- on adapter for
cooling system tester - V.A.G 1274/8- .
– Build up pressure of approx. 1.5 bar using hand pump of cool‐
ing system tester.
• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops by more than 0.2 bar, locate and rectify
leaks.
Note
The pressure drop of 0.2 bar within 10 minutes depends on the

how far the coolant can cool down. The colder the engine, the
lower the pressure drop. If necessary, repeat the check while the
engine is cold.
Check pressure relief valve in cap.
Note
The cap may have a different shape depending on the model

year.
– Screw cap -1- into adapter for cooling system tester - V.A.G
1274/9- -2-.
– Connect adapter for cooling system tester - V.A.G 1274/9- to
cooling system tester - V.A.G 1274 B- using connecting hose
supplied.
– Build up pressure using hand pump of cooling system tester.
Blue cap
♦ The pressure relief valve must open at a pressure of 1.4 bar.
Black cap
♦ The pressure relief valve must open at a pressure of 1.6 to
1.8 bar.
If the pressure relief valve opens prematurely:
– Renew cap.
1.3 Draining and adding coolant


equipment required
♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Safety glasses
♦ Safety gloves

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

Draining
CAUTION

– Open filler cap -arrow- of coolant expansion tank.
Golf Cabriolet, Polo:

– Carefully open filler cap -1- on coolant expansion tank -2- in
-direction of arrow-.
sulation .
– Disconnect connector -2- from radiator outlet coolant temper‐
ature sender - G83- -3-.
– Pull out retaining clip -1-, remove lower left coolant hose from
radiator and drain off coolant.

Golf, Golf Estate, SV, Touran, Golf Cabriolet version 1:

– Release retaining clip -arrow-, remove lower right coolant
hose from radiator for charge air cooling circuit and drain off
remaining coolant.
Golf, Golf Estate, SV, Touran version 2:

– Pull out retaining clips -1, 2-. Remove lower right coolant ho‐
ses from water radiator and remove radiator for charge air
cooling circuit.
– Drain coolant from radiator.
Polo:
– Pull hoses -1- off water radiator for charge air cooling circuit
-2-.
– Open spring-type clip -arrow- and pull off coolant hose down‐
wards.
– Drain coolant from radiator.
Filling

Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use 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
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- or refractometer - T10007B-
must be used to determine the current anti-freeze value.
♦ The scale -1- of the refractometer is calibrated for the coolant
additives G12++ and G12evo.
♦ The scale -2- of the refractometer is calibrated for the coolant
additive G13.
♦ If it is not possible to ensure that the same type of coolant
additive is filled: always determine anti-freeze protection using
the scale for G13.
♦ Frost protection must be guaranteed down to -25°C as a min‐
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.
♦ The temperature reading on the refractometer corresponds to
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

Frost Coolant additive Coolant ad‐ Distilled wa‐
protection to concentration ditive 1) ter 1)
-25°C 40% 3.2 l 4.8 l
-36°C 50% 4.0 l 4.0 l
1)The quantity of coolant can vary depending on the vehicle
equipment.
• Coolant: ⇒ Electronic Parts Catalogue .

– Connect coolant hoses ⇒ Fig. ““”“ , page 264 .
– Fill coolant reservoir of -VAS 6096- with at least 10 litres of

pre-mixed coolant in correct mixture ratio:
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
– Place cooling system charge unit - VAS 6096- on adapter -
V.A.G 1274/8- .
– Feed vent hose -2- into a small container -3-.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 to 10 bar.
– Open valve -B-; turn lever in direction of flow to do this.

• The suction-jet pump reduces pressure in the cooling system
to below atmospheric pressure. The needle on the gauge
should move into the green zone.
– Also briefly open valve -A- (turn lever in direction of flow to do
this) so that hose on -VAS 6096- coolant reservoir fills with
coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• The suction-jet pump will continue generating a vacuum in the
cooling system. The needle on the gauge must remain in the
green zone.
– Close valve -B-.
• The needle on the gauge must stay in the green zone. The low
pressure in the cooling system is then sufficient for subse‐
quent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ If the vacuum drops, the cooling system must be checked for
leaks.
– Pull off compressed air hose.

– Open valve -A-.
• Vacuum in cooling system causes coolant to be extracted from
-VAS 6096- coolant reservoir and coolant system to be filled.
– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank.

Coolant level:
– Fill coolant up to “max.” mark.
tion .
– Tighten cap of coolant expansion tank until it engages.
– Start engine and run alternately at approx. 1500 rpm to max‐
imum of 2800 rpm until radiator fan starts operating.
– Switch off engine and let it cool off.

– Screw adapter for cooling system tester - V.A.G 1274/8- again
onto expansion tank.
– Use cooling system tester - V.A.G 1274 B- to apply a pressure
of 1 bar to the cooling system.
– Use tester to relieve pressure and remove cooling system
tester - V.A.G 1274 B- .
– With the engine running, fill coolant up to approx. 5 mm

-arrow- above “max. mark”.
• When the engine is cold, the coolant level must be between
the min. and the max. markings.
• The coolant level can be at or above the max. mark when the
engine is at operating temperature.
Golf Cabriolet, Polo:

– Fill coolant up to max. mark.
tion .
– On vehicles with auxiliary heater, switch on auxiliary heater for
about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in the button must not light up.
– Tighten cap of coolant expansion tank until cap engages.
– Start engine and run alternately at approx. 1500 rpm to max‐
imum of 2800 rpm until radiator fan starts operating.
– Switch off engine and let it cool off.

– Screw adapter for cooling system tester - V.A.G 1274/8- again

onto expansion tank.
– Use cooling system tester - V.A.G 1274 B- to apply a pressure
of 1 bar to the cooling system.
– With the engine running, fill coolant up to approx. 5 mm above
max. mark.
• When the engine is cold, the coolant level must be between
the min. and the max. markings.
• The coolant level can be at or above the max. mark when the
engine is at operating temperature.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 235
⇒ “2.2 Assembly overview - electric coolant pump”, page 238
⇒ “2.3 Assembly overview - coolant temperature sender”,
page 240
⇒ “2.5 Removing and installing coolant pump”, page 243
pump”, page 250
⇒ “2.6 Removing and installing thermostat”, page 248
⇒ “2.4 Removing and installing electric coolant pump”,
page 241
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 251
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 252
⇒ “2.10 Removing and installing radiator fan thermal switch F18
”, page 252
2.1 Assembly overview - coolant pump, thermostat
2. Coolant pump, regulation of cooling system 235

1 - Thermostat housing
stalling thermostat”,
page 248
❑ Observe tightening se‐
quence when tightening
to coolant pump
stalling coolant pump”,
page 243 .
2 - Thermostat
❑ For cylinder block cool‐
ant circuit
❑ Up to 07.2016: Starts to
open at approx. 87 °C
❑ From 07.2016 onwards:
Starts to open at approx.
97 °C
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue .
installing thermostat for
cylinder block coolant
circuit”, page 249
3 - Seal
❑ Renew
❑ Ensure proper seating
of seal
❑ Lightly coat with coolant
before installing.
4 - Coolant pump
❑ Vehicles manufactured
as of June 2013 are fitted with a modified coolant pump ⇒ page 221
❑ Removing and installing ⇒ “2.5 Removing and installing coolant pump”, page 243
❑ If coolant pump is renewed, also renew toothed belt
5 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified torque.
⇒ Fig. ““Thermostat housing to coolant pump - specified torque and sequence”“ , page 238
6 - Seal
❑ Renew
❑ Ensure proper seating of seal
❑ Lightly coat with coolant before installing.
7 - Toothed belt guard
❑ For toothed belt for coolant pump
8 - Bolt
❑ Renew
❑ 20 Nm +90°
9 - Toothed belt

❑ For coolant pump drive
❑ Removing and installing ⇒ “2.5 Removing and installing coolant pump”, page 243
10 - Crankshaft
❑ For coolant pump drive
⇒ “2.7 Removing and installing toothed belt pulley for coolant pump”, page 250
❑ Before removing, set No. 1 cylinder to TDC.
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ Thread-cutting
⇒ Fig. ““Cover for thermostat to thermostat housing - specified torque”“ , page 238
13 - Cover
❑ For thermostat
14 - Seal
❑ Renew
❑ Lightly coat with coolant before installing.
15 - Thermostat
❑ For main coolant circuit (radiator)
❑ Up to 11.2012: Starts to open at approx. 80°C
❑ As of 11.2012: Starts to open at approx. 87°C
⇒ “2.6.1 Removing and installing thermostat for main coolant circuit”, page 248
❑ Fitting position ⇒ Fig. ““Installation position of thermostat for large cooling circuit”“ , page 237
16 - Bolt
❑ Specified torque and tightening sequence ⇒ page 247
Installation position of thermostat for large cooling circuit

• Must be positioned with centring pin in guide -arrow- in ther‐
mostat housing.

Thermostat housing to coolant pump - specified torque and se‐

quence
– Tighten bolts in sequence -A- through -F-.
1. -A … F- 8 Nm
Cover for thermostat to thermostat housing - specified torque

– Tighten bolts for cover -1- in sequence -A- to -D-.
1. -A … D- 8 Nm
2.2 Assembly overview - electric coolant pump


V188-
❑ with holder
stalling electric coolant
pump”, page 241
2 - Coolant hose
3 - Bolt
❑ 8 Nm
4 - Coolant hose

2.3 Assembly overview - coolant tempera‐

ture sender
⇒ “2.3.1 Assembly overview - coolant temperature sender, Golf,
Golf Estate, Golf SV, Touran, Golf Cabriolet”, page 240
⇒ “2.3.2 Assembly overview - coolant temperature sender, Polo”,
page 241
2.3.1 Assembly overview - coolant temperature sender, Golf, Golf Estate, Golf
SV, Touran, Golf Cabriolet
1 - O-ring
2 - Radiator outlet coolant tem‐
perature sender - G83-
stalling radiator outlet
coolant temperature
sender G83 ”,
page 252
3 - Support ring
4 - O-ring
G62-
page 251
6 - Bolt
❑ 8 Nm
7 - Retaining clip
❑ Check for firm seating

2.3.2 Assembly overview - coolant temperature sender, Polo
1 - Radiator fan thermal switch

- F18-
installing radiator fan
thermal switch F18 ”,
page 252
❑ 35 Nm
2 - O-ring
3 - Radiator/cooler
radiator
stalling radiator”,
page 268
4 - Bolt
❑ 8 Nm
G62-
page 251
6 - Support ring
7 - O-ring
2.4 Removing and installing electric coolant

pump
♦ Hose clamps to 25 mm - 3094-

Removing
CAUTION
– Open sealing cap of coolant expansion tank.

sulation .


– Clamp off coolant hoses on charge air cooling pump - V188-
using hose clamps up to 25 mm - 3094- .
– Release hose clip -3- and remove coolant hose.
– Unscrew bolt -2-, and remove charge air cooling pump -
V188- .
Installing
Note
Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .

tion .
– Check coolant level ⇒ page 233 .
Specified torque
page 238
2.5 Removing and installing coolant pump


equipment required
♦ Coolant system charge unit - VAS 6096-

♦ Release tool - T10527- and release tool - T10527/1-

Removing
– Drain coolant
324 .
– Remove air pipe
– Press release buttons and disconnect hose -1- leading to ac‐
tivated charcoal filter.
– Seal all openings in charge and intake air system using plugs
from engine bung set - VAS 6122- .
– Unscrew bolts -arrows- and remove crankcase breather hose.
– Lay wiring harness to one side -arrows-.

– Unscrew bolts -1, 3- and remove cover -2- for toothed belt for
coolant pump.
– Move clear electrical wiring harness -1- and coolant hose -2-.
– Release hose clips -arrows- and detach coolant hoses.

– Open retainer for coolant hose -1-.

– Free coolant hose -2-.
– Loosen and unscrew bolts in the sequence -5- to -1-.

– Detach coolant pump with toothed belt.
– Remove thermostat housing if coolant pump is being renewed
⇒ “2.6 Removing and installing thermostat”, page 248 .
Installing
Note
♦ Renew gaskets -arrows-.

♦ If coolant pump is being renewed, renew toothed belt as well.
♦ Secure hose connections with hose clips of the same standard
as that used during production ⇒ Electronic parts catalogue .
– Ensure proper seating of gaskets -arrows-.

– Lubricate seal for coolant pump lightly with coolant.
Note
♦ Always adhere to the sequence of work steps given below

when installing the coolant pump.
♦ This ensures that the toothed belt is correctly tensioned.
♦ The following work steps must be carried out with the aid of a
2nd mechanic.
♦ The toothed belt for the coolant pump cannot be reused be‐
cause it will no longer develop the necessary pretension.
– Renew the toothed belt of the coolant pump.

– Set No. 1 cylinder to TDC
– Fit toothed belt so that it is centred and move coolant pump
into installation position.
– Mount coolant pump on cylinder head with securing bolts.

– Pre-tightening sequence, coolant pump

1. -1 to 5- Screw onto stop by hand
2. -1 to 5- 10 Nm
– Loosen all bolts again by one turn.
– Apply torque wrench -VAS 6583- with hexagon key (10 mm)
-item 6- to coolant pump.
– Using hexagon on coolant pump, preload coolant pump in
clockwise direction to 30 Nm using 10 mm hexagon socket
-6-, extension and torque wrench - VAS 6583- .
– For ease of use, fit torque wrench - VAS 6583- on vertically.
Note
♦ Do not support torque wrench with your other hand.

♦ To ensure the poly V-belt is not over-tensioned, do not »push
the torque wrench again« after the specified torque has been
achieved.
♦ Have a second mechanic tighten securing bolts -2-, -1- and
-5- to specified torque, while holding the torque wrench - VAS
6583- to the specified torque.
– Pre-load coolant pump.

– While doing this, have a second mechanic pre-tighten secur‐
ing bolts of coolant pump in anti-clockwise direction to »stage
3«.
• By tightening securing bolts -2-, -1- and -5- to specified torque,
the desired belt tension is reached.
• After securing bolts have been tightened initially, torque
wrench - VAS 6583- can be removed.
– Then tighten securing bolts (»stage 4«).
Stage Bolting se‐ Specified torque
quence
3. -2, 1, 5- 10 Nm
4. -3, 4, 5, 1, 2- 12 Nm
Specified torques:
• Securing bolts for crankcase breather hose
⇒ “1.1 Assembly overview - turbocharger”, page 293
• Securing bolts for coolant pump toothed belt guard
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 235
• Coolant pump bolts, »pre-tightening torque« ⇒ page 247
• Securing bolts for battery and battery tray ⇒ Electrical system;
Rep. gr. 27 ; Battery; Assembly overview – battery

2.6 Removing and installing thermostat

⇒ “2.6.1 Removing and installing thermostat for main coolant cir‐
cuit”, page 248
⇒ “2.6.2 Removing and installing thermostat for cylinder block
coolant circuit”, page 249
2.6.1 Removing and installing thermostat for

main coolant circuit

Removing
– Drain coolant.
⇒ “1.3 Draining and adding coolant”, page 227
– Free air hose from air pipe.
– Remove air pipe
– Release hose clip -4- and detach coolant hose -3-.
– Remove bolts -arrows- and detach cover -2- from thermostat
housing -1-.

– Remove thermostat using special wrench - T10508- .

– Slightly push down special wrench - T10508- and turn it in
-direction of arrow- while doing so.
Installing
– Insert thermostat ensuring that the centring pin of thermostat

is seated in guide -arrow-.
– Install thermostat using special wrench - T10508- .

– Slightly push down special wrench - T10508- and turn it to stop
in -direction of arrow- while doing so.
– Renew seals.
– Moisten gasket with coolant.
Specified torques
♦ ⇒ Fig. ““Cover for thermostat to thermostat housing - specified
torque”“ , page 238
2.6.2 Removing and installing thermostat for

cylinder block coolant circuit
Removing
– Unscrew bolts in the sequence -F to A-.
– Detach coolant pump from thermostat housing.

– Detach thermostat -2- from coolant pump -1-.

Installing
– Renew seals.
– Moisten gasket with coolant.
– Fit thermostat housing onto coolant pump.

• Centring pins on thermostat must be fitted in guides -arrows-
on coolant pump.
– Tighten bolts for thermostat housing
⇒ Fig. ““Thermostat housing to coolant pump - specified torque
and sequence”“ , page 238 .
Specified torque
♦ ⇒ Fig. ““Thermostat housing to coolant pump - specified torque
and sequence”“ , page 238

pulley for coolant pump
♦ Counterhold - T10172A- with adapter -T10172/2-
Removing
Note
♦ The toothed belt must be renewed.

♦ The toothed belt for the coolant pump cannot be reused be‐
cause it will no longer develop the necessary pretension.

– Loosen bolt -1- using counterhold - T10172A- with adapters -

T10172/2- .
– Unscrew bolt and remove toothed belt pulley -2-.
Installing
– Fit toothed belt pulley:

• The grooves -1- and -2- in the camshaft are arranged asym‐
metrically.
• Cut-outs -arrows- in toothed belt pulley are also arranged
asymmetrically.
– Fit toothed belt pulley onto camshaft so that the asymmetrical
notches of the camshaft are fully centred within the cut-outs of
the toothed belt pulley.
Specified torque
page 235
2.8 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.
– Briefly open cap of coolant expansion tank to release residual
pressure in cooling system, then tighten again until cap en‐
gages.
– Separate electrical connector:
– Place a cloth underneath to catch escaping coolant.

– Unscrew bolt -1- and pull out coolant temperature sender -

G62- -item 2-.
Note
♦ If O-ring -3- with support ring -4- remains lodged in cylinder

head, lift out O-ring with support ring using a piece of wire.
♦ Insert new coolant temperature sender - G62- immediately in‐
to cylinder head in order to avoid loss of coolant.
Installing
– Renew O-ring.
Specified torque
♦ ⇒ “2.3 Assembly overview - coolant temperature sender”,
page 240
2.9 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.
– Briefly open cap of coolant expansion tank to release residual
pressure in cooling system, then tighten again until cap en‐
gages.
sulation .
– Release and pull off electrical connector -2-.
– Pull off retaining clip -1- and pull radiator outlet coolant tem‐
perature sender - G83- out of connection -3-.
Installing
Note
Insert new coolant temperature sender - G62- immediately into

connection in order to avoid loss of coolant.
– Renew O-ring.
– Install front noise insulation ⇒ General body repairs, exterior;
sulation .
2.10 Removing and installing radiator fan

thermal switch - F18-
Removing
• Engine cold.

– Briefly open cap of coolant expansion tank -1- to release re‐

sidual pressure in cooling system, then tighten again until cap
engages.
sulation .
– Release and pull off electrical connector -2-.

– Unscrew radiator fan thermal switch - F18- -1- from radiator
-3-.
Installing
Note
Insert new radiator fan thermal switch - F18- immediately into

connection in order to avoid loss of coolant.

– Renew O-ring.
– Install front noise insulation ⇒ General body repairs, exterior;
sulation .
Specified torque:
♦ ⇒ “4.1.4 Assembly overview - radiator/radiator fan, Polo”, page
263

3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 254
⇒ “3.2 Removing and installing coolant pipes”, page 254
3.1 Assembly overview - coolant pipes
1 - Coolant hose
2 - Coolant pipe
❑ Clipped onto intake
manifold (bottom)
❑ Carefully lever it out of
catches using a screw‐
driver when removing.
3 - Bolt
❑ 8 Nm
4 - Coolant hose
5 - Coolant hose
6 - Coolant line
manifold (top)
7 - Coolant hose
8 - Coolant hose
Note
The arrows on the coolant pipes and coolant hoses must be

aligned with each other.
3.2 Removing and installing coolant pipes


Removing
CAUTION
– Open cap -arrow-.
3. Coolant pipes 255

– Clamp off coolant hoses on coolant pipe using hose clamps

up to 25 mm - 3094- .
– Release hose clips -arrows- and detach coolant hoses.
– Lay intake manifold -1- on the workbench as shown.

– Place e.g. a block of wood -2- under intake manifold as an
underlay.
Note
To avoid damaging the intake manifold and coolant pipe, this pro‐
cedure must be carried out very carefully!
– Insert a flat-blade screwdriver into the slot -arrow 1-.
– Carefully push flat-blade screwdriver in direction of -arrow 2-

and lift coolant pipe -4- in direction of -arrow 3- until coolant
pipe works free from retainer.
– Continue to lift coolant pipe -1- in direction of -arrow- until

coolant pipe works free of retainer -2-.
Installing

– First push the coolant pipe onto mounting -1- until coolant pipe
engages.
– Then push coolant pipe onto mounting -2- until coolant pipe
engages.
– Check that the coolant pipe has properly engaged by pulling
on it.
Note
♦ Renew seals and O-rings.

♦ Secure all hose connections with correct type of hose clips (as

Specified torque
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 254
3. Coolant pipes 257

4 Radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 258
⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page
265
⇒ “4.3 Removing and installing radiator”, page 268
⇒ “4.4 Removing and installing water radiator for charge air cool‐
ing circuit”, page 276
⇒ “4.5 Removing and installing radiator cowl”, page 285
⇒ “4.6 Removing and installing radiator fan V7 ”, page 290
4.1 Assembly overview - radiator/radiator

fan
⇒ “4.1.1 Assembly overview - radiator/radiator fan, Golf, Golf Es‐
tate, Golf SV, Touran, version 1”, page 258
⇒ “4.1.2 Assembly overview - radiator/radiator fan, Golf, Golf Es‐
tate, Golf SV, Touran, version 2”, page 260
⇒ “4.1.3 Assembly overview - radiator/radiator fan, Golf Cabrio‐
let”, page 261
⇒ “4.1.4 Assembly overview - radiator/radiator fan, Polo”,
page 263
⇒ “4.1.5 Plug-in connectors of coolant hoses”, page 264
⇒ “4.1.6 Coolant hoses with pretensioned spring-type clips”, page
264
4.1.1 Assembly overview - radiator/radiator fan, Golf, Golf Estate, Golf SV, Tour‐
an, version 1


installing radiator, Golf,
Golf Estate, Golf SV,
Touran version 1”, page
268
placing
2 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect
⇒ Fig. ““”“ , page 264
3 - Retaining clip
4 - O-ring
❑ Renew
5 - Radiator outlet coolant tem‐
perature sender - G83-
stalling radiator outlet
coolant temperature
sender G83 ”, page 252
6 - O-ring
❑ Renew
7 - Coolant hose
remove
❑ Connect
⇒ Fig. ““”“ , page 264
8 - O-ring
❑ Renew
9 - Coolant hose
❑ Pull out retaining clip to remove
❑ Connect ⇒ Fig. ““”“ , page 264
10 - Air duct
11 - Air duct
12 - Rubber mounting
❑ For radiator
13 - Radiator for charge air cooling circuit
⇒ “4.4.1 Removing and installing water radiator for charge air cooling circuit, Golf, Golf Estate, SV, Touran
version 1”, page 276
14 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser
❑ For radiator
16 - O-ring
❑ Renew
4. Radiator, radiator fan 259

17 - Coolant hose
18 - O-ring
❑ Renew
4.1.2 Assembly overview - radiator/radiator fan, Golf, Golf Estate, Golf SV, Tour‐
an, version 2
1 - Coolant hose
remove
❑ Connect
⇒ Fig. ““”“ , page 264
2 - O-ring
❑ Moisten with coolant
3 - Radiator for charge air cool‐
ing circuit
installing water radiator
for charge air cooling
circuit, Golf, Golf Estate,
SV, Touran version 2”,
page 280
4 - Coolant hose
remove
❑ Connect
⇒ Fig. ““”“ , page 264
5 - O-ring
6 - Coolant hose
remove
❑ Connect
⇒ Fig. ““”“ , page 264
7 - O-ring
⇒ “4.3.2 Removing and installing radiator, Golf, Golf Estate, Golf SV, Touran version 2”, page 270
9 - Air duct
10 - Air duct
11 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser

❑ For radiator
❑ For radiator
14 - O-ring
15 - Coolant hose
Note
The arrows on the coolant pipes and coolant hoses must be

aligned with each other.
4.1.3 Assembly overview - radiator/radiator fan, Golf Cabriolet
1 - Condenser
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ;
Refrigerant circuit; Re‐
moving and installing
condenser
2 - Radiator mounting
ing circuit
circuit, Golf Cabriolet”,
page 280
4 - Rubber mounting
❑ Bottom of radiator in
lock carrier
5 - Refrigerant line
❑ To condenser
6 - O-ring
❑ For refrigerant line
7 - O-ring
❑ Connection, radiator for
charge air cooling circuit
8 - Retaining clip
❑ Connection for coolant
hose, charge air cooler

9 - Coolant hose
❑ On radiator for charge air cooling circuit
❑ Lift retaining clip to remove
10 - Bolts
❑ 5 Nm
❑ Removing and installing ⇒ “4.3.3 Removing and installing radiator, Golf Cabriolet”, page 272
12 - O-ring
❑ Connection, radiator
13 - Coolant hose
14 - Retaining clip
15 - Coolant hose
16 - O-ring
17 - Retaining clip
18 - Radiator outlet coolant temperature sender - G83-
❑ Removing and installing ⇒ “2.10 Removing and installing radiator fan thermal switch F18 ”, page 252
19 - Coolant hose
❑ On radiator for charge air cooling circuit

4.1.4 Assembly overview - radiator/radiator fan, Polo
❑ Lower radiator mount‐
ing in front end
ing circuit
circuit, Polo”, page 282
3 - Radiator fan thermal switch
- F18-
thermal switch F18 ”,
page 252
❑ Assembly overview
⇒ “2.3.2 Assembly over‐
view - coolant tempera‐
ture sender, Polo”, page
241
❑ 35 Nm
4 - O-ring
5 - Bolt
❑ 5 Nm
❑ Qty. 2
❑ Top
7 - Radiator/cooler
installing radiator, Polo”, page 273
❑ After renewing, renew entire coolant.
8 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 221
9 - Expansion tank
❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling
system tester - V.A.G 1274/8-
10 - Cap
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
❑ Checking ⇒ “1.2 Checking cooling system for leaks”, page 225
11 - Bolt
❑ 2 Nm
❑ Qty. 2
12 - Connector
13 - Radiator cowl with radiator fan - V7-
❑ Assembly overview ⇒ “4.2.3 Assembly overview - radiator cowl and radiator fan, Polo”, page 268
❑ Removing and installing ⇒ “4.5.3 Removing and installing radiator cowl, Polo”, page 288

❑ With radiator fan control unit - J293-
14 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 221
4.1.5 Plug-in connectors of coolant hoses

Connecting coolant hose with plug-in connector:
– Check seal -2- for damage, and renew it if necessary.
– Moisten O-ring with coolant, and insert it into coolant hose.
– Push coolant hose into connection -1- until it audibly engages.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.
4.1.6 Coolant hoses with pretensioned spring-

type clips
♦ Release tool - VAS 531 001-
Open clip:
– Press together spring-type clips using hose clip pliers until clip
engages.
– The clip is now open and coolant hose can be pulled off.
– It is not possible to detach clip from coolant hose.

Close clip:
– Install coolant hose.
– Carefully release pretensioned spring-type clips. Insert re‐
lease tool - VAS 531 001- as shown -1- and engage in direction
of -arrow-.
– Depending on available space, use appropriate release hook.
4.2 Assembly overview - radiator cowl and

radiator fan
⇒ “4.2.1 Assembly overview - radiator cowl and radiator fan, Golf,
Golf Estate, Golf SV, Touran”, page 265
⇒ “4.2.2 Assembly overview - radiator cowl and radiator fan, Golf
Cabriolet”, page 267
⇒ “4.2.3 Assembly overview - radiator cowl and radiator fan, Po‐
lo”, page 268
4.2.1 Assembly overview - radiator cowl and radiator fan, Golf, Golf Estate, Golf
SV, Touran

1 - Bolt
❑ 5 Nm
2 - Radiator cowl
installing radiator cowl,
Golf, Golf Estate, Golf
SV, Touran”, page 285
3 - Radiator fan - V7-
installing radiator fan,
Golf, Golf Estate, Golf
SV, Touran”, page 290

4.2.2 Assembly overview - radiator cowl and radiator fan, Golf Cabriolet
1 - Radiator cowl
Golf Cabriolet”,
page 286
2 - Bolt
❑ Radiator cowl to radiator
❑ 5 Nm
3 - Bolt
❑ 5 Nm
4 - Radiator fan 2 - V177-
Golf Cabriolet”,
page 290
Golf Cabriolet”,
page 290
6 - Bracket
❑ Coupling point
7 - Bolt
❑ 5 Nm
8 - Bolt
❑ 5 Nm

4.2.3 Assembly overview - radiator cowl and radiator fan, Polo
1 - Air guide ring

V7 , Polo”, page 291
3 - Radiator cowl
Polo”, page 288
4 - Nut
❑ 8 Nm
❑ Qty. 3
5 - Bracket
❑ For electrical connector
6 - Connector
❑ For radiator fan - V7- .
7 - Spreader rivet
❑ For securing air guide
ring
❑ Qty. 4
4.3 Removing and installing radiator

⇒ “4.3.1 Removing and installing radiator, Golf, Golf Estate, Golf
SV, Touran version 1”, page 268
SV, Touran version 2”, page 270
⇒ “4.3.3 Removing and installing radiator, Golf Cabriolet”,
page 272
⇒ “4.3.4 Removing and installing radiator, Polo”, page 273
4.3.1 Removing and installing radiator, Golf,

Golf Estate, Golf SV, Touran version 1
Removing
sulation .
– Drain coolant


– Open retainers for refrigerant lines -arrows-.
– Push refrigerant lines to one side.
from radiator.

– Release locking tabs -arrow- for radiator on left and right. Then
pull top of radiator backwards.

– To release, push a suitable screwdriver -A- from behind be‐

tween radiator for engine coolant -2- and radiator for charge
air cooling circuit -1-.
– Position screwdriver -A- as shown but do not lever when doing
so.
– Lift coolant radiator upwards off charge air cooling circuit ra‐
diator.
– Pull radiator out of mountings at bottom.
– Remove radiator downwards.
Installing
Note
If there are minor dents in the fins, refer to respective instructions

⇒ “3.7 Fitting radiator and condensers”, page 6 .
– Check O-rings for damage, and renew them if necessary.

– Insert radiator into mounting at bottom. Engage radiator/cooler
with one another. Ensure proper engagement by pulling.
– Install radiator cowl
– Connect coolant hose with plug-in connector
⇒ Fig. ““”“ , page 264 .
Specified torques
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 258
page 265
4.3.2 Removing and installing radiator, Golf,

Golf Estate, Golf SV, Touran version 2
Note
Radiator and water radiator for charge air cooling circuit are re‐
moved together.
Removing
– Drain coolant
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
– Remove centre guide on lock carrier ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Assembly overview - lock
carrier .


from radiator.
– Unclip air ducts -1- on both sides from lock carrier -2-
-arrows-.
– To do this, release catches -3- in -direction of arrow-, and pull
off air ducts.
– Pull left and right air duct -2- upwards off condenser.
– Release catches on both sides -arrow A- and detach con‐
denser -3- from water cooler for charge air cooling circuit -1-.
– Using a side cutter, release or pinch open fasteners -arrows-

for radiator mounting on left and right. Push radiator at top
slightly towards engine.
Note
The radiator mounting will be reused when reinstalling the radia‐

tor. It will then be bolted to lock carrier. For bolts, refer to ⇒

– Release catches on radiator for charge air cooling circuit -1-

-arrows A-.
– Remove radiator for charge air cooling circuit from radiator for
coolant -2- -arrow B- and detach it -arrow C-.
– Remove both radiators.
Installing
– Renew O-rings after removal.
– Swing charge air cooler into lock carrier. Ensure proper seat‐
ing of radiator mountings in lock carrier.
– Use bolts -arrows- to secure radiator mountings, whose fas‐

teners have been pinched off, to lock carrier. For bolts, refer
to ⇒ Electronic parts catalogue (ETKA) .
Bolts Specified torque
Bolt -arrows- 5 Nm
– Install radiator.
– Install front bumper cover ⇒ General body repairs, exterior;
cover .
⇒ Fig. ““”“ , page 264 .
Specified torques
page 265
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Front bumper;
Removing and installing bumper cover
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier;
Assembly overview - lock carrier
4.3.3 Removing and installing radiator, Golf

Cabriolet

Removing
– Drain coolant
– Release retaining clip -arrow-.
– Pull off coolant hose -1- from top of radiator.
– Unscrew radiator securing bolts -arrows- and remove radiator

-1- downwards.
Installing
– Fill with new coolant ⇒ page 233 .
Specified torques
4.3.4 Removing and installing radiator, Polo
Note
♦ Radiator and charge air cooler are separate components.

♦ Radiator is mounted onto charge air cooler.
♦ Parts of cooling system - body side
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 258 .
Removing
sulation .
– Drain coolant

– Unscrew bolts -arrows- from mounting -1- for air duct.

– Pull out mounting for air duct.
Vehicles with air conditioner:
cover .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier - bringing lock carrier into
service position and moving it back .

– Release and pull off connector -2- on radiator fan thermal
switch - F18- -1-.

– Pull upper coolant hose -1- off radiator -2-.

– Unscrew securing bolts -arrows-.

– Lift radiator out of lower mountings and press it slightly towards
rear.
Vehicles with air conditioning system
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.
Note
♦ There is a risk of damage to the refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Place condenser in lock carrier at front and secure it in place

to prevent it from falling down.
– Removing radiator.
Installing
Note
♦ If there are minor dents in the fins, refer to

♦ Renew O-rings.
– Install front bumper cover ⇒ Rep. gr. 63 ; Front bumper; Re‐

moving and installing bumper cover .
Note
Do not reuse coolant which has been drained off.
Specified torques

4.4 Removing and installing water radiator

for charge air cooling circuit
⇒ “4.4.1 Removing and installing water radiator for charge air
cooling circuit, Golf, Golf Estate, SV, Touran version 1”,
page 276
cooling circuit, Golf, Golf Estate, SV, Touran version 2”,
page 280
cooling circuit, Golf Cabriolet”, page 280
cooling circuit, Polo”, page 282
4.4.1 Removing and installing water radiator

for charge air cooling circuit, Golf, Golf
Estate, SV, Touran version 1
Removing
– Drain coolant
– Removing radiator
⇒ “4.3 Removing and installing radiator”, page 268 .
cover .
– Remove centre guide profile -A- from lock carrier -arrows-.

– Unclip air ducts -1- on both sides from lock carrier -2-
-arrows-.
– Release catches -arrows- of radiator mounting on left and

right, or pinch them off using side cutters. Push radiator at top
slightly towards engine.
Note
The radiator mounting will be reused when reinstalling the radia‐

tor. It will then be bolted to lock carrier. For bolts, refer to ⇒
– Unclip air duct -2- on left and right.

– Release left and right catches -arrow A-, and detach condens‐
er -3- upwards from water radiator for charge air cooling circuit
-1-.
– Tie up condenser on lock carrier.
– Lift water radiator for charge air cooling circuit -1- at bottom
out of radiator mountings -arrows-.
– Remove both radiators.

– If necessary, detach radiator from radiator for charge air cool‐

ing circuit.
– To do this, release catches -arrow-.
Installing
Note
If there are minor dents in the fins, refer to respective instructions

– Check O-rings for damage, and renew them if necessary.
– Insert radiator for charge air cooling circuit -1- at bottom into
radiator mountings -arrows-.
– Attach radiator to radiator for charge air cooling circuit.
– Install sealing strip -1- on right between radiator and condens‐

er -2- as shown -arrow A- and -arrow B-.

– Install sealing strip -1- on left between radiator and condenser

-2- as shown -arrow A- and -arrow B-.
– Fit radiator mountings -1- on left and right onto radiator. When
doing so, note the installation position -arrow-.
– Swing water radiator for charge air cooling circuit into lock
carrier. Ensure proper seating of radiator mountings in lock
carrier.

– Use bolts -arrows- to secure radiator mountings, whose catch‐

es have been pinched off, to lock carrier. For bolts, refer to ⇒
• Specified torque: 5 Nm
– Install front bumper cover ⇒ General body repairs, exterior;
cover .
⇒ Fig. ““”“ , page 264 .
Specified torques
page 265

for charge air cooling circuit, Golf, Golf
Estate, SV, Touran version 2
NOTICE
The radiator for engine coolant version 2 and water radiator for
charge air cooling circuit are removed together
SV, Touran version 2”, page 270 .

for charge air cooling circuit, Golf Cab‐
riolet
Note
♦ Hose connections are secured with spring-type clips. In case

of repair, only use spring-type clips.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.
♦ When installing coolant hoses, position them so they are free
of stress and do not come into contact with other components.
Observe markings on coolant connection and hose.
– Remove noise insulation or skid plate ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Drain coolant
– Remove radiator cowl with radiator fan

cover .
right) from radiator for charge air cooling circuit.
– Undo and remove coolant pump bolts -arrows- of the radiator

support.

Vehicles with air conditioning system

– Undo and remove condenser bolts -arrows-.
– Secure condenser to lock carrier.
Note
Make sure that the coolant lines/hoses are not excessively

stretched, kinked or bent.

– Pull bottom of radiator for charge air cooling circuit out of
mounting.
– Remove radiator for charge air cooling circuit downwards.
Installing
Specified torques
Bolt Specified torque
Threaded connection on 5 Nm
lock carrier
Condenser securing bolts 5 Nm
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Front bumper;
Assembly overview - bumper cover

for charge air cooling circuit, Polo
Note
♦ Radiator and charge air cooler are separate components.

♦ Remove the charge air cooler together with the radiator.
♦ Assembly overview - parts of cooling system, body side
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 258 .


Removing

Note
In order to avoid damage to charge air cooler, 2 mechanics are

needed to disconnect charge air cooler from radiator.
– Insert a wide flat-bladed screwdriver at front and rear into left

catch on water radiator for charge air cooling circuit -1-.
– Open latch by turning screwdriver in -direction of arrow A-.
– In this position, slightly pull water radiator for charge air cooling
circuit -1- on left side in -direction of arrow B- off radiator -2-.
– Lower water radiator for charge air cooling circuit -1- further in
-direction of arrow A-. At the same time, push it in direction of
-arrow B-.
– Detach water radiator for charge air cooling circuit -1- on right
from mounting -arrow- on radiator -2-.
– Remove water radiator for charge air cooling circuit -1- down‐
wards.
Installing

– Insert water radiator for charge air cooling circuit -2- into right
mounting.
– Properly engage water radiator for charge air cooling circuit
-2- in -direction of arrow- in mountings on radiator -1-.
– Check firm seating by pulling on it.
Note
♦ If there are minor dents in the fins, refer to ⇒ page 6 .

♦ Renew O-rings.
– Install front bumper cover ⇒ Rep. gr. 63 ; Front bumper; Re‐

moving and installing bumper cover .
Note
Do not reuse coolant which has been drained off.
Specified torques
page 265
4.5 Removing and installing radiator cowl

⇒ “4.5.1 Removing and installing radiator cowl, Golf, Golf Estate,
Golf SV, Touran”, page 285
⇒ “4.5.2 Removing and installing radiator cowl, Golf Cabriolet”,
page 286
⇒ “4.5.3 Removing and installing radiator cowl, Polo”, page 288
4.5.1 Removing and installing radiator cowl,

Golf, Golf Estate, Golf SV, Touran

CAUTION
Risk of injury to hands caused radiator fan which may start au‐
tomatically at any time.
– Do not grasp into the radiator fan when disconnecting con‐
nector.
Removing
– Release hose clip -1- and detach air intake hose.
– Remove bolt -2- on both sides.
– Unclip air duct at lock carrier and detach.
– Unplug electrical connector -1- for radiator fan (push retainer

to the rear -arrow A- and press down release catch).
– Press locking tabs on left and right sides of radiator cowl
-arrow B- and at the same time lift radiator cowl off radiator.
– Take out radiator cowl from underneath.
Installing
Specified torque

Golf Cabriolet

Removing
– Release spring-type clips -3-, and remove intake hose -1-.
– Unclip cover of intake air duct -2- -arrows-, and remove it.
– Press catches of lower part of intake air duct, and remove in‐
take air duct towards rear.
– Unscrew bolts of air duct on lock carrier -arrows-, and remove

air duct -1-.
CAUTION
Danger of injury; the radiator fans can run at any time.
– Disconnect electrical connectors:
– Remove bolts -1- at top.
Note
The left bolt is located below the coolant union.

sulation .
– Release connector -arrow- and pull off.

– Unscrew bolts -2- from below, and remove radiator cowl down‐
wards.
Installing
Install in reverse order.
Specified torques
page 265
♦ ⇒ “4.1.3 Assembly overview - radiator/radiator fan, Golf Cab‐
riolet”, page 261


Polo
CAUTION
Danger of injury; the radiator fans can run at any time.
– Disconnect electrical connectors:
Removing
– Loosen clamps -3-, and detach intake hose -1-.
– Release retaining lugs -1-, and pull off intake hose -2-.
– Unscrew bolts -arrows- from mounting -1- for air duct.

– Pull out mounting for air duct.
– Release and pull off connector -2- on radiator fan thermal

switch - F18- -1-.
CAUTION
Risk of injury to hands caused radiator fan which may start au‐
tomatically at any time.
– Do not grasp into the radiator fan when disconnecting con‐
nector.

– Disconnect electrical connector -arrow-.
– Open hose guides on cowl -2-.

– Push coolant hose -1- to one side.
– Using a suitable tool, release radiator cowl together with radi‐

ator fan - V7- from locking device.
– Push radiator cowl together with radiator fan - V7- upwards out
of mountings, and remove downwards.
Installing
– Move radiator cowling together with radiator fan - V7- to in‐
stallation position from below.
– Push evenly into all four mountings from above.
• The fan frame must engage audibly on the right and left at the
top.
– Check that it has engaged securely by pulling on it.
Specified torque
♦ ⇒ “4.2.3 Assembly overview - radiator cowl and radiator fan,
Polo”, page 268

4.6 Removing and installing radiator fan -

V7-
⇒ “4.6.1 Removing and installing radiator fan, Golf, Golf Estate,
⇒ “4.6.2 Removing and installing radiator fan, Golf Cabriolet”,
page 290
⇒ “4.6.3 Removing and installing radiator fan V7 , Polo”,
page 291
4.6.1 Removing and installing radiator fan,

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

– Separate electrical connector:
– Unscrew bolts -arrows- and remove radiator fan - V7- .
Installing
Specified torques
page 265
4.6.2 Removing and installing radiator fan,

Golf Cabriolet
Removing
– Separate electrical connector -arrow-.
– Unscrew bolts -1-, and remove radiator fan - V7- .
– Unscrew bolts -2-, and remove radiator fan - V177- .
Installing
Specified torques
page 265

4.6.3 Removing and installing radiator fan -

V7- , Polo
Removing
Note

– Remove connector for radiator fan from retainer.
– Push pins out of spreader rivets -arrows-.
– Carefully lift up fan ring on back of radiator cowling using a

suitable tool.
– Remove fan ring.
– Remove electric cable -1- from cable guide.

– Unscrew nuts -arrows- and remove radiator fan - V7- .
Installing

– Ensure proper seating of spreader rivets -arrows-.

Specified torques
page 265

21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 293
⇒ “1.2 Removing and installing turbocharger”, page 295
⇒ “1.3 Removing and installing charge pressure positioner V465
”, page 298
page 299
1.1 Assembly overview - turbocharger

⇒ “1.1.1 Assembly overview - turbocharger”, page 293
⇒ “1.1.2 Assembly overview - lines on turbocharger”, page 294
1.1.1 Assembly overview - turbocharger
1 - Turbocharger
stalling turbocharger”,
page 295
2 - Bolt
❑ 8 Nm
3 - Connection
4 - O-ring
❑ Before installing, coat
lightly with engine oil.
5 - Seal
6 - Heat shield
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 8 Nm
9 - Bolt/nut
❑ 8 Nm
10 - Nut
❑ 14 Nm
11 - Bolt
❑ 8 Nm +45°
12 - Operating lever
13 - Retaining clip
1. Turbocharger 293
14 - Charge air pressure controller - V465-

❑ Removing and installing ⇒ “1.3 Removing and installing charge pressure positioner V465 ”, page 298
1.1.2 Assembly overview - lines on turbocharger
1 - Oil return line

2 - O-ring
3 - Bolt
❑ 8 Nm
4 - O-ring
5 - Bolt
❑ 9 Nm
6 - Oil supply line
7 - O-ring
8 - Bolt
❑ 8 Nm
9 - Bolt
❑ 5 Nm
10 - O-ring
❑ Check part scope ac‐
cording to ⇒ Electronic
parts catalogue
11 - Hose
❑ For crankcase ventilation.
12 - Bolt
❑ 5 Nm
13 - O-ring
❑ Check part scope according to ⇒ Electronic parts catalogue
❑ Before installing, coat lightly with engine oil.
14 - Turbocharger
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 295
294 Rep. gr.21 - Turbocharging/supercharging

15 - Seal
❑ Renew
16 - Coolant lines
❑ Supply and return
17 - Bolt
❑ 8 Nm
18 - O-ring
19 - Bolt
❑ 8 Nm
1.2 Removing and installing turbocharger


Removing
Note
Attach all heat-shielding sleeves in the same places when instal‐

ling.
• If a mechanical fault is discovered on the turbocharger (e.g. a

destroyed compressor impeller), it is not sufficient to just re‐
new the turbocharger. To avoid any subsequent damage, the
following work must be carried out:
1. Turbocharger 295
• Check air filter housing, air filter element and air inlet hoses
for contamination.
• Check the whole charge air path and charge air cooler for for‐
eign objects.
• If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the charge
air cooler.
– Drain coolant
– Remove bolts -arrows- and detach oil supply line -1- and oil
return line -2-.

verter.
324 .
– Remove air pipe

coal filter.
– Unscrew bolts -arrows- and pull off crankcase breather hose.
Note


page 299 .
– Release hose clip -2- and detach coolant hose.

– Remove bolts -arrows- and pivot coolant lines -1- to right side.
– Unscrew bolts -arrows- and remove bracket with heat shield

-1-.
– Unscrew nuts -arrows- and remove turbocharger.

Installing
1. Turbocharger 297
– Fit screwdriver -2- in recess -arrow- on turbocharger and lever

out seal -1-.
Note
♦ Renew gaskets, O-rings and nuts for securing turbocharger to

cylinder head.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing, run the engine for about 1 minute at idling
speed to ensure that oil is supplied to the turbocharger.
♦ Make sure that engine is not operated at higher speeds at this
point.
– The bolts -arrows- are provided with a coating. These must be

renewed after removal.
Specified torques:
1.3 Removing and installing charge pres‐

sure positioner - V465-
♦ Locking tool - T40265-

Removing
– Pull off securing clip -2- using locking tool - T40265- .
– Remove bolts -arrows- and detach charge pressure positioner
- V465- .
Installing
• Renew securing bolts for charge pressure positioner
-arrows-.
• Renew circlip -2-.
– Adapt engine control unit - J623- to charge pressure positioner
- V465- using ⇒ Vehicle diagnostic tester; “Guided functions”
0001 - Calibration of boost press. actuator -
V465 .
Specified torques
1.4 Removing and installing connection for

turbocharger
♦ Socket Torx T 30 - T10405-
1. Turbocharger 299
♦ Ratchet insert 1/4" - VAS 6234-
♦ Torx bit T 30 - T10573-

324 .
– Remove air pipe

– Release and pull off electrical connectors -1- on coolant tem‐

perature sender - G62- .
– Release and pull off connectors -2- on charge pressure sender
- V465- .
– Lay wiring harness to one side.
– Open hose clip -1- and push coolant hose -2- to one side.
– Remove bolts -arrows- and detach connection -1-.

– Polo: unscrew bolts -arrows- using insert tool - T10572- and
bit TORX T30 - T10573- .
– All other vehicles: use socket T30 - T10405- .
Installing:
Note
Secure all hose connections with hose clips corresponding to the

series equipment ⇒ Electronic parts catalogue .
– Renew seals.
– Before installing, lightly moisten O-rings with clean engine oil.
– If bolts are tightened with insert - T10572- , Torx bit T 30 -
T10573- and torque wrench - V.A.G 1783- , observe torque.
– Set torque wrench - V.A.G 1783- to 4.2 Nm.
Specified torques
1. Turbocharger 301
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 302
⇒ “2.3 Removing and installing charge pressure sender GX26 ”,
page 306
⇒ “2.2 Removing and installing charge air cooler”, page 304
⇒ “2.4 Checking charge air system for leaks”, page 306
⇒ “2.5 Removing and installing air pipe”, page 308
2.1 Assembly overview - charge air system
1 - O-ring
❑ Before installing, lightly
moisten O-ring with
clean engine oil
2 - Union
3 - O-ring
❑ Before installing, lightly
moisten O-ring with
clean engine oil
4 - Air intake pipe
stalling air pipe”,
page 308
5 - Charge air pressure sender
- GX26-
❑ Consisting of
Charge pressure sender
- G31-
Intake air temperature
sender - G42-
stalling charge pressure
sender GX26 ”,
page 306
6 - O-ring
7 - O-ring
❑ Before installing, lightly moisten O-ring with clean engine oil
8 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified torque
❑ 7 Nm
9 - Retaining clip
❑ For air pipe

10 - Throttle valve module - GX3-

❑ Consisting of
Throttle valve module - J338-
Throttle valve drive for electronic power control - G186-
Throttle valve drive angle sender 1 for electronic power control - G187-
❑ Removing and installing ⇒ “3.3 Removing and installing throttle valve module GX3 ”, page 329
11 - O-ring
❑ Before installing, lightly moisten O-ring with clean engine oil
12 - Intake manifold
Removing and installing ⇒ “3.2 Removing and installing intake manifold”, page 327
13 - Seal
14 - Sealing lip
15 - Coolant hose
16 - Hose clamp
17 - Charge air cooler
❑ Removing and installing ⇒ “2.2 Removing and installing charge air cooler”, page 304
❑ Change coolant after renewing
18 - Bolt
❑ Specified torque and tightening sequence ⇒ “3.1 Assembly overview - intake manifold”, page 325
19 - Coolant hose
20 - Hose clamp
21 - Coolant hose
22 - Hose clamp
23 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified torque
❑ 7 Nm
24 - O-ring
❑ Renew
25 - Intake manifold sender - GX9-
❑ Consisting of
Intake air temperature sender 2 - G299-
Intake manifold pressure sender - G71-

❑ Removing and installing ⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 346
26 - Seal
❑ Qty. 4
2. Charge air system 303

2.2 Removing and installing charge air cool‐

er
Removing
– Open clip -1- and push hose -arrow- to one side.
air conditioning; Rep. gr. 87 ; Air conditioner compressor; Re‐
moving and installing air conditioner compressor from and to
bracket .

– Release hose clip -1- and remove coolant hose.

– Unscrew bolts -arrows- and remove charge air cooler.
– Pull charge air cooler -1- evenly towards front (in

-direction of arrow-) out of intake manifold.
Installing
– Fit sealing lip -1- in -direction of arrow- onto charge air cooler
-2-.
– Insert new gasket into groove on intake manifold.
– Tighten bolts -arrows- alternately and diagonally working from

centre outwards.
– Install hose clips -1-.
Note
If there are minor dents in the fins, refer to


– Check coolant level. ⇒ page 233
Specified torques
♦ ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air condi‐
tioning compressor; Removing and installing air conditioning
compressor from bracket

2.3 Removing and installing charge pres‐

sure sender - GX26-
Charge pressure sender - GX26- consists of:
♦ Charge pressure sender - G31-
♦ Intake air temperature sender - G42-
Removing
– Release fasteners -arrows-, and remove charge pressure
sender - GX26- .
Installing
– Renew O-ring.
Note
Alternatively, the charge pressure sender - GX26- can be attach‐

ed with 2 securing bolts ⇒ Electronic parts catalogue . Specified
torque ⇒ page 306 .
Torque
Charge pressure sender - GX26- 3 Nm
2.4 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-

324 .
– Press release buttons and remove hose -1-. Seal hose -1- us‐
ing suitable plugs from engine bung set - VAS 6122- .
Note

– Place a cloth underneath to catch engine oil.

– Unscrew bolts -arrows- and remove crankcase breather hose.
– Seal opening in turbocharger with suitable bung from engine
bung set - VAS 6122- .
– Seal opening in camshaft housing with suitable bung from en‐
gine bung set - VAS 6122- .
– Remove vacuum line. Seal connection on intake manifold us‐

ing a suitable plug from engine bung set - VAS 6122- .
– Seal breather line from activated charcoal filter solenoid valve

1 - N80- -3- to activated charcoal filter with hose clamps up to
25 mm - 3094- .
– Connect adapter - V.A.G 1687/15- with adapter -V.A.G

1687/11- to turbocharger.
– Connect hose -1- of charge air system tester -V.A.G 1687- to
adapter.

Prepare charge air system tester - V.A.G 1687- as follows:

– Completely unscrew pressure regulating valve -2-, close
valves -3- and -4-.
• To turn pressure regulating valve -2-, rotary knob must be
pulled upwards.
– Connect charge air system tester - V.A.G 1687- to com‐
pressed air -1- via commercial adapter.
Note
If there is water in the inspection window, drain it via the drain plug
-6-.
– Open valve -3-.
Note
♦ If pressure is set too high, it may result in damage.

♦ 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
tester - V.A.G 1842- .
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating
instructions
♦ Before removing the adapter, release pressure in the test cir‐
cuit by pulling off hose coupling.
Installing
Note
Renew seal and O-rings.
2.5 Removing and installing air pipe


♦ Release tool - T10527-
♦ Release tool - T10527/1-

Removing
Note
The catch -arrow- for the vacuum hose -1- does not need to be
released for this procedure.
– Move clear air hoses at charge air pipe.
– Release and pull off connector -arrow- of charge pressure

sender - GX26- -1-.
Polo:
– Release hose clips -arrows-, and unclip air duct from mount‐
ings -1-.
– Remove air duct -2-.

Golf Cabriolet:
– Loosen hose clips -3-, and detach air intake hose -1-.

– Open hose clips -arrows-, and remove air hose -1-.

– Release fasteners -arrows- using release tool - T10527- and
release tool - T10527/1-
– Remove air pipe -1-.
Installing
– Renew O-rings.

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 311
1.1 Overview of fitting locations - injection

system
⇒ “1.1.1 Overview of fitting locations - engine compartment, Golf,
Golf Estate, Golf SV, Touran”, page 311
⇒ “1.1.2 Overview of fitting locations - engine compartment, Golf
Cabriolet”, page 314
⇒ “1.1.3 Overview of fitting locations - engine compartment, Polo”,
page 316
⇒ “1.1.4 Overview of fitting locations - front view of engine”, page
318
⇒ “1.1.5 Overview of fitting locations - rear view of engine”, page
319
1.1.1 Overview of fitting locations - engine compartment, Golf, Golf Estate, Golf
SV, Touran
1. Injection system 311


1 - N205-
view - camshaft hous‐
ing”, page 125
2 - Lambda probe 1 before cat‐
alytic converter - GX10-
❑ Consisting of
Lambda probe - G39-
Lambda probe heater -

Z19-
view - Lambda probe”,
page 356
3 - Lambda probe 1 after cata‐
lytic converter - GX7-
❑ Consisting of
Lambda probe after cat‐
alytic converter - G130-
Lambda probe 1 heater

after catalytic converter -
Z29-
page 356
4 - Charge air pressure con‐
troller - V465-
positioner V465 ”, page 298
5 - Engine control unit - J623-
❑ Removing and installing ⇒ “8.1 Removing and installing engine control unit J623 ”, page 360
⇒ “2.9 Removing and installing radiator outlet coolant temperature sender G83 ”, page 252
7 - Hall sender - G40- ()
❑ Assembly overview ⇒ “1.1 Assembly overview - ignition system”, page 408
❑ Consisting of
❑ Assembly overview ⇒ “3.1 Assembly overview - intake manifold”, page 325
9 - Charge air pressure sender - GX26-
❑ Consisting of
Charge pressure sender - G31-
312 Rep. gr.24 - Mixture preparation - injection

Intake air temperature sender - G42-

❑ Assembly overview ⇒ “2.1 Assembly overview - charge air system”, page 302
❑ Consisting of

❑ Assembly overview ⇒ “2.2 Assembly overview - electric coolant pump”, page 238
12 - Ignition coils with output stages
♦ Ignition coil 1 with output stage - N70-
❑ Removing and installing ⇒ “1.2 Removing and installing ignition coils with output stage”, page 409

1.1.2 Overview of fitting locations - engine compartment, Golf Cabriolet

1 - N205-
stalling camshaft control
valve 1 N205 ”,
page 185
❑ Consisting of
Lambda probe - G39-

Z19-
stalling Lambda probe”,
page 357
❑ Consisting of

Z29-
page 357
troller - V465-
stalling charge pressure positioner V465 ”, page 298
❑ Fitting location: plenum chamber
❑ Removing and installing ⇒ “1.4 Removing and installing Hall sender”, page 411
❑ Consisting of

❑ Consisting of

❑ Removing and installing ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 306
❑ Consisting of

❑ Removing and installing ⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 346
❑ Removing and installing ⇒ “2.4 Removing and installing electric coolant pump”, page 241

1.1.3 Overview of fitting locations - engine compartment, Polo

1 - N205-
view - camshaft hous‐
ing”, page 125
❑ Consisting of
Lambda probe - G39-
Z19-
page 356
❑ Consisting of

Z29-
page 356
troller - V465-
positioner V465 ”, page 298
6 - Radiator fan thermal switch - F18-
❑ Camshaft position sensor
❑ Consisting of


❑ Consisting of

❑ Assembly overview ⇒ “2.1 Assembly overview - charge air system”, page 302
❑ Consisting of

❑ Assembly overview ⇒ “2.2 Assembly overview - electric coolant pump”, page 238

1.1.4 Overview of fitting locations - front view of engine
1 - Knock sensor 1 - G61-

view - ignition system”,
page 408
duced oil pressure - F378-
pressure F378 ”,
page 217
3 - Fuel pressure sender -
G247-
view - fuel rail with injec‐
tors”, page 331
4 - Activated charcoal filter sol‐
enoid valve 1 - N80-
5 - Injectors
♦ Injector, cylinder 1 - N30-
view - fuel rail with injec‐
tors”, page 331
6 - Fuel pressure regulating
valve - N276-
❑ On high-pressure pump
❑ Assembly overview ⇒ “6.1 Assembly overview - high-pressure pump”, page 350
7 - Engine speed sender - G28-

1.1.5 Overview of fitting locations - rear view of engine
1 - Oil level and oil temperature

sender - G266-
stalling oil level and oil
temperature sender
G266 ”, page 209
G62-
page 251

2 Air filter
⇒ “2.1 Assembly overview - air filter housing”, page 320
⇒ “2.3 Removing and installing resonator for intake air”,
page 324
2.1 Assembly overview - air filter housing

⇒ “2.1.1 Assembly overview - air filter housing, Golf, Golf Estate,
⇒ “2.1.2 Assembly overview - air filter housing, Golf Cabriolet”,
page 321
⇒ “2.1.3 Assembly overview - air filter housing, Polo”, page 322
2.1.1 Assembly overview - air filter housing, Golf, Golf Estate, Golf SV, Touran
1 - Air duct (bottom section)

❑ On lock carrier
2 - Air duct (top section)
❑ On lock carrier
3 - Cover
❑ For air duct
4 - Bolt
❑ 2 Nm
5 - Air filter lower part
❑ Remove dirt, leaves and
salt residues
6 - Air filter element
❑ Use only genuine air fil‐
ter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance ta‐
bles
let
7 - Air filter upper part
salt residues
8 - Hose
tion.
9 - Resonator for intake air
stalling resonator for in‐
take air”, page 324
10 - Bump stop
11 - Bolt
❑ 1.5 Nm

12 - Air intake hose

13 - O-ring
14 - Water drain hose
❑ Cleaning
15 - Bolt
❑ 2 Nm
2.1.2 Assembly overview - air filter housing, Golf Cabriolet
1 - Union
stalling connection for
turbocharger”,
page 299
2 - Spring-type clip
stalling resonator for in‐
take air”, page 324
salt residues
bles
let
7 - Bump stop
salt residues
9 - Bolt
❑ 3 Nm
10 - Water drain hose
❑ Clean water drain hose.
12 - Intake hose
14 - Cover
❑ For upper part of air duct
2. Air filter 321

15 - Upper part of air duct

16 - Lower part of air duct
❑ On lock carrier
2.1.3 Assembly overview - air filter housing, Polo
1 - Connection hose
2 - Cold air intake
❑ On lock carrier
3 - Bolt
❑ 2 Nm
4 - Water drainage pipe
❑ Clean if soiled.
5 - Bolt
❑ 1.5 Nm
6 - Bump stop
salt residues
bles
let
salt residues
10 - Hose
tion.
❑ Removing and installing ⇒ “2.3 Removing and installing resonator for intake air”, page 324
12 - Clip

2.2 Removing and installing air filter hous‐

ing
Removing
– Detach air hose -2-.
– Release hose clips -3- and -4- and remove air ducts.
– Lift air filter housing -1- off ball studs in the following sequence.
– First pull air filter housing off ball stud -C-.

– Then, and only then, pull air filter housing off ball studs -B- and
-A-.
Installing
• Keep to the sequence during assembly.
2. Air filter 323

– Press air filter housing -1- on ball studs -A- and -B-.
– Finally, press air filter housing on ball stud -C-.
Note
♦ If the air filter element is very dirty or wet, particles of dirt or

water may reach the components and falsify the measured air
mass value. Reduced performance may be experienced as a
lower injection quantity is calculated.
♦ Use original air filter element.
♦ A clean air filter housing is essential.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Use a silicone-free lubricant to install the air hoses.
♦ When using compressed air to blow out the air filter housing,
cover the critical air-carrying components such as air pipes,
etc. with a clean cloth. Potential malfunctions are avoided in
this way.
♦ Observe disposal regulations.
– Remove salt residues, dirt and leaves from top and bottom part
of air filter housing using a vacuum cleaner.
– Blow out water drain with compressed air.
Specified torque
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 320 .
2.3 Removing and installing resonator for

intake air
Removing
– Loosen hose clips -1- and -2-.
– Remove resonator for intake air.
Installing
Note
Reinstall hose clips in their original positions.

3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 325
⇒ “3.2 Removing and installing intake manifold”, page 327
⇒ “3.3 Removing and installing throttle valve module GX3 ”, page
329
⇒ “3.4 Cleaning throttle valve module GX3 ”, page 330
3.1 Assembly overview - intake manifold
1 - Coolant pipe
manifold.
2 - Intake manifold
❑ Combined with charge
air cooler
stalling intake manifold”,
page 327
3 - Coolant pipe
manifold.
4 - Bolt
tightening sequence
⇒ Fig. ““Intake manifold
tightening sequence”“ ,
page 326
5 - O-ring
6 - Intake manifold sender -
GX9-
❑ Consisting of
Intake air temperature
sender 2 - G299-
Intake manifold pressure

sender - G71-
stalling intake manifold
sender GX9 ”,
page 346
7 - Seals
❑ Consisting of

❑ Removing and installing ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 306
3. Intake manifold 325

9 - O-ring
10 - Union
11 - O-ring
❑ Moisten with engine oil before installing
12 - Air intake pipe
❑ Removing and installing ⇒ “2.5 Removing and installing air pipe”, page 308
13 - O-ring
❑ Moisten with engine oil before installing
14 - Bolt
❑ Thread-cutting
❑ 7 Nm
15 - Retaining clip
❑ For air intake pipe
❑ Consisting of
❑ Cleaning ⇒ “3.4 Cleaning throttle valve module GX3 ”, page 330
17 - Seal
18 - Vacuum line
19 - O-ring
❑ Renew after removal with vacuum line
20 - Vacuum line
21 - O-ring
❑ Renew after removal with vacuum line
Intake manifold - specified torque and tightening sequence

1. -Arrows- Starting in centre, screw in bolts alter‐
nately by hand until they make contact
2. -Arrows- Starting in centre, screw in bolts alter‐
nately to 8 Nm

3.2 Removing and installing intake manifold

Removing
sulation .
– Drain coolant
– Release and pull off fuel lines -1- and -2- ⇒ Rep. gr. 20 ; Plug-
in connectors .
– Unclip breather line -2- from coolant expansion tank and from
upper toothed belt guard, and move it aside.
– Remove air pipe
– Unscrew bolt -1-, and release clamps -arrows-.

– Pull off coolant hose.
– Unclip coolant hose retainer on front left of intake manifold.
– Release connectors and pull them off.

1 - For activated charcoal filter system solenoid valve 1 - N80-
3 - For throttle valve module - GX3-
4 - For intake manifold sender - GX9- .
– Unscrew bolt -arrow-.
coal filter.
– Unclip fuel supply line -5- and coolant line -6- from intake
manifold and push them to one side.

– Pull activated charcoal filter solenoid valve 1 - N80- -3- off in‐
take manifold and push it downwards slightly.
– Disconnect connector -2- on oil pressure switch for reduced
oil pressure - F378- -1-.
– Disconnect connector -1- from fuel pressure sender - G247-

-2-.
– Loosen hose clips -2- and pull off coolant hoses.


– Pull hose -3- for crankcase breather off intake manifold.

– Unclip wiring harness from intake manifold.
– Remove intake manifold -1-.
Installing
– Renew seals and O-rings.
– Ensure proper seating of lines in mountings on intake mani‐
fold.
tion .
Specified torques
♦ Assembly overview - intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 325
3.3 Removing and installing throttle valve

module - GX3-
Throttle valve module - GX3- consists of
♦ Throttle valve module - J338-
♦ Throttle valve drive for electronic power control - G186-
♦ Throttle valve drive angle sender 1 for electronic power control
- G187-
♦ Throttle valve drive angle sender 2 for electronic power control
- G188-
Removing
– Remove air pipe
– Unscrew bolts -arrows- and remove throttle valve module -
GX3- -1- with adapter -2-.
Installing
– After throttle valve module - GX3- has been renewed, throttle
valve module - GX3- must be readapted to engine control unit
- J623- ⇒ Vehicle diagnostic tester.
Specified torques

3.4 Cleaning throttle valve module - GX3-
Note
♦ If a new engine control unit - J623- is installed, the throttle

valve module must be adapted.
♦ Contamination and coking in end stop can result in incorrect
adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.

♦ Acetone (commercially available)
♦ Brush
– Remove throttle valve module - GX3-
⇒ “3.3 Removing and installing throttle valve module GX3 ”,
page 329 .
– Open throttle valve by hand and lock it in open position with a
wedge (plastic or wood) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe the inside of the throttle valve housing with a lint-free
cloth.
– Allow acetone to dry off completely.
– Install throttle valve module - GX3-
page 329 .
– Delete learnt values, and adapt engine control unit - J623- to
throttle valve module - GX3- ⇒ Vehicle diagnostic tester.

4 Injectors
⇒ “4.1 Assembly overview - fuel rail with injectors”, page 331
⇒ “4.2 Removing and installing fuel rail”, page 332
⇒ “4.3 Removing and installing injectors”, page 333
⇒ “4.4 Cleaning injectors”, page 343
4.1 Assembly overview - fuel rail with injectors
1 - Fuel pressure sender -

G247-
❑ Checking
⇒ “5.3 Checking fuel
pressure sender G247 ”,
page 347
stalling fuel pressure
sender G247 ”,
page 346
❑ Moisten taper and
thread with clean engine
oil
❑ 22 Nm
2 - Fuel distributor
stalling fuel rail”,
page 332
3 - High-pressure pipe
❑ Does not need to be re‐
placed
❑ Before installing used
high-pressure pipes,
check thoroughly for
leaks
❑ Unions must be free of
damage
❑ Do not alter shape.
stalling high-pressure
pipe”, page 353
❑ Lubricate thread of un‐
ion nuts with clean engine oil
❑ 16 Nm +45°
4 - Bolt
❑ Removing and installing ⇒ “4.2 Removing and installing fuel rail”, page 332
❑ 8 Nm +90°
5 - Support ring
❑ Renew
❑ Fuel rail exerts force which secures injector in cylinder head via this support ring
❑ Clipped to -item 8-
4. Injectors 331
6 - O-ring
❑ Renew
❑ Lubricate with clean engine oil
7 - Spacer ring
8 - Injection valve
❑ Removing and installing ⇒ “4.3 Removing and installing injectors”, page 333
9 - Combustion chamber seal
❑ Do not treat with grease or other lubricant.
❑ Renewing ⇒ “4.3 Removing and installing injectors”, page 333
4.2 Removing and installing fuel rail

Removing
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Release high pressure.
Note
Risk of functional impairment due to soiling.

– Remove high-pressure pipe
page 353 .


– Place a cloth underneath to catch escaping fuel.
– Remove bolts -arrows- and pull fuel rail off injectors.
Installing
– Visually inspect fuel rail and remove any foreign bodies or old
O-rings as necessary.
– Renew O-ring.
– If there is still an O-ring in the fuel rail, carefully lever out the
O-ring using removal wedge - 3409- .
• The sealing surfaces in the fuel rail must be free of scoring or
scratches. Complete unit must otherwise be renewed.
– Apply mountings on fuel rail onto injectors.
– Press fuel rail onto injectors as far as stop (first on right side,
then on left side).
– Firmly press down fuel rail in area of bracket and screw in bolts
by two full turns.
– Tighten bolts evenly and diagonally.
– Install high-pressure pipe
page 353 .
Specified torques
♦ ⇒ “4.1 Assembly overview - fuel rail with injectors”, page 331
4.3 Removing and installing injectors

⇒ “4.3.1 Removing and installing injectors, Bosch”, page 333
⇒ “4.3.2 Removing and installing injectors, Continental”,
page 338
4.3.1 Removing and installing injectors,

Bosch
♦ Tool set for FSI engines - T10133 C- with -T10133/16 A- and
-T10133/19-
4. Injectors 333
Removing
Note
♦ Risk of malfunction due to different procedures for installing

the injector seals.
♦ Depending on the vehicle type, production date and injection
pressure, injectors from different suppliers may be used.
♦ Identify the part number or the supplier as follows
⇒ page 334 .
♦ For allocation refer to ⇒ Electronic Parts Catalogue .
Identifying supplier or part number:

Item -A-: supplier information
Item -B-: part number
Note
♦ Risk of functional impairment due to soiling.

♦ ⇒ “3.1 Rules for cleanliness”, page 5
♦ Injectors must only be removed when the engine is cold.

– Removing fuel rail

⇒ “4.2 Removing and installing fuel rail”, page 332 .
– Remove O-ring -3- from injector -1-.
– Unplug electrical connector from corresponding injector.

– Lever support ring -1- off injector using a screwdriver -2-.
– Fit impact sleeve -T10133/18- over injector.
– Carefully loosen injector with light blows onto impact sleeve.
Note
♦ Use a torque wrench to pull out the injector.

♦ Set the torque wrench to 5 Nm.
4. Injectors 335
– Fit puller -T10133/19- to groove on injector.

– Fit removing tool -T10133/16 A- to puller.
– Pull out injector by screwing in bolt -1-.
– If torque limit of »5 Nm« has been reached and injector still
cannot be pulled out, remove puller. Use the impact sleeve
again to loosen the injector.
– Repeat the procedure on each injector.
Note
♦ If the torque limit is exceeded, the injector may become dam‐

aged.
♦ The combustion chamber ring seal must always be renewed
prior to reinstalling the injector.
– Remove gasket for lower part of intake manifold.
Dismantling injectors (Bosch):

– Pull support ring -4- and spacer ring -2- off injector -1-.
– Remove retaining ring -7-, upper sealing washer -5- and lower
sealing washer -6-.
– Carefully remove old combustion chamber ring seal -8-. To do
this, cut the ring open using a knife.
Note
Take care not to damage the groove of injector. The injector must
be renewed if the groove is damaged.
Installing
– Clean hole in cylinder head with nylon brush - T10133/4- .
Note
♦ Renew combustion chamber seal and O-ring.

♦ Renew spacer ring if damaged.

– Fit assembly cone -T10133/5- with a new combustion cham‐

ber seal -1- on injector -2-.
– Slide combustion chamber seal with assembly sleeve -

T10133/6- onto assembly cone -T10133/5- as far as it will go.
– Turn assembly sleeve -T10133/6- around and push combus‐

tion chamber ring seal into the respective groove.
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. Combustion chamber ring seal must be com‐
pressed again after sliding on and this is done in two stages as
described below.
– Push calibration sleeve -T10133/7- onto injector as far as stop

and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again, turning in opposite
direction.
4. Injectors 337
– Push calibration sleeve -T10133/8- onto injector as far as stop

and simultaneously turn it slightly (approx. 180°).
direction.
– Fit support ring -4- and spacer ring -2- onto injector -1-.
– Before installing injector -1- moisten new O-ring -3- with clean
engine oil.
Note
The combustion chamber seal -8- must not be lubricated.
– Push injectors by hand as far as they will go into the hole of

the cylinder head (must be free of oil and grease). Ensure in‐
jectors are positioned correctly in cylinder head.
Note
♦ The injectors must insert easily. If necessary, wait until the

combustion chamber ring seal has contracted sufficiently.
♦ Ensure injectors are correctly seated and positioned in cylin‐
der head.
• Electrical connector of injector must engage in respective re‐

cess in cylinder head.
– Installing fuel rail
– Connect vehicle diagnostic tester , and carry out Guided Func‐
tion 0001 - Delete injector adaptation values .
4.3.2 Removing and installing injectors, Con‐

tinental

♦ Tool set for FSI engines - T10133 C- with -T10133/16 A- and

-T10133/19-
Removing
Note
♦ Risk of malfunction due to different procedures for installing

the injector seals.
⇒ page 339 .

Note
♦ Risk of functional impairment due to soiling.

♦ ⇒ “3.1 Rules for cleanliness”, page 5
♦ Injectors must only be removed when the engine is cold.
Note
Injectors must only be removed when the engine is cold.

4. Injectors 339
– Removing fuel rail

– Remove O-ring -3- from injector -1-.
– Unplug electrical connector from corresponding injector.
– Lever support ring -1- off injector using a screwdriver -2-.
– Fit impact sleeve -T10133/18- over injector.

– Carefully loosen injector with light blows onto impact sleeve.
Note
♦ Use a torque wrench to pull out the injector.

♦ Set the torque wrench to 5 Nm.
– Fit puller -T10133/19- to groove on injector.

– Fit removing tool -T10133/16 A- to puller.
– Pull out injector by screwing in bolt -1-.
– If torque limit of »5 Nm« has been reached and injector still
cannot be pulled out, remove puller. Use the impact sleeve
again to loosen the injector.
– Repeat the procedure on each injector.
Note
♦ If the torque limit is exceeded, the injector may become dam‐

aged.
♦ The combustion chamber ring seal must always be renewed
prior to reinstalling the injector.
– Remove gasket for lower part of intake manifold.
Dismantling injectors (Continental):

– Pull support ring -4- and spacer ring -2- off injector -1-.
– Remove retaining ring -7-, upper sealing washer -5- and lower
sealing washer -6-.
– Carefully remove old combustion chamber ring seal -8-. To do
this, cut the ring open using a knife.
Note
Take care not to damage the groove of injector. The injector must
be renewed if the groove is damaged.
4. Injectors 341
Installing
– Clean hole in cylinder head with nylon brush - T10133/4- .
Note
♦ Renew combustion chamber seal and O-ring.

♦ Renew spacer ring if damaged.
– Fit assembly cone -T10133/5- with a new combustion cham‐

ber seal -1- on injector -2-.
– Slide combustion chamber seal with assembly sleeve -

T10133/6- onto assembly cone -T10133/5- as far as it will go.
– Turn assembly sleeve -T10133/6- around and push combus‐

tion chamber ring seal into the respective groove.
Note
The combustion chamber seal is widened when it is pushed onto

the injector. Combustion chamber ring seal must be compressed
again after sliding on, and this is done in two stages as described
below.
– Slide spacer ring -2- from ⇒ Electronic parts catalogue to stop

onto injector -1-.

– Push calibration sleeve -T10133/7- to stop onto injector -1-,

and at the same time turn it slightly (approx. 180°) -arrow-.
direction.
– Slide spacer ring -2- from ⇒ Electronic parts catalogue to stop
onto injector -1-.
– Push calibration sleeve -T10133/8- to stop onto injector -1-,

and at the same time turn it slightly (approx. 180°) -arrow-.
direction.
– Fit support ring -4- and spacer ring -2- onto injector -1-.
– Before installing injector -1- moisten new O-ring -3- with clean
engine oil.
Note
The combustion chamber seal -8- must not be lubricated.
– Push injectors by hand as far as they will go into the hole of

the cylinder head (must be free of oil and grease). Ensure in‐
jectors are positioned correctly in cylinder head.
Note
♦ The injectors must insert easily. If necessary, wait until the

combustion chamber ring seal has contracted sufficiently.
♦ Ensure injectors are correctly seated and positioned in cylin‐
der head.
• Electrical connector of injector must engage in respective re‐

cess in cylinder head.
– Installing fuel rail
– Connect vehicle diagnostic tester , and carry out Guided Func‐
tion 0001 - Delete injector adaptation values .
4.4 Cleaning injectors

4. Injectors 343
♦ Ultrasonic cleaning device - VAS 6418-

♦ Mounting plate - VAS 6418/1-
♦ Cleaning fluid ⇒ Electronic Parts Catalogue
Note
♦ Risk of malfunction caused by ultrasonic cleaning of injectors

which are not approved for this purpose.
♦ Ultrasonic cleaning is only permissible for injectors from Con‐
tinental.
⇒ page 344 .

Note
♦ The ultrasonic unit must be filled with cleaning agent to upper

edge of holes (see detail).
♦ Observe safety instructions and operating instructions for the
ultrasonic unit.

Cleaning
– Remove injectors
⇒ “4.3 Removing and installing injectors”, page 333 .
– Insert injectors -1- all the way into mounting plate - VAS
6418/1- -item 2-.
– Immerse injectors together with mounting plate - VAS 6418/1-
into cleaning fluid - VAS 6418/2- .
– Set rotary knob -4- to a temperature of 50°C.
– Set a cleaning time of 30 minutes with the rotating knob -5-.
– Press button -3- to switch on ultrasonic unit.
Note
The time set starts to elapse as soon as a cleaning temperature

of 50°C has been attained.
– After cleaning, renew combustion chamber ring seal for each

injector ⇒ “4.3 Removing and installing injectors”, page 333 .
4. Injectors 345
5 Senders and sensors

⇒ “5.1 Removing and installing intake manifold sender GX9 ”,
page 346
⇒ “5.2 Removing and installing fuel pressure sender G247 ”, page
346
⇒ “5.3 Checking fuel pressure sender G247 ”, page 347
5.1 Removing and installing intake manifold

sender - GX9-
Intake manifold sender - GX9- consists of:
♦ Intake air temperature sender 2 - G299-
♦ Intake manifold pressure sender - G71-
Removing
– Separate electrical connector -arrow-.
– Release fasteners, and remove intake manifold sender -
GX9- .
Installing
– Renew O-ring.
Note
If the retaining tabs broke off during removal, the sender can be
mounted using two securing bolts ⇒ Electronic parts catalogue .
Specified torque ⇒ page 346 .

Torque
Intake manifold sender - GX9- 3 Nm
5.2 Removing and installing fuel pressure

sender - G247-

♦ Assembly tool - T10118-
♦ Socket 27 mm - T40218- or commercially available 27 mm

hexagon socket insert
Removing
Note
Place a cloth underneath to catch escaping fuel.
– Unscrew fuel pressure sender - G247- -2- using socket 27 mm

- T40218- .
Installing
Note
Moisten thread and taper of fuel pressure sender with engine oil
before installing.
Specified torque
♦ ⇒ “4.1 Assembly overview - fuel rail with injectors”, page 331
5.3 Checking fuel pressure sender - G247-

5. Senders and sensors 347

♦ Pressure gauge - VAS 6550-
♦ ⇒ Vehicle diagnostic tester

Condition:
• 1/
4 of fuel tank filled with fuel.
– Pull off supply line -1-. Separate plug-in connectors ⇒ Fuel
supply system - petrol engines; Rep. gr. 20 ; Plug-in connec‐
tors; Separating plug-in connectors .
CAUTION
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
– Collect escaping fuel with a cleaning cloth.
– Connect hose - VAS 6550/1- to connection -A- of pressure

tester - VAS 6550- .
– Connect hose - VAS 6550/1- to fuel supply line -1- leading to
engine.
– Connect hose - VAS 6550/2- to connection -B- of pressure
tester - VAS 6550- .
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .
– Ensure plug-in connectors are secure properly by pulling.

– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Use ⇒ Vehicle diagnostic tester to check fuel pressure sender
- G247- . To do this, select following function:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics
♦ 0001 - Repair groups
♦ 24 - Mixture preparation/injection
♦ G247 - Check fuel pressure sender
5. Senders and sensors 349

6 High-pressure pump
⇒ “6.1 Assembly overview - high-pressure pump”, page 350
⇒ “6.2 Removing and installing high-pressure pump”, page 352
⇒ “6.3 Removing and installing high-pressure pipe”, page 353
6.1 Assembly overview - high-pressure

pump
Version 1, Hitachi
1 - Roller tappet
❑ When installing lubri‐
cate lightly with clean
engine oil
2 - O-ring
❑ Renew
engine oil
3 - High-pressure pump
❑ With fuel pressure regu‐
lating valve - N276- .
❑ Do not dismantle.
pump”, page 352
placed
leaks
pipe”, page 353
damage
ion nuts with clean en‐
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ Renew
6 - Hose clamp
7 - Fuel supply line
8 - Electrical connector

Version 2, Continental
1 - Roller tappet
engine oil
2 - O-ring
❑ Renew
engine oil
3 - High-pressure pump
❑ With fuel pressure regu‐
lating valve - N276- .
❑ Do not dismantle.
pump”, page 352
placed
leaks
pipe”, page 353
damage
ion nuts with clean en‐
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ Renew
6 - Hose clamp
7 - Fuel supply line
6. High-pressure pump 351

Specified torques and installation sequence

High-pressure pump - specified torque and tightening sequence
Install high-pressure pump as follows to avoid deformation of the
high-pressure pump flange:
1. -3- Screw onto stop by hand
2. -3- Tighten one turn alternately until
flange of high-pressure pump makes
contact with camshaft housing
3. -3- 20 Nm
4. -3- Turn 90° further
6.2 Removing and installing high-pressure

pump
♦ Ratchet attachment - V.A.G 1410/3-
♦ Bit XZN 10 - T10385-

Removing
• Engine cold.
CAUTION
Note
– Remove high-pressure pipe

page 353 .
– Release hose clip -2- and detach fuel supply hose.
– Unscrew bolts -3- and detach high-pressure pump with roller
tappet.
Installing
– Check roller tappet for damage and renew if necessary.
– Moisten roller tappet -1- with clean engine oil.
– Insert oiled roller tappet -1- into camshaft housing.
Note
Renew O-ring.
– Turn crankshaft in direction of engine rotation until roller tappet

is at bottom dead centre.
– Insert new, lubricated O-ring -2- in groove of high-pressure
pump -3-.
– Tighten bolts by hand.
Specified torque
♦ Tighten bolts in diagonal sequence to specified torque
⇒ page 352 .
– Check fuel system for leaks.
6.3 Removing and installing high-pressure

pipe

♦ Tool set - T10395 A-
Removing
– Remove throttle valve module - GX3-
page 329 .
CAUTION
Note

– Place a cloth underneath to catch escaping fuel.

– Unscrew union nuts -arrows- and detach high-pressure pipe.
Installing
– The high-pressure pipe can be reused after removal.
– Lubricate thread of union nuts with clean engine oil.
– Initially, tighten union nuts for high-pressure pipe by hand on
high-pressure pump (make sure that pipe is not under ten‐
sion).
– Use an open-end spanner to counterhold at the hexagon on
the high-pressure pump when tightening.
– Tighten union nuts using torque wrench - VAS 6854- and insert
- T10395/3- .
• Before conducting visual check for leaks, allow engine to run
at idling speed for at least 5 minutes.
– Install throttle valve module - GX3-
page 329 .
Specified torques
♦ ⇒ “6.1 Assembly overview - high-pressure pump”, page 350

7 Lambda probe
⇒ “7.1 Assembly overview - Lambda probe”, page 356
⇒ “7.2 Removing and installing Lambda probe”, page 357
7.1 Assembly overview - Lambda probe
Note
♦ New lambda probes are coated with an assembly paste. This

paste must not get into the slots on the Lambda probe body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue .
♦ During installation, the electrical connecting cable of the
Lambda probe must be secured at the same points. The wire
must be prevented from touching the exhaust pipe.

❑ Consisting of:

Z29-
page 357
❑ 55 Nm
❑ For Lambda probe 1 af‐
ter catalytic converter -
GX7- .
❑ For Lambda probe 1 be‐
fore catalytic converter -
GX10- .
❑ Consisting of:
Lambda probe - G39-

Z19-
page 357
❑ 55 Nm

7.2 Removing and installing Lambda probe

⇒ “7.2.1 Removing and installing Lambda probe 1 before catalytic
converter GX10 ”, page 357
⇒ “7.2.2 Removing and installing Lambda probe 1 after catalytic
converter GX7 ”, page 358
7.2.1 Removing and installing Lambda probe

1 before catalytic converter - GX10-
Lambda probe 1 before catalytic converter - GX10- consists of
♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-
♦ Lambda probe open ring spanner set - 3337-
Removing
– Disconnect connector -2- for Lambda probe 1 before catalytic
converter - GX10- .
7. Lambda probe 357

– Unscrew Lambda probe 1 before catalytic converter - GX10-

-2- using tool from Lambda probe open ring spanner set -
3337- .
Installing
Note

Specified torques
♦ ⇒ “7.1 Assembly overview - Lambda probe”, page 356
7.2.2 Removing and installing Lambda probe

1 after catalytic converter - GX7-
Lambda probe 1 after catalytic converter - GX7- consists of
♦ Lambda probe after catalytic converter - G130-
♦ Lambda probe 1 heater after catalytic converter - Z29-
♦ Lambda probe open ring spanner set - 3337-
Removing
– Disconnect connector -1- for Lambda probe 1 after catalytic
converter - GX7- .

– Unscrew lambda probe 1 after catalytic converter - GX7- -1-

using a suitable tool from lambda probe open ring spanner set
- 3337- .
Installing
Note

Specified torques
♦ ⇒ “7.1 Assembly overview - Lambda probe”, page 356
7. Lambda probe 359

8 Engine control unit

⇒ “8.1 Removing and installing engine control unit J623 ”,
page 360
⇒ “8.2 Assembly overview - engine control unit”, page 371
8.1 Removing and installing engine control

unit - J623-
⇒ “8.1.1 Removing and installing engine control unit J623 (with
metal locking plate)”, page 360
⇒ “8.1.2 Removing and installing engine control unit J623 (with
protective housing)”, page 362
⇒ “8.1.3 Removing and installing engine control unit J623 without
protective housing, Golf Cabriolet”, page 365
⇒ “8.1.4 Removing and installing engine control unit J623 with
protective housing, Golf Cabriolet”, page 366
⇒ “8.1.5 Removing and installing engine control unit J623 , Polo”,
page 370
⇒ “8.1.6 Disconnecting engine control unit J623 from protective
housing, Polo”, page 370
8.1.1 Removing and installing engine control

unit - J623- (with metal locking plate)
♦ Wiring harness repair set - VAS 1978 B-
♦ Hot air blower - VAS 1978/14A- -1- with nozzle attachment

-2- from wiring harness repair set - VAS 1978 B-
♦ Small grinder (commercially available)

♦ Vehicle diagnostic tester

Removing
– If engine control unit is renewed, select “Guided Function”
0001 - Replace engine control module on vehicle diag‐
nostic tester .
– Switch off ignition and remove key from ignition lock.
Note
♦ If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence.
♦ Therefore, disconnect the battery before removing the engine
control unit ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
– Release retaining clip -arrow- and take out engine control unit
- J623- .
– Make groove (for a screwdriver) in head of shear bolt -1- using

a small grinder -2-.
Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
– Set the hot air blower as shown in illustration. Set potentiom‐

eter for temperature regulation -2- to maximum heating output
and 2-stage switch for air volume -3- to position 3.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
8. Engine control unit 361

– Hold hot air blower - VAS 1978/14A- with nozzle attachment

-arrow- to thread of shear bolt and heat thread for about 20 to
30 seconds.
– Unscrew shear bolt -1- with screwdriver -2-.

– Detach metal locking plate from connectors for engine control
unit - J623- .
– Release and pull off connectors.
Installing
– The metal locking plate must always be re-fitted on the engine
control unit - J623- .
– Clean the threaded holes for the shear-head bolts of locking
compound residues. A thread chaser is suitable for cleaning.
– Use new shear-head bolts.
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
– Connect vehicle diagnostic tester .
– Activate engine control unit in “Guided functions” with 0001 -
Replace engine control module .

unit - J623- (with protective housing)
Removing
♦ Wiring harness repair set - VAS 1978 B-

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle -2- from
wiring harness repair set - VAS 1978 B-

Removing
– If engine control unit is renewed, select “Guided Function”
0001 - Replace engine control module of vehicle diag‐
nostic tester .
Note
♦ If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence.
♦ Therefore, disconnect the battery before removing the engine
control unit ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
To remove protective housing -1-, unscrew shear bolts -arrows-

as follows:
Note
Cover the area around the engine control unit, and protect it from
flying sparks.
– Make groove (for a screwdriver) in head of shear bolt -1- using

a small grinder -2-.

Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
– Set the hot air blower as shown in illustration. Set potentiom‐

eter for temperature regulation -2- to maximum heating output
and 2-stage switch for air volume -3- to position 3.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.
– Unscrew shear bolt -1- with screwdriver -2-.

– Release fastener -arrow- and detach engine control unit -1-.

– Release and pull off connectors for engine (motor) control unit
- J623- .
Installing
– It is essential that the engine (motor) control unit - J623- be
provided with the protective housing again.
– Clean the threaded holes for the shear-head bolts of locking
compound residues. A thread chaser is suitable for cleaning.
– Use new shear-head bolts.
– Connect vehicle diagnostic tester .
– Activate engine control unit using “Guided functions” with
0001 - Replace engine control module .

unit - J623- without protective housing,
Golf Cabriolet
Removing
– If the engine control unit is to be renewed, switch on ignition,
and select the following “function” on vehicle diagnostic tester :
♦ 0001 - Renew engine control unit
– Switch off ignition and take out ignition key.
– Detach wiring harness for engine control unit from inner side
of plenum chamber bulkhead.
– Remove plenum chamber bulkhead ⇒ General body repairs,
bulkhead .
– Release feed-through for wiring harness -arrow-, and pull it off
upwards.
– Detach wiring harness for engine control unit.
– Release and pull off connector on wiper motor ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system .
– Pull engine control unit as far as possible towards front right
wheel housing.

– Detach engine control unit from plenum chamber.

– Push down retaining frame in direction of -arrow- and remove
engine control unit.
– Push locking devices of connectors in -direction of arrow- and

pull off connectors.
Installing
– Fit connectors to engine control unit.
– Push locking devices to stop in -direction of arrow-.
– Insert engine control unit into retaining frame and push retain‐
ing frame upwards in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs,
bulkhead .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
– Switch on ignition and continue with the following menu op‐
tions on vehicle diagnostic tester :

unit - J623- with protective housing, Golf
Cabriolet

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle -2- from
wiring harness repair set - VAS 1978 B-

Removing
– If the engine control unit is to be renewed, switch on ignition,
and select the following “function” on vehicle diagnostic tester :
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Unclip wiring harness for engine control unit - J623- from re‐
tainer in plenum chamber.
– Open locking element -arrow-, and remove wiring harness
from guide.
– Detach wiring harness for engine control unit.
– Release and pull off connector on wiper motor ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system .
– Pull engine control unit as far as possible towards front right
wheel housing.
– Detach engine control unit from plenum chamber.

– Push down retaining frame in direction of -arrow- and remove

– Unscrew shear-head bolts -arrows- using a pair of pliers.
– Insert screwdriver between both locking plates -arrow-.

– Carefully push screwdriver in -direction of arrow-.
– At the same time, bend locking bar -1- upwards.
– Bend locking bar -1- in -direction of arrow- until locking bar can
be pulled off connector.
– Push locking devices of connectors in -direction of arrow- and

pull off connectors.

Installing
– Fit connectors to engine control unit.
– Push locking devices to stop in -direction of arrow-.
– Fit retaining bar -1- onto connectors and press it in direction

of -arrow-.
– Guide pin -2- to stop into hole on engine control unit.
– Use new shear-head bolts -arrows- to secure retaining bar on

– Evenly tighten shear-head bolts until bolt heads shear off
-arrows-.
– Insert engine control unit into retaining frame and push retain‐
ing frame upwards in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs,
bulkhead .
– Switch on ignition and continue with the following menu op‐
tions on vehicle diagnostic tester :


unit - J623- , Polo
Note
♦ If the engine control unit - J623- needs to be renewed, connect

⇒ Vehicle diagnostic tester, and carry out function 0001 -
Renew engine control unit .
♦ If engine control unit - J623- is renewed, electronic immobiliser

must be adapted by carrying out function 0001 - Adapt en-
gine control unit to immobiliser .
♦ Risk of damage to the electronic components when discon‐

necting the battery.
♦ Observe the necessary measures when disconnecting the
battery.
Removing
– Release catches of holder -1- from engine control unit - J623- .
– Press down tab -2-, and remove engine control unit - J623-
upwards.
Engine control unit with protective housing
– Disconnect engine control unit from protective housing
⇒ “8.1.6 Disconnecting engine control unit J623 from protec‐
tive housing, Polo”, page 370 .
All versions
– Using a screwdriver, lever out locking bar -1- of upper wiring

harness in direction of -arrow-.
– Using a screwdriver, lever out locking bars -2- of lower wiring
harness in direction of -arrow-.
– Pull connectors off engine control unit.
– Remove engine control unit.
Installing
Engine control unit with protective housing
– Secure engine control unit in protective housing
⇒ “8.1.6 Disconnecting engine control unit J623 from protec‐
tive housing, Polo”, page 370 .
8.1.6 Disconnecting engine control unit -

J623- from protective housing, Polo
♦ Angle grinder e.g. axial grinder - VAS 6682-

Note
The protective housing is secured with shear-head bolts. The

shear-head bolts cannot be removed without being damaged.
Use e.g. the axial grinder - VAS 6682- or a commercially available
angle grinder to remove the shear-head bolts. If the protective
housing is damaged, renew the protective housing.
Removing
– Remove engine control unit from holder
360 .
– Move clear wiring harness, and push it to one side as far as
possible.
– Remove bolts -A-. Remove retainer -B-.
– Remove engine control unit from protective housing.
Installing
– Push engine control unit into protective housing as far as it will
go.
– Fit locking element -B- onto protective housing, and secure it
with new shear bolts -A- ⇒ Electronic parts catalogue (ETKA) .
– First, insert engine control unit into tab -2- of holder.

– Push engine control unit into holder until upper tab -1- is en‐
gaged.
8.2 Assembly overview - engine control unit

1 - Bracket
stalling engine control
unit J623 ”, page 360
3 - Locking bar
⇒ “8.1.6 Disconnecting
engine control unit J623
from protective housing,
Polo”, page 370
4 - Bolt
❑ Tighten shear-head
screws evenly until
head shears off.
❑ For securing bracket to
engine control unit
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
5 - Bolt
screws evenly until
head shears off.
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
6 - Protective housing
7 - Bolt
screws evenly until
head shears off.
❑ For securing bracket to
engine control unit
❑ Allocation ⇒ Electronic parts catalogue (ETKA)

26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 373
⇒ “1.2 Separating exhaust pipes from silencers”, page 383
⇒ “1.3 Removing and installing silencer”, page 389
⇒ “1.4 Aligning exhaust system free of stress”, page 395
⇒ “1.5 Checking exhaust system for leaks”, page 395
⇒ “1.6 Installation position of clamp”, page 396
1.1 Assembly overview - silencers

⇒ “1.1.1 Assembly overview - silencers, Golf Saloon, Golf SV”,
page 373
⇒ “1.1.2 Assembly overview - silencers, Golf Estate”, page 376
⇒ “1.1.3 Assembly overview - silencers, Touran”, page 378
⇒ “1.1.4 Assembly overview - silencers, Golf Cabriolet”,
page 380
⇒ “1.1.5 Assembly overview - silencers, Polo”, page 382
1.1.1 Assembly overview - silencers, Golf Saloon, Golf SV
1. Exhaust pipes and silencers 373

1 - Retaining loop
2 - Bolt
❑ 20 Nm
3 - Mounting »A«
❑ Only for rear silencer
❑ Aligning ⇒ page 375
4 - Rear silencer
❑ Combined in one unit
with front silencer as
original equipment. Can
be renewed individually
for repair purposes.
stalling silencer”,
page 389
❑ Separating exhaust
pipes from silencers
⇒ “1.2 Separating ex‐
haust pipes from silenc‐
ers”, page 383
❑ Aligning exhaust sys‐
tem free of tension
⇒ “1.4 Aligning exhaust
system free of stress”,
page 395 .
5 - Rear clamp
❑ Align exhaust system
free of tension before
tightening
page 395 .
❑ Fitting position ⇒ “1.6 Installation position of clamp”, page 396
❑ Tighten threaded connections evenly.
6 - Nut
❑ 30 Nm
7 - Retaining loop
8 - Bolt
❑ 20 Nm +90°
❑ Renew
9 - Mounting »B«
❑ Only for front silencer
10 - Front silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Removing and installing ⇒ “1.3 Removing and installing silencer”, page 389
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 383
374 Rep. gr.26 - Exhaust system

❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
Aligning mounting »A«

– Pre-tighten bolt.
– Align mounting at elongated hole as necessary.
– Align holes of mounting -A- 90° to longitudinal member.
– Use a commercially available 8 mm drill bit for this purpose.
– Then tighten to specified torque.
Aligning mounting »B«

– Align holes -arrows- of mounting -B- parallel to longitudinal
member.

1.1.2 Assembly overview - silencers, Golf Estate
1 - Front silencer
with rear silencer as
page 389
ers”, page 383
tem free of tension
page 395 .
2 - Retaining loop
3 - Mounting »A«
4 - Bolt
❑ x 25
❑ 20 Nm
5 - Nut
❑ 30 Nm
6 - Rear clamp
tightening ⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
7 - Mounting »B«
8 - Bolt
❑ x 25
❑ 20 Nm
9 - Rear silencer
❑ Combined in one unit with front silencer as original equipment. Can be renewed individually for repair
purposes.
10 - Mounting »B«

11 - Retaining loop
12 - Bolt
❑ x 25
❑ 20 Nm

– Align holes -arrows- of mounting -A- parallel to longitudinal
member.

– Align holes -arrows- of mounting -B- parallel to longitudinal
member.

Mounting »C«
– Align holes -arrows- of mounting -C-.
1.1.3 Assembly overview - silencers, Touran
1 - Front clamping sleeve

tightening
page 395 .
⇒ “1.6 Installation posi‐
tion of clamp”,
page 396
❑ Tighten threaded con‐
nections evenly.
2 - Front silencer
with rear silencer as
page 389
ers”, page 383
tem free of tension
page 395 .
3 - Retaining loop
4 - Mounting »B«

5 - Bolt
❑ x 25
❑ 20 Nm
6 - Nut
❑ 30 Nm
7 - Rear clamp
❑ Align exhaust system free of tension before tightening
⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
8 - Retaining loop
9 - Retaining loop
10 - Mounting »A«
11 - Bolt
❑ x 25
❑ 20 Nm
12 - Rear silencer
❑ Combined in one unit with front silencer as original equipment. Can be renewed individually for repair
purposes.
13 - Retaining loop
14 - Mounting »A«
15 - Bolt
❑ x 25
❑ 20 Nm


– Align holes of mounting -A- 90° to longitudinal member.

– Align mounting centrally on hole.
– Align holes of mounting -B-.
1.1.4 Assembly overview - silencers, Golf Cabriolet

1 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
page 389
⇒ “1.2.4 Separating ex‐
haust pipes/silencers,
Golf Cabriolet”,
page 386
tem free of tension
page 395 .
2 - Mounting
3 - Bolt
❑ 20 Nm
4 - Retaining loop
5 - Rear clamp
tightening
page 395 .
⇒ “1.6 Installation position of clamp”, page 396
❑ Specified torque ⇒ Fig. ““Specified torque for clamp”“ , page 382
6 - Mounting
7 - Retaining loop
8 - Bolt
❑ 20 Nm
9 - Nut
❑ 20 Nm
10 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Separating exhaust pipes from silencers
⇒ “1.2.4 Separating exhaust pipes/silencers, Golf Cabriolet”, page 386

Specified torque for clamp

Clamp -A- with 2 individual clips:
Specified torque 25 Nm
Clamp -B- with continuous clip:
Specified torque 35 Nm
1.1.5 Assembly overview - silencers, Polo
1 - Clamping sleeve
⇒ “1.6 Installation posi‐
tion of clamp”,
page 396
❑ 23 Nm
2 - Tunnel cross-piece
❑ Note installation posi‐
tion (mark before re‐
moval, if necessary).
• Depending on version, re‐
move underbody cladding
on left and right sides ⇒
General body repairs, exte‐
rior; Rep. gr. 66 ; Under‐
body cladding .
⇒ Rep. gr. 66 ; Under‐
body cladding; Remov‐
ing and installing tunnel
cross-piece
3 - Securing nuts
❑ 20 Nm
4 - Front silencer
5 - Mounting
6 - Bracket
7 - Bolts
❑ 23 Nm
8 - Coupling point
❑ ⇒ “1.2 Separating ex‐
ers”, page 383

9 - Rear silencer
10 - Bracket
❑ With mounting
11 - Securing bolts
❑ 23 Nm
1.2 Separating exhaust pipes from silencers

⇒ “1.2.1 Separating exhaust pipes, silencers, Golf Saloon, Golf
SV”, page 383
⇒ “1.2.3 Separating exhaust pipes/silencers, Touran”,
page 385
⇒ “1.2.4 Separating exhaust pipes/silencers, Golf Cabriolet”,
page 386
1.2.1 Separating exhaust pipes, silencers,

Golf Saloon, Golf SV
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.
♦ Chain-type pipe cutter - VAS 6254-
– Cut through exhaust pipe at right angles at separating point
-arrow- using chain pipe cutter - VAS 6254- .

– Position clamp centrally at side marks -arrows- when instal‐

ling.
– Note installation position of clamp
⇒ “1.6 Installation position of clamp”, page 396 .
– Align exhaust system free of stress
1.2.2 Separating exhaust pipes/silencers, es‐

tate

– When installing, position clamp centrally (-dimension a-) be‐

tween side marks -arrows-.
– Fit rear clamp
1.2.3 Separating exhaust pipes/silencers,

Touran
– Remove rear left underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding .
– Remove rear silencer
⇒ “1.3.3 Removing and installing rear silencer, Touran”, page
391 .
– Attach rear silencer.

– When installing, position clamp centrally (-dimension a-) be‐

tween side marks -arrows-.
– Fit rear clamp
1.2.4 Separating exhaust pipes/silencers,

Golf Cabriolet
♦ A separating point has been engineered in the connecting pipe
should the centre silencer and rear silencer need to be re‐
placed separately.
♦ The separating point is marked with indentations on the out‐
side of the exhaust pipe.
♦ Safety glasses
Disconnecting
CAUTION
Danger of severe burns from hot exhaust system.
Risk of burns to hands and other parts of body.
– Allow exhaust system to cool.
Note
To avoid injury from metal shavings, wear eye protection and

protective clothing.

– Cut through exhaust pipe -arrow B- at right angles at the sep‐

arating point with e.g. chain pipe cutter - VAS 6254- .
Connecting
Note
A second mechanic is required to bolt on the repair clamp-type

clip.
– Fit front silencer to retainers. Front clamp remains loose on

pipes.
– Align rear silencer horizontally and hold it in that position.
– Position repair clamp-type clip so that it is flush with the mark‐

ings -arrow A- and -arrow C-.
– Turn repair clamp -2- as shown in illustration, and tighten it.

– Installation position of rear clamp
1.2.5 Separating exhaust pipes/silencers, Po‐

lo

CAUTION
Risk of injury from swarf being flung into air.
Irritation and injury to skin and eyes possible.
Separating point on rear silencer

– Cut through exhaust pipe -top arrow- at right angles at centre
separating point with e.g. chain pipe cutter - VAS 6254- .
– Position repair double clamp centrally between outer markings
-lower arrow-.
– Take installation position of clamp into account

1.3 Removing and installing silencer

⇒ “1.3.1 Removing and installing front silencer, Golf, Golf Estate,
⇒ “1.3.2 Removing and installing rear silencer, Golf, Golf Estate,
Golf SV”, page 389
⇒ “1.3.3 Removing and installing rear silencer, Touran”,
page 391
⇒ “1.3.4 Removing and installing silencer, Golf Cabriolet”,
page 392
⇒ “1.3.5 Removing and installing front silencer, Polo”, page 393
⇒ “1.3.6 Removing and installing rear silencer, Polo”, page 394
1.3.1 Removing and installing front silencer,

Removing
– If fitted, remove rear left underbody cladding ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody cladding .
– Remove rear tunnel cross-piece ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody cladding .
Separating point without clamp
– Separate silencers
Separating point with clamp
– Loosen clamp at rear, and push it to rear.
– Detach front silencer from rubber mounting.
– Loosen clamp -arrow- at front, and push it forwards.
– Remove front silencer.
Installing
Specified torques
• ⇒ “1.1 Assembly overview - silencers”, page 373
• ⇒ “2.1 Assembly overview - emission control”, page 397
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding
1.3.2 Removing and installing rear silencer,

Golf, Golf Estate, Golf SV
Removing

CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
Golf saloon and Golf SV with coupling point without clamp

Golf saloon and Golf SV with coupling point with clamp
– Loosen clamp -arrow-, and push it forwards.
– Remove bolt -2- on both sides.
– Remove rear silencer -1-.
Golf Estate with coupling point without clamp
– Separate silencer
⇒ “1.2 Separating exhaust pipes from silencers”, page 383 .
Golf Estate with coupling point with clamp

– Loosen clamp -arrows-, and push it forwards.
– Unscrew bolts -1- and -2-.

– Unscrew bolt -3-, and remove rear silencer -4-.
Installing

Note
Make sure to obtain the same distance -dimension a- to the marks

-arrows-.

Specified torques
cladding

Touran
Removing
– Remove rear left underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding .
CAUTION

– Loosen clamp -arrow-, and push it forwards.
– Unscrew bolts on left -2- and right -4-.
– Detach rubber mounting -1-, and remove rear silencer -3-.
Installing

Note
Make sure to obtain the same distance -dimension a- to the marks

-arrows-.

Specified torques
cladding
1.3.4 Removing and installing silencer, Golf

Cabriolet
CAUTION
Danger of severe burns from hot exhaust system.
Risk of burns to hands and other parts of body.
– Allow exhaust system to cool.
Removing
– Remove rear tunnel cross-piece ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody cladding .
– Remove cross brace -3- for subframe ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Rear axle .

– Unscrew nuts -arrows- of tunnel cross-piece -3-.

– Detach rubber mountings -4-.
CAUTION
– Unscrew bolts -2-, and remove silencer -1-.

Installing
– Note installation position
Specified torques
♦ ⇒ “1.1.4 Assembly overview - silencers, Golf Cabriolet”, page
380
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle
1.3.5 Removing and installing front silencer,

Polo
Removing
CAUTION

– Separate rear silencer from front silencer
– Loosen clamp -1- between catalytic converter and front si‐
lencer, and push it in direction of travel -arrow-.
– Loosen clamp between front and rear silencer, and push it in
opposite direction of travel.

– Bend heat shield -1- in direction of -arrow-.

• Bracket -2- needs to be guided past heat shield -1-.
– Unscrew bolts -3- from bracket -2-. Guide bracket -2- past heat
shield -1-.
– Detach front silencer, and guide it out.
Installing
– Note installation position of clamps
Specified torques
• ⇒ “1.1.5 Assembly overview - silencers, Polo”, page 382

Polo
Removing
CAUTION

– Unscrew bolts -1- from bracket -2-.
– Remove bracket -2-.
– Loosen clamp -1-, and push it to one side towards front si‐
lencer -2-.
– Remove rear silencer.
Installing


• Note installation position of clamp
Note
Make sure to obtain the dimension -a = approx. 5 mm- between

the marks -arrows-.

Specified torques
• ⇒ “1.1.5 Assembly overview - silencers, Polo”, page 382
1.4 Aligning exhaust system free of stress

• The exhaust system must be aligned when cold.
– Loosen bolt connections for front clamp -arrow-.
– Push exhaust system towards front of vehicle until preloading

at mounting for exhaust pipe -a- = 5 mm.
– Fit front clamp
Specified torques
♦ Specified torques for clamp securing bolts
⇒ “1.1 Assembly overview - silencers”, page 373
♦ Specified torques
⇒ “2.1 Assembly overview - emission control”, page 397
1.5 Checking 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.
– Check (by listening) points of connection between exhaust
manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.

1.6 Installation position of clamp

– Fit clamp in position shown.
• Bolt -arrow- must not protrude beyond lower edge of clamp.
• The threaded connection must face towards right relative to
direction of travel.
Installation dimension of clamp:

1 - Clamping sleeve
2 - Exhaust pipe
a - Installation dimension
A - Marking on exhaust system
Installation dimension -a- for clamp:
a - 8.5 mm
Installation dimension of front clamp between silencers:

– Position clamp centrally at side marks -arrows- when instal‐
ling.
Specified torque:
♦ ⇒ “1.1 Assembly overview - silencers”, page 373

2 Emission control
⇒ “2.1 Assembly overview - emission control”, page 397
⇒ “2.2 Removing and installing catalytic converter”, page 400
2.1 Assembly overview - emission control

⇒ “2.1.1 Assembly overview - emission control, Golf, Golf Estate,
Golf SV, Touran, Golf Cabriolet”, page 397
⇒ “2.1.2 Assembly overview - exhaust gas treatment, Polo”, page
399
2.1.1 Assembly overview - emission control, Golf, Golf Estate, Golf SV, Touran,
Golf Cabriolet
1 - Bolt
❑ 20 Nm
2 - Mounting
3 - Nut
tightening sequence
⇒ Fig. ““Installing cata‐
lytic converter - speci‐
fied torque and se‐
4 - Bolt
❑ 20 Nm
5 - Nut
tightening sequence
6 - Bracket
7 - Bracket
8 - Bolt
tightening sequence
9 - Bolt
tightening sequence
lytic converter - specified torque and sequence”“ , page 398
10 - Front exhaust pipe with catalytic converter
❑ Do not bend flexible joint more than 10°. Otherwise, it can be damaged.
❑ Install flexible joint so that it is not under tension
❑ Take care not to damage wire mesh on decoupling element.
❑ Protect catalytic converter from damage by knocks and impact
2. Emission control 397

❑ Removing and installing ⇒ “2.2 Removing and installing catalytic converter”, page 400
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
11 - Screw-type clamp
❑ Renew
⇒ Fig. ““Installing catalytic converter - specified torque and sequence”“ , page 398
12 - Seal
❑ Renew
13 - Turbocharger
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 295
❑ Specified torque and tightening sequence ⇒ “1.1 Assembly overview - turbocharger”, page 293
14 - Nut
❑ 30 Nm
15 - Front clamping sleeve
Installing catalytic converter - specified torque and sequence

1. – Fit catalytic converter to tur‐
bocharger, attach screw-type
clip -arrow- without tightening
2. – Loosely screw in bolts -3, 5- • It should still be
and bolts -1, 2, 4- by hand possible to move
catalytic converter
and bracket.
3. – Tighten screw-type clip 15 Nm

-arrow-
4. – Tighten bolts and nuts in the 20 Nm
sequence -1 … 5-

2.1.2 Assembly overview - exhaust gas treatment, Polo
1 - Bracket
2 - Bracket
3 - Retaining bracket
4 - Bolt
❑ 20 Nm
5 - Bracket
6 - Nut
tightening sequence
fied torque and tighten‐
ing sequence”“ ,
page 400
7 - Turbocharger
8 - Screw-type clamp
❑ Renew
tightening sequence
fied torque and tighten‐
ing sequence”“ ,
page 400
9 - Seal
❑ Renewing
⇒ Fig. ““Renewing
seal”“ , page 400
10 - Front exhaust pipe with
catalytic converter
❑ Do not bend flexible joint more than 10° - otherwise it can be damaged.
❑ Install flexible joint so that it is not under tension
❑ Take care not to damage wire mesh on flexible joint.
❑ Protect catalytic converter from damage by knocks and impact
❑ Removing and installing ⇒ “2.2.2 Removing and installing catalytic converter, Polo”, page 403
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
11 - Clamping sleeve
❑ 23 Nm

Installing catalytic converter - specified torque and tightening se‐

quence
1. – Fit catalytic converter -1- to ♦ Hand-tight
turbocharger and attach new
screw-type clip -2- loosely
without tightening it.
2. – Screw on nuts -1- and -2- • It should still be
loosely by hand. possible to move
catalytic converter
and bracket.
3. – Ensure proper seating of cat‐

alytic converter -1- on turbo‐
charger.
4. – Tighten bolt -3- 15 Nm
5 – Screw nuts -4- to -6- loosely ♦ Hand-tight
onto bracket -7-.
6. – Tighten nuts in the sequence 20 Nm
-4 … 5 … 6-.
Renewing seal
– Fit screwdriver -2- in recess -arrow- on turbocharger.
– Lever out seal -1-.
– Renew oil seal -1-.
2.2 Removing and installing catalytic con‐

verter
⇒ “2.2.1 Removing and installing catalytic converter, Golf, Golf
⇒ “2.2.2 Removing and installing catalytic converter, Polo”, page
403
2.2.1 Removing and installing catalytic con‐

verter, Golf, Golf Estate, Golf SV, Tour‐
an, Golf Cabriolet
Note
The catalytic converter is removed together with the front exhaust

pipe.
Removing
Note


324 .
– Remove electrical connectors -1- and -2- from retainer and
disconnect.

Note
♦ Do not loosen bolts on turbocharger.

♦ Coolant lines on turbocharger are not removed.
– Unscrew nuts and bolts -arrows-.

– Thread out heat shield -1- and remove it.
– Raise coolant lines slightly when doing this.
Note
♦ Prior to loosening the connection between the catalytic con‐

verter and the turbocharger, mark the position of the clamp
⇒ Fig. ““Clamp position”“ , page 404 .
♦ The mark is to be made on the component opposite to the
component to be renewed.
♦ Make sure that the clamp is fitted at the same position on re‐
installation.
Clamp position


– Remove bolt -1- and nuts -arrows-.
– Unscrew bolts -arrows- of bracket.
– Unscrew right nut -arrow- of bracket.
– Unscrew nut -arrow- to the left of the bracket.

– Remove heat shield ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody cladding .
– Remove front tunnel cross-piece ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody cover .


– Detach connector from retainer and lay wire leading to Lamb‐
da probe to one side.

– Remove catalytic converter with front exhaust pipe towards
rear.
– Fit screwdriver -2- in recess -arrow- on turbocharger and lever

out seal -1-.
Installing
– Renew seals/gaskets and self-locking nuts.
Specified torques:
sequence”“ , page 398
2.2.2 Removing and installing catalytic con‐

verter, Polo
♦ High-temperature paste ⇒ Electronic parts catalogue .
Note
The catalytic converter is removed together with the front exhaust

pipe.

Removing
– Lay wires -2- to one side.
– Unclip wires -4- from retainer -1-.
– Remove wires from heat shield of turbocharger.

Note
♦ Do not loosen bolts on turbocharger.

♦ Coolant lines on turbocharger are not removed.
– Unscrew bolts -arrows- and remove heat shield -1-.
Note
♦ Prior to loosening the connection between the catalytic con‐

verter and the turbocharger, mark the position of the clamp
⇒ Fig. ““Clamp position”“ , page 404 .
♦ The mark is to be made on the component opposite to the
component to be renewed.
♦ Make sure that the clamp is fitted at the same position on re‐
installation.
Clamp position

– Loosen bolt -1- until clamp -2- can be pushed in direction of

-arrow- over catalytic converter.
– Remove lambda probe after catalytic converter - GX7-
⇒ “7.2 Removing and installing Lambda probe”, page 357 .
– Remove underbody cover -1- on right and left.

– To do this, unscrew nuts -2- from studs -3-.
Note
The illustrations show the left-hand side. Adapt the procedure ac‐
cordingly for the right-hand side.
– Remove tunnel cross-piece -1-.

– To do this, unscrew nuts -2- from studs -3-.
– Unbolt right drive shafts on inside ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Lay drive shaft to one side.

– Loosen clamp -1- between catalytic converter and front si‐

lencer, and push it in direction of travel -arrow-.
– Separate rear silencer from front silencer
• Bracket -2- needs to be guided past heat shield -1-.
– Loosen clamp between front and rear silencer, and push it in
opposite direction of travel.
– Bend heat shield -1- in direction of -arrow-.

– Unscrew bolts -3- from bracket -2-. Guide bracket -2- past heat
shield -1-.
– Lower the front silencer.
– Detach exhaust hangers -3- of catalytic converter -1- from

subframe -2- in direction of -arrow-.

– Remove screw-type clip -1-.
– Unscrew nuts -arrows- and tie up catalytic converter -3-.

– Unscrew bolts -arrows- and remove bracket -1-.
– Remove heat shield -1-. To do this, unscrew bolts -2-.

– Unbolt lock washers -3-.
– Thread out heat shield -1- and remove it.
– Guide out catalytic converter with front exhaust pipe between
body and assembly carrier.
Installing
– Renew seals/gaskets and self-locking nuts.
– Coat exhaust manifold studs with high-temperature paste;
high-temperature paste ⇒ Electronic parts catalogue .
– Fit screwdriver -2- in recess -arrow- on turbocharger.

– Lever out seal -1-.
– Renew oil seal -1-.
Specified torques
♦ ⇒ “1.1.5 Assembly overview - silencers, Polo”, page 382
tightening sequence”“ , page 400
Removing and installing drive shaft .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding

28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 408
page 409
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 411
⇒ “1.4 Removing and installing Hall sender”, page 411
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
412
1.1 Assembly overview - ignition system
1 - Bolt
❑ The specified torque in‐
fluences the function of
the knock sensor.
❑ 20 Nm
2 - Knock sensor 1 - G61-
stalling knock sensor 1
G61 ”, page 411
3 - Spark plug
❑ Remove and install with
spark plug socket and
extension - 3122 B-
let 819
❑ Specified torque: 22 Nm
❑ Change interval ⇒
Maintenance tables
4 - Ignition coil with output
stage
♦ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stage - N292-
❑ To remove, use puller -
T10530- .
❑ Observe notes on disas‐
sembly
⇒ “1.2 Removing and installing ignition coils with output stage”, page 409
5 - Bolt
❑ 8 Nm
408 Rep. gr.28 - Ignition system

6 - Bolt
❑ 8 Nm
❑ Removing and installing ⇒ “1.4 Removing and installing Hall sender”, page 411
8 - O-ring
9 - Sender wheel
❑ For engine speed sender - G28-
10 - Sealing flange, gearbox side
11 - Engine speed sender - G28-
❑ Removing and installing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 412
12 - Bolt
❑ 4.5 Nm
1.2 Removing and installing ignition coils

with output stage
♦ Puller - T10530-
Note
♦ The ignition coils are easier to remove when the engine is

warm.
♦ The grease used upon assembly in the factory makes it easier
to remove ignition coils or the spark plug connectors when the
engine is warm.
♦ When installing used ignition coils with output stage, the igni‐
tion coils must be lubricated with silicone paste ⇒ Electronic
parts catalogue (ETKA) .
♦ Ignition coils with output stage and spark plug connectors are
available individually for repairs ⇒ Electronic parts catalogue
(ETKA)
Removing
Ignition coils “cyl. 2, 3 and 4”:
324 .
1. Ignition system 409

All ignition coils (continued):

– Push puller - T10530- as far as stop into hole in ignition coil

-1-.
Note
The spark plug connectors are removed from the ignition coils by
hand.
Installing
– Apply a thin bead of silicone paste around sealing hose of ig‐

nition coil ⇒ Electronic parts catalogue (ETKA) .
– Slide spark plug connector -1- by hand onto ignition coil as far
as stop.

The vent drilling -2- must be centred relative to connector housing

-3- while doing so.
– Insert all ignition coils loosely into spark plug hole.
– Align ignition coils with connectors and simultaneously push
all connectors onto ignition coils.
– Press ignition coils evenly onto spark plugs by hand (do not
use tools).
Specified torque
1.3 Removing and installing knock sensor 1

- G61-
Removing
– Remove air conditioner compressor from bracket and tie up ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Assembly view - air conditioner compressor drive
unit .
– Unscrew bolt -2- and remove knock sensor 1 - G61- .
Installing
– Install A/C compressor.
Specified torque
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Assembly overview - drive unit of air conditioner
compressor
1.4 Removing and installing Hall sender

Removing Hall sender - G40-
324 .


– Unscrew bolt -2- and remove Hall sender - G40- .
Installing
– Install in reverse order.
Specified torque
1.5 Removing and installing engine speed

sender - G28-
♦ Socket, 4 mm - T10370-
Removing
– Remove noise insulation -1- ⇒ General body repairs, exterior;
sulation .
– Unscrew bolt -arrow-, and push charge air cooling pump -
V188- to one side.


– Unscrew bolt -2- and remove engine speed sender - G28- .
Installing
Note
♦ Carefully insert engine speed sender - G28- in bore!

♦ This will prevent the engine speed sender - G28- from falling
between engine and gearbox.
– Install in reverse order.

tion .
Specified torque
page 238

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Service

Service Department. Technical Information

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

4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

1.1 Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

1.2 Safety measures when working on vehicles with start/stop system

1.4 Safety precautions when working on the cooling system

1.5 Safety precautions when working on ignition system

Risk of damage to components

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

Engine code CJZA CJZB CYVA CYVB CYVD CJZD CJZC

Engine code CJZA CJZB CYVA CYVB CYVD CJZD CJZC

4 Rep. gr.00 - Technical data

3.1 Rules for cleanliness

3.2 General information

system, observe safety precautions

3.3 General repair instructions

3.4 Foreign objects in engine

In the event of mechanical damage to the turbocharger, proceed

3.5 Contact corrosion

3.6 Routing and attachment of lines

3.7 Fitting radiator and condensers

3.8 Checking vacuum system

6 Rep. gr.00 - Technical data

♦ Hand operated vacuum pump - VAS 6213-

10 – Removing and installing engine

1.1 Removing engine

1.1.1 Removing engine, Golf, Golf Estate, Golf SV, Touran

Special tools and workshop

♦ Release lever - 80 - 200-

8 Rep. gr.10 - Removing and installing engine

♦ Extension -2024 A /1- of lifting tackle - 2024 A-

♦ Locking pin - T10060 A-

♦ Commercially available stepladder

♦ The engine is removed downwards together with the gearbox.

1. Removing and installing engine 9

– Open cap -arrow- on coolant expansion tank.

Continued for all vehicles:

– Lift retaining clip -arrow- and disconnect coolant hose (top

– Cover radiator using protective mat - VAS 531003- .

10 Rep. gr.10 - Removing and installing engine

Vehicles with no auxiliary heater

Vehicles with auxiliary heater

Continued for all vehicles

– Unscrew bolts -arrows- from heat shield -1- of turbocharger,

1. Removing and installing engine 11

– Unscrew bolt -2- and remove screw-type clip.

– Undo bolts -arrow- and remove bracket.

– Release hose clip -1- and pull off coolant hose.

12 Rep. gr.10 - Removing and installing engine

– Open retainer for coolant hose -1-.

– Disconnect upper connector -1- on engine control unit - J623- .

1. Removing and installing engine 13

– Disconnect connector -2-.

– Release catches -arrows- and detach cover -1- for electronics