D3E801B26A2-4-Cylinder Common Rail Engine (1 6 L EA189)

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4-cylinder common rail engine (1.6 l, EA189)

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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D3E801B26A2

Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 ➤ , Passat 2006 ➤ ...
4-cylinder common rail engine (1.6 l, EA189) - Edition 02.2016
Contents
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00 - Technical data . r.is.ed. . . . . . . . . . . . . . . . . . . . . . . .ua.ra.nt . . . . . . .
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1 Identification
aut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a . . . . . ................... 1
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1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... 1
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2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.2 Safety precautions during road tests in which testing and measuring equipment is used . . 4
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2.3 Safety precautions when working on vehicles with a Start/Stop system . . . . . . . . . . . . . . 4
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2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Testing vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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2.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.8 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.2 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.3 Measuring piston projection at “TDC” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Contents i
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.3 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.5 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.1 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.3 Measuring radial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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3.5 Removing and installing
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3.6 Checking hydraulic
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compensation elements . . . . . . . . . t.ee.o. . . . . . . . . . . . . . . . . . . . . . . . . 208
3.7 au installing valve stem seal . . . . . . . . . . . . . .r a.c. . . . . . . . . . . . . . . . . . . . . . .
Removingssand 209
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

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4.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

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4.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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4.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

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4.4 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 t to the co
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

1.3 Removing and installing oil level and oil temperature sender G 266 . . . . . . . . . . . . . . . . 224
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1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

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1.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

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2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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2.3 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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3.1 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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3.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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3.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
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3.4 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

4.1 Assembly overview - oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.2 Removing and installing oil supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.3 Oil spray jets/nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
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2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

2.4 Checking thermostat . . . . . . . . . . . . . .ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G
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2.5 Removing and installing 4/2-wayy valve o lksw with thermostat . . . .es. n. o.t . . . . . . . . . . . . . . . . . . . . . 271
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2.6 Electric coolant pump . . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . 277
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2.7 Removing and installing acoolant
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h temperature sender . . . . . . . . . . . . . .or.a . . . . . . . . . . . . . 280
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3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
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4 Coolers, radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Assembly overview - radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
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4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
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4.3 Removing and installing radiator cowling with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . 311
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
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1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
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1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

1.3 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

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2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
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2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
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2.3 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

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2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
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1.2 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
AG.
1.3 Filling, bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
2.1 Schematic diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
3 Injectors and fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
3.1 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
3.2 Adapting correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.3 Testing jammed-open injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.4 Check pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3.5 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
3.6 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
3.7 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
4.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
4.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
5.1 Removing and installing fuel pressure regulating valve N 276 . . . . . . . . . . . . . . . . . . . . . . 416
5.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
5.3 Removing and installing fuel pressure sender G 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.4 Checking fuel pressure sender G 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
5.5 Checking fuel metering valve N 290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
5.6 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 422
6 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
6.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
6.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Contents iii
7.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

7.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
8 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
8.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
8.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
8.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
9.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464

1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
1.2 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
1.3 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
2.1 Assembly overview – emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
2.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
2.3 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
3.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 506
3.2 Removing and installing parts of exhaust gas temperature regulation . . . . . . . . . . . . . . . . 509
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
4.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
4.2 Checking changeover for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . 521
4.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 522
4.4 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
1.1 Removing and installing glow plugs . . . . .A.G.. V. o. lk. s.w.a.ge. n.A. . . . . . . . . . . . . . . . . . . . . . . . . . . 531
gen G
1.2 Checking glow plugs . . . . . . . . .V.o.lk.sw. a. . . . . . . . . . . . . . . .d.oe.s.n.ot. . . . . . . . . . . . . . . . . . . . . 533
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1.3 Removing and installing Hall issender
ed
b G40 . . . . . . . . . . . . . . . . . . .ua.ra.n. . . . . . . . . . . . . . . . . 533
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1.4 Removing and installing engine
ut
ho speed sender G 28 . . . . . . . . . . . . . . e. o.r . . . . . . . . . . . . . . 535
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Contents
00 – Technical data
1 Identification
(VRL008861; Edition 02.2016)
1.1 Engine number, engine data

⇒ “1.1.1 Engine number”, page 1
⇒ “1.1.2 Engine data”, page 1
1.1.1 Engine number

The first 3 digits refer to the mechanical configuration of the en‐
gine. They are stamped onto the engine.
The fourth digit indicates the output of the engine. It depends on
the engine control unit.
The four digit engine code can be found on the identification plate,
the vehicle data sticker and on the engine control unit.
The engine number (“engine code” and “serial number”) can be
found at the joint between engine and gearbox -arrow-.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”. n AG. Volkswagen A ge G do
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The engine code can also
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The engine numberthoconsists
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“engine code”, and the second part (6 characters), the “serial
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number”. If more than 999,999 engines were produced with the

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same code letters, the first of the six digits is replaced by a letter.
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1.1.2 Engine data

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Engine code CAYA CAYA CAYB CAYC CAYC

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Manufac‐ Golf 04.09 06.09 06.09

tured ► ► ►
rrectness of i
Golf 07.11
Cabrio ►
l purpos
Golf 04.09 06.09 06.09

Plus ► ► ►
nform
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Polo 05.09 05.09 07.09 07.09

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► ► ► ►
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sat 20 ►
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Emissions fulfil EU5 EU4 EU5 EU5 EU3

stand‐ stand‐ stand‐ stand‐ stand‐
ard ard ard ard ard
Capacity 1.6 1.6 1.6 1.6 1.6
Output KW at 55/400 55/400 66/420 77/440 77/440
rpm 0 0 0 0 0
1. Identification 1
Torque Nm at 195/ 195/ 230/ 250/ 250/

rpm 1500 .. 1500 .. 1500 .. 1500 .. 1500 ..
. 2000 . 2000 . 2500 . 2500 . 2500
Bore Diam‐ 79.5 79.5 79.5 79.5 79.5
eter
mm
Stroke mm 80.5 80.5 80.5 80.5 80.5 agen
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Valves per cylinder 4 4 4 4 d by V 4
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Compression ratio 16.5 16.5 16.5 16.5
hor 16.5 eo
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Fuel In ac‐ DIN DIN DIN ss DIN
a
DIN c
cord‐ EN EN EN EN EN
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Firing or‐ 1-3-4- 1-3-4- 1-3-4- 1-3-4- 1-3-4-
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Catalytic converter yes yes yes yes yes
hole
spec
Exhaust gas recir‐ yes yes yes yes yes
es, in part or in w
culation
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Turbocharging/su‐ yes yes yes yes yes
percharging
rrectness of i
Charge air cooler yes yes yes yes yes
l purpos
Particulate filter yes no yes yes no
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2 Rep. gr.00 - Technical data

AG. Volkswagen AG d
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2 Safety instructions
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⇒ “2.1 Safety precautions when working onthfuel
or supply system”, eo
page 3 ss au ra
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⇒ “2.2 Safety precautions during road tests in which testing and
nl
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measuring equipment is used”, page 4
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⇒ “2.3 Safety precautions when working on vehicles with a Start/
ility
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Stop system”, page 4
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⇒ “2.4 Safety precautions when working on cooling system”, page hole
spec
4
es, in part or in w
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2.1 Safety precautions when working on
fuel supply system
rrectness of i
l purpos
WARNING
The fuel line is under pressure.
nf
ercia
orm
Risk of injury to eyes and skin from fuel.
m
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Wear eye protection and protective clothing to avoid eye inju‐
n in
or c
ries and skin contact. Before loosening hose connections,
thi
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wrap a cloth around the connection. Then release pressure by

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carefully opening the connection point.
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To prevent injuries to persons and destruction of the injection and yri
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glow plug system, the following must be noted: cop Vo
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♦ Always switch off the ignition before connecting or discon‐
AG.
necting electrical wiring of injection and glow plug system or

connecting/disconnecting tester cables.
♦ Wash the engine only with the ignition switched off.
♦ Entries have been stored in the event memory of the engine
control unit if the engine was started after electrical connectors
had been disconnected: Read event memory in vehicle
self-diagnosis ⇒ Vehicle diagnostic tester .
Caution
♦ Observe prescribed procedures when disconnecting bat‐

tery ⇒ Electrical system; Rep. gr. 27 ; Battery; Discon‐
necting and reconnecting battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
2. Safety instructions 3
2.2 Safety precautions during road tests in

which testing and measuring equipment
is used
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accident hazard as a result of distraction and inadequate se‐

curing of test and measuring equipment
Danger as a result of activation of passenger airbag in event
of an accident
Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this loca‐
tion.
2.3 Safety precautions when working on ve‐

hicles with a Start/Stop system
WARNING
Risk of injury from automatic start of engine on vehicles with

Start/Stop system. agen
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♦ In the case of vehicles with activated
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(indicated by a message inhthe rise dash panel insert), it is nte
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possible that the engine will
au start automatically when nec‐ ra
c
essary. ss
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♦ Always ensure that the Start/Stop system is deactivated

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when working on vehicle (switch ignition off, switch ignition

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on again as required).
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2.4 Safety precautions when working on

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

ss
sure.
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Hot steam/hot coolant can escape - risk of scalding.

form
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Cover filler cap on expansion tank with a cloth and open care‐
om
fully to dissipate pressure.

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♦ Tighten cap of coolant expansion tank until it engages. Prote
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3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 Testing vacuum system”, page 6
3.1 Rules for cleanliness

⇒ “3.1.1 Rules for cleanliness when working on fuel supply sys‐
tem/injection system”, page 5
⇒ “3.1.2 Rules for cleanliness when working on turbocharger”,
page 6
3.1.1 Rules for cleanliness when working on

fuel supply system/injection system
♦ Clean tools and workbench etc. before working on injection
system.
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ When removing components, seal all open connections im‐
mediately with suitable clean sealing caps.
♦ Do not remove sealing caps from components until immedi‐
ately prior to installation. Place removed components in new
sealable plasticwbags
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♦ Beforetho
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tee
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vis‐
ually;
s au they must be undamaged and free of lint. Make acsure the
injector
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bores in the cylinder head are clean. Wipe out if nec‐
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essary using a clean cloth, taking care not to cause damage.

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Do not use sharp objects of any kind.

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♦ If high-pressure lines are not renewed, they must be labelled

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on removal. High-pressure fuel lines must always be re-instal‐

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led in their original positions (i.e. on the same cylinder).

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♦ The following components and seals/O-rings must always be

renewed when injectors are removed and installed: “copper

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seal”, “O-ring for injector bore”, “injector return clip” “also to be

used if necessary:” “O-ring for injector return connection” “,
injector seal”.
rrectne
♦ The following components, seals and O-rings must renewed

on renewing an injector: “included in the scope of supply are
ss o
” “copper seal”, “O-ring for injector bore”, “injector return clip”;

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“also to be used if necessary:” “O-ring for injector return line”,

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“injector seal”.
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♦ Always fit new copper seals for the injectors. Check all new O-
o
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rings for damage before installing. Lubricate O-rings lightly

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with assembly oil or clean engine oil before installing.

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♦ Take care not to damage the injectors when removing the old
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♦ Align high-pressure lines free from tension. First tighten all
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♦ On high-pressure lines, tools may be used only for loosening
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or tightening.
♦ Never attempt to reshape high-pressure fuel lines.
♦ Disassembling individual common high-pressure accumulator
components is not permitted.
♦ The components should be replaced as complete units if faul‐
ty.
3. Repair instructions 5
♦ Never attempt to bleed the common high-pressure accumu‐

lator system by loosening high-pressure components after
starting the engine.
♦ Do not carry out any installation work on common high-pres‐
sure accumulator system whilst engine is running. AG. Volkswagen AG d
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♦ In particular, do not open or release high-pressure lines and d by
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♦ All cable ties which were opened or cut open during
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♦ Also ensure that no diesel fuel comes into contact with the
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coolant hoses. Should this occur, the hoses must be cleaned
spec
immediately. Damaged hoses must be renewed.
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3.1.2 Rules for cleanliness when working on
turbocharger
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Caution
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When a mechanical fault is found on the turbocharger, e.g. a
form
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destroyed compressor impeller, it is not only sufficient to renew
atio
the turbocharger. To avoid subsequent damage, the following
om
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work must be carried out:
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♦ Check air filter housing, air filter element and intake hoses
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be renewed, if necessary.
When working on the turbocharger, pay careful attention to the

following rules for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
♦ When the system is open: Do not work with compressed air.
Do not move vehicle unless absolutely necessary.
3.2 Testing vacuum system

Special tools and workshop equipment required

♦ Hand vacuum pump - VAS 6213- lkswage es n
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Procedure
rrectness of i
– Check all vacuum lines throughout entire vacuum system for:
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♦ Cracks
nform
ercia
♦ Marten bites
m
at
♦ Crushing
om
ion
c
in t
r
♦ Porous areas and other leaks

o
his
ate
do
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– Check vacuum line to solenoid valve and from solenoid valve

p
cum
or
to relevant component.
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– If event is entered in memory, check vacuum lines to specified Cop py
component, but also additionally the other vacuum lines to
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– If pressure cannot be built up using hand vacuum pump - VAS
AG.
6213- or pressure immediately drops again, check hand vac‐

uum pump and connecting hoses for leaks.
3. Repair instructions 7
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 8
⇒ “1.2 Separating engine and gearbox”, page 48
⇒ “1.3 Securing engine on engine and gearbox support”,
page 50
⇒ “1.4 Installing engine”, page 51
1.1 Removing engine

⇒ “1.1.1 Removing engine, Golf, Golf Plus, Golf Cabriolet, Polo”,
page 8
⇒ “1.1.2 Removing engine, Passat”, page 21
⇒ “1.1.3 Removing engine, Touran”, page 35
1.1.1 Removing engine, Golf, Golf Plus, Golf Cabriolet, Polo

AG. Volkswagen n AG do
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Special tools and workshop ris
ed ran
tee
equipment required au
tho
or
ac
ss
♦ Lifting tackle - 3033-
ce
le
un
pt
an
d
♦ Hose clamps, up to 25 mm
itte
y li
- 3094- (for vehicles with
rm
ab
pe
manual gearbox)
ility
ot
wit
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♦ Torque wrench - V.A.G
h re
hole
1331-
spec
es, in part or in w
t to the co
1332-
♦ Stepladder - VAS 5085-
rrectness of i
♦ Workshop hoist - VAS
l purpos
6100-
nform
mercia
a
com
tion in
r
te o
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8 Rep. gr.10 - Removing and installing engine

♦ Drip tray for workshop hoist - VAS 6208-
♦ Spring-type clip pliers - VAS 6362-
♦ Transportation lock - T10403- swage

es n
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es, in part or in w
t to the co
♦ Engine bung set - VAS 6122- (not shown)
rrectness of i
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Note
nform
ercia
♦ Before carrying out further work, disconnect battery earth

strap. Check whether a coded radio is fitted. Obtain anti-theft
m
coding if necessary.
com
tion in
r
♦ The engine is removed forwards together with the gearbox.

te o
thi
s
iva
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♦ All cable ties that are opened or cut through when the engine
r
rp
cum
is removed must be renewed in the same position when the

fo
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engine is installed.
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1. Removing and installing engine 9

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

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ e.g. for fuel, hydraulics, activated charcoal filter system,
coolant and refrigerant, brake fluid, vacuum.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Removing
– Remove engine cover ⇒ page 76 .
– With ignition switched off, disconnect earth strap from battery.
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery
Polo
– Disconnect electrical connector -2-.
– Remove bolt -1-.
– Expose vacuum hoses -arrows- and place charge pressure
control solenoid valve - N75- on the engine.
AG. Volkswagen AG d
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Continuation for all vehicles olksw
oes
not
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ara
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– Remove air filter housing withoris air mass meter and connecting
e nte
eo
pipe. aut
h
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
– Detach vacuum line -arrow- on brake booster.

wit
, is n
h re
hole
– Remove noise insulation:

spec
es, in part or in w
Golf, Golf Plus, Golf Cabriolet, Passat 2006, Passat Variant

t to the co
2006, Polo, Touran ⇒ General body repairs, exterior; Rep. gr.

50 ; Noise insulation; Assembly overview - noise insulation
rrectness of i
– Drain coolant ⇒ page 259 .

l purpos
Vehicles with air conditioner

– Extract refrigerant from air conditioning system ⇒ Heating, air
nform
ercia
conditioning system; Rep. gr. 00 ; Repair instructions; Drain‐

ing the refrigerant circuit .
m
a
com
tion in
r
– Unbolt refrigerant lines -arrows- at condenser ⇒ Heating, air

te o
thi
conditioning; Rep. gr. 87 ; Refrigerant circuit; Disconnecting

s
iva
do
and connecting refrigerant lines .

r
rp
cum
fo
en
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Continuation for all vehicles

n
t.
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Cop py
– Remove lock carrier ⇒ General body repairs, exterior; Rep. ht. rig
rig ht
gr. 50 ; Lock carrier; Removing and installing lock carrier .
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull vacuum line -1- off vacuum pump -2-.

Golf
– Separate connectors.
AG. Volkswagen AG d
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♦ -1- Exhaust gasuthtemperature sender 1 - G 235-
o eo
ra
s a c
♦ -2- Exhaust gas
s temperature sender 4 - G 648-
ce
e
nl
pt
du
♦ -3- Lambda probe - G 39-
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itte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
– Disconnect connector for exhaust temperature sender 3 - G
l purpos
495- -1- (secured behind bracket).

– Guide lines out of brackets on plenum chamber bulkhead and nf
ercia
o
on turbocharger.
rm
m
atio
m
– Remove windscreen wiper arms and plenum chamber cover

o
n in
c
⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system;

or
thi
e
Removing and installing windscreen wiper arms .

t
sd
iva
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rp
cu
– Remove plenum chamber bulkhead ⇒ General body repairs,

o
m
f
exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Assembly

en
ng
t.
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overview - bulkhead . . Cop py
rig
ht ht
rig
– Remove engine control unit from its bracket ⇒ page 449 . py by
co Vo
by lksw
cted agen
Prote AG.
– Release connector for engine wiring harness -arrow- and pull
off from engine control unit.

– Open catch -A- of passage in plenum chamber bulkhead and

pull top part out upwards.
– Pull off vacuum hoses -1- and -2- for charge air control.
lkswage es n
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pt
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itte
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erm
ab
ility
– Unbolt positive cable -arrow- from starter at central electrics
ot p
and lay cable on engine. wit

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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
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– Separate connectors -1- and -2-.

o
n in
or c
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– Remove engine control unit wiring harness from cable duct.

t
sd
iva
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– Place engine wiring harness on engine.

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– Pull connector -2- off pressure differential sender - G 505- .

– Unscrew bolts -3 + 4-.
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– Unclip lines for pressure differential
auth
sender - G 505- out of up‐ or
ac
per toothed belt guard together with bracket -1-.
ss
ce
e
nl
pt
– Lay pressure differential sender - G 505- aside to rear together
du
an
itte
with lines.
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ility
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es, in part or in w
t to the co
rrectness of i
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– Unscrew bolts -1- for pressure differential sender - G 505-

bracket. nform
ercia
– Remove pressure differential sender - G 505- bracket.

m
at
– Remove fuel filter with bracket and place fuel filter on engine.
om
io
⇒ Rep. gr. 20 ; Fuel filter; Removing and installing fuel filter

n
c
in t
or
his
e
– Catch any escaping fuel.

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priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
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by
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Prote AG.

– Unscrew bolt -arrow-, and lay filler neck for windscreen waster
system reservoir aside.
Volkswa
– Remove lower sections of wheel shousing
agen liners on left
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right. by Vol not
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pt
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itte
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ab
ility
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wit
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hole
spec
– Unbolt positive cable -1- at positive distributor on battery.
es, in part or in w
t to the co
– During further procedure, lay cable down on engine.
– Remove air filter housing with air mass meter and connecting
rrectness of i
pipe ⇒ page 438 .
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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– Disconnect connectors -arrow-. cu

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f
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ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
– Carefully loosen engine wiring harness at its fastening points

-arrows-.
– Place engine wiring harness on engine.

– In order to ensure that vacuum hose -arrow 1- from brake ser‐

vo to engine is not damaged, you must remove it ⇒ Brake
systems; Rep. gr. 47 ; Brake servo/brake master cylinder;
Assembly overview - brake servo/brake master cylinder .
Pre-heater line -arrow 2- is not necessarily installed.

– Separate connectors at engine control unit ⇒ page 449 .
♦ -1- Exhaust gas temperature sender 1 - G 235-

AG. Volkswagen AG d
♦ -4- Lambda probe - G 39- lksw
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pt
du
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itte
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erm
ab
ility
ot p
wit
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– Disconnect electrical connector -2- at pressure differential h re

sender - G 505- .
hole
spec
es, in part or in w
– Unscrew bolt -3- from pressure differential sender - G 505-

t to the co
bracket.
rrectness of i
with lines.
l purpos
nf
ercia
orm
m
atio
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or c
thi
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sd
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

– Separate fuel supply line and return line at fuel transfer point.
The procedure for this is explained in ⇒ Rep. gr. 20 ; Detaching
plug-in connector .
– Using a finger, release lug from fuel pre-heater valve.

– Pull fuel pre-heater valve upwards out of coolant expansion
tank guide.
lkswage es n
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ir se tee
tho
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a ac
– Unclip fuel filter from lower part ofssfuel filter.
ce
le
un
pt
– Take fuel filter out upwards.
an
d
itte
y li
– Place fuel filter and fuel hoses together with fuel pre-heater
rm
ab
pe
ility
valve on engine.
ot
wit
, is n
– Remove lower part of fuel filter ⇒ Rep. gr. 20 ; Fuel filter;

h re
hole
Removing and installing fuel filter .

spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Filler neck: Unclip windscreen washer system reservoir -1-.

nform
ercia

m

a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
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V Golf 2009 ➤ , Golf Cabriolet g2012 ➤ , Golf Plus 2009 ➤ , Passat 2006 ➤ ...
ol not
d by ua
rise 4-cylinder common ran
rail
te engine (1.6 l, EA189) - Edition 02.2016
ho eo
aut ra
c
– During further
ss procedure, unscrew securing bolt for refrigerant
ce
e
line -arrow- from air conditioner compressor ⇒ Heating, air
nl
pt
du
an
conditioning; Rep. gr. 87 ; Air conditioner compressor; Re‐
itte
y li
moving and installing refrigerant lines from and to air condi‐
erm
ab
tioner compressor .
ility
ot p
wit
, is n
– Pull off refrigerant line at air conditioner compressor and lay it
h re
aside without kinking.
hole
spec
es, in part or in w
t to the co
– Remove coolant expansion tank and lay down on engine.
rrectness of i
l purpos
– Unscrew bolt -arrow- (attached), unscrew intake hose -A-

clockwise out of its bracket and remove.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Disconnect coolant hoses from heat exchanger for heater; lift‐

ing retaining clips -1 and 2- to do so.
Vehicles with dual clutch gearbox:
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Release catch on mechatronic connector by pulling -arrow-

and pull connector off.
Vehicles with manual gearbox:
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
anism .

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
– Remove bolts -arrows- and lay clutch slave cylinder aside. Do
y li
erm
ab
not open hydraulic system.
ility
ot p
– Guide clutch slave cylinder under strut -1-.
wit
, is n
h re
hole
spec
es, in part or in w
– Unbolt earth cable on gearbox.
t to the co
– Disconnect all connectors between starter, gearbox and body.
rrectness of i
l purpos
nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect connector on oil level and oil temperature sender

- G266- .

– Remove right drive shaft cover.

– Remove drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Tie up drive shafts as high as possible.
– Remove bolts -2…3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
– Remove securing clamp -1- between particulate filter and tur‐
an
itte
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bocharger.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– If necessary, securing clamp -2- between particulate filter and

orm
turbocharger must also be removed from above.
m
atio
om
n in
Golf
or c
thi
te
sd
iva
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f
en
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t.
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Cop py
t. rig
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by c lksw
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Prote AG.

lkswage es n
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byV ua
d ran
ir se tee
o
Golf 2009 ➤ , Golf Cabriolet 2012 ➤au , Golf Plus 2009 ➤ , Passat 2006 ➤ ...
th or
ac
ss
ce
e
nl
pt
du
an
– Loosen securing nuts above particulate filter bracket -1- using
itte
y li
ratchet wrench, 13 mm - T10384- .
erm
ab
ility
ot p
– Unscrew securing nuts -2- for particulate filter bracket on
wit
, is n
crankcase.
h re
hole
spec
Polo
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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op
– Unscrew bolts -1- and nuts -2-. C py
t. rig
gh ht
yri
– Remove particulate filter bracket.
p by
co Vo
by lksw
cted agen
Prote AG.
– Push particulate filter aside and fix it in position on plenum

chamber bulkhead using suitable means.
Note
Check that all hose and line connections between engine, gear‐
box and body have been detached.
– Use lifting tackle - 3033- and workshop hoist - VAS 6100- to

support »engine/gearbox assembly« in installation position.
Vibration damper end:
• Position 2.
Flywheel end:
• Position 8.
Golf
– Unscrew securing bolts -arrows- of assembly mounting at en‐

gine.

– Unscrew securing bolts -arrows- of assembly mounting at

gearbox.
Polo
Remove complete engine assembly mounting ⇒ page 63 .
– Unscrew nut -1- and expose earth line

Remove assembly mounting at gearbox.
– To do this, undo bolts -arrows- for support arm of engine

mounting.
Note
. Volkswagen AG
gen AG does
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Carefully guide »engine/gearbox assembly« when removing
by
Vol
k to not
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avoid damage to body. rised ara
nte
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– Slightly lift »engine/gearbox assembly« and
ss
remove forwards. c
ce
e
nl
pt
du
Secure engine on engine and gearbox support - VAS 6095- to

an
itte
carry out repairs ⇒ page 50 .

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erm
ab
ility
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1.1.2 Removing engine, Passat

wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Read out radio anti-theft code as the battery earth strap has
to be disconnected during the next work steps.
rrectness of i
♦ The engine is removed downwards together with the gearbox.

l purpos
is removed must be renewed/replaced in the same position
nform
ercia
when the engine is installed.

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

WARNING

tions:
♦ Route all types of lines so that the original routing is re‐
stored.
hot components.
Special tools and workshop

equipment required
♦ Hose clamps up to 25 mm -
3094- n AG. Volkswagen AG do
lkswage es n
o ot g
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♦ Engine bracket - T10012- ir se
d b ran
tee
tho
or
♦ Torque wrench - V.A.G au ac
1331- ss
ce
e
nl
pt
du
an
itte
y li
1332-
erm
ab
ility
ot p
♦ Engine and gearbox jack -
wit
, is n
V.A.G 1383 A-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
kswGolf 2009 ➤ , Golf Cabrioletnot 2012 ➤ , Golf Plus 2009 ➤ , Passat 2006 ➤ ...
agen oes
ol
d by
V
4-cylinder common
gu
ara rail engine (1.6 l, EA189) - Edition 02.2016
rise nte
ho eo
♦ ut pliers - VAS 6340-
Hose clip
a ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Disconnect electrical connector on air mass meter - G70- .
pipe ⇒ page 437 .
– Unscrew bolts -arrows- and remove air duct from lock carrier.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove connector from engine wiring harness; to do this, en‐
gine control unit with protective housing must be be removed.
Removing and installing engine control unit with protective hous‐
ing, Passat 2006► ⇒ page 459
Removing and installing engine control unit with protective hous‐
ing, Passat 2011► ⇒ page 461

– Release feed-through for engine wiring harness -arrow- and

pull off upwards.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
– Unscrew bolts -arrows-ss and remove battery mounting bracket c
-1-.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
♦ -3- Lambda probe - G 39- atio

om
n in
c
♦ -4- Charge pressure control solenoid valve - N75-

or
thi
te
sd
a
– Unscrew charge pressure regulation solenoid valve - N75-

iv
o
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rp
cu
-arrows-.
o
m
f
en
ng
t.
yi
– Place charge pressure control solenoid valve - N75- with vac‐
Co
op py
uum lines on engine.
t. C rig
gh ht
pyri by
Vo
– Guide lines out of brackets on plenum chamber bulkhead and
co lksw
by
cted agen
on turbocharger. Prote AG.
– Unscrew bolts -upper arrows- for cowling.
Note
♦ The bolts -lower arrows- are removed at a later stage.

♦ Disregard -item 1-.
– Remove charge pressure regulating valve from plenum cham‐

ber bulkhead and lay it on engine together with vacuum hoses.

– Slide the two clips in the direction of the -arrows- and remove
cover from E-box in engine compartment.
– Unscrew lines -arrows- at central electrics and lay lines on en‐

gine.
– Open cable guide retainer -arrows-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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– Disconnect engine wiring harness connector -arrow- below left

mer
headlight.
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– Free electrical connector -1- and disconnect.

– Open retainer -2- for wiring guide located below.
– Remove wiring harness for engine control unit from wiring duct
and place on engine.
– Pull vacuum hose -arrow- off brake booster. agen

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– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ; ed b y V gu
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Selector mechanism; Removing and installing selector mech‐ horis nte
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Caution
Risk of destroying clutch slave cylinder.

♦ Do not press clutch pedal when clutch slave cylinder is
removed.

– Unscrew nut -1- for earth line.

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WARNING byV
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pt
lines can reach 100°C after the engine is switched off. Al‐
an
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spec
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– Disconnect electrical connector -1- at fuel temperature sender
rrectness of i
- G81- .
Remove fuel filter complete with fuel lines.
l purpos
Removing and installing fuel filter (Golf, Golf Plus, Passat 2006►,
nform
ercia
Touran) ⇒ Rep. gr. 20 ; Fuel filter; Removing and installing fuel

filter .
m
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Removing and installing fuel filter, 6.0 bar low-pressure fuel sys‐
n in
r
tem (Passat 2011 ►) ⇒ Rep. gr. 20 ; Fuel filter; Removing and

te o
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rig ht
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-2-, unscrew securing bolts -1-. by c lksw
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– Unclip lines for pressure differential sender - G 505- out of up‐

– Lay pressure differential sender - G 505- on particulate filter
together with bracket.
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– Unscrew bolts -arrows- on engine mounting approx. 2 turns.

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w agen does n
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noise insulation
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– Remove lower right and left wheel housing liner parts.
t to the co
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– Remove charge air line, loosen hose clips -1- and -2- for this.
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cted AG.
agen
– Seal open lines and unions with clean plugs from engine seal‐
ing plug set - VAS 6122- .

– Unscrew bolts -lower arrows- and take out cowling down‐
wards.
Note
Ignore -arrows-.

– Disconnect electrical connectors -3- and -2- »if fitted«.

conditioning system; Rep. gr. 00 ; Repair instructions; Drain‐
ing the refrigerant circuit . AG. Volkswagen AG d
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es, in part or in w
pressor.
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– Remove nuts -1 and 2-.

– Tie up particulate filter to rear.
Caution
Avoid damage to the flexible joint.

♦ Do not bend decoupling element in front exhaust pipe
more than 10°.
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nl
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spec
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Drain coolant ⇒ page 259 .
– Place drip tray for workshop hoist - VAS 6208- under engine
for this.
rrectness of i
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– Disconnect bottom coolant hose leading to continued coolant
nform
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circulation pump (loosen hose clip -arrow-) and drain off cool‐
ant.
m
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Separate quick-release couplings at cooler.

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– Disconnect left upper coolant hose from radiator, lift retaining

clip -arrow- when doing this.

– Disconnect right lower coolant hose from radiator, lift retaining

clip -arrow- when doing this, and drain off coolant.
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– Remove bolts -arrow up- -arrow down- and lift radiator up and
h re
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out.
spec
t to the co
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cial p
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atio
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– Disconnect quick-release couplings for heat exchanger
thi
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-arrows- on plenum chamber bulkhead.

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– Open clip -item 1- and pull coolant hose from expansion tank.

– Open clip -item 3- and pull off coolant return hose.
– Disconnect electrical connector -arrow- on oil level and oil

temperature sender - G266- .
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– Loosen hose clip -2-.
hole
spec
es, in part or in w
– Remove bolts -arrows-.
t to the co
– Disconnect electrical connection -1- on charge pressure send‐
er - G31- / intake air temperature sensor - G42- and remove
rrectness of i
air pipe.
– Free coolant hose -3-.
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– Unscrew securing bolt -arrow- for continued coolant circulation

pump.

– Remove front noise insulation -1- for sump, loosen securing

parts -arrows- for this.
– Insert engine bracket - T10012- in engine and gearbox jack -
V.A.G 1383 A- .
– Bolt engine bracket - T10012- with securing bolt -1- and nut
-2- to cylinder block (tightening torque: approx. 20 Nm).
– Raise engine/gearbox assembly slightly.
AG. Volkswagen AG d
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To unscrew bolts for assembly mounting use stepladder -
ce
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VAS 5085- .
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– Completely unscrew bolts -arrows- for engine mounting.

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– Completely unscrew bolts -arrows- for gearbox mounting.
Caution
Danger of damage to hose and line connections as well as

engine compartment.
♦ Check that all hose and line connections between engine,
gearbox, subframe and body have been disconnected.
♦ When lowering, carefully guide engine/gearbox assembly
out of engine compartment.
♦ Ensure clearance to air conditioner compressor.
– First lower engine/gearbox assembly slightly.

– Then swing gearbox end of engine/gearbox assembly for‐
wards and only then lower further.
1.1.3 Removing engine, Touran
Special tools and workshop n AG. Volkswagen AG do

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♦ Lifting tackle - 2024 A- utho
or
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♦ Engine bracket - T10012- s
ce
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un
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♦ Support clamp - VW 313-
an
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itte
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♦ Engine and gearbox sup‐
pe
ility
port - VW 540-
ot
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♦ Workshop hoist - V.A.G
hole
spec
1202 A-
es, in part or in w
♦ Drip tray - V.A.G 1306- t to the co

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1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -
VAS 5024-
♦ Guide rods - T10093-
♦ Cable ties
AG. Volkswagen AG d
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coding first if necessary.
nf
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♦ The engine is removed downwards together with the gearbox.

orm
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is removed must be renewed/replaced in the same position

or c
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when the engine is installed.

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WARNING Cop
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When doing any repair work, especially in the engine compart‐ pyri by
Vo
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lksw
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Prote
tions:
AG.
♦ Route all the various lines as well as electrical wiring so

that they are in their original positions.
hot components.

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Golf 2009h➤ oris , Golf Cabriolet 2012 ➤ , Golf Plus 2009nte➤ e o , Passat 2006 ➤ ...
t
s au 4-cylinder common rail engine (1.6 l, EA189) r a - Edition 02.2016
c
s
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Removing
du
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– Disconnect electrical connector -1- from air mass meter -
wit
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G70- .
h re
hole
spec
– Pull hose -3- off air filter housing.
es, in part or in w
t to the co
– Loosen bolt -arrow 4-.
– Remove air filter housing with air mass meter and intake hose.
rrectness of i
l purpos

nf
ercia
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
or
27 ; Battery; Removing and installing battery .
m
m
atio
m
– Remove plenum chamber bulkhead. ⇒ General body repairs,

o
n in
or c
thi
e
overview - bulkhead .
t
sd
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– Remove shear head bolts -arrows- from anti-theft-secured en‐
en
ng
t.
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gine control unit - J623- ⇒ page 454 . . Cop py
rig
ht ht
rig
– Release engine wiring harness connector from engine control py by
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unit and disconnect.
by c lksw
cted agen
Prote AG.
WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
Note
Do not place the vehicle on the ground once the centre bolt has
been removed.

– Apply the brakes: Loosen hexagon bolt -arrow- for drive shaft
on right at wheel hub (2nd mechanic) ⇒ Running gear, axles,
drive shaft .
– Remove lower connecting hoses leading to charge air cooler
⇒ page 353 .
conditioning system; Rep. gr. 00 gen;ARepair
G. Volkswinstructions;
agen AG
does
Drain‐
ing the refrigerant circuit V.olkswa not
g
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db ran
rise tee
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Cautionauth or
ac
ss
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e
Danger of damage to air conditioner compressor, refrigerant

nl
pt
du
an
lines and hoses.
itte
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erm
ab
ility
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wit
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hole
spec
– Detach refrigerant lines -arrows- from air conditioner com‐
es, in part or in w
pressor.
t to the co
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
rrectness of i
installing air conditioner compressor .

l purpos

nf
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orm
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Cop py
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Prote AG.

– Open all cable guide fasteners -arrows-.

– Remove wiring harness from cable guide on longitudinal mem‐
ber and lay to side on engine.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and gearbox and move to one side.
– Separate all connecting, vacuum and intake hoses from en‐
gine.
Vehicles with manual gearbox
Caution
Risk of destroying clutch slave cylinder.

♦ Do not press clutch pedal when clutch slave cylinder is
removed.
– Remove slave cylinder for hydraulic clutch ⇒ Rep. gr. 30 ;

AG. Volkswagen
Clutch mechanism; Assembly overviewlk-swclutch
agen hydraulics . AG does
n o ot g
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– Unbolt selector mechanism fromrisegearbox
db ⇒ Rep. gr. 34 ; ran
tee
Selector mechanism; Removing utho and installing selector mech‐ or
anism . ss
a ac
ce
le
– Remove clutch slave cylinder and put to side; do not open line
un
pt
an
d
circuit.
itte
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ility
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– Unscrew bolts -arrows- on gearbox mounting approx. 2 turns.
wit
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Vehicles with dual clutch gearbox
ole,
spec
– Remove selector lever cable from gearbox. ⇒ Rep. gr. 34 ;
t to the co
anism
rrectness o
cial p
f inform
mer
atio
om
– Release mechatronic unit connector by pulling and pull off

c
i
or
connector ⇒ Rep. gr. 34 ; Mechatronic unit; Removing and

thi
te
sd
a
installing mechatronic unit .

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Cop py
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Unscrew bolts -2- on gearbox mounting approx. 2 turns.

Loosen particulate filter ⇒ page 480 .

bocharger.
AG. Volkswagen AG d
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– Remove bolt -1-. olksw not
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– Slide the two clips in the direction of the -arrows- and remove
cover from E-box in engine compartment. rrectness of i
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Cop py
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– Unscrew lines -arrows- at central electrics and lay lines on en‐

gine.
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– Disconnect engine wiring harness connector -arrow- below left
ility
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headlight.
wit
is n
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spec
t to the co
rrectness o
cial p
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mer
atio
– Free electrical connector -1- and disconnect.
om
n
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i
– Open retainer -2- for wiring guide located below.
or
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sd
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– Remove wiring harness for engine control unit from wiring duct
i
o
pr
cum
and place on engine.
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fo
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t.
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Cop py
t. rig
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by c lksw
cted agen
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– Pull vacuum hose -arrow- off brake booster.

– Unscrew nut -1- for earth line.

WARNING
Danger of scalding from very hot fuel.

♦ In extreme cases, the temperature of the fuel and the fuel
lines can reach 100°C after the engine is switched off. Al‐
low the fuel to cool down before disconnecting the lines -
danger of scalding.
♦ Wear eye protection.
– Disconnect electrical connector -1- at fuel temperature sender

- G81- .
– Open clips -items 2, 4- and pull off fuel supply line and fuel
return line.
– Disconnect fuel supply line and fuel return line at

-items 2 and 3-. agen
AG. Volkswagen AG d
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olks ot g
The procedure for this is explained ined⇒
by Rep. gr. 20 ; Push-on
V ua
ran
couplings; Detaching plug-in connector
ho
ris . tee
t or
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Remove fuel filter complete with
ss fuel lines.
ce
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pt
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t to the co
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mer
atio
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c
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or
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t.
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Cop py
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– Loosen bolt -1-.

– Remove bolt -2- and nut -3-.
– Take hose retainer -4- off fuel filter, place fuel filter -7- aside
(fuel hoses -5- and -6- remain connected).
– Disconnect connector at pressure differential sender - G 505-

-2-, unscrew securing bolts -1-.
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– Lay pressure differential sender - G 505- on particulate filter

om
together with bracket.

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by lksw
cted agen
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– Unscrew bolts -arrows- for engine mounting approx. 2 turns.

– Seal open lines and unions with clean plugs from engine seal‐
ing plug set - VAS 6122- .

– Unscrew bolts -lower arrows- and take out cowling down‐
wards.
Note
Ignore -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
– Disconnect electrical connectors -3- and -2- »if fitted«.d by V gu
ara
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– Disconnect electrical connector -1-. rrectness of i
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Prote AG.

– Unscrew bolts -1…3- and remove pendulum support.

AG. Volkswagen AG d
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es, in part or in w
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– Remove nuts -1 ... 2-.
– Tie up particulate filter to rear.
rrectness of i
Caution
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nform
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♦ Do not bend decoupling element in front exhaust pipe

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a
more than 10°.
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– Unscrew bolts -arrows- and remove heat shield for right drive
shaft.
– Unbolt drive shafts from gearbox ⇒ Running gear, axles,
drive shaft .
– Tie up left drive shaft.
– Place a drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
Drain coolant ⇒ page 259 .
– Disconnect left upper coolant hose from radiator, lift retaining

clip -arrow- when doing this.

– Disconnect quick-release couplings for heat exchanger

-arrows- on plenum chamber bulkhead.
– Open clip -item 1- and pull coolant hose from expansion tank. AG. Volkswagen AG d
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– Open clip -item 3- and pull off coolant return hose.
– Separate all other coolant hoses from engine.
rrectness of i
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– Disconnect electrical connector -1- on oil level and oil temper‐ C py
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– Unclip retainer -2- on subframe for electrical line to oil level cted agen
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and oil temperature sender - G266- .


air pipe.
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– Remove front noise insulation -1- isedfor
b sump, loosen securing ara
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parts -arrows- for this. hor eo
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– Insert engine bracket - T10012-
s in engine and gearbox jack -
ce
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V.A.G 1383 A- .
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– Bolt engine bracket - T10012- with securing bolt -1- and nut
-2- to cylinder block (tightening torque: approx. 20 Nm).
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Ask a second mechanic for assistance.

nf
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– Raise engine/gearbox assembly slightly.

orm
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To unscrew bolts for assembly mounting use stepladder - . Volkswag

VAS 5085- . swa
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– Completely unscrew bolts -arrows- for risengine mounting. nte
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– Completely unscrew bolts -arrows- for gearbox mounting.
h re
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spec
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Caution
t to the co
Danger of damage to hose and line connections as well as
engine compartment.
rrectness of i
♦ Check that all hose and line connections between engine,
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gearbox, subframe and body have been disconnected.

♦ When lowering, carefully guide engine/gearbox assembly
nf
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out of engine compartment.
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♦ Ensure clearance to radiator.

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– First lower engine/gearbox assembly slightly.
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– Lower engine/gearbox assembly forwards slightly.

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1.2 Separating engine and gearbox

♦ Hooks - 10 - 222 A /2-

♦ Workshop hoist - VAS 6100-
♦ Lifting tackle - T40013-
AG. Volkswagen AG d
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Procedure Volksw not
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• Engine/gearbox
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bracket
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– Attach lifting tackle - T40013- to gearbox and close lock.
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– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /

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2- to lifting tackle.
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– Unscrew bolts -1- and -2-, and take starter off gearbox.
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– Unscrew bolts -1, 3, 4- from gearbox/engine connection.

– Pull gearbox off engine.
Note
Disregard -items 2, 5, A-
1.3 Securing engine on engine and gearbox

support
Before carrying out repair work, secure engine on engine and
gearbox support - VAS 6095/1- using universal mounting - VAS
6095- .

equipment required
♦ Lifting tackle - 3033-
♦ Workshop hoist - VAS
6100-
port - VAS 6095-
AG. Volkswagen AG d
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Procedure
C py
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Gearbox detached from engine.
op Vo
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– Attach lifting tackle - 3033- as follows and lift slightly with

workshop hoist - VAS 6100- .
Flywheel end: position 4.
Vibration damper end: position 8.
– Secure engine on engine and gearbox support - VAS 6095/1-
using universal mounting - VAS 6095- .
1.4 Installing engine

⇒ “1.4.1 Notes on installing, Golf, Golf Plus, Golf Cabriolet, Polo”,
page 51
⇒ “1.4.2 Notes on installing, Passat, Touran”, page 53
⇒ “1.4.3 Installing engine”, page 55
n AG. Volkswagen AG
1.4.1 Notes on installing, Vol
kswGolf, Golf Plus, Golf
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Caution
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When installing a new short engine, it is compulsory to tighten
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the clamping jaws of the injectors to the specified torque after
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installing the high-pressure lines ⇒ Item 20 (page 374) .

wit
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Clamping jaws are only secured »hand-tight« for setting the

injectors while installing high-pressure lines. Non-observance h re
hole
of these notes may lead to damage to engine. spec

es, in part or in w
t to the co
Installation is performed in the reverse sequence. In the process,

note the following:
rrectness of i
Repairing clutch: ⇒ Rep. gr. 30 ; Clutch mechanism; Overview

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of fitting locations - clutch mechanism

nf
– Check whether dowel sleeves for centring engine/gearbox

ercia
have been fitted in cylinder block, insert if necessary.

rm
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– When installing »engine/gearbox assembly«, ensure sufficient

o
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c
clearance to subframe and radiator.

or
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Golf, Golf Plus

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– Adjusting assembly mountings ⇒ page 60 .

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Specified torques: t. C rig
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⇒ “2.1 Assembly overview - assembly mountings”, page 60 . yri
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Specified torques:
⇒ “2.1.2 Assembly overview - assembly mountings, Polo”,
page 62 .
Electrical connections and routing ⇒ Electrical system; Rep. gr.
00 ; Repair instructions; Routing and securing wires .
Vehicles with manual gearbox:
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;
Removing and installing clutch slave cylinder .

– Install gearbox selector mechanism and adjust if necessary ⇒

Rep. gr. 34 ; Manual gearbox; Removing and installing man‐
ual gearbox .
Vehicles with dual clutch gearbox:
– Install selector lever cable and adjust if necessary ⇒ Rep. gr.
34 ; Selector mechanism; Removing and installing selector
mechanism .
Note
♦ After working on particulate filter, ensure it is installed free of

stress. . Volkswagen AG
gen AG does
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♦ Renew self-locking nuts, seals, gaskets and securing clamps.
by
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♦ The further procedure must be followed in the specified
ris se‐ nte
tho eo
quence to ensure that the particulate filter is installed
au tension- ra
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free.
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Caution
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Avoid damage of decoupling element behind particulate filter.
h re
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When removing and installing:
spec
es, in part or in w
♦ Do not bend decoupling element more than 10°.
t to the co
♦ Install decoupling element so that it is not under tension.
♦ Take care not to damage wire mesh on decoupling ele‐
rrectness of i
ment.
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Observe sequence when installing particulate filter:
nform
mercia
1. Position particulate filter on turbocharger and secure clip
at
om
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-1- loosely.
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2. Screw bolts and nuts -2 … 5- in/on by hand loosely
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• Particulate filter and retainer must be able to move

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3. Tighten clip -1-

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Polo: specified torques - particulate filter ⇒ page 476
Golf, Golf Plus; Passat, Touran: specified torques - particulate
filter ⇒ page 472 .
– Bolt drive shafts to gearbox ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .

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– Install heat shield for drive shaft (right
au
th side)
o
-1-. e or
ac
ss
Specified torque for bolts for drive shaft heat shield -1- ⇒ Running
ce
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nl
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
pt
du
an
itte
installing drive shaft heat shield .
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– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
ility
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50 ; Lock carrier; Removing and installing lock carrier .
wit
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hole
– Secure refrigerant lines to air conditioner compressor and
spec
condenser such that they are tension-free ⇒ Heating, air con‐es, in part or in w
ditioning; Rep. gr. 87 ; Refrigerant circuit; Disconnecting and
t to the co
connecting refrigerant lines from and to condenser .
– Fill air conditioning system ⇒ Air conditioning systems with
rrectness of i
refrigerant R134a; Rep. gr. 00 ; Working with air conditioner
service station; Filling refrigerant circuit using air conditioner
l purpos
service station .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
nf
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– Observe notes after connecting battery ⇒ Electrical system;

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Rep. gr. 27 ; Battery; Disconnecting and reconnecting battery .

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– Replenish coolant ⇒ page 261 .

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– Filling fuel system ⇒ page 383 .
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– Read event memories of all control units.
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– Clear all entries which may have occurred during installation co Vo
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⇒ Vehicle diagnostic tester.
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Prote AG.
– Check headlight adjustment and correct if necessary ⇒ Main‐

tenance ; Booklet 20.1 .
Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm1)
1) Specified torque for M 12 flange bolts: 75 Nm
1.4.2 Notes on installing, Passat, Touran
Caution

installing the high-pressure lines ⇒ Item 20 (page 374) .
Clamping jaws are only secured »hand-tight« for setting the
injectors while installing high-pressure lines. Non-observance
of these notes may lead to damage to engine.
Installation is carried out in the reverse order. When installing,

note the following:
Repairing clutch: ⇒ Rep. gr. 30 ; Clutch
– When installing »engine/gearbox assembly«, ensure sufficient
clearance to subframe and charge air cooler.

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– On vehicles with manual agearbox,
ut
h check clutch release bear‐ e or
ac
ing for wear, and renewssif necessary. Lightly grease splines
on input shaft with G 000 100.
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nl
pt
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itte
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Touran
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hole
– Position right driver shaft in installation position together with
spec
engine/gearbox assembly.
es, in part or in w
t to the co
Continuation for Passat, Touran
– Align assembly mountings so that they are tension free by
rrectness of i
shaking them, then adjust ⇒ page 60 .
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Specified torques for assembly mountings ⇒ page 60 Overview

- assembly mountings.
nform
ercia
Electrical connections and routing ⇒ Electrical system; Rep. gr.

00 ; Repair instructions; Routing and securing wires .
m
at
om
io
– Bolt drive shafts to gearbox ⇒ Running gear, axles, steering;
n
c
in t
or
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
his
ate
do
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– Install particulate filter ⇒ page 480 .

p
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– Install hydraulic line for hydraulic clutch ⇒ Rep. gr. 30 ; Clutch

n
t.
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mechanism; Assembly overview - clutch hydraulics . C py
t. rig
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yri
– Install selector mechanism and adjust cables if necessary ⇒
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Rep. gr. 34 ; Selector mechanism; Removing and installing Prote
cted AG.
agen
selector mechanism .
– Install refrigerant lines of air conditioning system and fill air
conditioning system ⇒ Air conditioning systems with refriger‐
ant R134a; Rep. gr. 00 ; Working with air conditioner service
station; Filling refrigerant circuit using air conditioner service
station .
– Install the battery and battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery .
– Install noise insulation:
noise insulation
– Carry out road test and read all event memories.
Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm

1.4.3 Installing engine
Caution

installing the high-pressure lines ⇒ Item 20 (page 374)en.AG. Volkswagen AG
Clamping jaws are only secured »hand-tight« for settingVol
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injectors while installing high-pressure lines. Non-observance
edb
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au ac
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Specified torques
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Note
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♦ Specified torques only apply to lightly greased, oiled, phosph‐
hole
spec
ated or blackened nuts and bolts.
es, in part or in w
t to the co
♦ Additional lubricant such as engine oil or gear oil may be used,
but do not use lubricant containing graphite.
rrectness of i
♦ Do not use degreased parts.
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♦ Tolerance for specified torques is ± 15%.
nform
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Component Nm
m
Nuts and bolts M6 10
at
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ion
M7 15
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M8 20
at
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M10 40
um
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M12 65
t.
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Except for the following:
t. rig
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Drive shaft heat shield to cylinder block 35
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Prote AG.

Gearbox to engine attachment

Item Bolt Nm
1 M12 x 55 80
2 1) M12 x 150 80
3 M10 x 50 40
4 M12 x 60 80
5 2) M6 x 8 10
A Dowel sleeves for centralising
• 1) Also secures starter
• 2) Cover plate for flywheel

note the following:
• Engine/gearbox assembly mounted on engine bracket -
T10012- .
Note
♦ Renew bolts tightened through an additional specified angle.

♦ Renew self-locking nuts and bolts as well as gaskets, seals
and O-rings.
♦ Hose connections as well as pipes and hoses of air channels
agen
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must be free of oil and grease when installing. Vol
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♦ Secure all hose connections with the hose clips corresponding
ho
ris
e
tee
to original equipment ⇒ Electronic Parts Catalogue
au
t (ETKA) . or
ac
ss
♦ All cable ties must be secured again in the same position on
ce
le
un
pt
installation.
an
d
itte
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ab
ility
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– Ensure that the intermediate plate is engaged on the sealing

wit
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flange and pushed onto the dowel sleeves -arrows-.

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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– If no dowel sleeves -A- for aligning engine and gearbox are

i
or
n thi
fitted in cylinder block, install dowel sleeves.

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sd
iva
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– If clutch release bearing is worn, renew it ⇒ Rep. gr. 30 ;

p
cum
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fo
Clutch mechanism; Repairing clutch release mechanism .

en
ng
t.
yi Co
op
– Lightly grease gearbox input shaft splines with grease for
C py
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clutch plate splines ⇒ Electronic Parts Catalogue (ETKA) .
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– Check centring of clutch plate.
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Prote AG.
– Secure gearbox to engine.

– Guide engine/gearbox assembly into body.

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aut 4-cylinder common rail engine (1.6 l, EA189) r a - Edition 02.2016
c
ss
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– First screw bolts -arrows- for engine mountings into stop by
pt
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an
hand.
itte
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ility
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es, in part or in w
t to the co
rrectness of i
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– First screw bolts -arrows- for gearbox mountings into stop by
nf
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o
hand.
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or c
Note
thi
te
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iva
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cu
(Golf, Golf Plus, Passat): The bolts are tightened to final torque
o
m
f
only after adjusting the assembly mountings ⇒ page 60 .
en
ng
t.
yi Co
Cop py
t. rig
– Remove engine bracket - T10012- from engine.
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Installing continued coolant circulation pump ⇒ page 285 .

– Installing charge air pipe ⇒ page 352 .
– (Golf, Golf Plus, Passat) Installing intake unions
– (Polo) Installing intake unions
– Installing intake hoses with screw-type clips ⇒ page 360 .
– Install drive shafts, transverse link and coupling rod ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor
wage
n AG. Vo.lkswagen AG do
es ks not
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– Install poly V-belted⇒bypage 80 . ara
nte
is
or e
– Install starterau ⇒ Electrical system; Rep. gr. 27 ;
th Starter; Re‐or a
moving and installing starter.
ss c
ce
e
nl
pt
– Install wheel housing liner front parts ⇒ General body repairs,
du
an
itte
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
y li
erm
ab
installing wheel housing liner .
ility
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wit
– Installing radiator ⇒ page 306 .
, is n
h re
hole
– Connect coolant hoses with plug-in connector to heat ex‐

spec
changer for heater.
es, in part or in w
t to the co
– Install pressure differential sender - G 505- ⇒ page 422 .
– Install washer fluid reservoir filler pipe with filler neck.
rrectness of i
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;

l purpos
Removing and installing clutch slave cylinder .

– Install cable with cable support bracket ⇒ Rep. gr. 34 ; Se‐
nform
ercia
lector mechanism; Assembly overview - selector mechanism .

m
at
– Install pendulum support ⇒ page 60 .

om
ion
c
in t
r
– (Golf, Golf Plus, Passat) Adjust assembly mounting

o
his
te
⇒ page 60
a
do
priv
cum
or
– Electrical connections and routing ⇒ Electrical system; Rep.

f
en
g
gr. 00 ; Repair instructions; Routing and securing wires .

n
t.
yi Co
Cop py
.
– Install battery mounting and battery ⇒ Electrical system; Rep.
t rig
gh ht
yri by
gr. 27 ; Battery; Removing and installing battery . cop Vo
by lksw
cted agen
Prote
– Install and adjust wiper arms ⇒ Electrical system; Rep. gr.
AG.
92 ; Windscreen wiper system; Removing and installing wiper

arms .
– Install air filter housing ⇒ page 437 .
– Check oil level ⇒ page 227 .
Caution
Danger of destroying control units through excessive voltage.

♦ Never use battery charging equipment for boost starting.



noise insulation
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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au ra
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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Vo
co lksw
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Prote AG.

4-cylinder common rail eengine (1.6 l, EA189) - Edition 02.2016
n AG. Volkswagen AG ag does
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2 Assembly mountings thoris nte
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s au ra
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⇒ “2.1 Assembly
s
overview - assembly mountings”, page 60
ce
e
nl
pt
du
⇒ “2.3 Adjusting assembly mountings”, page 72
an
itte
y li
erm
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⇒ “2.1.3 Removing and installing assembly mountings”,
ility
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page 63
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⇒ “2.2 Supporting engine in installation position”, page 66
hole
spec
2.1 Assembly overview - assembly mount‐
es, in part or in w
t to the co
ings
⇒ “2.1.1 Assembly overview - assembly mountings, Golf,
rrectness of i
Golf Plus, Passat, Touran”, page 60
l purpos
⇒ “2.1.2 Assembly overview - assembly mountings, Polo”,

page 62
nf
ercia
o
2.1.1 Assembly overview - assembly mountings, Golf, Golf Plus, Passat, Touran
rm
m
atio
om
n in
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1 - Centre hex stud
thi
te
sd
iva
❑ Fastening the engine

o
r
rp
cu
bracket to engine
o
m
f
en
ng
t.
yi
❑ Renew
Co
Cop py
t. rig
❑ Specified torques and yri
gh by
ht
installation sequence
op Vo
by c lksw
⇒ page 61 .
cted agen
Prote AG.
2 - Engine bracket
❑ Removing and installing
⇒ page 95 .
3 - Bolt
❑ Fastening the engine
bracket to engine
❑ Renew
❑ Specified torques and
installation sequence
⇒ page 61 .
4 - 40 Nm + turn 90° further
❑ Renew
❑ Engine mounting to
body
5 - Connecting bracket
6 - 20 Nm + 90°
❑ Renew
❑ Connecting bracket to
body
7 - 20 Nm + 90°
❑ Renew
❑ Connecting bracket to
engine mounting
8 - 60 Nm + 90°
❑ Renew
❑ Fastening the engine bearing to engine bracket

9 - Engine mounting
❑ With support arm.
10 - Pendulum support
11 - 100 Nm + 90°
❑ Renew
❑ Pendulum support to subframe
12 - 50 Nm + 90°
❑ Renew
❑ Pendulum support to gearbox
13 - 50 Nm + 90°
❑ Renew
14 - 60 Nm + 90°
❑ Renew
❑ Gearbox mounting to gearbox support
15 - 40 Nm + 90°
❑ Renew
❑ Gearbox mounting to body.
16 - Gearbox mounting
❑ With support arm. lkswage es n
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byV ua
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17 - Gearbox support o
ir se
ran
tee
th or
u
18 - Bolt ss
a ac
ce
le
❑ Gearbox support to gearbox

un
pt
an
d
❑ Specified torque ⇒ Rep. gr. 34 ; Assembly mountings; Assembly overview - assembly mountings
itte
y li
erm
ab
19 - Bolt
ility
ot p
wit
❑ Support to gearbox.
is n
h re
ole,
spec
20 - Support
t to the co
21 - Bolt
❑ Support to gearbox mounting
rrectne
ss o
cial p
f in
Engine bracket - specified torques and installation sequence

form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
va
Renew bolts for engine bracket.

i
o
pr
cum
r
fo
en
ng
t.
yi
– Tighten bolts in 3 stages in the sequence shown:
Co
Cop py
t. rig
gh ht
yri
Stage Bolts Specified torque/torque angle
p by
co Vo
by lksw
cted agen
1. -1 … 3- 7 Nm Prote AG.
2. -1 … 3- 40 Nm
3. -1 … 3- 180° further
2. Assembly mountings 61
2.1.2 Assembly overview - assembly mount‐

ings, Polo
♦ Removing and installing assembly mountings ⇒ page 63
1 - Engine bracket
2 - Bolt
❑ Specified torque and
tightening sequence
⇒ page 63 .
3 - Assembly mountings
⇒ page 63 .
4 - Bolt
❑ Renew
❑ 20 Nm + 90°
5 - Support arm
6 - Nut
❑ It is only permissible to
undo this nut in order to
renew engine mounting
-item 3-
❑ Renew
❑ 40 Nm + 90°
7 - Stud n AG. Volkswagen AG do
lkswage es n
o ot g
❑ Renew d byV ua
ran
ir se
❑ 30 Nm + 90° utho tee
or
a ac
8 - Bolt ss
ce
e
nl
pt
❑ Renew
du
an
itte
y li
❑ 30 Nm + 90°
erm
ab
ility
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9 - Pendulum support
wit
, is n
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10 - Bolt
hole
spec
❑ Pendulum support to
es, in part or in w
subframe
t to the co
❑ Specified torque ⇒ Rep.

gr. 34 ; Assembly mountings; Assembly overview - assembly mountings
rrectness of i
11 - Bolt
l purpos

nf
ercia
12 - Bolt
rm
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atio
m

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thi
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13 - Bolt
o
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o

f
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ng
t.
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❑ Specified torque ⇒ Rep. gr. 34 ; Assembly mountings; Assembly overview - assembly mountings t. Cop py
rig
gh ht
yri
14 - Gearbox mounting p by
co Vo
by lksw
cted agen
15 - Gearbox support Prote AG.
16 - Bolt

17 - Bolt
18 - Bolt
Engine bracket - tightening torque and sequence
Note
Renew bolts tightened with specified tightening angle.
Caution
Danger of engine bracket breaking due to application of ex‐

cessive torque.
♦ Always comply with prescribed torque and tightening se‐
quence.
– Tighten bolts in 3 stages in the sequence shown:

Stage Bolts Specified torque/ additional specified
angle
1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
3. -1 … 3- 180° further
AG. Volkswagen AG d
agen oes
olksw not
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2.1.3 Removing and installing assembly d b ara
rise nte
o eo
mountings th
au ra
ss c
ce
e
Removing
nl
pt
du
an
itte
y li
– Remove engine cover -arrows-.

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
63
Prote AG.
2. Assembly mountings

– Unscrew bolt -2-, place pressure differential sender - G 505-
to one side.
Note
Disregard -item 1-.
– Release fastener -arrow- and pull fuel pre-heater valve out of

guide on coolant expansion tank.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le

un
pt
an
d
itte
y li
– Disconnect electrical connector -1- for coolant shortage indi‐
erm
ab
cator switch - F66- and push coolant expansion tank to side.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– Set up support bracket - 10 - 222 A- with necessary adapters

inform
and support engine in installation position ⇒ page 71 .

mer
atio
m
– Attach hook of spindle - 10 - 222 A /10- to engine lifting eye.

o
n
c
i
or
– Pretension spindle slightly.

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew nut -1- and expose earth line

– Unscrew bolts -arrows- and remove engine mounting together

with engine bracket.
WARNING
Risk of accidents.
♦ It is only permissible to undo nut -1- to renew engine
mounting.
Installing AG. Volkswagen AG d

agen oes
olksw not
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Installation is carried out in the reverse order; note the following:
ised b ara
nte
or eo
h
• Specified torques ⇒ page 62 . s aut ra
c
s
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
Renew bolts tightened through an additional specified angle.
wit
, is n
h re
hole
spec
– Place assembly mounting on longitudinal member.
es, in part or in w
t to the co
• The positioning holes -arrows- must be in line; check with ap‐
propriate drill if necessary.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– First screw in bolts -arrows- as far as stop by hand.

– Tighten bolts.
Note
Disregard -item 1-.
– First screw in bolts -arrows- for support arm of engine mount‐

ing as far as stop by hand.
• Make sure support arm is not twisted when bolts are tightened.
– Tighten bolts.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV ua
Disregard -item 1-. ir se
d b ran
tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
2.2 Supporting engine in installation posi‐

erm
ab
ility
tion
ot p
wit
is n
h re
⇒ “2.2.1 Supporting engine in installation position, Golf, Golf Cab‐

ole,
spec
riolet, Passat”, page 66

t to the co
⇒ “2.2.2 Supporting engine in installation position, Golf Plus”,

page 68
⇒ “2.2.3 Supporting engine in installation position, Touran”, page
rrectne
70
s
⇒ “2.2.4 Supporting engine in installation position, Polo”,

s o
page 71
cial p
f inform
2.2.1 Supporting engine in installation posi‐

mer
atio
m
tion, Golf, Golf Cabriolet, Passat

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
♦ Support bracket - 10-222 A-

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

♦ Adapter - 10-222 A/3-
♦ Adapter - 10-222 A/18-
♦ Adapter - 10-222 A/1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
♦ Mud wing compensation plate for Golf - T10311- wit

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
♦ Torque wrench - V.A.G 1331-

thi
s
iva
do
r

rp
cum
fo
en
ng
Procedure
t.
yi Co
Cop py
t.
– When hose and cable connections are located close to engine
rig
gh ht
yri by
lifting eyes for support bracket - 10 - 222 A- , they must now cop Vo
by lksw
be removed. cted agen
Prote AG.
Golf
– Insert mud wing compensation plates - T10311- between up‐
per wheel housing longitudinal member and underlying wing
mounting plate on both sides of vehicle.
All other vehicles continued
– Set up support bracket - 10-222 A- with necessary adapters

as illustrated and support engine in installation position.
AG. Volkswagen AG d
agen
oes
olksw not
byV gu
ara
tion, Golf Plus
ed
ris nte
ho eo
aut ra
Special toolss and workshop equipment required
s c
ce
e
nl
pt

du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
68
cted agen
Prote AG.
Rep. gr.10 - Removing and installing engine
♦ Adapter - 10-222 A/3-
♦ Adapter - 10-222 A/8-

♦ Spring-type clip pliers - VAS 6362- n AG. Volkswagen AG do
lkswage es n
• To prevent damage to edges of wings, cover bloweryV
o areas of ot g
ua
both adapters - 10 - 222 A /8- with wovenoradhesive
ise
d
tape ran
tee
-arrow- ⇒ Electronic Parts Catalogue a(ETKA)
uth . or
ac
ss
Procedure
ce
e
nl
pt
du
– When hose and cable connections are located close to engine an

itte
lifting eyes for support bracket - 10 - 222 A- , they must now y li

erm
ab
ility
be removed.
ot p
wit
, is n
– Use:
h re
hole
spec
♦ Adapter - 10-222 A /3-

es, in part or in w
t to the co
♦ Adapter - 10-222 A /8-

♦ Adapter - 10-222 A /16-
rrectness of i
– Then hook spindle into right lifting eye on engine.

l purpos
Rear left lifting eye on engine points upwards -arrow-:

nf
ercia
– Hook in hook - 10-222 A /2- .

orm
m
atio
– Then connect hook -10-222 A /2- to adapter - 10-222 A /16- .

om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Volkswa
– Set up support bracket - 10-222agenA- with necessary
AG. gen AG
doeadapters
ksw s no
as illustrated and support
by V engine in installation position.
ol t gu
a
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
tion, Touran
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Adapter - 10-222 A/3-
♦ Adapter - 10-222 A /30-

♦ Adapter - 10-222A/16-
♦ 3 x shackle - 10-222A/12-
Procedure

Fit support bracket - 10-222 A- with the necessary adapters as

shown and take up weight of engine in installation position.
– First, fit adapter - 10-222A/30- -A- on left-hand side behind the
narrow web --. Volkswa AG. gen AG
agen do
– Then, fit support bracket Vol - 10-222A- behind bonnet support.
ksw es n
ot g
Also place the right d by
adapter - 10-222A/30- behind the narrow
ua
ran
se
web on the bolted
thori
flange for wing panel. tee
o
au ra
c
– Bolt supportssbracket - 10-222A- to adapter - 10-222A/30-
ce
le
un
pt
– Connect adapter - 10-222A/16- to engine by means of the
an
d
itte
y li
shackle - 10-222A/12- at rear on left.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
2.2.4 Supporting engine in installation position, Polo
ss o
cial p
f
inform
equipment required
mer
atio
m

o
n
c
i
or
n
♦ Adapter - 10 - 222 A /8-
thi
te
sd
va
♦ Hooks - 10-222 A/10-

i
o
pr
cum
r
fo
en
ng
♦ Shackle - 10-222 A/12-

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Adapter - 10-222 A/18-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
To prevent damage to edges of wings, cover lower areas of both
pt
du
an
adapters - 10 - 222 A /8- with woven adhesive tape -arrow- ⇒
itte
y li
erm
Electronic Parts Catalogue (ETKA) .
ab
ility
ot p
Procedure
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.3 Adjusting assembly mountings
WARNING

tions:
stored.
hot components.

– Remove air filter housing ⇒ page 437 .
– Remove intake hose between air mass meter - G70- and in‐
take connecting pipe.

Caution
To prevent damage to the electronic components when dis‐

connecting the battery :
♦ Observe notes on procedure for disconnecting the bat‐
tery .
– Disconnect earth wire -arrow- from battery with ignition switch‐

ed off ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnect‐
ing and reconnecting battery .
– Remove battery and battery tray -arrows-.

Golf Plus, Touran
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n

h re
ole,
spec
– Push washer fluid reservoir filler pipe with filler neck -2- to side.
t to the co
Note
rrectne

s
♦ For reasons of clarity, diagram shows installation position with

s o
cial p
removed fuel filter.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Free air guide hose at retainer -2-.

– Pull retainer for fuel lines off upwards -arrow- and lay to side.
– Unscrew bolts -1-, remove retainer and lay to side.

– Remove bolt -2- and nut -3-.
♦ Golf, Golf Cabriolet, Passat ⇒ page 66
♦ Golf Plus ⇒ page 68
♦ Touran ⇒ page 68 .
Note
The securing bolts for the assembly mountings may only be re‐
moved if the engine is supported with support bracket - 10-222
A- . ⇒ page 60 G. Volkswage
A n AG d
agen oes
olksw not
V gu
d by ara
– Unscrew engine mounting orise bolts -arrows- in succession and nte
renew (if not alreadyaut carried out on installing engine).
h eo
ra
ss c
– First screw bolts in loosely.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Renew gearbox mounting bolts -arrows- in succession (if not

already carried out) and screw in hand-tight.
l purpos
– First screw bolts in loosely.

nform
ercia
Engine mounting
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Using an assembly lever between engine bracket and support

arm -1-, adjust position of engine until the specifications listed
below are obtained:
• There must be a distance of -a- = 13.5 mm between engine
bracket -2- and right longitudinal member.
• The side of the engine bracket casting -2- must be aligned
parallel to the support arm -1- (dimension -x- must be identical
on both sides).
Note
Distance -a- = 13.5 mm can be checked with a metal rod of suit‐

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

Gearbox mounting
– On the gearbox side, ensure that the edges of the support arm
-2- and gearbox support -1- are parallel.
• Dimension -x- must be identical on both sides of mounting.
– Tighten bolts for gearbox mounting.
• Specified torques ⇒ page 60 .
The remaining installation steps are carried out in the reverse se‐
quence. In the process, note the following:
• Ensure that fuel lines are tight. AG. Volkswagen AG d
agen oes
lksw not
• Do not interchange supply line and return line (return
d by Vline blue
o gu
ara
or with blue marking, supply line black). orise nte
th eo
u ra
– Observe notes after connecting battery ⇒ ssElectrical
a system; c
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3 Engine cover
⇒ “3.1 Removing and installing engine cover”, page 76
3.1 Removing and installing engine cover

Removing
Caution
Bracket for engine cover on cylinder head cover may break off
if removed improperly. Always remove engine cover according
to following instructions.
– Pull engine cover upwards out of fasteners in areas of

-arrows- and in sequence shown. To do this, grip as far be‐
neath engine cover as possible.
Installing
Caution
. Volkswagen AG
gen AG doe
swa
Ensure that the 4 fasteners (ball sockets)
yV
olk are correctly posi‐ s not gu
tioned before installing the engine
ris
ed
b
cover; if necessary, bring ara
nte
them into correct position. Otherwise
ut
ho the engine cover may be eo
damaged. ss a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
– Press engine cover ball sockets into correct position.

ab
ility
ot p
– Position engine cover on securing points and press corners

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

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 77
⇒ “1.2 Removing and installing poly V-belt”, page 80
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 84
⇒ “1.4 Removing and installing vibration damper”, page 88
⇒ “1.5 Removing and installing ancillary bracket”, page 89
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 91
⇒ “1.7 Removing and installing sealing flange on pulley end”,
page 92
⇒ “1.8 Removing and installing engine bracket”, page 95
1.1 Assembly overview - poly V-belt drive

⇒ “1.1.1 Assembly overview - poly V-belt drive with tensioning
roller and air conditioner compressor”, page 77
⇒ “1.1.2 Assembly overview - poly V-belt drive with tensioning
element and air conditioner compressor”, page 79
⇒ “1.1.3 Assembly overview - poly V-belt drive without air condi‐
tioner compressor”, page 80
1.1.1 Assembly overview - poly V-belt drive with tensioning roller and air condi‐
tioner compressor agen
AG. Volkswagen AG d
w oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder block (pulley end) 77

1 - Poly V-belt
❑ Check for wear.
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
❑ Removing and instal‐
ling: vehicles with air
conditioner compressor
and tensioning element
⇒ page 77
❑ Do not kink.
❑ When installing, make
sure it is properly seated
on poly V-belt pulleys.
2 - Tensioning roller for poly V- olkswage es n
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❑ Removing and installing tho tee
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⇒ page 81 . ss
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❑ Coat guide surfaces in
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bricating paste; lubricat‐
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ab
ing paste ⇒ Electronic
ility
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Parts Catalogue (ET‐
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KA) .
h re
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spec
3 - Vibration damper
❑ With poly V-belt pulley.
t to the co
❑ Installation position:
hole in vibration damper
rrectne
must align over protru‐
sion on crankshaft pul‐
ley.
ss o
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⇒ page 88 .
form
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❑ only use genuine bolts ⇒ Electronic Parts Catalogue (ETKA) .

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❑ Removing and installing ⇒ page 89 .
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
8 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor
9 - Dowel sleeve
10 - Bolt
❑ Specified torques and installation sequence ⇒ page 82 .
78 Rep. gr.13 - Crankshaft group

1.1.2 Assembly overview - poly V-belt drive with tensioning element and air con‐
ditioner compressor
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
⇒ page 83 .
2 - Poly V-belt tensioning ele‐
ment
❑ Swing with open-end
spanner to slacken poly wagen AG. Volkswagen AG does
V-belt ⇒ page 83 olks not
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3 - Belt pulley and vibration
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Catalogue (ETKA) .
❑ 10 Nm + 90°
5 - Dowel sleeves rrectness of i
❑ Check for correct seat‐
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6 - Bracket
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⇒ page 89 .
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❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
py by
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9 - Air conditioner compressor Prote AG.
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor
10 - Dowel sleeves

1.1.3 Assembly overview - poly V-belt drive without air conditioner compressor
1 - Belt pulley and vibration

damper
❑ Fitting possible in one
position only. The holes
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⇒ page 88 . horis nte
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2 - Alternator ss c
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⇒ Electrical system;
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Rep. gr. 27 ; Alternator;
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⇒ page 89 .
4 - Poly V-belt
rrectness of i
❑ Renew.
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⇒ page 80
nform
mercia
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1.2 Removing and installing poly V-belt

⇒ “1.2.1 Removing and installing poly V-belt, poly V-belt drive
without air conditioner compressor”, page 80
⇒ “1.2.2 Removing and installing poly V-belt, poly V-belt drive with
tensioning roller and air-conditioning compressor”, page 81
⇒ “1.2.3 Removing and installing poly V-belt, poly V-belt drive with
tensioning element and air-conditioning compressor”, page 83
1.2.1 Removing and installing poly V-belt,

poly V-belt drive without air conditioner
compressor
Note
The poly V-belt repair kit with tools contains tool -T10367- and
illustrated instructions.


noise insulation
– Loosen right wheel housing liner in front area.
– Cut through poly V-belt.
– Further work sequence is carried out as described in the illus‐
trated instructions enclosed with the spare part.
note the following:
– Secure front part of right wheel housing liner again.
Passat 2011, Passat Variant 2011 ⇒ VGeneral body repairs,
AG. olkAssembly
exterior; Rep. gr. 66 ; Noiseswinsulation;
swagen AG
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and air-conditioning compressor

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Passat 2011, Passat Variant 2011 ⇒ General body repairs, cted agen
Prote AG.
noise insulation
– Loosen right wheel housing liner in front area.

Polo
– Unscrew bolts -3, 4, 6-.
– Carefully push coolant lines -5- slightly to the side.
• To create space to remove bolt for idler pulley/poly V-belt -2-.
– Unscrew bolt for poly V-belt idler pulley -arrow- until poly V-
belt can be removed easily.
– Remove poly V-belt.
Installing
– Using a brush, coat guide surfaces of idler pulley with lubri‐
cating paste. ⇒ Electronic Parts Catalogue (EKTA) G 052 751
A1.
– Fit poly V-belt on poly V-belt pulley:

1- Vibration damper
2- Idler pulley
3- Alternator AG. Volkswagen AG d
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– Now insert idler pulley, with its bolt, into guide
ut
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Tightening sequence for poly V-belt idler pulley.

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– Tighten bolt in 5 stages.

spec
es, in part or in w
Stage Bolt Specified torque/torque angle

t to the co
1. -2- Screw in to contact by hand

• The poly V-belt is tensioned
rrectness of i
2. -2- Turn until tensioning roller bolt rea‐

l purpos
ches stop
• The poly V-belt is tensioned further
nform
ercia
3. -2- Turn back 90°

m
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4. -2- 30 Nm
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5. -2- Turn 90° further

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s c 02.2016
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• Now check, as shown in illustration, whether the end of the
d
itte
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bolt for idler pulley/poly V-belt protrudes over the running sur‐
rm
ab
pe
faces of the idler pulley. Dimension -a- = approx. 2.5 mm
ility
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This ensures that the idler roller bolt was tightened up to its end
h re
position.
hole
spec
es, in part or in w
Polo
t to the co
rrectness of i
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nform
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– Move coolant lines -5- back to installation positions and tighten

-3, 4, 6-. 8 Nm.
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tion in
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– Turn engine at least one turn in direction of rotation at the belt
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pulley/vibration damper central bolt.

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Note
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♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
cted agen
Prote AG.
nator, air conditioner compressor) are secured tightly.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
After completing repair:

– Start engine and check belt running.
– If necessary, install front right wheel housing liner.
noise insulation

poly V-belt drive with tensioning element
and air-conditioning compressor
♦ Locking pin - T10060 A-

Removing . Volkswagen AG
gen AG does
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– Remove noise insulation: y Volk not
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Golf, Golf Plus, Golf Cabriolet,
thoris
Passat 2006, Passat Variant eo
2006, Polo, Touran ⇒ sGeneral
au body repairs, exterior; Rep. gr. ra
c
s
ce
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nl
pt
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noise insulation
ility
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– Mark direction of rotation of poly V-belt.
h re
hole
spec
– Swing tensioning element in direction of arrow to relieve ten‐
es, in part or in w
sion on poly V-belt.
t to the co
rrectness of i
l purpos
nform
mercia
at
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c
in t
or
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ate
do
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– Align holes -arrows- and lock tensioning element in position
cum
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with locking pin - T10060 A- .

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– Remove poly V-belt.
C py
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Installing
op Vo
by c lksw
cted agen
Prote AG.
– Install in reverse order.
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
– Fit poly V-belt on pulleys.

1- Crankshaft
2- Tensioning element
3- Alternator
4- Air conditioner compressor
After completing repair:
– Start engine and check belt running.
1.3 Removing and installing tensioner for

poly V-belt
Special tools, testers, measuring instruments and auxiliary items
required
Torque wrench - V.A.G 1332-

Golf 2009 ➤ , Golf Cabriolet 2012A➤ , oGolf
G. V lkswaPlus 2009 ➤ , Passat 2006 ➤ ...
gen AG
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Removing oris eo
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– Remove poly V-belt ⇒ page 83 . ss
ce
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– Loosen clips -1- + -2-, remove connecting hose on »cold side«.
an
itte
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ab
Golf, Golf Plus, Passat, Touran
ility
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– Remove cowling together with radiator fan - V7- and radiator
wit
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h re
fan on right of radiator - V35- ⇒ page 311 .
hole
spec
Polo
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unscrew bolts -3, 4, 6-.

m
at
– Carefully push coolant lines -5- slightly to the side.
om
ion
c
in t
r

o
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew securing bolts -arrows- from charge air pipe and dis‐
connect connector -1- from charge air pressure sender - G31- .

– Open clamp -2-, lay coolant hose -3- to side and remove
charge air pipe.
– Remove air conditioner compressor; do not detach refrigerant
lines on air conditioner compressor.
– Refrigerant circuit remains closed.
– Use suitable means to suspend air conditioner compressor on
body ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner
compressor; Removing and installing air conditioner compres‐
sor .
– Unscrew securing bolt -2-.

– Detach tensioner for poly V-belt -1-.
Polo
– Pull tensioning element forwards slightly. AG. Volkswagen AG d

agen oes
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t to the co
– Turn tensioning element clockwise through 180°.

rrectness o
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pyri by
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cted agen
Prote AG.

– Pull tensioning element under alternator downwards at an an‐

gle out of its retainer.
Installing
Tensioning element installation is carried out in the reverse se‐
quence of removal. In the process, note the following:
G. Volkswagen
– Screw tensioning element
lksw
aunder
gen A alternator A
into
G doits retainer.
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– Turn tensioning element anticlockwise through 180°.
rrectness o
cial p
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Cop py
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– Guide tensioning element into its retainer. opyri
gh by
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by c lksw
♦ Renew bolt for tensioning element Prote
cted AG.
agen
♦ Specified torques for poly V-belt drive with tensioning element

⇒ page 79 .

Move coolant lines -5- back to installation positions and tighten

-3, 4, 6-. 8 Nm.
– Install poly V-belt ⇒ page 80 .
AG. Volkswagen AG d
agen oes
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1.4 Removing and installing vibration damp‐ ised byV gu
ara
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er or eo
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Removing
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– Remove poly V-belt ⇒ page 80 .

itte
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– Remove cap for vibration damper.
ility
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– Loosen bolts -arrows- for vibration damper, counterholding on
h re
ole,
crankshaft toothed belt sprocket bolt with ring spanner to do
spec
this.
t to the co
rrectness o
cial p
f inform
mer
atio
om
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i
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– Unscrew bolts and remove vibration damper.

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Installing
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t.
Installation is in the reverse sequence of removal. Observe the
yi Co
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following:
C py
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Specified torques ⇒ Item 27 (page 178) .
co Vo
by lksw
cted agen
Prote AG.
– Install vibration damper with new bolts ⇒ Electronic Parts

Catalogue (ETKA) .
• The vibration damper can only be installed in one position. The
hole in the vibration damper must be located over the projec‐
tion on the toothed belt pulley -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
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ho Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf e o Plus 2009 ➤ , Passat 2006 ➤ ...
ra
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1.5 Removing and installing ancillary brack‐
an
itte
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ab
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ility
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Removing
h re
hole
spec
– Remove high-pressure pump ⇒ page 410 .
es, in part or in w
t to the co
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
rrectness of i
l purpos
WARNING
nform
ercia
The air conditioner refrigerant circuit must not be opened.

m
at
om
ion
c
– Unbolt air conditioner compressor from ancillary bracket, then
in t
or
his
e
secure to lock carrier ⇒ Heating, air conditioning; Rep. gr. 87 ;

at
do
riv
Air conditioner compressor; Removing and installing air con‐

p
cum
or
ditioner compressor .
f
en
ng
t.
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All other vehicles continued ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove idler pulleys -1- and -2-, and unscrew bolt for toothed
belt guard -arrow-.
– Loosen engine bracket securing bolt -1-.


– Unscrew bolts -6…1- and remove ancillaries bracket.

Installing
WARNING
AG. Volkswagen AG d
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Specified torque: Ancillaryisebracket ⇒ page 90 .
d b ara
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Specified torque: Engine
s aut bracket ⇒ page 95 . ra
c
s
Install in reverse order. In the process, note the following:
ce
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un
pt
an
d
itte
♦ Note any fitted sleeves in ancillary bracket and renew missing
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ones if necessary.
ility
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♦ Renew all bolts to be tightened with torque angle.
wit
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♦ Tack engine bracket bolt before tightening bolts for ancillary
spec
bracket.
t to the co
rrectness
Note
o
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Renew securing bolts for ancillary bracket.
mer
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– Insert bolts as follows: i

or
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♦ Bolts -1- and -2- M10 x 52.

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♦ Bolts -3- and -4- M10 x 30.

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♦ Bolts -5- and -6- M10 x 60. C py
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♦ Lifting eye bolts -A- and -B- 20 Nm.
p by
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– Tighten bolts -1 to 6- in 4 stages in the sequence shown:
Prote AG.
Sta Bolts Specified torque/tor‐

ge que angle
1. -1 … 6- Screw in to contact by
hand
2. -1 … 6- 40 Nm
3. -3- and turn 45° further
-4-
4. -1, 2, 5, 6- Turn 90° further
– Install high-pressure pump ⇒ page 409 , install toothed belt
and adjust valve timing ⇒ page 181 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .

– Renew and tighten engine bracket securing bolt -1-

⇒ page 95 .
AG. Volkswagen AG d
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All other vehicles continued olksw
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– Installing high-pressure pumpor⇒ is page 410 .
e nte
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– Remove air conditioner compressor
ss a
from lock carrier, then po‐ c
sition on ancillary bracket and tighten ⇒ Heating, air condi‐
ce
le
un
pt
tioning; Rep. gr. 87 ; Air conditioner compressor; Removing
an
d
itte
and installing air conditioner compressor .
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ility
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hole
– Filling/bleeding high-pressure pump/fuel system
spec
⇒ page 383 .
es, in part or in w
t to the co
1.6 Renewing crankshaft oil seal - belt pulley end
rrectness of i
l purpos

equipment required
nform
ercia
♦ Oil seal extractor - 3203-

m
♦ Counterhold - 3415-
a
com
tion in
♦ Assembly tool - T10053-
r
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s
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♦ Torque wrench (5…50 Nm)
do
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- V.A.G 1331-
um
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♦ Torque wrench (40 … 200
Co
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Nm) - V.A.G 1332-
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Removing
– Remove toothed belt ⇒ page 181 .

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

using counterhold - 3415- .
– To guide oil seal extractor - 3203- , screw central bolt by hand
into crankshaft to stop.
– Unscrew inner part of oil seal extractor two turns (approx. 3
mm) out of outer part and lock with knurled screw.
– Oil threaded head of oil seal extractor.
– Using great pressure, screw oil seal extractor as far as possi‐

ble into seal.
AG. Volkswagen AG d
– Loosen knurled screw and turn inner part against crankshaft agen oes
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until oil seal is pulled out. d by
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Installing aut
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Note
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The oil seal sealing lip must not be additionally oiled or greased.
ility
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– Remove oil residue from crankshaft journal using clean cloth.
hole
spec
es, in part or in w
t to the co
– Place guide sleeve - T10053/1- onto crankshaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.
rrectness of i
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nform
mercia
at
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ion
c
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ate
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– Press oil seal in to stop using assembly tool - T10053- and

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centre bolt. C py
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– Install crankshaft pulley.
p by
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by c lksw
cted agen
– Specified torque of new centre bolt ⇒ page 177 .
Prote AG.
– How to install and tension toothed belt ⇒ page 181 .
1.7 Removing and installing sealing flange on pulley end

4-cylinder common rail engine (1.6AGl, .EA189)
Volkswage-nEdition 02.2016 n AG do
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Special tools and workshop ed
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equipment required oris tee
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♦ Counterhold - 3415- ss
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- V.A.G 1331-
ility
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♦ Torque wrench (40 … 200
h re
hole
Nm) - V.A.G 1332-
spec
es, in part or in w
♦ Hand drill with plastic brush
t to the co
♦ Sealant as per ⇒ Electronic
Parts Catalogue (ETKA)
rrectness of i
♦ Flat scraper
l purpos
nform
mercia
at
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ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
Removing
– Remove crankshaft pulley. To do this, lock toothed belt pulley
using counterhold - 3415- .
– Drain engine oil.
– Remove sump ⇒ page 219 .
– Pull off front sealing flange.
– Remove sealing flange; if necessary, loosen by applying light
blows with a rubber-headed hammer.
– Remove sealant residue from cylinder block with a flat scraper.

– Remove residual sealant from sealing flange using a plastic

rotary brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe expiry date of sealing compound.

♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.
– Cut off tube nozzle at forward marking (diameter of nozzle ap‐

prox. 3 mm).
Note
♦ The thickness of the sealant bead may not exceed 2 … 3 mm.

♦ Otherwise excess sealant could get into the sump and block
the strainer in the oil pump suction line.
♦ Sealant may also not drip onto the sealing surface of the
crankshaft oil seal.
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♦ Before applying sealant bead,
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– Apply silicone
ss sealant bead as shown to the clean sealing sur‐
ce
face of sealing flange.

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– Install sealing flange immediately and tighten all bolts lightly.

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When fitting sealing flange with oil seal installed use guide sleeve
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- T10053/1- .
– Tighten securing bolts for sealing flange to 15 Nm using alter‐

rrectness of i
nate and diagonal sequence.

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– Install crankshaft pulley.

– Specified torque of new centre bolt ⇒ Item 2 (page 177) .
nform
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– Install sump ⇒ page 219 .

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1.8 Removing and installing engine bracket

⇒ “1.8.1 Removing and installing engine bracket, Golf, Golf Cab‐
riolet, Passat”, page 95
⇒ “1.8.2 Removing and installing engine bracket, Touran”,
page 97
⇒ “1.8.3 Removing and installing engine bracket, Golf Plus”, page
100
⇒ “1.8.4 Removing and installing engine bracket, Polo”,
page 105
1.8.1 Removing and installing engine bracket,

Golf, Golf Cabriolet, Passat
♦ Special tools, testers, measuring instruments and auxiliary
items required ⇒ page 66
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– Remove engine cover ⇒ page 76 . d by
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– Intake line between air mass meter - G70- uand
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– Lay fuel filter to one side ⇒ Rep. gr. 20 ; Fuel filter; Removing s
ce
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and installing fuel filter .
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couplings; Detaching plug-in connector .
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and support engine in installation position.
♦ Installing support bracket, Golf, Golf Cabriolet, Passat
⇒ page 66
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket 10-222A!
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
– Unscrew bolts -1- and -2- and remove connecting bracket.

– Unscrew bolts -3 … 6- and remove engine mounting.
– Disconnect electrical connector -3- on radiator outlet coolant

– Remove nut -1- and bolt -2-, and free coolant pipe.
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– Remove front right wheel
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When raising and lowering engine using support bracket -
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Note
es, in part or in w
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The securing bolt -1- is accessible through an aperture in the

wheel housing. If necessary, raise and lower engine using spindle
of support bracket - 10 - 222 A- to remove or start bolts -2- and
rrectness of i
-3-.
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Rep. gr.13 - Crankshaft group Prote AG.
– Remove securing bolts from engine bracket in sequence

-3…1-.
– Remove engine bracket upwards.
Installing
Install in reverse order. In the process, note theolkfollowing:
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Note
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– First tighten new securing bolts hand-tight in sequence
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-1…3-.
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Tightening sequence for engine bracket
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specified torque ⇒ page 60 .

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– Position engine assembly mounting and first tighten bolts -3-

and -6-, then tighten bolts -1- and -2-. Specified torque
– Bring engine bracket into contact with assembly mounting us‐
ing spindle.
– Insert bolts -4- and -5- and then tighten. Specified torque
⇒ page 60 .
Further assembly is basically the reverse of the dismantling se‐
♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).

Touran
♦ Special tools, testers, measuring instruments and auxiliary
items required ⇒ page 70

Removing
– Intake line between air mass meter - G70- and turbocharger.
– Lay fuel filter to one side ⇒ Rep. gr. 20 ; Fuel filter; Removing
and installing fuel filter . n AG. Volkswagen AG do
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– To do this, open quick-released bcouplings
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♦ Installing support bracket (Touran) ⇒ page 70 .
Note



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– Disconnect electrical connector -3- on radiator outlet coolant s
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– Remove nut -1- and bolt -2-, and free coolant pipe.
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– Remove front right wheel housing liner.
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WARNING
spec
es, in part or in w
t to the co
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nform
ercia
-3…1-.
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The tightening sequence and specified torques for the engine
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bracket securing bolts must always be followed. Otherwise the Prote
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-1…3-.



⇒ page 60 .
– Bring engine bracket into contact with assembly mounting us‐
ing spindle.
– Insert bolts -4- and -5- and then tighten. Specified torque
⇒ page 60 .
1.8.3 Removing and installing engine bracket, Golf Plus

equipment required
♦ Support bracket - 10 - 222
A-
♦ Adapter - 10 - 222 A / 8-
♦ Hooks - 10 - 222 A /2-
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /16-
♦ Gearbox support - 3282-
AG. Volkswagen AG d
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Special tools and workshop equipment required C py
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♦ Hose clamps up to 25 mm - 3094-
♦ Hose clip pliers - VAS 6362-
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♦ Torque wrench
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During subsequent work process, support bracket - 10-222 A- is

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positioned on longitudinal members with adapters - 10 - 222 A /

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

spec
both adapters - 10 - 222 A /8- with woven adhesive tape

t to the co
-arrow- ⇒ Electronic Parts Catalogue (ETKA) .

Removing
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WARNING
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form
mer
tions:
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– Remove engine cover ⇒ page 76 . yri
p by
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agen
Prote AG.
– Remove intake hose between air mass meter - G70- and in‐
take connecting pipe.
– Lay fuel filter to one side ⇒ Rep. gr. 20 ; Fuel filter; Removing
and installing fuel filter .

– To do this, open quick-release couplings -A- and -B- of fuel

lines.
AG. Volkswagen AG d
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Caution
ss
To prevent damage to the electronic components when dis‐

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connecting the battery :

inform
mer
♦ Observe notes on procedure for disconnecting the bat‐

atio
m
tery .
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– Disconnect earth wire -arrow- from battery with ignition switch‐

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ed off ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnect‐

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– Remove battery and battery tray -arrows-.

– When hose and cable connections are located close to engine
lifting eyes for support bracket - 10 - 222 A- , they must now
be removed.
♦ Supporting engine in installation position, Golf Plus
⇒ page 68
Note AG. Volkswagen AG d

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The securing bolts for the assembly mountings may be removedised b ara
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only if the engine is supported with support bracket - 10-222
hor A- ! eo
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– Clamp off coolant hoses with hose clamps -3094- and remove
thi
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from coolant pipe, release hose clips -arrows- for this.
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– Remove nut -1- and bolt -2-, remove right coolant pipe. opyri
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– Remove front right wheel housing liner. Prote
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WARNING

Note

-3-.


-3…1-.
Installing
The remaining installation steps are carried out in the reverse se‐
Caution AG. Volkswagen AG d

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The tightening sequence and specified
orise torques for the engine nte
bracket securing bolts must aalways be followed. Otherwise the
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engine bracket can be stressed
ss and it can break. c
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-1…3-.
nform
ercia

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⇒ page 60 .
– Use the spindle to bring the engine bracket to rest on the as‐
sembly mounting.
– Insert bolts -4- and -5- and then tighten. Specified torques
⇒ page 60 .
– Observe notes after reconnecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery. .


Polo
required ⇒ page 71
Removing

AG. Volkswagen AG d
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and support engine in installation position ⇒ page 71 .
hole
spec
es, in part or in w
t to the co
Note

supported with support bracket 10-222A! rrectness of i
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nform
ercia

m
at
om
ion
c
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– Release coolant expansion tank to create space to remove

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engine bracket.
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– Separate fuel supply line and return line at fuel transfer point.
The procedure for this is explained in ⇒ Rep. gr. 20 ; Push-on
couplings; Detaching plug-in connector .
– Use a finger to release locking lug of fuel pre-heater valve.

tank guide.
– Unclip fuel filter from lower part of fuel filter.

– Remove fuel filter upwards.
gen AG
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– Place fuel filter and
db
y Vfuel hoses together with fuel pre-heater
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valve on engine.
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– Remove slower
sa part of fuel filter ⇒ Rep. gr. 20 ; Fuel filter; ac
ce
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nl
pt
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– Remove upper toothed belt guard -arrows-.

t to the co
rrectness of i
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– Remove assembly mounting completely ⇒ page 63 .
AG. Volkswagen AG d
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– Remove pendulum support ⇒ page 62 .
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WARNING
rrectness of i
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nform
mercia
a
– Pull engine as far as possible towards radiator.
com
tion in
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Note
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Remove securing bolt -1- together with engine bracket. Raise and
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lower the engine using the supporting bracket - 10 - 222 A- spindle Cop py
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AG. Volkswagen AG d
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Golf 2009 ➤ , Golf Cabrioletau2012
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➤ , Golf Plus 2009 ➤ , Passat 2006 ➤ ... eo
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• Available installation space is very restricted.
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• Proceed with caution to avoid damaging vehicle and engine.
hole
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– Remove engine bracket upwards. es, in part or in w
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Installing
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Caution
nform
ercia
The tightening sequence and specified torques for the engine

bracket securing bolts must always be followed. Otherwise the
m
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Fit securing bolt -1- together with engine bracket. Raise and lower
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engine using spindle of support bracket - 10 - 222 A- to remove
Prote AG.
or start bolts -2- and -3-.

-1…3-.

specified torque ⇒ Item 31 (page 180) .
– Position engine assembly mounting but first tighten bolts -A-.

Specified torque ⇒ page 62 .
– Next bring engine bracket into contact with assembly mount‐
ing using spindle.
– Fit bolts -B- in place and then tighten to specified torque
⇒ page 62
Further assembly is performed in the reverse order of removal. In
the process, note the following:

2 Cylinder block, gearbox end

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⇒ “2.1 Assembly overview - cylinder block,
waggearbox end”, n AG does n
page 109 Volks ot g
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⇒ “2.2 Removing and installing
ut
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⇒ “2.3 Removing and installing
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page 111 un
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2.1 Assembly overview - cylinder block, gearbox end
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1 - Bolt
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❑ Renew
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❑ 60 Nm + 90°
2 - Flywheel
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flywheel ⇒ page 110
s
❑ Assembly through offset
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one position
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3 - Sender wheel
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❑ For engine speed send‐
c
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⇒ page 111 .
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❑ Removing and installing by c lksw
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⇒ page 535 . Prote AG.
5 - Bolt
❑ 4.5 Nm
6 - Dowel pin
❑ Qty. 2.
7 - Intermediate plate
❑ Do not damage or bend
when assembling.
❑ Installing ⇒ page 110 .
8 - Sealing flange with oil seal
⇒ page 111
❑ With sender wheel for
engine speed.
❑ Renew complete only.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
9 - Bolt
❑ Specified torque and tightening sequence ⇒ page 110 .
2. Cylinder block, gearbox end 109

Installing intermediate plate

– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel pins -arrows at bottom-.
Sealing flange on gearbox side - Prescribed torque and
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wtightening
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1. -1 … 6- Screw in to contact by hand
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2. -1 … 6- In diagonal sequence and in stages;
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final torque 15 Nm
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2.2 Removing and installing flywheel
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s
♦ Counterhold - 3067-
s o
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mer
atio
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Cop py
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Prote AG.
Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Caution
To prevent damage to the dual-mass flywheel when removing,

the bolts -B- must not be removed with an impact wrench or
similar. The bolts may be removed only by hand.
– Mark position of dual-mass flywheel in relation to engine.

– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
– When unscrewing bolts -B-, ensure that none of the bolt heads
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged when the bolts are un‐
screwed further.
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– Insert counterhold - 3067- in hole on cylinder block -B-.
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– Unscrew dual-mass flywheel.
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note the following:
• Specified torque ⇒ Item 1 (page 109) .
rrectne
– Use new bolts for securing.
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mer
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c
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– Insert counterhold - 3067- in hole on cylinder block -A-.
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Prote AG.
2.3 Removing and installing sealing flange on gearbox side


equipment required
♦ Torque wrench -
V.A.G 1331-
♦ Tool insert 24 mm - V.A.G
1332/11-
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mer
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c
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♦ Depth gauge - VAS 6082-

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Cop py
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Prote AG.
♦ 3 hexagon bolts M 6 x 35 mm
♦ 2 hexagon bolts M 7 x 35 mm
2.3.1 Pressing out sealing flange with sender

wheel
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
– Remove flywheel ⇒ page 109 .

– Detach intermediate plate at sealing flange and dowel pins

-arrows-.
AG. Volkswagen AG d
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– Turn crankshaft at bolt for toothed belt pulley until crankshaft
e
nl
pt
du
is at “TDC” of cyl. 1.
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ility
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Note
hole
spec
es, in part or in w
t to the co
♦ The work procedures are depicted with engine removed to
simplify explanation.
♦ The procedure is identical whether the engine is installed or
rrectness of i
removed.
l purpos
– Remove engine speed sender - G28- -1- ⇒ page 535 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove bolts for sealing flange -1 ... 6-.

Note
Press sealing flange together with sender wheel from crankshaft.
– To press out, screw in 3 bolts M6x35 -arrows- alternately into

sealing flange not more than 1/2 turn at a time.
AG. Volkswagen AG d
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– Remove sealing flange with sender wheel. olksw not
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un
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2.3.2 Pressing in sealing flange with sender
itte
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spec
Note
es, in part or in w
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♦ The sealing flange with a PTFE seal is equipped with a sealing
lip support ring. This support serves as an assembly sleeve.
The support ring must not be removed before installation.
rrectness of i
♦ Sealing flange and sender wheel must not be separated or
l purpos
turned after removal from packaging.

♦ The sender wheel is held in its installation position on the as‐
nform
ercia
sembly device - T10134- by a locating pin.

m
a
♦ The sealing flange and seal are one unit. The unit can only be
com
tion in
renewed together with sender wheel.
r
te o
thi
s
♦ The assembly device - T10134- is held in its position relative
iva
do
r
to the crankshaft by a guide pin inserted into a hole in the

rp
cum
fo
crankshaft.
en
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Cop py
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Assembly tool - T10134- gh ht
pyri by
Vo
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by
A - Clamping surface Prote
cted AG.
agen
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)

olkswagen AG
en AG. V
2.3.3 a) Securing
yV
olks
wag seal with sender
does
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assembly tool - T10134-
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– Screw sin
s a hexagon nut -B- to just before clamping surface a-A-
c
of threaded spindle.
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spec
t to the co
rrectnes
– Clamp assembly device - T10134- in a vice on clamping sur‐
s o
face -A- of threaded spindle.
cial p
f inform
– Press assembly housing -C- downwards until it rests against
mer
hexagon nut -B- -arrow-.
atio
om
n
c
– Screw hexagon nut onto threaded spindle until inner part of
i
or
n thi
e
assembly device and assembly housing are at same height.

t
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
twisted.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.

4-cylinder common rail engine (1.6 l, EA189) - AEdition 02.2016
G. Volkswagen A n G do
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Volks ot g
– Push sealing lip support ring -A- downwards ed
by in direction of ar‐ ua
ran
row until it lies on flat surface. oris tee
th or
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spec
es, in part or in w
t to the co
rrectness of i
– Upper edge of sender wheel and front edge of sealing flange
must align -arrows-.
l purpos
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mercia
a
com
tion in
r
te o
thi
s
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Cop py
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– Place sealing flange with front side on assembly tool - T10134- by c lksw
cted agen
so that locating pin -B- can be inserted in sender wheel hole Prote AG.
-A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening three
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
2.3.4 b) Securing assembling tool - T10134-

with sealing flange on crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder

– Screw hexagon nut -B- to end of threaded spindle.

– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing on sump side of crankcase
sealing surface.
– Secure assembly tool - T10134- to crankshaft flange using

hexagon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
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– To guide sealing flange into cylinder block, screw in 2 M7 x
pt
an
d
35 mm bolts (or bolts of comparable length ⇒ ⇒ Electronic

itte
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erm
Parts Catalogue (ETKA) , standard parts) -A-.
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ility
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2.3.5 c) Bolting assembly tool - T10134- onto
form
mer
crankshaft flange atio

om
n
c
– Push assembly housing -C- by hand in direction of arrow until

or
n thi
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sealing lip support ring -B- contacts crankshaft flange -A-.

t
sd
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pr
cum
– Push guide pin for diesel engines (black knob) -D- into hole in
r
fo
en
ng
crankshaft. This ensures that the sender wheel reaches its fi‐
t.
yi Co
nal installation position. Cop py
t. rig
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by
cted
Note
agen
Prote AG.
The guide pin for petrol engines (red knob) -F- must not be inser‐
ted in threaded hole of crankshaft.
– Hand-tighten both hexagon socket head bolts of assembly

tool.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.

2.3.6 D - Pressing sender wheel onto crank‐

shaft flange using assembly tool -
T10134-
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐
ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G
1332/11- .
Note
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
2.3.7 E - Checking sender wheel installation

position on crankshaft
– Screw hexagon nut -E- to end of threaded spindle.
– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
AG. Volkswagen AG d
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olksw not
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– The sender wheel is in the correct installation position on the

pt
du
an
crankshaft if a gap -a- = 0.5 mm exists between crankshaft

itte
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erm
flange -A- and sender wheel -B-.

ab
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
– Position depth gauge - VAS 6082- on crankcase flange.

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

AG. Volkswagen AG d
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olksw no
Golf 2009 ➤ , Golf Cabriolet
d by V 2012 ➤ , Golf Plus 2009 ➤ , tPassatgu
ara 2006 ➤ ...
e
4-cylinderoris common rail engine (1.6 l, EA189) - Edition
nte
e 02.2016
th or
s au ac
s
– Measure distance between crankshaft flange -A- and sender
ce
le
un
wheel -B-.
pt
an
d
itte
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• Specification: dimension -a- = 0.5 mm
erm
ab
ility
ot p
If distance -a- is too small:
wit
is n
h re
– Re-press sender wheel ⇒ page 119 .
ole,
spec
If distance -a- is attained:
t to the co
rrectness
– Tighten bolts for sealing flange ⇒ page 110 .
o
cial p
f inform
– Install engine speed sender - G28- ⇒ page 535 .
mer
atio
m

o
n
c
i
or
n
– Install intermediate plate.
thi
te
sd
iva
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– Install flywheel using new bolts. Tighten securing bolts to
pr
cum
r
fo
60 Nm + 90° further.
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.3.8 Re-pressing sender wheel F

– Secure assembly tool - T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool - T10134- by hand to sealing flange.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.

– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐

ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again. ⇒ page 118
If dimension -a- is still too again:
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again. ⇒ page 118
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orm
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Prote AG.

3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 121
⇒ “3.2 Renewing needle bearing in crankshaft”, page 122
⇒ “3.3 Crankshaft dimensions”, page 123
⇒ “3.4 Measuring axial clearance of crankshaft”, page 123
⇒ “3.5 Measuring radial clearance of crankshaft”, page 124
3.1 Assembly overview - crankshaft
1 - Bearing shell
❑ For cylinder block with
oil groove.
❑ Mark used bearing
shells for re-installation
but not on bearing sur‐
face.
2 - Toothed belt pulley
❑ For oil pump drive.
❑ Not available as sepa‐ agen
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3 - Bearing shell ho
ris tee
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❑ For bearingsscap without
a ac
oil groove.
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pt
❑ Mark used bearing

an
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shells for re-installation

erm
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but not on bearing sur‐

ility
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face.
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❑ Renew bearing shells

ole,
worn down to base lay‐

spec
er.
t to the co
4 - Thrust washers
❑ For bearing 3.
rrectne
❑ Various versions for cyl‐

inder block and bearing
s
cap.
s o
cial p
❑ Note fixing arrange‐

inform
ment.
mer
atio
m
5 - Bolts
o
n
c
i
or
❑ Renew
thi
te
sd
a
❑ 65 Nm + 90°
iv
o
pr
cum
r
fo
6 - Bearing cap
en
ng
t.
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❑ Bearing cap 1: belt pul‐ Cop py
. rig
ley end.
ht ht
rig by
opy Vo
❑ Bearing cap 3 with recesses for thrust washers. by c lksw
cted agen
Prote AG.
❑ Installation position: bearing shell retaining lugs in cylinder block and bearing caps must align vertically.
7 - Crankshaft
❑ Axial clearance new: 0.07…0.17 mm, wear limit: 0.37 mm.
❑ Measure radial clearance using Plastigage; new: 0.03 … 0.08 mm; wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 123 .
3. Crankshaft 121
3.2 Renewing needle bearing in crankshaft

Vehicles with dual clutch gearbox only.
required
1 - -1- KUKKO 21/2 and -4-

KUKKO 22/1
2 - Centring mandrel - 3176-
3 - Drift - VW 207 C-
AG. Volkswagen AG d
agen oes
olksw not
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an
d
itte
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rm
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pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
7-speed dual clutch gearbox: Always renew needle bearing

-arrow- when removing engine or gearbox.
Procedure
• Gearbox is separated from engine
Pulling needle bearing out:

– Pull out using commercially available puller -A-, e.g. KUKKO

21/2 and KUKKO 22/1.
Installing
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ss
– Drive needle bearing in with drift - VW 207 C- or with centring
ce
le
un
pt
mandrel - 3176- .
an
d
itte
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erm
ab
– Carefully drive needle bearing in.
ility
ot p
– Always measure the driving depth when driving in.
wit
is n
h re
ole,
Renew bearing, if driving depth is too deep.
spec
t to the co
rrectness o
cial p
• Driving depth: Dimension -a- = 1.5 to 1.8 mm.
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.3 Crankshaft dimensions

(Dimensions in mm)
Crankshaft bearing Conrod
journal diameter journal diameter
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042
3.4 Measuring axial clearance of crankshaft

3. Crankshaft 123
AG. Volkswagen AG d
agen oes
♦ Universal dial gauge bracket - VW 387- Volksw not
gu
by ara
ed nte
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th
au ra
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t to the co
♦ Dial gauge - VAS 6079-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
o Vo
Procedure by c lksw
cted agen
Prote AG.
– 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:
• New: 0.07 … 0.17 mm.
• Wear limit: 0.37 mm
3.5 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
– Remove bearing cap.
– Remove bearing cap and clean bearing journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the journal or into the bearing shells.
• The Plastigage must lie in the middle of the bearing shell.
– Fit bearing cap and tighten bolts to 65 Nm without turning fur‐
ther angle and without rotating crankshaft.
– Remove bearing cap again.

. Volkswagen AG
a gen AG does
– Compare width of Plastigage with the
Vol measurement scale.
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by ara
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Radial clearance: oris nte
eo
th
au ra
• New: 0.03 … 0.08 mm. ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Crankshaft 125
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus . Vo2009
lkswag➤ , Passat 2006 ➤ ...
en A
gen AG G do
4-cylinder common rail engine (1.6Vol,lkEA189)
swa - Edition 02.2016 es n
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4 Pistons and conrods
ss
au ra
c
ce
e
nl
⇒ “4.1 Assembly overview - pistons and conrods”, page 126
pt
du
an
itte
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⇒ “4.2 Removing and installing pistons”, page 129
erm
ab
ility
⇒ “4.3 Measuring piston projection at TDC ”, page 130 ot p
wit
, is n
h re
⇒ “4.4 Separating new conrod”, page 132
hole
spec
⇒ “4.5 Checking radial clearance of conrods”, page 132
es, in part or in w
t to the co
4.1 Assembly overview - pistons and con‐
rods
rrectness of i
l purpos
Note
nf
ercia
o
Oil spray jet and pressure relief valve ⇒ page 252
rm
m
atio
om
n in
or c
thi
e
1 - Circlip
t
sd
iva
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r
❑ Renew
rp
cu
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m
f
en
ng
2 - Piston ring
t.
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op py
❑ compression ring
. C rig
ht ht
rig by
py
❑ Offset gaps by 120°. co Vo
by lksw
cted agen
❑ Use piston ring pliers to Prote AG.
remove and install.

❑ Installation position
marking: “TOP” or side
with lettering towards
piston crown.
identification: “dots or
dashes marking” near
-arrows-, towards piston
crown
❑ Measuring ring gap
⇒ page 128
❑ Measuring ring-to-
groove clearance
⇒ page 128
3 - Piston ring
❑ compression ring
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
marking: “TOP” or side
with lettering towards
piston crown.
identification: “dots or
dashes marking” near
-arrows-, towards piston
crown
❑ Measuring ring gap ⇒ page 128
❑ Measuring ring-to-groove clearance ⇒ page 128

4 - Piston ring
❑ Oil scraper ring
❑ Offset gap 120° from bottom compression ring
❑ Use piston ring pliers to remove and install.
❑ Installation position marking: “TOP” or side with lettering towards piston crown.
❑ Installation position identification: “dots or dashes marking” near -arrows-, towards piston crown
❑ Measuring ring gap ⇒ page 128 gen AG
. Volkswagen AG
swa does
❑ Measuring ring-to-groove clearance y V ⇒ page 128
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5 - Bolt ho
ris e
ut or
❑ Renew ss
a ac
ce
e
❑ Oil threads and contact surface.

nl
pt
du
an
itte
❑ 30 Nm + 90°
y li
erm
ab
6 - Conrod bearing cap
ility
ot p
wit
, is n
❑ The conrod bearing cap only fits in one position and only on the appropriate conrod due to the breaking
h re
procedure (cracking) separating the cap from the conrod.
hole
spec
❑ Mark cylinder allocation in colour -A-.
es, in part or in w
t to the co
❑ Installation position: Marking -B- faces towards pulley end.
7 - Bearing shells
rrectness of i
❑ Installation position ⇒ page 129 .
l purpos
❑ Mark used bearing shells for re-installation but not on bearing surface.
❑ Renew bearing shells worn down to base layer.
nf
ercia
❑ Upper bearing shell (towards piston) made of a more wear resistant material. Identification on new bear‐
or
ing shells: black line on bearing surface in area of joint
m
m
atio
m
❑ Check for secure seating.

o
n in
or c
thi
8 - Bolt with pressure relief valve
te
sd
iva
❑ Specified torque ⇒ page 219 . o

r
rp
cu
o
m
f
en
ng
9 - Oil spray jet (for cooling of pistons)

t.
yi Co
Cop py
10 - Conrod ht. rig
rig ht
py by
❑ Renew as set only.
co Vo
by lksw
cted agen
Prote
❑ With industrially cracked conrod bearing cap
AG.
❑ Separate new conrod ⇒ page 132

❑ Mark cylinder allocation in colour -B-.
❑ Installation position: markings -A- towards belt pulley end
❑ Axial clearance: wear limit: 0.37 mm
❑ Measuring radial clearance ⇒ page 132
11 - Circlip
❑ Renew
12 - Piston pin
❑ If difficult to remove, heat piston to approx. 60 °C.
❑ Remove and install using drift - VW 222 A- .
13 - Piston
❑ With combustion chamber.
❑ Mark installation position and cylinder number ⇒ page 128 .
❑ Checking ⇒ page 128 .
❑ Install using piston ring clamp.
❑ Piston and cylinder dimensions ⇒ page 129 .
❑ Measuring cylinder bore ⇒ page 129
❑ Measuring piston projection at “TDC” ⇒ page 130
4. Pistons and conrods 127

Measuring piston ring gap

– Push piston ring at right angles to cylinder wall from above
down into cylinder bore to approx. 15 mm from bottom end of
cylinder.
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– Push in using a piston
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2nd compression ring 0.20 … 0.40 1.00
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Oil scraper ring 0.25 … 0.50 1.00
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Measuring ring-to-groove clearance
hole
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– Clean annular groove of piston before check.
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Piston ring New Wear limit
mm mm
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1st compression ring 0.06 … 0.09 0.25
l purpos
2nd compression ring 0.05 … 0.08 0.25

Oil scraper ring 0.03 … 0.06 0.15
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Checking piston
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from the lower edge, perpendicular to the piston pin axis.
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• Maximum deviation from nominal dimension: 0.04 mm
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Nominal dimension ⇒ page 129 Prote
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agen
Note
If piston skirt is cracked, renew piston.
Installation position and allocation of piston to cylinder

• Arrow on piston crown points towards belt pulley end
-arrows-.

Installation position of bearing shells in conrods

– Centre bearing shells on conrod and on conrod bearing cap.
• Dimension -a- = 2.5 mm.
Checking cylinder bores

– 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: 0.10 mm AG. Volkswagen A
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Nominal dimension ⇒ page 129 Volks ot g
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4.1.1 Piston and cylinder dimensions
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Honing dimension Piston diameter Cylinder bore diam‐

mm eter
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mm orm
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Basic dimension 79.455 1) 79.50

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or
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4.2 Removing and installing pistons

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Special tools and workshop equipment required gh ht
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by
♦ Drift - VW 222 A- Prote
cted AG.
agen
♦ Piston ring clamp, commercially available

Removing
• Engine secured on engine and gearbox support ⇒ page 50
– Removing cylinder head ⇒ page 134
– Mark installation position and allocation of conrod bearing
caps to conrods as an aid for reinstalling ⇒ page 126 .
– Unscrew conrod bearing cap.
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– Withdraw piston upwards together with conrod. agen oes
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If the piston pin is difficult to move, heat the piston to approx. 60° nl
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– Remove circlip from piston pin eye.
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– Drive out piston pin using drift - VW 222 A- .
hole
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Installing
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Note
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Renew bolts tightened through an additional specified angle.
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– Oil running surfaces of bearing shells.
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– Install piston with piston ring clamp.

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Installation position:
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• Piston ⇒ page 128
Co
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• Bearing shells in conrods ⇒ page 129 .
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cted
– Install conrod bearing cap in accordance with marking.
agen
Prote AG.
– Installing cylinder head ⇒ page 134 .
4.3 Measuring piston projection at “TDC”
Note
♦ Piston projection at “TDC” must be measured when installing

new pistons or a short engine.
♦ If you have measured the piston projection and it is not same
for all pistons, use the highest value to determine the correct
gasket size.
♦ Install the appropriate cylinder head gasket depending upon
piston projection, according to following table:


equipment required
♦ Measuring bridge -
VW 382/7- from measuring
tool - VW 382-
♦ Measuring plate -
VW 385/17- from universal
measuring tool - VW 385-
AG. Volkswagen AG d
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Procedure
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– Secure dial gauge - VAS 6079- with measuring bridge -

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VW 382/7- and measuring plate -VW 385/17- to cylinder block
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as shown in the illustration.

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– Measure the projection of each piston at the two points marked C py
ht. rig
with -arrows- (at the rear side and front side of the piston seen rig ht
py by
in the longitudinal direction of the engine).
co Vo
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cted agen
Prote AG.
– Install the appropriate cylinder head gasket depending upon
piston projection, according to following table:
Piston projection over upper Identification
edge of cylinder block (No. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
1.11 … 1.20 3

Cylinder head gasket identification

1- Part number
2- Holes
3- Ignore
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4.4 Separating new conrod
rrectne
On new conrods it is possible that the breaking point is not fully
separated. When the conrod bearing cap cannot be removed by
hand, proceed as follows:
ss o
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– To avoid damage, gently clamp conrod in a vice with protection
inform
jaws, as shown in illustration.
mer
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• Clamp conrod below dashed line.

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– Unscrew bolts -arrows- around 5 turns.
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– Using a plastic hammer, carefully knock against conrod bear‐
C py
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ing cap -arrow- until it is loose.
rig ht
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4.5 Checking radial clearance of conrods

♦ Plastigage
Removing
– 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 and without rotating crankshaft.
– Remove conrod bearing cap again.

– Compare width of Plastigage with the measurement scale.

Radial clearance:
– Renew conrod bolts.
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Cop py
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Prote AG.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 134
⇒ “1.2 Removing and installing cylinder head”, page 137
⇒ “1.3 Assembly overview - cylinder head cover”, page 165
⇒ “1.4 Removing and installing cylinder head cover”, page 166
⇒ “1.5 Removing and installing vacuum pump”, page 174
⇒ “1.6 Checking compression”, page 175
1.1 Assembly overview - cylinder head
Note
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♦ If the cylinder
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♦ If there are slight cracks, max. 0.5 mm wide, re-use cylinder

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heads with cracks between the valve seats.

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134 Rep. gr.15 - Cylinder head, valve gear

1 - Cylinder head
⇒ page 137 .
❑ After renewing, renew
entire coolant
2 - Washer
❑ For cylinder head bolt.
3 - Cylinder head bolt
❑ Observe sequence
when loosening and
tightening ⇒ page 137 .
❑ Before installing, place
washers in cylinder
head
⇒ Item 2 (page 135) .
4 - Oil pressure switch - F1- ,
22 Nm . Volkswagen AG
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❑ Identification: green Volkswa not
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❑ 0.5 bar. rised
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❑ If seal is leaking,
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❑ Checking ⇒ page 239
pt
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5 - 20 Nm
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6 - Lifting eye
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7 - Glow pin plug, 18 Nm h re

hole
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8 - Gasket
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❑ Renew
9 - Vacuum pump
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10 - 10 Nm
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11 - Clip
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12 - G 62
❑ Coolant temperature sender
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13 - Seal
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❑ Renew
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14 - 10 Nm
um
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15 - Coolant hose connection
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16 - Seal rig ht
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❑ Renew
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17 - 25 Nm
18 - Lifting eye
19 - Cylinder head gasket
❑ Renew
❑ Note marking ⇒ page 136 .
❑ After renewing, renew entire coolant
20 - Hall sender - G40-
❑ For camshaft position
❑ To remove and install, toothed belt must be removed from camshaft pulleys and idler pulley must be
released.
1. Cylinder head 135

21 - 10 Nm
– Checking cylinder head for distortion.

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♦ Straightedge 500 ris mm - VAS 6075-
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♦ Feeler gauges
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Checking cylinder head for distortion

un
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– Use straight edge 500 mm - VAS 6075- and feeler gauge to
erm
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measure cylinder head for distortion at several points.
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Max. permissible distortion: 0.1 mm
h re
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spec
Note
t to the co
Reworking diesel cylinder heads is not permissible.
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Cylinder head gasket identification
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2- Holes
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3- Ignore
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♦ Different thicknesses of cylinder head gasket are fitted de‐ Cop py
pending on the piston projection. When renewing gasket, ht. rig
rig ht
install new gasket with same identification.
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♦ Piston projection at TDC must be determined when installing
Prote AG.
new pistons or a short engine ⇒ page 126 .

1.2 Removing and installing cylinder

en AG. V
head
olkswagen AG
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⇒ “1.2.1 Removing and installing cylinderbyhead, Polo, Golf, Golf gu
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⇒ “1.2.2 Removing and installingsscylinder
a head, Passat”, ra
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page 152
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1.2.1 Removing and installing cylinder head, Polo, Golf, Golf Plus, Golf Cabrio,
itte
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Touran
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equipment required
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♦ Guide pins - 3070-
♦ Diesel injection pump lock‐
rrectness of i
ing pin - 3359-
l purpos
♦ Crankshaft stop - T10050-

♦ Counterhold - T10051-
nform
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♦ Puller - T10052-
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♦ Bit XZN 10 - T10385-
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♦ Torque wrench - V.A.G lksw
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♦ Torque wrench - V.A.G ut
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♦ Drip tray for workshop hoist
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- VAS 6208-
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♦ Tool set - T100395-
ility
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Cop py
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rig ht
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Prote AG.
Additional special tools required for Polo


equipment required
♦ Adapter - 10 - 222 A /8-
♦ Hooks - 10-222 A/10-
♦ Shackle - 10-222 A/12-
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♦ Adapter - 10-222 A/18-

form
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Note

♦ All cable ties which are opened or cut through when cylinder
head is removed must be fastened in the same position when
cylinder head is installed.
♦ All connectors which are separated during disassembly must
be reconnected in the original position
agen when installing.
AG. Volkswagen AG d
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WARNING au
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♦ When doing any repair work, especially in the engine com‐

un
pt
partment, pay attention to the following due to the cram‐
an
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itte
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erm
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hot components.
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Removing
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inform
mer
Polo, Golf, Golf Plus, Touran

atio
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– Remove wiper arms: ⇒ Electrical system; Rep. gr. 92 ; Wind‐

n
c
i
or
screen wiper system; Removing and installing wiper arms .

thi
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sd
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Polo, Golf, Golf Plus, Touran

pr
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t.
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op
exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Assembly C py
ht. rig
overview - bulkhead . rig ht
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Continuation for all vehicles Prote
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agen

– Remove air filter housing together with air mass meter and
intake hose ⇒ page 437 .


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gen AG d
– Disconnect connector for
Vol
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not 3-G
495- -1- (securededbehind
by bracket). gu
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– Unscrew bolts -3 + 4-. rrectness of i
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with lines.

– Unscrew bolts -1- for pressure differential sender - G 505-

bracket.
– Remove pressure differential sender - G 505- bracket.
Remove fuel filter with bracket.
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nf
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– Unclip retainer for coolant hose -1- by pushing it to one side.

orm
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– Undo and remove securing bolts of lower part of fuel filter.

om
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– Separate fuel supply line and return line on engine side.

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Prote AG.
– Remove vacuum lines upwards from air filter -1- together with
bracket.
– Pull connector off charge pressure control solenoid valve -
N75- -3-.
– Unbolt charge pressure control solenoid valve - N75- with
bracket at -2-.
– Place charge pressure control solenoid valve - N75- with vac‐
uum lines on engine.



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♦ -4- Lambda probe - G 39- yV
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– Disconnect electrical connector -2- at pressure differential
hole
spec
sender - G 505- .
es, in part or in w
t to the co
– Unscrew bolt -3- from pressure differential sender - G 505-
bracket.
rrectness of i
with lines.
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lines.

tank guide.

– Separate fuel supply line and return line at engine end. agen
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– Catch any escaping fuel. ss a c
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– Remove lower part of fuel filter ⇒ Rep. gr. 20 ; Fuel filter; pt

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– Remove cylinder head cover ⇒ page 166 .
rrectness of i
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nform
mercia
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com
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Cop py
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rig ht
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Prote AG.

– Unclip vacuum lines -arrow- and lay to side.
AG. Volkswagen AG d
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un
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– Detach vacuum line -2-.
an
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ab
– Lay vacuum lines to side.
ility
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t to the co
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– Separate electrical connector -1- on oil pressure switch - F1- .
mer
atio
– Remove bolt -arrow-.
om
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Cop py
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Prote AG.
– Disconnect electrical connector -4- at coolant temperature

sender - G62- .

– Unclip engine pre-wiring harness from retainer -arrow-.

Vehicles with intake manifold flap motor - V157- .
lkswage es n
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– Disconnect connector -3- from intake manifoldedflap motor -
by ua
ran
V157- . tho
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Continuation for all vehicles ss
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un
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– Lay engine wiring to side.
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– Pull connectors off throttle valve module - J338- -2-.
l purpos
– Open clamp -3- and pull off charge air hose.

– Remove bolt from oil dipstick attachment -4-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
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by
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– Unscrew bolts -2, 5- and -arrows-.

– Free electrical lines and hoses on left charge air pipe.
– Loosen hose clip -3- and remove left charge air pipe.

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4-cylinder
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– Unscrew bolts -arrows- and remove pulsation damper -2-.
du
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– Carefully push charge air pipe to side as far as possible.
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Caution
h re
hole
spec
Ensure that decoupling element of connecting pipe is not bent
es, in part or in w
t to the co
and thus stretched. There is a danger of cracking.
rrectness of i
Loosen particulate filter.
l purpos
To create space for removing and installing the oil supply line with
turbocharger support.
nf
ercia
or
m
m
atio
bocharger.
om
n in
or c
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– Remove nuts -2-.

AG. Volkswagen
– Now you can access the securing bolt on
wagen the retaining clamp
AG do
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-arrow- for the oil return line on d bythe turbocharger support. Re‐ t gua
V o
move bolt -arrow-. o
ir se
ran
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c
ss
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le
un
pt
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erm
ab
ility
ot p
wit
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h re
ole,
spec
t to the co
– Remove connecting pipes -A- to exhaust gas recirculation
cooler.
rrectne
ss
– Remove oil supply line and turbocharger support
o
cial p
f i
⇒ page 244 .
nform
mer
Polo
atio
om
n
c
i
or
n thi
⇒ page 244 .
te
sd
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t.
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– Remove coolant hoses from connections, loosen hose clips p by
co Vo
-1- and -2- for this.
by lksw
cted agen
Prote AG.
– Separate connector of Hall sender - G40- -1-.

– Unscrew securing nut of toothed belt tensioning roller.
Set up support bracket - 10 - 222 A- with necessary adapters and
support engine in installation position ⇒ page 66 .
Note

– Removing engine mounting completely ⇒ page 63 .

– Remove engine bracket ⇒ page 105 .

– Unscrew and remove securing bolt -arrow- of rear toothed belt

guard.
– Remove toothed belt from camshaft and high-pressure pump
⇒ page 181 .
– Now toothed belt tensioning roller can be removed.
– Install engine bracket again, tightening old bolts by hand
⇒ page 105 .
– Install assembly mountings again, tightening old bolts by hand
⇒ page 105 .
– Remove support bracket - 10 - 222 A- .

– Detach camshaft pulley from hub.
– Remove camshaft hub and pull off camshaft hub using puller
- T10052- .
– Counterhold hub with counterhold - T10051- and loosen se‐

curing bolt -1- of hub.
– Loosen hub securing bolt about 2 turns.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
– Fit puller - T10052-
orise and align it with holes in hub. nte
eo
th
u ra
– Tighten securing
ss a
bolts -1-. c
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nl
– Apply tension to hub by evenly tightening puller -2- until hub

pt
du
an
separates from taper of camshaft.

itte
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erm
ab
ility
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wit
Note
, is n
h re
hole
spec
When doing this, hold puller with 30 mm spanner.

es, in part or in w
t to the co
– Remove hub from taper of camshaft.

rrectness of i
– Golf, Golf Plus, Passat, Touran: Unscrew and remove secur‐

l purpos
ing bolt -arrow- of rear toothed belt guard.

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

– Unscrew Hall sender - G40- -arrow-.
– Maintain sequence when loosening cylinder head bolts.
Note
♦ A second mechanic is required to remove the cylinder head.

♦ The toothed belt tensioning roller is pulled off the stud when
the cylinder head is lifted out.
– First lift cylinder head on gearbox side and guide it out of

toothed belt guard. Make sure that toothed belt tensioner does
not fall down.
Installing
Note
♦ Always renew cylinder head bolts.

♦ In cases of repair, carefully remove gasket remains from cyl‐
wage
e
inder head and cylinder block. Ensure that no long scores Vol or
ks s no
t gu
by
scratches are made on the surfaces. When using rabrasive
ise
d ara
nte
paper do not use a grade less than 100. ut
ho eo
ra
sa c
♦ Carefully remove emery and abrasive remains.
s
ce
e
nl
pt
du
♦ Do not remove new cylinder head gasket from packaging until

an
itte
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it is ready to be fitted.
erm
ab
ility
ot p
♦ Handle gasket very carefully. Damage to the silicone coating

wit
, is n
or the indented area will lead to leaks.

h re
hole
♦ Exercise extreme caution. Ask a second mechanic for assis‐

spec
es, in part or in w
tance.
t to the co
♦ Guide the cylinder head in the timing belt guard.

♦ When doing this, the cylinder head must not scrape over the
rrectness of i
dowel sleeves.
l purpos
♦ If there are slight cracks, max. 0.5 mm wide, re-use cylinder

heads with cracks between the valve seats.
nform
ercia
– Before fitting cylinder head, remove crankshaft stop - T10050-

m
at
om
and turn crankshaft opposite direction of rotation until all pis‐

ion
c
tons are nearly uniformly below TDC.

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

– Note cylinder head gasket identification:

1- Part number
AG. Volkswagen AG d
2- Holes lksw
agen oes
not
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by
3- Ignore rised ara
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– Cylinder head
aut gasket must lie with identification facing up‐ or a
s c
wards. s
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– To centre, screw guide pins -3070/9- into outer threaded holes

on intake side.
nform
mercia
at
om
io
Note
n
c
in t
or
his
te
♦ Golf, Golf Plus: The tensioning roller must be inserted on the

a
do
riv
pins when fitting the cylinder head.

p
cum
for
en
ng
t.
♦ Polo: Tensioning roller must be pushed onto stud after fitting
yi Co
op
cylinder head.
C py
t. rig
gh ht
yri by
♦ Polo: Support engine again.
op Vo
by c lksw
cted agen
Prote AG.
♦ If the cylinder head gasket or cylinder head has been replaced,
select the new cylinder head gasket according to the number
of holes on the old cylinder head gasket.
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be selected by measuring the
piston projection at “TDC” ⇒ page 126 .
– Fit cylinder head.

– Insert 8 cylinder head bolts and screw in by hand until contact
is made.
– Unscrew guide pins -3070/9- through bolt holes in cylinder
head and screw remaining cylinder head bolts by hand until
contact is made.
– Tighten cylinder head in 4 stages in sequence shown as fol‐

lows:
1- Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2- Turn further with rigid spanner:
Stage III = turn 90° further.
Stage IV = turn 90° further.

– Re-fit Hall sender - G40- -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Secure rear toothed belt guard -arrow- on cylinder head. s
ce
e
nl
pt
du
Polo
an
itte
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erm
ab
– Secure rear toothed belt guard -arrow- on cylinder head after
ility
ot p
supporting it.
wit
, is n
h re
hole
spec
– Install hub and camshaft pulley.
es, in part or in w
t to the co
– Lock camshaft and high-pressure pump with diesel injection
pump locking pin - 3359-
rrectness of i
l purpos
– Now rotate crankshaft in direction of rotation to TDC and lock

crankshaft using crankshaft stop - T10050- .
nform
ercia
Further installation is carried out in the reverse order. In the proc‐

m
at
om
ess, note the following: ion

c
in t
or
Polo
his
ate
do
riv
Support engine again ⇒ page 105 .

p
cum
for
en
g
– Re-install toothed belt ⇒ page 181 .

n
t.
yi Co
Cop py
– Install engine bracket ⇒ page 105 .
t. rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
– Golf, Golf Plus, Passat, Touran: Re-install toothed belt
⇒ page 181
– Install cylinder head cover ⇒ page 166 .
– Install oil supply line and turbocharger support ⇒ page 235 .
– Top up engine oil ⇒ page 227 .
After any work on the fuel system
Connect a diagnosis tester.
Perform the function “Filling/bleeding high pressure pump/fuel
system” in “Guided functions” ⇒ page 383 .
1.2.2 Removing and installing cylinder head, Passat


equipment required
♦ Guide pins - 3070-
ing pin - 3359-
♦ Crankshaft stop - T10050-
AG. Volkswagen AG d
♦ Counterhold - T10051- agen oes
olksw not
byV gu
ara
♦ Puller - T10052- rised
nte
ho eo
ut
♦ Bit XZN 10 - T10385-
ss a ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.


1331-
1332-
- VAS 6208-
♦ Tool set - T100395-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
ss c
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un
pt
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d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
Note spec
es, in part or in w
t to the co

rrectness of i
♦ All cable ties which are opened or cut through when cylinder
l purpos
head is removed must be fastened in the same position when

cylinder head is installed.
nform
ercia
♦ All connectors which are separated during disassembly must

be reconnected in the original position when installing.
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.

. Volkswage
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ k,sw
Golf
agenPlus 2009 ➤ ,APassat
AG n Gd
oes 2006 ➤ ...
not
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4-cylinder commond brail
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ar
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WARNING ss
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♦ When doing any repair work, especially in the engine com‐
itte
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erm
partment, pay attention to the following due to the cram‐
ab
ility
ped conditions:
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
hot components.
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Removing
nform
ercia

m
at
om
io
n
c
in t
r

o
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ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

– Remove electrical line from retainer -2 -.


– Remove bolts -1-.

– Lay pressure differential sender - G 505- to side together with
lines.
lkswage es n
o ot g
byV ua
d ran
ir se tee
– To do this, open quick-release acouplings
utho
-A- and -B- of fuel or
ac
lines. ss
ce
e
nl
Passat 2006►, Remove fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Re‐
pt
du
an
itte
moving and installing fuel filter .

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erm
ab
Passat 2011►, Remove fuel filter, 6.0 bar low-pressure fuel sys‐
ility
ot p
tem ⇒ Rep. gr. 20 ; Fuel filter, Removing and installing fuel filter .
wit
, is n
h re
hole

spec
es, in part or in w

t to the co

rrectness of i
– Unclip vacuum lines -arrow- and lay to side.

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



Passat 2006►
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
sender - G62- .
h re
ole,
spec
(Passat 2011►)
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c

i
or
n thi
sender - G62- .
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Unscrew bolts - 2, 5, 7-
– Free electrical lines and hoses on left charge air pipe.
– Loosen hose clip -3- and remove left charge air pipe.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unclip engine pre-wiring harness from retainer -arrow-.
nf
ercia
o
(Passat 2006►)
rm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect connector -3- from intake manifold flap motor -

V157- .
– Lay engine wiring to side.
noise insulation

– Pull connectors off throttle valve module - J338- -2-.

– Open clamp -3- and pull off charge air hose.
– Remove bolt from oil dipstick attachment -4-.
– Take off pulsation damper -2-.

– Carefully push charge air pipe to side as far as possible.
Caution
Ensure that decoupling element of connecting pipe is not bent

and thus stretched. There is a danger of cracking.

. Volkswagen AG
turbocharger support. kswagen AG does
n
Vol ot g
d by ua
ran
e
– Remove securing clamp -1- betweenhoparticulate
ris filter and tur‐ tee
bocharger. aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

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

– Remove nuts -2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Now you can access the securing bolt on the retaining clamp
hole
spec
-arrow- for the oil return line on the turbocharger support. Re‐
es, in part or in w
move bolt -arrow-.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Remove connecting pipes -A- to exhaust gas recirculation

iv
o
r
rp
cu
cooler.
o
m
f
en
ng
t.
yi Co
op py
⇒ page 244 . . C rig
ht ht
rig by
py
co Vo
by lksw
cted agen
Prote AG.
– Remove coolant hoses from connections, loosen hose clips

-1- and -2- for this.

– Detach connector for Hall sender - G40- -1-.

⇒ page 181 . agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Unthread engine wiring harness -arrows-, if necessary dis‐
es, in part or in w
connect connectors and lay engine wiring harness to side.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Unscrew bolts -arrows- for coolant expansion tank. um
fo
en
ng
t.
yi
Co
op py
cator switch - F66- .
t. C rig
gh ht
pyri by
Vo
o
The coolant expansion tank can thus be placed to one side.
c by lksw
cted agen
Prote AG.
⇒ page 181 .
– Unscrew securing nut of toothed belt tensioning roller.
– Remove camshaft hub and pull off camshaft hub using puller
- T10052- .
– Counterhold hub with counterhold - T10051- and loosen se‐

curing bolt -1- of hub.

– Fit puller - T10052- and align it with holes in hub.

– Tighten securing bolts -1-.
Note

AG. Volkswagen AG d
– Remove hub from taper of camshaft. lksw
agen oes
not
o
byV gu
ara
ed
is nte
– Unscrew and remove securing bolt -arrow-
hor
of rear toothed belt eo
ut
guard. ss a ra
c
ce
e
Unscrew cylinder head bolts.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Maintain sequence when loosening cylinder head bolts.
l purpos
nform
ercia
Note
m
at
om
♦ A second mechanic is required to remove the cylinder head.
ion
c
in t
or
♦ The toothed belt tensioning roller is pulled off the stud when his
ate
the cylinder head is lifted out.

do
priv
cum
for
en
g
– First lift cylinder head on gearbox side and guide it out of

n
t.
yi Co
op
toothed belt guard. Make sure that toothed belt tensioner does C py
ht. rig
not fall down. rig ht
py by
co Vo
by lksw
Installing cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
Note ir se tee
tho
u or
a ac
ss
♦ Always renew cylinder head bolts.
ce
e
nl
pt
du
♦ In cases of repair, carefully remove gasket remains from cyl‐
an
itte
y li
inder head and cylinder block. Ensure that no long scores or
erm
ab
scratches are made on the surfaces. When using abrasive
ility
ot p
paper do not use a grade less than 100.
wit
, is n
h re
♦ Carefully remove emery and abrasive remains.
hole
spec
es, in part or in w
♦ Do not remove new cylinder head gasket from packaging until
t to the co
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
rrectness of i
or the indented area will lead to leaks.
l purpos
♦ Exercise extreme caution. Ask a second mechanic for assis‐

tance.
nform
ercia
♦ Guide the cylinder head in the timing belt guard.

m
♦ When doing this, the cylinder head must not scrape over the
at
om
io
dowel sleeves.
n
c
in t
or
his
ate
– Before fitting cylinder head, remove crankshaft stop - T10050-
do
priv
c
and turn crankshaft opposite direction of rotation until all pis‐
um
for
en
g
tons are nearly uniformly below TDC.

n
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Note cylinder head gasket identification:

1- Part number
2- Holes
3- Ignore
– Cylinder head gasket must lie with identification facing up‐
wards.

– To centre, screw guide pins -3070/9- into outer threaded holes wage
es n
on intake side. yV
olks ot g
ua
d b ran
ir se tee
tho
u or
Note ss
a ac
ce
le
un
pt
♦ Golf, Golf Plus: The tensioning roller must be inserted on the
an
d
itte
y li
pins when fitting the cylinder head.
erm
ab
ility
ot p
♦ Polo: Tensioning roller must be pushed onto stud after fitting
wit
is n
cylinder head.
h re
ole,
♦ Polo: Support engine again.
spec
t to the co
♦ If the cylinder head gasket or cylinder head has been replaced,
select the new cylinder head gasket according to the number
of holes on the old cylinder head gasket.
rrectne
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be selected by measuring the
s
piston projection at “TDC” ⇒ page 126 .
s o
cial p
f inform
– Fit cylinder head.
mer
atio
m
– Insert 8 cylinder head bolts and screw in by hand until contact

o
n
c
is made.
i
or
n thi
te
sd
a
– Unscrew guide pins -3070/9- through bolt holes in cylinder

iv
o
pr
c
head and screw remaining cylinder head bolts by hand until
um
r
fo
contact is made.
en
ng
t.
yi Co
Cop py
t. rig
– Tighten cylinder head in 4 stages in sequence shown as fol‐
gh ht
yri by
lows:
cop Vo
by lksw
cted agen
Prote AG.
1- Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2- Turn further with rigid spanner:
Stage III = turn 90° further.
Stage IV = turn 90° further.
– Re-fit Hall sender - G40- -arrow-.

– Secure rear toothed belt guard -arrow- on cylinder head.

– Install hub and camshaft pulley.
– Lock camshaft and high-pressure pump with diesel injection
pump locking pin - 3359-
– Now rotate crankshaft in direction of rotation to TDC and lock

crankshaft using crankshaft stop - T10050- .
G. Volkswagen nA AG do
wage e
Further installation is carriedyout
Vol in the reverse order. In the proc‐
ks s no
t gu
ess, note the following: rised b ara
nt ee
tho or
– Re-install toothed
s a belt ⇒ page 181 .
u ac
s
ce
e

nl
pt
du
an
itte
– Install oil supply line and turbocharger support ⇒ page 235 .
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Top up engine oil ⇒ page 227 .
es, in part or in w
t to the co
Connect a diagnosis tester.
Perform the function “Filling/bleeding high pressure pump/fuel rrectness of i
l purpos
system” in “Guided functions” ⇒ page 383 .

nform
ercia
1.3 Assembly overview - cylinder head cover

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

1 - 5 Nm
2 - High-pressure accumulator
❑ With injection lines
❑ Do not attempt to bend
injector pipes to a differ‐
ent shape.
3 - 22 Nm
4 - Injector (piezo injector)
⇒ page 394 .
5 - 8 Nm + turn 180° further.
❑ Renew
6 - Clamping piece
❑ One clamping piece
⇒ page 389 for 2 injec‐
tors ⇒ page 394 . n AG. Volkswagen AG do
lkswage es n
7 - Sleeve d byV
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ua
ran
❑ Fastening for high-pres‐ ir se tee
tho
or
sure accumulator au ac
ss
❑ Renew if damaged.
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8 - Seal
itte
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❑ Renew
ility
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9 - Seal
is n
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ole,
❑ Renew
spec
10 - Cap
t to the co
11 - Cylinder head cover
rrectne
⇒ page 166 .
12 - Gasket
ss o
cial p
❑ Renew if damaged or leaking. f inform

mer
13 - 10 Nm
atio
m
❑ Observe tightening sequence ⇒ page 166 .

o
n
c
i
or
14 - Cable guide
thi
te
sd
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15 - Heat shield
p
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Cop py
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1.4 Removing and installing cylinder head
gh ht
pyri by
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co
cover
by lksw
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Prote AG.
⇒ “2 Safety instructions”, page 3

⇒ “1.1.1 Schematic overview - fuel system, Polo”, page 366
⇒ “1.4.1 Removing and installing injector seal in cylinder head
cover”, page 172

AG. Volkswagen AG d
agen oes
olksw not
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or eo
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un
pt
an
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itte
♦ Lambda probe open ring spanner set - 3337-
y li
rm
ab
pe
ility
ot
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Pliers - 3314-
m
a
com
tion in
r
te o
thi
s
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Removing
– Remove noise insulation at injectors.
– Remove injectors ⇒ page 394 .
– Position pliers - 3314- with groove -arrow A- on support sleeve
shoulder -arrow B-.

– Carefully pull connector off glow plug in direction of -arrow-.

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Volks not
gu
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ility
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hole
spec
es, in part or in w
t to the co
– Pull connector of position sender for charge pressure posi‐
tioner - G581- -arrow- off turbocharger and guide wiring out of
retainers.
rrectness of i
Polo
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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– Unclip coolant return hose -arrows- and place coolant line to Cop py
. rig
one side.
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rig by
copy Vo
The installation position of the coolant return hose can vary.
by lksw
cted agen
Prote AG.
Golf, Golf Plus, Golf Cabriolet, Passat, Touran
– Unscrew the securing bolt -arrows- and place the coolant re‐
turn line to the side.

– Golf: Pull connector -2- off pressure differential sender - G

505- .
– Unscrew the securing bolts on the intake manifold -arrows-

and move the coolant return
gen AG
. Volksline
wageto
n Athe
G d side.
wa oes
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ris
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nl
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hole
spec
es, in part or in w
t to the co
– Unscrew bolts -3- + -4-, remove lifting eye.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
– Remove high-pressure line between high-pressure pump -1-
yi Co
op
and high-pressure accumulator -3-.
C py
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– Open clamp -arrow- and pull line off high-pressure accumula‐

tor.
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es, in part or in w
t to the co
rrectness of i
l purpos
– Pull connector off fuel pressure regulating valve - N 276-
nform
-arrow-.
mercia
– Remove wiring harness from high-pressure accumulator and
a
com
tio
place wiring harness to one side.
n in
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fo
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t.
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Cop py
t. rig
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co lksw
by
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Prote AG.
– Remove the connector on the fuel pressure sender - G 247-

-2-.

– Remove high pressure accumulator.
Caution
Make sure that no wiring connections are damaged when dis‐

connecting the connectors. Otherwise the whole wiring har‐
ness will need to be renewed. Do not compress the pliers -
3314- too firmly to separate the connectors, otherwise the
support sleeve may be damaged.
– Pull vacuum line off cylinder head cover -arrow A-.

– Remove remaining vacuum hoses from bracket on cylinder
head cover.
– Remove remaining electric cables/wires.
– Remove upper toothed belt guard.
– Remove breather line between cylinder head cover and intake
hose. Press quick-release couplings to do this.
– Remove securing bolts from cylinder head cover.
– Remove cylinder head cover.
– Unclip the cylinder head cover at the locking lugs -arrows - on

the rear toothed belt guard.
AG. Volkswagen A
Installation is performed in the lkreverse
swa
gen sequence. In G
the
doeprocess,
s no
note the following: db
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ar
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ris tee
⇒ “2 Safety instructions”,
ut
ho page 3 or
sa ac
⇒ “3.1 Rules for cleanliness”,
s
page 5
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e
nl
pt
du
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itte
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ab
Note
ility
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Renew seal for bolts if damaged.

h re
hole
spec
– Screw on cylinder head cover hand-tight in the sequence -1…

es, in part or in w
t to the co
6-.
– Tighten bolts to 10 Nm in the sequence -1…6-.

rrectness of i
– Ensure that cylinder head cover is correctly clipped to toothed

l purpos
belt guard.
nform
ercia
Note
m
at
om
ion
For clarity of illustration, the camshaft sprocket is not shown.

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

– To do this, press toothed belt guard (using a screwdriver if

necessary) against cylinder head cover in area of clips
-arrows- until clips audibly engage in each other.
– Check clearance between hub and toothed belt guard. AG. Volkswagen AG d
agen oes
lksw not
After any work on the fuel system by Vo gu
ara
d
ise nte
Connect a ⇒ Vehicle diagnostic tester. uthor eo
a ra
s c
Perform the function “Fuel pump activation (Filling/bleeding fuel s
ce
e
system)” in “Guided functions” ⇒ page 383 .
nl
pt
du
an
itte
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erm
ab
ility
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1.4.1 Removing and installing injector seal in
hole
spec
cylinder head cover
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
♦ Tool set - T10055-
om
n in
or c
♦ Assembly tool - T10208/2-
thi
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t.
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♦ Oil seal extractor - T 40195- t. C rig
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pyri by
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by
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Prote AG.

♦ Injector remover - T40402-
Removing
– Remove only injectors for which the injector seal is to be re‐
newed ⇒ page 394 .
– Move affected return lines slightly aside.
Adhere strictly to rules of cleanliness. No dirt must be allowed to
enter the disconnected fuel return lines or the open connections
on the injectors.
Caution
Proceed very carefully to prevent unnecessary dismantling or

further damage. en AG. V
olkswagen AG
ag does
lksw n
Adhere strictly to rules of cleanliness.
yV
o No dirt may get into theot gua
db
injector holes on the cylinder
or
ise head cover. ran
te
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ut
First remove leaked soil
s a or fuel with workshop equipment.
ra
c
ce
e
nl
pt
du
an
itte
– Apply puller - T10055- with injector remover - T10402- -1- and

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-2- as shown in illustration and pull injectors out upwards by

ility
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tapping gently.
wit
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– Using great pressure, screw oil seal extractor - T40195- as far

hole
spec
as possible by hand into seal.

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

Pull the injector seal upwards by tapping gently using the seal
extractor - T40195- , the adapter - T10133/2- and the slide ham‐
mer - T10133/3- .
– After removal, check whether the spring washer is still on the
old seal.
If not, check that the spring washer is not still on the injector seat.
Installing
Caution
wage es n
Proceed very carefully to prevent unnecessary
yV
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dismantling or ot g
ua
further damage. ir se
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tee
tho
Remember that the cylinder headau cover is made of plastic. or
ac
ss
A plastic cylinder head cover is damaged easily during repairs.
ce
le
un
pt
an
d
itte
Check cylinder head cover for damage.
y li
rm
ab
pe
ility
ot
wit
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– Fit new injector seal at first by hand.
h re
hole
spec
– Then carefully push the new injector seal in as far as it will go
es, in part or in w
with the assembly tool - T10208/2- .
t to the co
Further assembly is carried out in the reverse order of removal.
rrectness of i
1.5 Removing and installing vacuum pump
l purpos
DANGER!
nform
ercia
The vacuum pump may, under no circumstances, be disman‐

m
a
com
ti
tled as the vacuum part could otherwise malfunction. This
on in
would result in the failure of the brake booster.

r
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s
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fo
Removing
en
ng
t.
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op
Golf, Golf Plus, Passat, Touran C py
t. rig
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yri by
– Remove air filter housing together with air mass meter and cop Vo
by lksw
connecting pipe ⇒ page 437 . cted agen
Prote AG.
Polo
connecting pipe ⇒ page 438 .
– Unscrew securing bolts of charge air pipe, and then push
charge air pipe down slightly to gain access to rear threaded
connection of vacuum pump.

– Unscrew vacuum pump securing bolts -arrows-.

– Remove vacuum pump -2- from cylinder head.
Installing
note the following:
Note
♦ Ensure that vacuum pump coupling seats properly in cam‐

shaft.
♦ Renew vacuum pump seal.
– Install vacuum pump and tighten securing bolts to 10 Nm.

– Connect brake booster vacuum line to vacuum pump -1-.
AG. Volkswagen
agen AG do
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Vol ot g
1.6 Checking compression
by ua
ed ran
oris tee
th or
Special au and workshop equipment
tools required ac
ss
ce
le
♦ Jointed wrench 10 mm - 3220-

un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

1763/8-
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test prerequisite
• Engine oil temperature min. 80°C.
• Battery voltage at least 12.5 V
Test procedure

– Disconnect electrical connector from fuel pressure regulating

valve - N 276- -arrow- on high pressure accumulator.
– Start engine briefly to reduce fuel pressure in high-pressure
accumulator.
– Remove all glow pin plugs using jointed spanner - 3220-

⇒ page 531 .
– Screw in adapter - V.A.G 1763/8- in each place where glow
plugs were and connect compression
olks
wage tester - V.A.G 1763- es n.
o
yV t gu
db ara
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tho eo
Note au ra
c
ss
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un
Using compression tester ⇒ operating instructions .
pt
an
d
itte
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ab
– Have a 2nd mechanic operate starter until tester shows no
pe
ility
further pressure increase.
ot
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Compression pressures bar
hole
spec
es, in part or in w
New 25.0 … 31.0

Wear limit 19.0 t to the co
Maximum difference between cylinders 5.0

rrectness of i

l purpos
– Install glow plugs ⇒ page 531 .

nform
ercia
– Entries are stored in the event memory of the engine control

unit because electrical connectors were disconnected and the
m
a
com
engine was started: Read event memory in vehicle self-

tion in
diagnosis ⇒ .
r
te o
thi
s
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do
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cum
fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt”, page 177
⇒ “2.2 Removing and installing toothed belt”, page 181
2.1 Assembly overview - toothed belt

⇒ “2.1.1 Assembly overview - toothed belt, Golf, Golf Plus, Golf
Cabriolet, Passat, Touran”, page 177
⇒ “2.1.2 Assembly overview - toothed belt, Polo”, page 179
2.1.1 Assembly overview - toothed belt, Golf, Golf Plus, Golf Cabriolet, Passat,
Touran
1 - Toothed belt
❑ Check for wear. AG. Volkswagen AG d
agen
❑ Do not kink. olksw
oes
not
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ara
❑ Removing, installing
rised
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and tensioningutho eo
ra
⇒ page 181 s.s a c
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un

pt
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itte
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❑ Renew
rm
ab
pe
❑ Use counterhold - 3415

ility
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- to loosen and tighten. wit

, is n
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❑ Do not additionally oil or
hole
spec
grease the threads and
es, in part or in w
shoulder
t to the co
❑ Turning further can be

done in several stages.
rrectness of i
3 - Crankshaft pulley
l purpos
4 - 20 Nm
5 - Idler pulley
nform
ercia

m
a
com
tio
7 - Tensioning roller
n in
r
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thi
❑ Remove engine bracket

s
iva
do
in order to remove and

r
rp
cum
install ⇒ page 95
fo
en
ng
t.
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8 - 20 Nm + turn 45° further . Cop py
rig
ht
❑ Renew rig ht
py by
co Vo
by lksw
9 - Camshaft toothed belt pul‐ cted agen
Prote AG.
ley
10 - 15 Nm
11 - 100 Nm
12 - Hub
❑ Use counterhold - T10051- to loosen and tighten.
❑ To remove, use puller - T10052-
2. Toothed belt drive 177

13 - Rear toothed belt guard

14 - 20 Nm
15 - 10 Nm
❑ Renew
16 - Idler pulley
❑ Renew
18 - Hub
❑ To remove, use puller - T40064- .
wage es n
19 - 95 Nm yV
olks ot g
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d b ran
20 - Toothed belt pulley on high-pressure pump ir se tee
tho
u or
a ac
21 - 20 Nm ss
ce
❑ Renew le
un
pt
an
d
itte
y li
22 - Coolant pump
rm
ab
pe
ility
❑ Removing and installing ⇒ page 267
ot
wit
, is n
23 - 15 Nm
h re
hole
spec
24 - Toothed belt guard upper part
es, in part or in w
t to the co
25 - Toothed belt guard lower part
26 - 9 Nm
rrectness of i
l purpos
❑ Renew
28 - Belt pulley and vibration damper
nform
ercia
❑ Can only be installed in one position, holes are offset.

m
a
com
ti
29 - 5 Nm
on in
r
te o
❑ Only fitted with protective plate from ⇒ Electronic Parts Catalogue (ETKA) .
thi
s
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do
30 - Protective plate
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fo
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n
t.
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❑ Renew t. C rig
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❑ Observe tightening sequence ⇒ page 97 . cop Vo
by lksw
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Prote
32 - Engine bracket
AG.

Lower toothed belt guard

– Tighten bolts -arrows- to 9 Nm.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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aut ra
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nl
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ility
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es, in part or in w
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2.1.2 Assembly overview - toothed belt, Polo
nform
mercia
at
om
1 - Toothed belt
ion
c
in t
r

o
his
te

a
do
priv
c
❑ Check for wear.
um
for
en
ng
❑ Do not kink.
t.
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Cop py
❑ Removing, installing ht. rig
rig ht
and tensioning py by
co Vo
lksw
⇒ page 181 .
by
cted agen
Prote AG.
❑ Renew
❑ Use counterhold - 3415
- to loosen and tighten.
❑ Do not additionally oil or
grease the threads and
shoulder
❑ Turning further can be
done in several stages.
3 - Crankshaft pulley
4 - 20 Nm
5 - Idler pulley
❑ Renew
7 - Tensioning roller
❑ Remove engine bracket
in order to remove and
install ⇒ page 105
❑ Renew

9 - Camshaft toothed belt pulley

10 - 15 Nm AG. Volkswagen AG d
agen oes
11 - 100 Nm olksw not
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nte
12 - Hub horis
eo
ut ra
❑ Use counterhold - T10051- to loosen and tighten. ss a c
ce
e
❑ To remove, use puller - T10052-
nl
pt
du
an
itte
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erm
ab
13 - Rear toothed belt guard
ility
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14 - 20 Nm
h re
hole
spec
15 - 10 Nm
es, in part or in w
t to the co
❑ Renew
16 - Idler pulley
rrectness of i
l purpos
18 - Hub
nf
ercia
orm
m
atio
19 - 95 Nm
om
n in
or c
20 - Toothed belt pulley on high-pressure pump
thi
te
sd
iva
21 - 20 Nm
o
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rp
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❑ Renew
f
en
ng
t.
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op
22 - Coolant pump
C py
ht. rig
rig ht
❑ Removing and installing ⇒ page 267 py by
co Vo
by lksw
cted agen
23 - 15 Nm Prote AG.
24 - Toothed belt guard upper part

25 - Toothed belt guard lower part
26 - 9 Nm
❑ Renew
28 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
29 - 5 Nm
❑ Only fitted with protective plate from ⇒ Electronic Parts Catalogue (ETKA) .
30 - Protective plate
❑ Renew
❑ Observe tightening sequence ⇒ page 108 .
32 - Engine bracket

Lower toothed belt guard

wage
– Tighten bolts -arrows- to 9 Nm. olks es n
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d ran
ir se tee
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un
pt
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itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
2.2 Removing and installing toothed belt

m
a
com
tion in
r
te o
thi
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do
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fo
en
ng
t.
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Cop py
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Vo
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by
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Prote AG.


equipment required
♦ 2x diesel injection pump
locking pin - 3359-
AG. Volkswagen AG d
agen
♦ Crankshaft stop - T10050- Volksw
oes
not
gu
d by ara
♦ Counterhold - T10172- orise nte
eo
h
ut ra
♦ Angled screwdriver - ss a c
T10264- for tensioning roll‐
ce
le
un
pt
er -A-
an
d
itte
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rm
♦ Locking tool - T10265-
ab
pe
ility
ot
♦ Bit XZN 10 - T10385-
wit
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h re
♦ Angled screwdriver -
hole
spec
T10409- for tensioning roll‐
es, in part or in w
er -B-
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Not illustrated:
Note
2 versions of tensioning roller are fitted. They are interchangea‐

ble. When performing adjusting measures, check first to see
which tensioning roller is installed.
Observe different directions of rotation during tensioning

Features tensioning roller A
♦ Locking tool - T10265- required for installation.
♦ Check tensioning roller is seated correctly in timing belt guard.
♦ Tension toothed belt by turning tensioning roller eccentric
»clockwise«
Features tensioning roller B
♦ Locking tool not required. . Volkswagen AG
gen AG does
swa
♦ The tensioning roller doesbnot
y V sit in the timing belt guard t gua
olk no
ed ran
is
♦ Tension toothed beltthby
or rotating tensioning roller eccentric tee
or
»anticlockwise« s au ac
s
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un
pt
an
d
Note
itte
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erm
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ility
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Adjustment work on toothed belts must be performed only on cold

wit
is n
engines, as the indicator position on the tensioning element varies

h re
ole,
depending on the engine temperature.

spec
t to the co

– With ignition switched off, disconnect battery. ⇒ Electrical
system; Rep. gr. 27 ; Battery; Disconnecting and connecting
rrectne
battery
s

s o
cial p

inform

mer

atio
om
n
c

i
or
n thi
e

t
sd
va
noise insulation
i
o
pr
cum
r
fo

en
ng
t.
yi Co
op py
Continuation for Golf, Golf Plus, Golf Cabriolet, Passat, Touran t. C rig
gh ht
⇒ page 183 pyri by
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cted
Continuation for Polo ⇒ page 185
agen
Prote AG.


– Push washer fluid reservoir filler pipe with filler neck -2- to side.
Note

♦ For reasons of clarity, diagram shows installation position with
removed fuel filter.
– Free air guide hose at retainer -2-.

– Pull retainer with fuel hoses off upwards -arrow- and lay to
side.
– Unscrew bolts -1-, lay pressure differential sender - G 505-
with bracket aside.
AG. Volkswagen AG d
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olksw not
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– Loosen bolt -1-. orised
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– Remove bolt -2-ssand nut -3-.
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Cop py
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Prote AG.


– Unscrew nut -1- and bolt -2-.
– Free coolant pipe on right with coolant hoses connected
-arrows-.
AG. Volkswagen AG d
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– Remove upper toothed belt cover, release clips -arrows- for
pe
ility
this.
ot
wit
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– Unscrew coolant reservoir and put aside.
hole
spec
Polo
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
t
– Disconnect electrical connector -2- at pressure differential
ion in
sender - G 505- .
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– Remove pressure differential sender - G 505- from bracket
do
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-3-.
um
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with lines.
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by lksw
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Prote AG.

lines.


tank guide.

– Separate fuel supply line and return line at engine end.
– Remove fuel filter and fuel lines together with fuel preheater
valve.
– Remove lower part of fuel filter ⇒ Rep. gr. 20 ; Fuel filter;
– Unscrew bolts -arrows- for coolant expansion tank.

cator switch - F66- .
The coolant expansion tank can thus be placed to one side.
AG. Volkswagen AG d
agen oes
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– Open clips -arrows- and remove toothed belt guard.

wit
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hole
spec

es, in part or in w
t to the co
– Remove vibration damper ⇒ page 88 .

rrectness of i
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.


– Remove toothed belt guard downwards.
Polo
Note
Engine bracket must be removed to change tensioning roller and

to remove and install toothed belt ⇒ page 105 .
Note
The engine bracket always also has to be removed in order to

change the tensioning roller ⇒ page 95 .
– Turn engine to TDC and lock crankshaft pulley in position with

crankshaft stop - T10050- . Fit the crankshaft stop in the teeth
from the face side of the toothed belt pulley.
• The mark -2- on the toothed pulley and the arrow -1- on the
crankshaft stop - T10050- must align -arrow-. When doing this,
the pin of the crankshaft stop must engage in the drilling of
sealing flange.
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The arrow on the camshaft pulley must be at almost »12 o'clock«.

pt
du
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– Mark direction of rotation of toothed belt.

erm
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ility
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t to the co
rrectness of i
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nf
– Loosen bolts -arrows- approx. 90° for camshaft toothed belt

ercia
pulley.
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Cop py
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pyri by
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co lksw
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Prote AG.

– Loosen bolts -2- approx. 90° for high-pressure pump toothed

belt pulley using bit XZN 10 - T10385- .
Tensioning roller A:
AG. Volkswagen A
– Loosen securing nut of tensioning roller l-1- kswand turn tensioning
agen G do
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roller eccentric using socket - T10264-d by Vo counter-clockwise ua
ran
-arrow- until tensioning roller can
ori be locked with locking pin -
se
tee
T10265- . au
th or
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spec
t to the co
– Now turn tensioning roller eccentric clockwise -arrow- onto
stop and tighten securing nut -1- hand-tight.
rrectne
Tensioning roller B:
ss o
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mer
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n
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.

– Loosen nut -1- for tensioning

wage
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Volkswagen AG
does
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– Use angled screwdriver
ed
by 8mm - T10409- to rotate eccentric
ua
ran of
tensioningthoroller
ris clockwise -arrow- until tensioning roller
tee is
o
loosened.
sa
u ra
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s
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– Retighten securing nut by hand.

un
pt
an
d
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ab
Caution
ility
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Risk of irreparable damage if direction of rotation is reversed
h re
ole,
on previously used toothed belt.
spec
♦ Before removing toothed belt, mark direction of rotation
t to the co
with chalk or felt tipped pen for installation purposes.
rrectne
– Remove toothed belt first from idler pulley and then from re‐
maining toothed belt pulleys.
ss o
Installing
cial p
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mer
atio
m
Note
o
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c
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♦ The toothed belt may only be adjusted on cold engines, as the

t
sd
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indicator position on the tensioning element varies depending

i
o
pr
cum
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on the engine temperature.

fo
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♦ If the tensioning roller is to be renewed, the engine bracket Cop py
always also has to be removed.
ht. rig
rig ht
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co Vo
♦ Removing and installing engine bracket ⇒ page 95
by lksw
cted agen
Prote AG.
• Tensioning roller must be locked with locking tool - T10265-

and secured to right stop.
• Crankshaft is locked using crankshaft stop - T10050- .
Tensioning roller B:

– Place tensioner for tensioning roller in 9 o'clock position.

– Tighten tensioning roller to 2 - 4 Nm.
lkswage es n
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Crankshaft is locked using thcrankshaft stop - T10050- .
o tee
or
au ac
Continuation for both tensioning rollers ss
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nl
pt
du
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Note
erm
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If necessary, turn camshaft hub with counterhold - T10172- and
, is n
h re
adapters - T10172/4- until camshaft can be secured in position.
hole
spec
To do this, hand-tighten at least one securing bolt -1-.
es, in part or in w
t to the co
rrectness of i
– Lock camshaft hub with locking pin - 3359- . To do this, slide
l purpos
locking pin through outer free elongated hole into hole in cyl‐
inder head.
nf
ercia
orm
m
atio
om
n in
or c
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Cop py
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co lksw
by
cted agen
– Loosen bolt which had been tightened only hand-tight.
Prote AG.
Loosely tightened bolts -arrows-.

It should just be possible to turn camshaft toothed belt pulley
without axial movement.
Note
If necessary, turn hub of high-pressure pump at bolt heads with

screwdriver until it can be secured in position.

Positioning hub of high-pressure pump
– Lock hub of high-pressure pump with locking pin - 3359- . To

do this, slide locking pin into adjustment hole outside toothed
belt pulley.
Loosely tightened bolts -1-.
It should just be possible to turn high-pressure pump toothed belt
pulley without axial movement.
AG. Volkswagen AG d
agen oes
olksw not
– Turn camshaft pulley -3- and toothed belt pulley of high-pres‐
ed by
V gu
ara
sure pump -5- in their elongated holes clockwise tohstop.
oris nte
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aut ra
– Fit toothed belt in sequence described: ss c
ce
e
nl
pt
1- Crankshaft pulley
du
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2- Tensioning roller
erm
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ility
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3- Camshaft toothed belt pulley

wit
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4- Coolant pump toothed belt pulley h re

hole
spec
es, in part or in w
5- High-pressure pump toothed belt pulley

t to the co
6- Idler pulley
rrectness of i
– Loosen tensioning roller securing nut and pull out locking tool
l purpos
- T10265- .
nf
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orm
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Cop py
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Vo
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by c lksw
cted agen
Prote AG.

Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
– Screw eccentric of tensioning roller clockwise carefully using

angled screwdriver - T10264- . Indicator -2- must be roughly
past the centre of the gap in the base plate (rectifies itself dur‐
ing pretensioning).
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° further.
– Apply counterhold - T10172- as shown. Press counterhold -

T10172- in direction of arrow, keeping camshaft toothed belt
pulley under tension.
– In this position, first tighten securing bolts -1- of camshaft pul‐
ley and of toothed belt pulley for high pressure pump by hand
and then tighten to 20 Nm.
AG. Volkswagen AG d
Tensioning roller B: lksw
agen oes
not
Vo gu
by ara
d
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– Carefully turn eccentric on tensioning roller counter clockwise

ility
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using angled screwdriver - T10409- . Indicator -2- must be

wit
roughly past the centre of the gap in the base plate (rectifies
is n
h re
itself during pretensioning).

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Markings on tensioning element and tensioning roller -arrow- are

now almost aligned.
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut -1-: 20 Nm and turn 45° further.
– Apply counterhold - T10172- as shown. Press counterhold -

T10172- in direction of arrow, keeping camshaft toothed belt
pulley under tension.
– Tighten securing bolts -arrows- for camshaft pulley hand-tight

at first and then to 20 Nm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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nl
pt
du
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ab
– Tighten securing bolts of high pressure pump sprocket by ility
ot p
hand initially and then to 20 Nm.

wit
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Continuation for both tensioning rollers

hole
spec
es, in part or in w
– Remove locking pins - 3359- and crankshaft stop - T10050- .

t to the co
– Turn crankshaft at least 2 rotations in engine direction of ro‐

tation and set again to TDC no. 1 cylinder.
rrectness of i
– Fit crankshaft stop - T10050- again to crankshaft belt pulley.

l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
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for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Now turn crankshaft in engine direction of rotation until pin of

crankshaft stop -arrow- engages in sealing flange from rota‐
tional movement.
Note
During the following checking procedure, only the camshaft and

crankshaft must be secured in position. It is very difficult to find
the securing position of the high-pressure pump hub again. How‐
ever, a slight deviation -arrow- does not influence the engine
operation. n AG. Volkswagen A G do
wage es n
Volks ot g
– Check if: ed
by ua
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oris tee
♦ Camshaft hub th
au can be locked with locking pin - 3359- . or
ac
ss
♦ Belt tensioner indicator is centred or maximum 5 mm to right
ce
le
un
pt
of base plate notch.

an
d
itte
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rm
ab
If camshaft hub cannot be locked:

pe
ility
ot
– Pull crankshaft stop - T10050- back until pin uncovers hole.

wit
, is n
h re
hole
– Turn crankshaft in opposite direction of engine rotation slightly

spec
past TDC.
es, in part or in w
t to the co
– Now turn crankshaft slowly in direction of engine rotation until

camshaft hub can be secured in position.
rrectness of i
– After locking, loosen securing nuts of crankshaft pulley.

l purpos
If pin of crankshaft stop - T10050- is standing on left next to hole:
– Turn crankshaft in engine direction of rotation until crankshaft

nform
ercia
stop pin engages in sealing flange whilst turning.

m
a
com
ti
– Tighten securing bolts of camshaft toothed belt pulley by hand

on in
first and then tighten to 20 Nm.

r
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thi
s
iva
do
If pin of crankshaft stop - T10050- is standing on right next to hole:

r
rp
cum
fo
– Slightly turn crankshaft in opposite direction of engine rotation.

en
ng
t.
yi Co
op
– Now turn crankshaft in engine direction of rotation until crank‐
C py
ht. rig
shaft stop pin engages in sealing flange whilst turning.
rig ht
py by
co Vo
by lksw
cted
– Tighten securing bolts of camshaft toothed belt pulley by hand
agen
Prote AG.
first and then tighten to 20 Nm.
Continuation
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Turn crankshaft at least 2 rotations in engine direction of ro‐
tation and set again to TDC no. 1 cylinder.
– Repeat check.
– If camshaft hub can be secured in position, tighten securing
bolts as follows:

♦ Camshaft toothed belt pulley: turn 45° further. Counterhold

with counterhold - T10172- and adapters - T10172/4- .
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper: specified torque 10 Nm +
90° further.
– Install poly V-belt.
– Install upper toothed belt guard.
or with blue marking, supply line white).
– Install wheel housing liner.
noise insulation
lkswage es n
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pt
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 196
⇒ “3.2 Measuring axial play of camshaft”, page 197
⇒ “3.3 Measuring radial play of camshaft”, page 198
⇒ “3.4 Removing and installing camshaft oil seal”, page 199
⇒ “3.5 Removing and installing camshaft”, page 201
⇒ “3.6 Checking hydraulic compensation elements”, page 208
⇒ “3.7 Removing and installing valve stem seal”, page 209
3.1 Assembly overview - valve gear
1 - Valve
❑ Must not be machined; agen
AG. Volkswagen AG d
oes
only grinding-in is per‐ Volksw not
gu
missible d by ara
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❑ Mark installation posi‐ aut
ho eo
ra
tion for re-installation. ss c
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nl
pt
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❑ Valve dimensions
y li
erm
ab
⇒ page 216
ility
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❑ Checking valve guides
wit
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⇒ page 216 .
h re
hole
spec
2 - Cylinder head
es, in part or in w
t to the co
❑ See note ⇒ page 134 .
⇒ page 137
rrectness of i
3 - Valve stem seal
l purpos
❑ Renew with cylinder

head installed
nform
ercia
⇒ page 209
❑ Renewing with cylinder
m
at
om
head removed
on
c
⇒ page 212 .
in t
or
his
ate
4 - Valve spring
do
priv
cum
or
5 - Valve spring plate

f
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ng
t.
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6 - Valve cotters
C py
t. rig
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yri by
7 - Cap
op Vo
by c lksw
cted agen
❑ Renew Prote AG.
❑ Removing: With retain‐

ing frame installed,
pierce one side of cap
with an awl and pry out.
❑ Installing: Drive in with‐
out sealant using an appropriate thrust piece.
❑ Insertion depth 1 … 2 mm
8 - Oil seal
❑ Renew ⇒ page 199
9 - Exhaust camshaft
❑ Measuring axial clearance ⇒ page 197 .

10 - Bolt
❑ Sequence when loosening
❑ Specified torque and tightening sequence ⇒ page 197 .
11 - Retaining frame n AG. Volkswagen AG do
wage
❑ With integrated camshaft bearings. olks es n
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❑ Removing and installing ⇒ page 201 .rised ran
te
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12 - Inlet camshaft ss
a ra
c
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nl
pt
du
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❑ Measuring axial clearance ⇒ page 197 . itte
y li
erm
ab
ility
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13 - Roller rocker finger
, is n
h re
❑ Mark installation position.
hole
spec
❑ Do not interchange
es, in part or in w
t to the co
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
rrectness of i
l purpos
14 - Securing clip
❑ For hydraulic compensation element.
nf
ercia
o
15 - Hydraulic compensation element
rm
m
atio
❑ Mark installation position for re-installation.
om
n in
c
❑ Lubricate contact surfaces before installing.

or
thi
te
sd
iva
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Retaining frame - specified torques and installation sequence
en
ng
t.
yi Co
op py
– Tighten bolts in 2 stages in the sequence shown: t. C rig
gh ht
pyri by
Vo
o
Stage Bolts Specified torque
c by lksw
cted agen
Prote AG.
1. -1 … 24- Screw in to contact by hand
• The retaining frame must make
contact with the cylinder head over
the entire contact surface.
2. -1 … 24- 10 Nm
3.2 Measuring axial play of camshaft

3. Valve gear 197

♦ Universal dial gauge bracket - VW 387-
AG. Volkswagen AG d
agen oes
olksw not
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pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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Procedure
p
cum
for
en
– Remove retaining frame.

ng
t.
yi Co
op py
– Fasten dial gauge - VAS 6079- to retaining frame, using uni‐
. C rig
ht ht
rig
versal dial gauge bracket - VW 387- as shown in the illustra‐ py by
co Vo
tion.
by lksw
cted agen
Prote AG.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048…0.118 mm
• Wear limit: 0.17 mm.
3.3 Measuring radial play of camshaft

♦ Plastigage
Procedure
– Remove roller rocker finger.
– Remove bearing cap and clean crankshaft journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the journal to be measured or into the bearings.
• Plastigage must lie in the middle of the bearing.
– Fit retaining frame and tighten to 10 Nm ⇒ page 197 without
twisting crankshafts.
– Remove retaining frame.
– Compare width of Plastigage with the measurement scale.

• Radial clearance: 0.035 … 0.085 mm.
3.4 Removing and installing camshaft oil

seal agen AG. Volkswagen AG d
w oes
olks not
byV gu
ara
ed nte
Note ris
tho eo
au ra
c
ss
♦ A modified oil seal is gradually being introduced.
ce
e
nl
pt
du
an
♦ The “old version” of the oil seal -item A- forms a continuous
itte
y li
erm
surface between the camshaft and the cylinder head.
ab
ility
ot p
♦ The “new version” of the oil seal -item B- forms a stepped sur‐
wit
, is n
face between the camshaft and the cylinder head.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e

t
sd
iva
equipment required
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f
♦ Fitting tool - V.A.G 10-203-

en
ng
t.
yi Co
op py
♦ Oil seal extractor - 3240-
. C rig
ht ht
rig by
py
co Vo
by lksw
cted
1331/-
agen
Prote AG.

1332/-
♦ Use bolt M12 x 1.5 x 75
3. Valve gear 199

-10203- .
Puller - T10443- for “new version” of oil seal

Removing
– Take toothed belt off camshaft and high-pressure pump
⇒ page 181 .
– Remove camshaft pulley and hub ⇒ page 201 .
“Old version” of oil seal:
– Insert thrust piece -3240/1- into camshaft.

– Unscrew inner part of oil seal extractor - 3240- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
– Lubricate threaded head of oil seal extractor, place it in posi‐ ab

ility
ot p
tion and, exerting firm pressure, screw it into oil seal as far as wit
, is n
possible. h re
hole
spec
– Loosen knurled screw and turn inner part against camshaft

es, in part or in w
until oil seal is pulled out.

t to the co
– Clamp oil seal extractor on flats in a vice and remove oil seal
using pliers.
rrectness of i
l purpos
nform
mercia
at
om
“New version” of oil seal:

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ate
Caution
do
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♦ If unscrewed too far, the internal thrust plate of the puller

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-T10443- detaches from the thrust screw. In this case, the Cop py
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pressure plate must be pressed back on to the thrust bolt.
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– Carefully turn back grub screw -arrow- of puller -T10443- until
a slight resistance is felt.

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ran
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4-cylinder
tho common rail engine (1.6 l, EA189) t-eeEdition
or 02.2016
au ac
ss
– Position puller - T10443- straight, as shown in illustration, and
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lock by screwing grub screw -A- in.
du
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– Screw in thrust bolt -B- until seal is extracted.
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Installing
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– Clean contact surface and sealing surface.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
The oil seal sealing lip must not be additionally oiled or greased.
l purpos
– Remove oil residue from camshaft journal using a clean cloth.
nform
ercia
– Fit guide sleeve -10-203- onto camshaft as shown in illustra‐

tion.
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at
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ion
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– Carefully slide oil seal -1- over guide sleeve onto camshaft.
in t
or
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ate
do
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Prote AG.
– Press seal in onto stop using thrust piece from fitting tool
10-203 and M12x1.5x75 bolt.
– Install camshaft pulley and hub ⇒ page 201 .
– Install toothed belt and adjust valve timing ⇒ page 181 .
3.5 Removing and installing camshaft
3. Valve gear 201


equipment required
ing pin - 3359-
♦ Puller - T10052-
♦ Camshaft fitting tool -
T40094-
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♦ Camshaft clamping tool - Volksw not
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T40095- d by ara
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♦ Camshaft fitting tool - aut ra
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T40096- ss
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es, in part or in w
t to the co
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nform
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ion
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♦ Torque wrench - V.A.G 1331/-
AG.

♦ Torque wrench - V.A.G 1332/-
♦ Sealant as per ⇒ Electronic Parts Catalogue (ETKA)
3.5.1 Removing
– Remove fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 181 .
– Unscrew securing bolts -1- of camshaft sprocket.
AG. Volkswagen AG d
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– Counterhold hubauwith
th counterhold - T10051- and loosen se‐ ra
curing bolt -1- of hub. ss c
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un
pt

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pe
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spec
es, in part or in w
t to the co
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nform
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tion in
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3. Valve gear
agen
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– Fit puller - T10052- and align it with holes in hub.

– Tighten securing bolts -1-.
Note
– Remove hub from taper of camshaft.

– Remove vacuum pump ⇒ page 174 .
– Remove securing bolts of retaining frame in sequence

-24…1-.
– Release retaining frame carefully from adhesive.
– Mark camshafts for re-installation and remove.
AG. Volkswagen AG d
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3.5.2 Installing
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Note
es, in part or in w
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♦ Gradual discontinuation of two-piece camshaft sprocket

♦ Note the differences in the »Installing« procedure.
rrectness of i
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Remove one-piece -arrow- camshaft sprocket

nf
ercia
Caution
orm
m
atio
m
The camshafts may be installed only with the camshaft fitting

o
n in
c
tool - T40094- as described below. Otherwise the axial bear‐

or
thi
ings in the retaining frame will be destroyed and the cylinder

te
sd
a
head must be replaced.

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Cop py
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– Remove remaining sealant and from cylinder block and re‐ yri
gh by
ht
taining frame using, for example, a rotating plastic brush. cop Vo
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Caution
Danger of soiling lubrication system and bearings.

♦ Cover open parts of engine.
– Clean sealing surfaces. They must be free of oil and grease.

– Oil the camshaft running surfaces.

Prepare camshaft fitting tool - T40094- as follows:

– Bolt supports -T40094/9- and -T40094/10- (with -T40094/11- )
to the base plate as shown in illustration. Remove any bolted-
on supports here if necessary.
AG. Volkswagen AG d
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– Place support -T40094/1- in position -F- and support -

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T40094/2- in position -A-.
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– Insert inlet camshaft into supports -T40094/1- and - C py
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T40094/2- .
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– Turn inlet camshaft so that it can be locked in “TDC” position cted agen
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with locking ruler -arrow-.
• The indentation -arrow 2- for the cylinder head bolt must face
outwards.
3. Valve gear 205

– Insert exhaust camshaft into supports -T40094/9- and -

T40094/10- .
– Lock exhaust camshaft with cover -T40094/11- .
• The lug -1- of the cover must engage in the slot -2- in the cam‐
shaft.
Vehicles with two-piece camshaft sprocket:
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
• The wider arm must engage in the wider gear half.
– Tighten clamping tool using knurled wheel so that faces of
gear teeth are in alignment.
– Slide inlet camshaft towards exhaust camshaft until teeth en‐
gage.
– Place retaining frame -1- on camshafts.

• All camshaft bearings must be seated on the camshafts.
– Fit camshaft fitting tool - T40095- and fix camshafts in position
in retaining frame as shown in the illustration.
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– Remove -T40094/11- cover.

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spec
Note
es, in part or in w
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♦ Observe expiry date of sealing compound.

♦ Seal parting surface between retaining frame and cylinder
rrectness of i
head using silicone adhesive sealant - D 176 501 A1- .

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

prox. 2 mm).
– Apply beads of sealant onto clean sealing surfaces of cylinder
head as illustrated.
• Thickness of sealant beads: 2…3 mm.
– Install new cap flush on cylinder head.

– Take camshafts out of camshaft fitting tool - T40095- together
with retaining frame and camshaft fitting tool - T40094- .
– Carefully insert camshafts and retaining frame into cylinder
head.
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– Unscrew retaining frame securing bbolts yV
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Tighten finger-tight initially. rised ran
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• The retaining frame should ss
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make contact with the cylinder ac
head over the complete surface.
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– Tighten retaining frame bolts to final torque in the sequence

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-1 … 24-. Specified torque setting: 10 Nm

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– Remove camshaft fitting tool - T40095- and clamping tool -

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T40096/1- .
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hole
spec
– Renew camshaft seal ⇒ page 199 .

es, in part or in w
t to the co
Perform further installation in reverse order, paying attention to

the following:
rrectness of i
Note
l purpos
♦ After installing camshafts wait for approx. 30 minutes before

nform
ercia
starting engine. The hydraulic compensation elements must

settle (otherwise valves will strike pistons).
m
at
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♦ After working on valve gear, carefully crank engine at least 2

n
c
in t
r
revolutions by hand to ensure that no valves make contact on

o
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starting.
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– Place hub onto camshaft.

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Prote AG.
3. Valve gear 207

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eo
➤ ...
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4-cylinder commons a rail engine (1.6 l, EA189) - Edition 02.2016
ut ra
c
s
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nl
– Tighten hub securing bolt -1- to 100 Nm. To do this, use the
pt
du
an
counterhold - T10051- .
itte
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ility
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es, in part or in w
t to the co
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– Push camshaft sprocket onto hub.
nf
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orm
m
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om
Note
n in
or c
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The toothed segment -arrow- of the camshaft belt pulley must be

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on top.
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– Hand tighten securing bolts -1- at camshaft pulley so that there
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– Lock hub with locking pin - 3359- . cted agen
Prote AG.
– Install toothed belt and adjust valve timing ⇒ page 181 .

– Install vacuum pump ⇒ page 174 .
– Install fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and
3.6 Checking hydraulic compensation ele‐

ments
Note
♦ The hydraulic compensation elements cannot be repaired.

♦ Irregular valve noise during starting is normal.

♦ Plastic wedge
♦ Feeler gauges
Procedure
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2,500 rpm for 2 minutes; per‐
form road test if necessary.
Note
If the irregular valve noises stop but recur repeatedly during short
journeys, the oil filter bracket ⇒ page 235 with integrated oil re‐
tention valve must be renewed.

– If the hydraulic compensation elements are still noisy, find out

which is the defective compensation element as follows:
– Turn crankshaft by the bolt for the toothed belt wheel until cam
of supporting element to be tested is facing upwards.
– Press roller rocker finger downwards -arrow- with a plastic
wedge to check clearance between cam and roller rocker fin‐
ger.
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– If a 0.20 mm feeler gauge can be inserted between cam andVolkswa not
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roller rocker finger, renew hydraulic compensation elemented
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⇒ page 201 . thoris eo
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Concluding measures ss c
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3.7 Removing and installing valve stem seal
t to the co
⇒ “3.7.1 Removing and installing valve stem seals with cylinder
head installed”, page 209
rrectne
⇒ “3.7.2 Removing and installing valve stem seals with cylinder
head removed”, page 212
ss
3.7.1 Removing and installing valve stem seals with cylinder head installed
o
cial p
f inform
mer
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Cop py
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Prote AG.
3. Valve gear 209


equipment required
♦ 10 mm jointed spanner -
3220-
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation
device for valve cotters -
VAS 5161- with guide plate
- VAS 5161/23- and knurled
spacer ring - VAS
5161/23-1-
AG. Volkswagen AG d
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Procedure
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nl
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du
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– Remove all glow plugs using U/J extension and socket - 3220-
y li
erm
ab
⇒ page 531 .
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– Remove camshafts ⇒ page 201 .

, is n
h re
hole
– Remove roller rocker fingers; make a note of the installation

spec
position ⇒ Item 13 (page 197) .

es, in part or in w
t to the co
– Fit guide plate - VAS 5161/23- onto cylinder head.

– Secure guide plate on intake manifold side with knurled screw
rrectness of i
- VAS 5161/12- and tighten it hand-tight to studs using M 6

collarless nuts -1-.
l purpos
– Screw sealing pin - VAS 5161/10- into guide plate.

nf
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– Screw adapter - VAS 5161/11- hand-tight into glow plug hole

of relevant cylinder.
– Insert drift - VAS 5161/3- into guide plate and knock valve cot‐
ters loose using a plastic hammer.
– Screw engaging fork - VAS 5161/5- with snap-in device -

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VAS 5161/6- into guide
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– Slide knurled isspacer
ed
b ring - VAS 5161/23-1- onto assembly
ua
ran
cartridge - VAS
thor 5161/8- . tee
o
u ra
sa c
– Connects adapter - VAS 5161/11- to compressed air line using
ce
le
a commercially available connection piece, and apply constant

un
pt
an
d
air pressure.
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ab
• Minimum pressure: 6 bar

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ility
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– Attach pressure fork - VAS 5161/2- to snap-in device and push

h re
assembly cartridge down.

hole
spec
– At the same time, turn knurled screw of assembly cartridge

es, in part or in w
t to the co
clockwise until tips engage in valve cotters.

– Move knurled screw back and forth lightly to press apart valve
cotters and capture them in the assembly piece.
rrectness of i
– Release pressure fork.

l purpos
– Take out assembly cartridge with knurled spacer ring, valve

plate and valve spring.
nform
mercia
a
com
– Remove valve stem oil seals using valve stem seal puller -
tion in
3364- .
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s
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Installing
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Cop py
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3. Valve gear 211

Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to

new valve stem oil seal -B-.
– Lightly lubricate sealing lip of valve stem oil seal.
– Slip valve stem oil seal over plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– If necessary, use a plastic head hammer and tap lightly on
fitting tool until valve stem oil seal is fitted to stop.
– Remove plastic sleeve.
– Insert valve spring and valve spring plate into cylinder head.
– If valve cotters have been removed from assembly cartridge ,

they need to be put into insertion device - VAS 5161/18- first.
Note
Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above

and pick up valve cotters.
AG. Volkswagen AG d
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– Re-insert assembly cartridge - VAS 5161/8- intothoguide plate .
r eo
au ra
– Push pressure fork down and pull knurled screw
ss
upwards c
ce
le
while turning to left and right - this will insert the valve cotters.
un
pt
an
d
itte
– Release pressure fork with knurled screw still in pulled posi‐ y li

rm
ab
tion.
pe
ility
ot
wit
Further installation is carried out in reverse order; note the fol‐
, is n
h re
lowing:
hole
spec
– Install camshafts ⇒ page 201 .

es, in part or in w
t to the co
– Install glow plugs ⇒ page 531 .

rrectness of i
Note
l purpos
♦ Engine is not to be rotated for approx. 30 minutes after instal‐

ling camshafts. The hydraulic compensation elements must
nform
ercia
settle (otherwise valves will strike pistons).

m
a
com
♦ After working on the valve gear, turn the engine carefully at

ion in
least 2 rotations to ensure that none of the valves make con‐

r
te o
thi
tact when the starter is operated.

s
iva
do
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rp
cum
fo
en
ng
t.
3.7.2 Removing and installing valve stem seals with cylinder head removed
yi Co
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equipment required
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365- en AG. V
olkswagen AG
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♦ Removal and installationVol gu
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device for valve
ris cotters -
ed
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VAS 5161-auwith
tho guide plate eo
ra
-VAS 5161/23-
ss and sleeve - c
VAS 5161/23-1-
ce
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un
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port - VAS 6095-
ility
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♦ Cylinder head tensioning
wit
is n
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device - VAS 6419-
ole,
spec
♦ 2x M6x30 bolts
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
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sd
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fo
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Cop py
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Prote AG.
Procedure
– Remove camshafts ⇒ page 201 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Clamp cylinder head in cylinder head clamping device as
shown in illustration.
Operating instructions for the cylinder head tensioning device -
VAS 6419- are enclosed with unit.
– 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.
3. Valve gear 213

– Place guide plate -VAS 5161/23- onto cylinder head.

– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts until it makes
contact. olkswage es n
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hole
– Insert drift -VAS 5161/3- into guide plate and use a plastic
spec
hammer to knock loose the firmly seated valve cotters.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Screw toothed piece -VAS 5161/6- with hooking fork -

p
cum
or
VAS 5161/5- into guide plate.

f
en
ng
t.
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op
– Push sleeve -VAS 5161/23-1- onto assembly cartridge - C py
t. rig
VAS 5161/8- .
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pyri by
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– Attach pressure fork -VAS 5161/2- to toothed piece and press cted agen
Prote AG.
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 assembly cartridge with knurled spacer ring.
– Remove valve spring and valve spring plate.
– Pull off valve stem seal using valve stem seal puller - 3364- .

Caution
Risk of damage when installing valve stem seals.

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

– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device -
VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto valve insertion device from
AG. Volkswagen AG d
above and pick up valve cotters. lksw
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– Insert assembly cartridge into guide plate -VAS 5161/23-
y li
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ab
again.
ility
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– Press pressure fork downwards and pull knurled screw up‐
is n
h re
wards, turning it clockwise and anticlockwise. This inserts the
ole,
valve cotters.
spec
t to the co
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
rrectne
Reassembly
ss
o
cial p
f in
– Ensure that all roller rocker fingers contact valve stem ends
form
mer
correctly and are clipped into relevant hydraulic compensation atio

m
elements.
o
n
c
i
or
– Install camshafts ⇒ page 204 .

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fo
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3. Valve gear 215

4 Inlet and exhaust valves

⇒ “4.1 Valve dimensions”, page 216
⇒ “4.2 Reworking valve seats”, page 216
⇒ “4.3 Checking valve guides”, page 216
⇒ “4.4 Checking valves”, page 216
4.1 Valve dimensions

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Valves must not be reworked. Only lapping-in is permitted.
ss
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pt
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d
Dimension Inlet valve Exhaust valve

itte
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ab
Diameter a mm 26.50 … 26.70 24.4 … 24.60
pe
ility
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wit
Diameter b mm 5.968 … 5.982 5.958 … 5.972
, is n
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c mm 99.30 99.10
hole
spec
es, in part or in w
α ∠° 45 45
t to the co
4.2 Reworking valve seats
rrectness of i
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Note
nform
ercia
Valve seats must not be reworked due to the very small toleran‐
ces.
m
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com
tion in
r
4.3 Checking valve guides

te o
thi
s
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t.
♦ Universal dial gauge bracket - VW 387- Cop
yi Co
py
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♦ Dial gauge gh ht
pyri by
Vo
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by
– Insert new valve into guide. The end of the valve stem must Prote
cted AG.
agen
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
4.4 Checking valves

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

17 – Lubrication
AG. Volkswagen AG d
1 Sump, oil pump Volksw
agen oes
not
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⇒ “1.1 Assembly overview - sump/oil pump”, page 217 horis nte
eo
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⇒ “1.2 Removing and installing oil sump”, page 219 ss c
ce
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nl
⇒ “1.3 Removing and installing oil level and oil temperature send‐
pt
du
an
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er G 266 ”, page 224
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ab
⇒ “1.4 Removing and installing oil pump”, page 225
ility
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⇒ “1.5 Engine oil”, page 226
h re
hole
spec
1.1 Assembly overview - sump/oil pump es, in part or in w
t to the co
1 - Oil level and oil temperature
sender - G266-
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⇒ page 224 .
2 - O-ring
nform
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❑ Renew
m
at
om
io
3 - Oil drain plug
n
c
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or
❑ 30 Nm
his
ate
do
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4 - Seal
p
cum
for
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❑ Renew
n
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5 - Bolt
t. C rig
gh ht
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❑ Specified torque and
op Vo
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tightening sequence
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Prote AG.
⇒ Fig. ““Oil sump -
specified torques and
installation sequence”“ ,
page 219 .
6 - Oil sump
❑ Clean sealing surface
before fitting.
❑ Install with sealant ac‐
cording to ⇒ Electronic
Parts Catalogue (ET‐
KA) .
⇒ “1.2 Removing and in‐
stalling oil sump”,
page 219 .
7 - Bolt
❑ 16 Nm
8 - Oil pump
❑ With 12 bar pressure re‐
lief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
Note
♦ If toothed belt or oil pump have

to be removed.
1. Sump, oil pump 217

♦ Check oil pump for free move‐

ment.
♦ It should be possible to turn belt
pulley easily with 1 finger.
♦ Renew if tight/sticking.
9 - Toothed belt
❑ Check for damage and wear agen
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❑ Replace if necessary by Vo gu
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Note s aut ra
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♦ Belts which have been in use nl
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longer can sag.
itte
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♦ This is not a fault and does not
ility
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necessarily mean belt needs re‐
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placing.
h re
hole
spec
10 - Dowel sleeves
es, in part or in w
t to the co
11 - Cylinder block
12 - O-ring
rrectness of i
❑ Renew
l purpos
13 - Bolt
❑ 9 Nm
nform
ercia
14 - Clip
m
at
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ion
15 - Dipstick guide tube
c
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or
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16 - Bolt
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do
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c
❑ 9 Nm
um
for
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t.
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17 - Oil suction pipe
Co
Cop py
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gh
18 - Baffle plate
ht
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19 - Bolt cted agen
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❑ 16 Nm
20 - Bolt
❑ Self-locking.
❑ Renew
❑ 9 Nm
218 Rep. gr.17 - Lubrication

Oil sump - specified torques and installation sequence
Note
– Tighten bolts in 3 stages:

Stage Bolts Specified torque
1. -1 … 20- in diagonal sequence, 5 Nm n AG. Volkswagen AG do
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2. -arrows- 40 Nm d byV
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3. -1 … 20- in diagonal sequence tandho in stages; tee
or
final torque 13 Nm ss au ac
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Oil spray jet and pressure relief valve
an
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1- Bolt with pressure relief valve, 27 Nm
ility
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2- Oil spray jet (for cooling of pistons)
, is n
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hole
spec
es, in part or in w
Note
t to the co
When renewing the oil spray jet, ensure correct allocation to the
piston ⇒ Electronic Parts Catalogue (EKTA) .
rrectness of i
l purpos
nf
ercia
1.2 Removing and installing oil sump
orm
m
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or c
thi
te
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t.
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Cop py
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Prote AG.


equipment required
VAS 3185-
♦ Allen key - T10058-
- V.A.G 1331-
♦ Used oil collection and ex‐
traction unit - V.A.G 1782-
AG. Volkswagen AG d
agen oes
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es, in part or in w
♦ Sealant as per ⇒ Electronic Parts Catalogue (ETKA)

t to the co
♦ Hand drill with plastic brush

rrectness of i
♦ Eye protection
♦ Flat scraper
l purpos
nform
ercia
Note
m
at
om
♦ Metal shavings or a large quantity of small metal particles

on
c
in t
found during engine repair could indicate that the crankshaft

or
his
e
bearings or conrod bearings are damaged. To avoid any sub‐

at
do
riv
sequent damage, you must carry out the following work fol‐
p
cum
or
lowing repair:
f
en
ng
t.
yi Co
♦ Thoroughly clean oil channels. Cop py
ht. rig
rig ht
♦ Renew engine oil cooler ⇒ page 229 .
py by
co Vo
by lksw
cted agen
♦ Renew oil filter element ⇒ page 235 .
Prote AG.
♦ Oil capacities, oil specifications, viscosity grades

⇒ page 226 .
♦ Oil spray jet and pressure relief valve ⇒ page 219

Removing
2006, Polo, Touran ⇒ General body repairs, exterior;
AG. VolRep.
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en AG
agen does
50 ; Noise insulation; Assembly overview
Volks-wnoise insulation not
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Passat 2011, Passat Variant 2011 ris ⇒ General body repairs,
e
tee
ho
exterior; Rep. gr. 66 ; Noise ainsulation;
ut Assembly overview - or
ac
noise insulation ss
ce
le
un
pt
– Place used oil collection and extraction unit - V.A.G 1782- un‐
an
d
itte
der engine and drain engine oil.
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erm
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ility
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Note
h re
ole,
spec
Observe environmental regulations for disposal.
t to the co
– Remove connecting hose on »cold side«.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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ng
t.
yi Co
op py
t. C rig
gh ht
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er - G 31- / intake air temperature sensor - G 42- and remove p by
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right charge air pipe.
lksw
cted agen
Prote AG.
– Remove securing bolts -arrows- of charge air pipe and press
pipe aside.

– Remove securing bolt -arrow- and push coolant circulation

pump 2 - V178- aside.
– Remove securing bolts -arrows- of charge air pipe on »hot

side«.
AG. Volkswagen AG d
– Disconnect electrical connector -arrow- on oil level and woil
agen oes
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temperature sender - G266- . db
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, is n
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spec
es, in part or in w
t to the co

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

– Remove connecting bolts -arrows- for sump to gearbox.

– Remove oil sump securing bolts in diagonal sequence.
– Release oil sump carefully from adhesive.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sealant residue from cylinder block using a flat scra‐
per.
Caution
Danger of soiling lubrication system and bearings.

♦ Cover open parts of engine.
WARNING
Wear eye protection.
– Remove sealant residues from sump and agen

cylinder block
AG. Volkswagen Ausing
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rotating plastic brush or similar. Volksw es n
ot g
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– Clean sealing surfaces; they
or must be oil and grease free.
ise tee
th or
au
Installing ss
ac
ce
le
un
pt
an
d
itte
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ility
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ole,
spec
t to the co
Note
rrectne
Observe expiry date of sealing compound.

ss o
cial p
f i
– Cut off nozzle on tube at front marking (diameter of nozzle

nform
approx. 2 mm).
mer
atio
m
– Apply bead of sealant onto clean sealing surface of sump as

o
n
c
illustrated.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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Golf 2009 ➤ , Golf Cabriolet 2012 ➤ ,riGolf
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• Thickness of sealant bead: 2…3 mm.
nl
pt
du
an
itte
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♦ Run bead along inner side of bolt holes -arrows-.
erm
ab
ility
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Caution
h re
hole
spec
Danger of blocking lubrication system with excess sealant.
es, in part or in w
t to the co
♦ Do not apply sealant bead thicker than specified.
rrectness of i
l purpos
Note
nf
♦ Take particular care when applying sealant bead in area of
ercia
o
rear sealing flange -arrows-.
rm
m
atio
m
♦ Oil sump must be installed within 5 minutes after applying

o
n in
c
sealant.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Position oil sump and tighten bolts ⇒ page 219 .

t.
yi Co
op py
• The oil sump must be flush with the gearbox flange at the in‐
. C rig
ht ht
rig
termediate plate. py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ When installing sump with engine removed, ensure that sump

is flush with crankcase at flywheel end.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.

quence.
– Replenish engine oil and check oil level ⇒ page 227 .
1.3 Removing and installing oil level and oil

temperature sender - G 266-
Removing
– Drain engine oil ⇒ Maintenance ; Booklet 24.1 .
– Disconnect electrical connector -arrow- on oil level and oil


– Unscrew bolts -1- and remove oil level and oil temperature
sender - G266- -item 4-.
Installing
• Specified torque ⇒ Item 20 (page 218) .
Note
Renew seal -2- and self-locking bolts -1-.

AG. Volkswagen AG d
agen oes
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– Replenish engine oild band
y V check oil level ⇒ page 227 . t gua
ran
e
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
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1.4 Removing and installing oil pump

h re
hole
spec
Removing
es, in part or in w
t to the co

– When oil pump is to be renewed, unscrew bolts -4- and remove
rrectness of i
oil intake pipe -3-.

l purpos
– Unscrew bolts -arrows- and remove baffle -2-.

– Detach oil pump -1- from toothed belt and remove pump.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Installing
Note swage
es n
olk ot g
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Renew O-ring.
d ran
ir se tee
tho
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a ac
ss
– Insert new dowel sleeves when oil pump has no dowel sleeves
ce
le
-arrows- for centring oil pump.

un
pt
an
d
itte
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– Check oil pump for ease of movement, turn toothed belt pulley
erm
ab
with one finger for this.
ility
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wit
is n
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ole,
Note
spec
t to the co
Renew tight or sticking oil pump.
– Check toothed belt for oil pump.
rrectness
Note
o
cial p
f inform
♦ Renew damaged toothed belt.
mer
atio
m
♦ The toothed belt can sag after long use, this is not a fault.
o
n
c
i
or
n thi
te
– Fit oil pump with toothed belt pulley into toothed belt and tight‐
sd
iva
o
r
en along with baffle.

p
cum
r
fo
en
ng

t.
yi Co
Cop py
. rig
– Replenish engine oil and check oil level ⇒ page 227 .
t
gh ht
pyri by
Vo
co lksw
by
cted agen
1.5 Engine oil
Prote AG.
Draining engine oil ⇒ Maintenance ; Booklet 24.1

Engine oil specification ⇒ Maintenance ; Booklet 24.1
⇒ “1.5.1 Oil capacities”, page 226
⇒ “1.5.2 Checking engine oil level”, page 227
1.5.1 Oil capacities

With oil filter change: 4.3 l
Without oil filter change: 4.0 l

1.5.2 Checking engine oil level
Note
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
ing. This is normal and regulates itself automatically. No engine AG. Volkswagen AG d
oil needs to be drained. lksw
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1 - min. mark ho
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2 - Max. mark ss c
ce
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un
pt
a - Oil level in min. mark area: replenish engine oil!
an
d
itte
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rm
b - Oil level in middle range: can be topped-up with engine oil.
ab
pe
ility
ot
c - Oil level in max. mark area: Do not replenish engine oil!
wit
, is n
h re
d - The oil level may be in this area as a result of particular driving
hole
spec
conditions.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 228
⇒ “2.2 Removing and installing engine oil cooler”, page 229
⇒ “2.3 Checking engine oil cooler for leaks”, page 231
2.1 Assembly overview - engine oil cooler
Note
Metal shavings or a large quantity of small metal particles found

during engine repair could indicate that the crankshaft bearings
or conrod bearings are damaged. To avoid any subsequent dam‐
age, the following work must be carried out following the repair:
Carefully clean oil channels and renew oil spray jets, engine oil
cooler and oil filter.
1 - Cap
AG. Volkswagen AG d
❑ 25 Nm agen oes
olksw not
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2 - O-ring rised
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❑ Renew aut ra
c
ss
3 - O-ring
ce
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nl
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❑ Renew
itte
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4 - O-ring
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❑ Renew
, is n
h re
hole
5 - Oil filter element

spec
es, in part or in w

t to the co

⇒ Maintenance ; Book‐
let .
rrectness of i
6 - Engine oil cooler

l purpos

❑ Coolant hose schematic
nf
ercia
diagram ⇒ page 253 .

rm
m
atio
m

o
n in
c
⇒ page 229 .
or
thi
e
❑ Change coolant after re‐

t
sd
iva
newing.
o
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rp
cu
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f
en
ng
7 - 11 Nm
t.
yi Co
Cop py
8 - Gaskets ht. rig
rig ht
py by
❑ Renew
co Vo
by lksw
cted agen
Prote AG.
9 - Bolt
❑ Renew
10 - Oil filter housing
❑ With integrated oil re‐
tention valve.
❑ Removing and installing ⇒ “3.2 Removing and installing oil filter housing”, page 236 .
11 - Gaskets
❑ Renew

2.2 Removing and installing engine oil cool‐

er
♦ Used oil collection and extraction unit - V.A.G 1782-
AG. Volkswagen AG d
agen oes
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d
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ab
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ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
Removing
a
com
tion in

r
te o
thi
s
iva
Golf, Golf Plus, Passat

do
r
rp
cum
fo

en
ng
t.
yi Co
op
– Remove cowling ⇒ page 311 . C py
ht. rig
rig ht
by
Polo copy Vo
by lksw
cted agen
Prote
– Remove cowling ⇒ page 313 .
AG.

2. Engine oil cooler 229

– In addition to draining coolant from engine, detach coolant

hose from oil filter holder -arrow-.
– Remove oil filter element.

AG. Volkswagen AG d
agen oes
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d by ara
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or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Unscrew bolts -arrows-.
mer
atio
m
– Remove oil cooler from housing.

o
n
c
i
or
n thi
Installing
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
♦ Renew gaskets, seals and O-rings.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
must be free of oil and grease when installing.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic Parts Catalogue
(ETKA) .
Install in reverse order.

– Insert new seals ⇒ Item 8 (page 235) into oil free lugs
-arrow- on oil filter bracket.
– Carefully slide engine oil cooler onto centring pins.
– Press oil cooler on until it is flush -1- with end of centring pins.
– Start new bolts and screw in until heads make contact.
– Tighten bolts -arrows- in 3 stages and in diagonal sequence.

♦ Step 1: tighten by hand
♦ Step 2: tighten to 5 Nm
♦ Step 3: tighten to 11 Nm
– Install oil filter element, replenish engine oil and check oil level
⇒ page 227 . wage
e ks s no
Vol t gu
– Replenish coolant in cooling system, change coolantedifbengine
y ara
oil cooler has been renewed ⇒ page 261 . tho
ris nte
eo
au ra
c
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le
un
pt
an
d
itte
2.3 Checking engine oil cooler for leaks

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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required wage
es ks not
Vol gu
♦ Refractometer - T10007-
ed
by ara
nte
is
or eo
♦ Hose clampsautup
h
to 25 mm - ra
3094- ss c
ce
e
nl
pt
♦ Cooling system tester -
du
an
itte
V.A.G 1274-
y li
erm
ab
ility
♦ Adapter for cooling system
ot p
wit
tester - V.A.G 1274/8-
, is n
h re
hole
spec
VAS 5024 A-
es, in part or in w
t to the co
- VAS 6208-
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.


Not illustrated
♦ Expansion tank - 1K0 121 407 A- or expansion tank - 1J0 121
407 B-
AG. Volkswagen AG d
♦ Plug - 191 211 343- agen oes
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V gu
d by ara
♦ Cap - 1J0 121 324- orise nte
h eo
ut ra
♦ Coolant hose - 251 265 056- ss a c
ce
e
nl
Prerequisites:
pt
du
an
itte
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• Engine cold
erm
ab
ility
ot p
Test procedure
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
noise insulation
nform
ercia
– Loosen hose clips on engine oil cooler using spring type clip
m
pliers - VAS 5024- .
at
om
ion
c
– Remove engine oil cooler with housing ⇒ page 235 .
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
♦ Collect escaping coolant with drip tray - V.A.G 1306- or drip t. C rig
gh ht
tray - VAS 6208- . yri
p by
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by c lksw
cted
♦ Collect leaking engine oil with a cleaning cloth, if necessary.
agen
Prote AG.

AG. Volkswagen AG d
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Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , eGolfd b Plus 2009 ➤ , Passat 2006 ➤ ...uara
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4-cylinder common rail engine (1.6 thl,o EA189) - Edition 02.2016
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Checking when removed
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nl
pt
du
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– Clamp housing with old seal on a suitable, level clean surface.
itte
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erm
ab
– Secure sealing plug -2- to breather connection of expansion
ility
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tank -1-.
wit
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– Secure coolant hose -3- to engine oil cooler and expansion
hole
spec
tank.
es, in part or in w
t to the co
– Fill expansion tank up to “Max” marking.
– Attach cooling system tester - V.A.G 1274- with cooling sys‐
rrectness of i
tem tester adapter - V.A.G 1274/8- to expansion tank.
l purpos
– Use hand pump on tester to create a pressure of about 1.6 bar.

– Watch pressure drop on pressure gauge. A pressure drop
nf
ercia
within 10 minutes is not permitted.
orm
m
If pressure drops:
atio
om
n in
c
– Renew engine oil cooler ⇒ page 229 .

or
thi
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note the following:
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– Renew seal for housing.
Co
Cop py
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– Check coolant level, replenish coolant if necessary
gh ht
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⇒ page 261 .
co Vo
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Prote AG.
– Check engine oil level, replenish oil if necessary
⇒ page 227 .

3 Oil filter, oil pressure switch

⇒ “3.1 Assembly overview - oil filter housing”, page 235
⇒ “3.2 Removing and installing oil filter housing”, page 236
⇒ “3.3 Checking oil pressure and oil pressure switch”,
page 239
⇒ “3.4 Removing and installing oil pressure switch F1 ”,
page 242
3.1 Assembly overview - oil filter housing
WARNING
The rubber seals, items 8 and 11, must not be lubricated with
oil. The coolant seals would otherwise swell up.
1 - Cap, 25 Nm
2 - O-ring
❑ Renew
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - Oil filter element AG. Volkswagen AG d
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❑ See note ⇒ page 228 . ed by
V gu
ara
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❑ Observe change inter‐ ut
ho eo
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vals. ss a c
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❑ See note ⇒ page 228 . y li

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⇒ “3.2 Removing and in‐

wit
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stalling oil filter hous‐

h re
ole,
ing”, page 236 .

spec
❑ Renew coolant after re‐

t to the co
placing.
❑ Checking engine oil
cooler for leaks
rrectne
⇒ page 231
s
7 - 11 Nm
s o
cial p
f i
8 - Rubber seals
nform
mer
❑ Renew
atio
m
❑ Insert into lugs on en‐

o
n
c
gine oil cooler.

or
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❑ May not be lubricated

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with oil
cum
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fo
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9 - Bolt
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❑ Renew
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❑ Specified torques and installation sequence ⇒ page 236 .
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10 - Oil filter bracket
❑ Ensure clearance to adjacent components.
3. Oil filter, oil pressure switch 235

11 - Rubber seals
❑ Renew
❑ Fit into lugs on oil filter bracket.
❑ May not be lubricated with oil
Note
♦ To change oil filter lkswage es n
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♦ Unclip vacuum lines ir se-arrows- and lay to side.
d ran
o tee
th or
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Oil filter bracket - specified torques and installation sequence
es, in part or in w
t to the co
Note
rrectness of i
Renew oil filter bracket bolts -arrows-.
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– First tighten upper left and lower right bolts.

nform
ercia
– Tighten bolts in 2 stages:

m
at
om
Stage Bolts Specified torque/torque angle

ion
c
in t
or
1. -arrows- In diagonal sequence, 14 Nm

his
ate
do
riv
2. -arrows- turn 180° further using diagonal se‐

p
cum
or
quence
f
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Cop py
Oil pressure switch - F1-
t. rig
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co
♦ With seal.
by lksw
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♦ Renew seal
♦ Switch pressure 0.3…0.6 bar
♦ Removing and installing ⇒ page 242 .
♦ Checking ⇒ page 239 .
♦ Specified torque: 20 Nm
3.2 Removing and installing oil filter housing


♦ Removal lever - 80 - 200-

AG. Volkswagen AG d
agen oes
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nl
pt
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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♦ Drip tray for workshop hoist - VAS 6208- C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
Golf, Golf Plus, Passat

Polo
– Remove cowling
– Remove oil filter element. wage
es n
olks ot g
byV ua
d ran
ir se tee
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u or
a ac
ss
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un
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pe
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Remove air hose, loosen hose clips -1- and -2- for this.
a
com
tion in
r
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thi
s
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cum
fo
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t.
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t. rig
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– Pull out oil dipstick slightly, unscrew bolt -1-.

– Press off clip -2- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side.
– Place drip tray for workshop hoist - VAS 6208- under point of
separation.
– Remove coolant hose, loosen hose clip -1- for this.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing AG. Volkswagen AG d
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lksw not
• Specified torques ⇒ page 235 . byV
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Installation is carried out in the reverse order; unote
tho the following: eo
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s a c
s
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nl
pt
Note
du
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must be free of oil and grease when installing. h re
hole
spec
es, in part or in w
t to the co

(ETKA) .
rrectness of i
– Install oil filter element, replenish engine oil and check oil level
⇒ page 227 .
l purpos
– Replenish coolant in cooling system, change coolant if engine

nf
ercia
oil cooler has been renewed ⇒ page 261 .

orm
m
atio
m
3.3 Checking oil pressure and oil pressure

o
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switch
thi
te
sd
iva
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⇒ “3.3.1 Checking oil pressure”, page 239

o
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ng
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⇒ “3.3.2 Checking oil pressure switch”, page 240
yi Co
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ht. rig
3.3.1 Checking oil pressure
rig ht
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Special tools and workshop equipment required Prote AG.

♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK.
• Engine oil temperature approx. 80°C
– Remove oil pressure switch - F1- ⇒ page 242 .
– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch - F1- .
– Screw an old oil pressure switch into hole on oil pressure tester
- V.A.G 1342- to seal hole.
– Start engine.
AG. Volkswagen AG d
• Oil pressure at idling speed: at least
olks
0.6
wagen bar. oes
not
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• Increase engine speed further.
ris
ed At 2,000 rpm and an oil tem‐ ara
nte
perature of 80°C the oiluthpressure should be at least 1.0 bar.
o eo
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ss
At higher engine speeds, the oil pressure must not exceed 5.0
ce
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nl
bar. If oil pressure exceeds 5.0 bar:

pt
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– Renew oil pump.

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ility
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3.3.2 Checking oil pressure switch

wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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t. rig
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Prote AG.


equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Voltage tester - V.A.G
1527 B-
♦ Auxiliary measuring set -
V.A.G 1594 C-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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pt
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Test prerequisites
wit
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• Oil level OK, checking ⇒ page 227

hole
spec
• Engine oil temperature at least 80°C (radiator fan must have

es, in part or in w
t to the co
run once)
rrectness of i
Note
l purpos
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
nf
ercia
Fitting locations
orm
m
atio
m
– Remove oil pressure switch - F1- ⇒ page 242 .

o
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thi
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sd
iva
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f
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.

– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch. agen
AG. Volkswagen AG d
oes
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V
– Screw oil pressure switch - F1- -item 2- into hole in oil pressure ed by gu
ara
tester. horis nte
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– Connect brown line -1- of oil pressure tester to earth (–).ss c
ce
le
un
pt
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
an
d
itte
and oil pressure switch - F1- using cables from auxiliary test
y li
rm
ab
set - V.A.G 1594 C- .
pe
ility
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• LED should not light up.
, is n
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hole
spec
es, in part or in w
Note
t to the co
If LED lights up now, replace oil pressure switch - F1- .
rrectness of i
– Start engine.
l purpos
Note
nform
mercia
a
Observe oil pressure tester and LED while starting, as switching
com
tio
point of oil pressure switch may already be exceeded when start‐
n in
r
te o
ing.
thi
s
iva
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• LED should light up at 0.3…0.6 bar.
fo
en
ng
t.
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– If LED does not light up, replace oil pressure switch - F1- Cop py
⇒ page 242 .
t. rig
gh ht
pyri by
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3.4 Removing and installing oil pressure
Prote AG.
switch - F1-
Removing
– Remove crankcase breather hose -1-, press release buttons
for this.
– Free vacuum hoses -arrows-.
– Release hose clips -3- and pull air hose off air filter housing.
– Unscrew bolt -2-, swing intake hose with intake connection to
rear and pull off of turbocharger.

– Unscrew bolts -2- and -3-, remove engine lifting eyes -1-.
– Disconnect electrical connector -arrow-.
– Remove oil pressure switch - F1- .
Installing
• Specified torques ⇒ page 236 ⇒ page 134 .
Note
AG. Volkswagen AG d
agen oes
Renew the seal. y Vo lksw not
gu
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– Install vacuum
auth line to exhaust gas recirculation cooler. ra
ss c
– Install intake connection.
ce
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nl
pt
du
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itte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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t. rig
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Prote AG.

4 Oil circuit
⇒ “4.1 Assembly overview - oil circuit”, page 244
⇒ “4.2 Removing and installing oil supply line”, page 246
⇒ “4.3 Oil spray jets/nozzles”, page 252
4.1 Assembly overview - oil circuit

⇒ “4.1.1 Assembly overview - oil supply line, Golf, Golf Plus, Golf
⇒ “4.1.2 Assembly overview - oil supply line, Polo”, page 245
4.1.1 Assembly overview - oil supply line, Golf, Golf Plus, Golf Cabriolet, Passat,
Touran
1 - Ribbed bolt
❑ Renew.
❑ 14 Nm
2 - Oil supply line
3 - Oil return line
❑ Renew seal.
4 - 14 Nm
5 - 22 Nm
❑ Renew AG. Volkswagen AG d
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6 - Connection pipe to exhaust d by ara
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gas recirculation cooler hor eo
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❑ Renew seals and gas‐ ss c
kets.
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nl
pt
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7 - 10 Nm
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8 - Support
ility
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❑ For turbocharger
h re
hole
9 - Banjo bolt, 60 Nm
spec
es, in part or in w
❑ Renew
t to the co
❑ Renew rrectness of i
❑ Renew sealing rings

l purpos
11 - 9 Nm
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
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Prote AG.

4.1.2 Assembly overview - oil supply line, Polo
1 - Ribbed bolt
❑ Renew.
❑ 14 Nm
olkswagen AG
en AG. V
2 - 22 Nm ksw
ag does
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❑ Union ed nuts of oil supply
b ara
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ris
line
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3 - Oil
s supply line
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nl
pt
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4 - Oil return line
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❑ Renew seal.
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5 - 14 Nm
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6 - 22 Nm
hole
spec
❑ Renew
es, in part or in w
t to the co
7 - Connection pipe to exhaust
gas recirculation cooler
rrectness of i
❑ Renew seals and gas‐
kets.
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8 - 10 Nm nf
ercia
9 - Support
orm
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❑ Renew
t
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❑ Renew
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❑ Renew sealing rings
t. rig
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12 - 9 Nm
c by lksw
cted agen
Prote AG.
4. Oil circuit 245

AG. Volkswagen AG d
agen oes
lksw not
4.2 Removing and installing oil supply line
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byV gu
ara
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o eo
⇒ “4.2.1 Removing and installing oil supply line, Polo”,
aut
h
ra
page 246 ss c
ce
e
nl
pt
⇒ “4.2.2 Removing and installing oil supply line, Golf, Golf Plus,
du
an
itte
Golf Cabriolet, Passat, Touran”, page 251
y li
erm
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ility
4.2.1 Removing and installing oil supply line,
ot p
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Polo
h re
hole
spec
Torque wrench - V.A.G 1331-
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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om
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Tool set, 17 mm - T10395-
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
Used oil collection and extraction unit - V.A.G 1782-

Removing

AG. Volkswagen AG d
agen oes
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Golf 2009 d➤by,VGolf Cabriolet 2012 ➤ , Golf Plus gu 2009 ➤ , Passat 2006 ➤ ...
ara
e
horis 4-cylinder common rail engine (1.6 l,ntEA189)
ee - Edition 02.2016
aut or
ac
ss
– Remove drive shaft shield.
ce
le
un
pt
an
Loosen particulate filter to create space for removing and instal‐
d
itte
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ling the oil supply line with turbocharger support.
rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull electrical connector -2- from pressure differential sender

- G 505- .
nform
ercia
– Unclip pressure differential sender - G 505- from lower part of

m
a
com
ti
fuel filter.
on in
r
te o
thi
s
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cum
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Cop py
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rig ht
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Prote AG.

bocharger.
bocharger.
4. Oil circuit 247

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , GolfutPlus
ho 2009 ➤ , Passat 2006 ➤ ... eo
ra
a
ss - Edition 02.2016 c
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un
pt
– Unscrew nuts -2-, nuts -1- should be disregarded.
an
d
itte
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
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iva
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fo
en
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– Now unscrew bolt -1-. . Cop py
rig
ht ht
– Push particulate filter aside and fix it in position on plenum
rig by
opy Vo
chamber bulkhead using suitable means. by c lksw
cted agen
Prote AG.
– Remove connection pipe -2- leading to cooler for exhaust gas

recirculation.
– Loosen oil supply line union nuts -arrow- on turbocharger.

Catch leaking oil used oil collection and extraction unit - V.A.G
1782- .
– Loosen the banjo bolt of the oil supply line
⇒ Item 11 (page 245) on the cylinder block.

– Now you can access the securing bolt -arrow- on the retaining
clamp for the oil return line on the turbocharger support.
– Unscrew oil supply pipe at turbocharger.

– Remove oil supply line.
Caution
Exhaust gas temperature sender 1 - G 235- conceals the upper

bolt of the exhaust gas turbocharger support. Exhaust gas
temperature sender 1 - G 235- must not be bent. It must there‐
fore be removed.
– Remove exhaust gas temperature sender 1 - G 235- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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un
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spec
t to the co
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cial p
f inform
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om
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Cop py
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Prote AG.
4. Oil circuit 249

– Unscrew upper bolt -arrow- from support on turbocharger.

– Remove banjo bolt ⇒ Item 10 (page 245) of turbocharger sup‐
port.
– Remove bolts for oil return line ⇒ Item 1 (page 245) .
– Remove turbocharger support with oil return pipe.
Installing
Note
♦ Renew the seals, gaskets, O-rings and self-locking nuts ⇒

♦ Renew the particulate filter clamp ⇒ Electronic Parts Cata‐
logue (ETKA) .
♦ If particulate filter or pressure differential sender - G 505- is
exchanged, pressure differential sender - G 505- must be
adapted using vehicle diagnostic testera:gGuided
en AG. V functions;
olkswagen AG
does
Adapting pressure differential sender
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olks-wG 505- . not
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ed ran
♦ After working on the exhaust
ho
rissystem, ensure that the system tee
is not under tension ands athat
ut there is sufficient clearance to or
ac
the bodywork. If necessary, loosen double clamp and align
s
ce
le
silencer and exhaust pipe so that sufficient clearance is main‐

un
pt
tained to the bodywork and the support rings are evenly loa‐
an
d
itte
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ded.
rm
ab
pe
ility
ot
wit
• The work procedure must be followed to ensure that the oil
, is n
h re
supply and return lines together with the turbocharger support
hole
spec
are installed tension-free.
es, in part or in w
• Furthermore this ensures that the turbocharger support is in‐ t to the co

stalled tension-free between crankcase and turbocharger.
– Position oil return line on turbocharger together with turbo‐
rrectness of i
charger support on turbocharger and crankcase.

l purpos
– Position oil supply line on turbocharger and crankcase.

– First, bolt the turbocharger support onto the crankcase
nform
ercia
⇒ Item 10 (page 245) and turbocharger ⇒ Item 5 (page 245)

m
by hand.
a
com
tion in
– Then tighten the turbocharger support bolts in several steps

r
te o
thi
up to the specified torque alternating between the crankcase

s
iva
do
⇒ Item 10 (page 245) and turbocharger ⇒ Item 5 (page 245) .

r
rp
cum
fo
en
g
– Next tighten the oil supply line union nuts and the banjo bolt
n
t.
yi Co
for the oil supply line on the crankcase. ht. Cop py
rig
rig ht
– Finally tighten the bolt on the oil supply line/turbocharger sup‐ py by
co Vo
port clamp.
by lksw
cted agen
Prote AG.
Specified torques ⇒ page 245 .
– Further assembly in reverse order of removal.
Install particulate filter ⇒ page 480 .
Installation position of exhaust gas temperature sender -G 235- .

Angled shaft must have a distance -a- = 3 … 5 mm to bolting of

4.2.2 Removing and installing oil supply line,

Golf, Golf Plus, Golf Cabriolet, Passat,
Touran
Removing
Passat 2011, Passat Variant 2011 ⇒ General body repairs, n AG. Volkswagen AG
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview
ksw -
age does
not
noise insulation y Vol gu
db ara
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ris nte
Vehicles with four-wheel drive utho eo
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a c
ss
– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing bevel
ce
e
nl
box .
pt
du
an
itte
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erm
ab
ility
ot p
– Unscrew bolts -1, 2- and banjo bolts -4, 5-, and remove tur‐
wit
, is n
bocharger support with oil supply line.
h re
hole
spec
Installing
es, in part or in w
t to the co
Installation is carried out analogously in the reverse order; note
the following:
– Fit turbocharger support with oil supply line in position.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Renew seals and gaskets, fit bolts -1, 2- and banjo bolts
in t
or
his
e
-4, 5- in position and tighten, specified torques ⇒ page 244 .

at
do
priv
Vehicles with four-wheel drive

um
for
en
ng
t.
yi
– Install bevel box ⇒ Rep. gr. 34 ; Bevel box; Installing bevel
Co
op py
box . t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
noise insulation
4. Oil circuit 251

4.3 Oil spray jets/nozzles

Oil spray jet and pressure relief valve
1- Bolt with pressure relief valve, 27 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
Note
♦ Do not bend oil spray jets.

♦ Bent oil spray jets must be renewed.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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un
pt
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rm
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
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Cop py
t. rig
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Prote AG.

AG. Volkswagen AG d
agen oes
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19 – Cooling
Vol
by gu
d ara
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or eo
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aut ra
s c
1 Cooling system, coolant
s
ce
e
nl
pt
du
an
itte
⇒ “1.1 Coolant hose schematic diagram”, page 253
y li
erm
ab
⇒ “1.2 Checking cooling system for leaks”, page 257
ility
ot p
wit
, is n
⇒ “1.3 Draining and filling coolant”, page 259
h re
hole
spec
1.1 Coolant hose schematic diagram
es, in part or in w
t to the co
⇒ “1.1.1 Coolant hose schematic diagram (vehicles with auxiliary
heater, Polo)”, page 253
rrectness of i
⇒ “1.1.2 Coolant hose schematic diagram (vehicles with 4/2 way
valve, Polo)”, page 254
l purpos
⇒ “1.1.3 Schematic diagram for coolant hoses (vehicles with ther‐

mostat, Golf, Golf Plus, Passat)”, page 255
nform
ercia
⇒ “1.1.4 Coolant hose schematic diagram (vehicles with 4/2-way

m
at
om
valve, Golf, Passat, Touran)”, page 256
ion
c
in t
or
1.1.1 Coolant hose schematic diagram (vehicles with auxiliary heater, Polo)
his
ate
do
priv
c
Coolant hose schematic diagram (Polo)
um
for
en
ng
t.
yi Co
Cop py
t.
1 - Expansion tank
rig
gh ht
pyri by
Vo
o
by c
2 - Radiator
lksw
cted agen
Prote AG.
❑ For exhaust gas recircu‐
lation
❑ Check exhaust gas re‐
circulation cooler for
leaks ⇒ page 527 .
3 - Heat exchanger for heater
unit
❑ With quick-release cou‐
pling
4 - Cylinder head/cylinder
block
6 - Coolant circulation pump -
V178-
7 - Upper coolant hose
pling
8 - Radiator
⇒ page 307 .
placing
9 - Lower coolant hose
pling
10 - Coolant pump and ther‐
mostat
1. Cooling system, coolant 253

⇒ page 267 .
❑ Renew coolant after replacing
1.1.2 Coolant hose schematic

swa
gen AG
. Volksdiagram
wagen AG
doe(vehicles
s
with 4/2 way valve, Polo)
k not
Vol gu
d by ara
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ris
1 - Radiator utho eo
ra
a
❑ Change coolant
ss after re‐ c
ce
le
newing.
un
pt
an
d
itte
2 - Coolant circulation pump 2
y li
rm
ab
- V178-
pe
ility
ot
wit
3 - Thermostat
, is n
h re
❑ (vehicles with 4/ way
hole
spec
valve, Polo)
es, in part or in w
t to the co
4 - Coolant pump
5 - Radiator outlet coolant tem‐
rrectness of i
perature sender - G83-
l purpos
6 - Coolant expansion tank

7 - Cap
nform
ercia
8 - Exhaust gas recirculation

m
cooler
a
com
tion in
r
te o
thi
newing.
s
iva
do
❑ Check exhaust gas re‐

r
rp
cum
circulation cooler for

fo
en
ng

t.
yi Co
Cop py
t. rig
9 - Cylinder head/cylinder yri
gh by
ht
block cop Vo
by lksw
cted agen
❑ Change coolant after re‐ Prote AG.
newing.
10 - Coolant temperature
sender - G62-
unit
newing.
❑ Change coolant after renewing.
254 Rep. gr.19 - Cooling

1.1.3 Schematic diagram for coolant hoses (vehicles with thermostat, Golf,
Golf Plus, Passat)
Coolant hose schematic diagram
1 - Expansion tank
2 - Radiator
❑ For exhaust gas recircu‐ AG. Volkswagen AG d
lation agen oes
o lksw not
yV gu
❑ Check exhaust gas e d bre‐ ara
nte
is
circulation coolerhor for eo
ut
leaks ⇒ pagess a 527 . ra
c
ce
le

un
pt
an
unit
d
itte
y li
erm
ab
ility
ot p
pling
wit
is n
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ole,
block
spec
t to the co
V178-
rrectne
s
s o
pling
cial p
f inform
8 - Radiator
mer
atio
m

o
n
c
⇒ page 306 .
i
or
n thi
e

t
sd
iva
placing.
pr
cum
r
fo
en
ng

t.
yi Co
op py
❑ With quick-release cou‐ t. C rig
gh ht
pling yri
p by
o Vo
by c lksw
cted
10 - Coolant pump and ther‐
agen
Prote AG.
mostat
⇒ page 267 .
❑ Renew coolant after replacing.
11 - Auxiliary heater
❑ if fitted

1.1.4 Coolant hose schematic diagram (vehicles with 4/2-way valve, Golf, Passat,
Touran)
Coolant hose schematic diagram
1 - Expansion tank
2 - Radiator AG. Volkswagen AG d
agen oes
ksw
❑ For exhaust gas recircu‐ by Vol not
gu
ara
lation rise
d
nte
ho eo
❑ Check exhaust gas re‐ aut ra
c
circulation cooler for ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
unit
ility
ot p
wit
, is n
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pling
hole
spec
es, in part or in w
block
t to the co
rrectness of i
V178-
l purpos

nform
ercia
pling
m
at
om
i
8 - Radiator
on
c
in t
or
his
ate
⇒ page 306 .
do
priv
cum
for
en
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placing.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted
pling
agen
Prote AG.
10 - 4/2-way valve with ther‐

mostat
⇒ page 271 .
11 - Coolant pump and thermostat
❑ Renew coolant after replacing.
12 - Auxiliary heater
❑ if fitted

1.2 Checking cooling system for leaks

equipment required
♦ Cooling system tester -
V.A.G 1274 B-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
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un
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spec
t to the co
rrectnes
Note
s o
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f in
Before a leakage test can be properly carried out, the cooling

form
mer
system tester - V.A.G 1274 B- must undergo as self-test.

atio
om
n
c
i
or
Self-test of cooling system tester - V.A.G 1274 B-

thi
te
sd
va
– Operate cooling system tester - V.A.G 1274 B- several times.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.

Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 ➤ , Passat 2006 AG. ➤
Volk...
swagen AG
4-cylinder common rail engine (1.6 l, EA189) - Edition 02.2016 agen does
olksw not
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db ara
se nte
– Build up a pressure of 3.0 bar on cooling system tester . thori eo
au ra
c
– Observe pressure on pressure gauge of cooling systemss tester
ce
e
for 30 seconds.
nl
pt
du
an
itte
y li
If no pressure builds up, or if the pressure drops again:
erm
ab
ility
ot p
The cooling system tester - V.A.G 1274 B- leaks and cannot be
wit
used.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Checking cooling system for leaks
l purpos
• Coolant temperature at least 40 °C
nf
ercia
orm
WARNING
m
atio
om
n in
c
The cooling system is under pressure when the engine is hot.

or
thi
e
Steam or hot coolant can escape - risk of scalding.

t
sd
iva
o
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rp
cu
Risk of scalding to skin and other body parts.
o
m
f
en
ng
t.
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Co
Cop py
ht. rig
♦ Wear eye protection. rig ht
py by
co Vo
by lksw
♦ Release pressure by covering cap of coolant expansion
cted agen
Prote AG.
tank with a cloth and opening it carefully.
– Open cap -1- on coolant expansion tank.
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- on coolant expansion tank.
– 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 is caused by the

coolant which cools down. The colder the engine, the lower the
pressure loss.
WARNING
Steam or hot coolant can escape - risk of scalding.

Risk of scalding to skin and other body parts.
• Relieve pressure: press pressure relief valve on cooling
system tester until reading on pressure gauge is 0.

Checking pressure relief valve in filler cap

– Place cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- on filler cap.
– Using hand pump of cooling system tester, build up pressure
and check the opening pressure of the filler cap.
Colour of filler cap Opening pressure
Blue 1.4 … 1.6 bar
Black 1.6 … 1.8 bar
– Renew filler cap, if pressure relief valve does not open as de‐
scribed. wage
e ks s no
Vol t gu
d by ara
1.3 Draining and filling coolant tho
ris
e nte
eo
au ra
c
⇒ “1.3.1 Draining coolant”,
ss page 259
ce
e
nl
pt
du
⇒ “1.3.2 Filling with coolant”, page 261
an
itte
y li
erm
ab
1.3.1 Draining coolant
ility
ot p
wit
, is n
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WARNING
hole
spec
es, in part or in w
Hot steam/hot coolant can escape - risk of scalding.
t to the co
The cooling system is under pressure when the engine is hot.
rrectness of i
Cover filler cap on expansion tank with a cloth and open care‐
fully to dissipate pressure.
l purpos
nf
ercia
– Open filler cap -1- on coolant expansion tank. orm

m

atio
om
n in
c

or
thi
e

t
sd
iva

o
r
rp
cu
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t.
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exterior; Rep. gr. 66 ; Noise insulation; Assembly overview - Cop py
noise insulation
t. rig
gh ht
pyri by
Vo
o
by c
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
lksw
cted agen
Prote
gine.
AG.
Note
To prevent ingress of coolant, seal union on turbocharger using

a clean plug from engine sealing plug set - VAS 6122-
Golf, Golf Plus, Touran, Passat

– Pull off coolant hose -arrow- from coolant circulation pump 2 -

V178- .
– Disconnect lower coolant hose from radiator, lift retaining clip

-arrow- when doing this, and drain off coolant.
Polo
– Pull off coolant hoses -2- from coolant circulation pump 2 - agen AG. Volkswagen AG do
V178- . Vol
ksw es n
ot g
y ua
db ran
rise tee
tho or
s au ac
s
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un
pt
an
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itte
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ility
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wit
is n
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ole,
spec
t to the co
– Disconnect lower coolant hose from radiator, loosen hose
clamp -arrow- to do so and then drain off coolant.
rrectne
– Open clamp -arrow- for this.

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

. Volkswagen AG
gen AG does
– Disconnect lower coolant hose on right from radiator, loosen
Vol
ksw
a
not
hose clamp -arrow- to do so and then drain off coolant.
ed
by gu
ara
is nte
or
– Disconnect coolant hose from oil filter housing,auloosen
th hose eo
ra
clamp -arrow- to do so and then drain off remaining
ss coolant. c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– To drain coolant from engine, also remove coolant hose from
rrectness of i
engine oil cooler -arrow-.
l purpos
Note
nform
ercia
Observe environmental regulations for disposal.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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1.3.2 Filling with coolant pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
If large components (e.g. engine, radiator etc.) are to be re‐

moved/installed, it is absolutely necessary to drain the cooling
system.
If the coolant has been drained off, the cooling system must be
filled using the cooling system charge unit - VAS 6096-
⇒ page 262 .

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

influence on its effectiveness. Because the water quality dif‐
fers from country to country and even region to region, Volks‐
wagen has decided to define the quality of the water to be used
in the coolant system. Distilled water fulfils all requirements.
♦ 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.
♦ The correct coolant solution ratio helps prevent damage due
to freezing and corrosion as well as scaling. Moreover, the
boiling temperature is raised. Therefore, the cooling system
must be filled all year round with coolant additive.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection must be guaranteed down to about -25°C (in
countries with arctic climates, down to about -35°C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
♦ If a stronger anti-freeze mixture is necessary due to harsher
weather conditions, the coolant additive content can be in‐
creased. However, this is only permitted to 60% (antifreeze swa
gen AG
. Volkswagen AG
does
protection to about -40°C). Otherwise, the antifreeze protec‐ by V olk not
gu
tion will be reduced again and the cooling effect will be im‐rised ara
nte
paired. ut
ho eo
r
sa ac
♦ If radiator, heat exchanger, cylinder head or cylinder shead
ce
le
gasket is renewed, do not reuse old coolant.

un
pt
an
d
itte
y li
♦ The refractometer - T10007A- is recommended for determin‐
erm
ab
ing the current anti-freeze density.
ility
ot p
wit
is n
h re
Recommended mixture ratios:
ole,
spec
• Coolant additive (40%) and distilled water (60%) for frost pro‐
t to the co
tection to -25°C
tection to -35°C rrectne
s
tection to -40°C
s o
cial p
Installing
inform
mer
– Reconnect coolant hoses.

atio
om

c
i
or
n thi
te

sd
iva
o
r

p
cum
r
fo

en
ng
t.
yi Co
op
Passat 2011, Passat Variant 2011 ⇒ General body repairs, C py
t. rig
gh ht
pyri by
noise insulation
o Vo
by c lksw
cted agen
Prote AG.
Using cooling system charge unit - VAS 6096- :
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.

4-cylinder common rail Aengine (1.6 l, EA189) - Edition 02.2016
G. Volkswagen
n AG do
wage es n
olks ot g
– Fill coolant circuit using cooling system charge ed
bunit
y V
- ua
ran
VAS 6096- oris tee
th or
au ac
Operating instructions for cooling system charge
ss unit - VAS 6096-
are enclosed with unit.
ce
e
nl
pt
du
an
itte
– Fill coolant expansion tank of cooling system charge unit - VAS
y li
erm
ab
6096- with at least 8 litres of pre-mixed coolant in correct mix‐
ility
ot p
ture ratio.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Exhaust air takes a slight quantity of coolant along with it; this
should be collected -2-.
rrectness of i
Without cooling system charge unit - VAS 6096- :
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
– Slowly fill coolant to upper marking of shaded field on expan‐
C py
t. rig
gh
sion tank.
ht
pyri by
Vo
co lksw
by
– Fit expansion tank cap.
cted agen
Prote AG.
– Start engine and maintain an engine speed of about 2,000 rpm

for about 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
at the upper mark; when the engine is cold, in the middle of
the hatched field.

2 Coolant pump, regulation of cooling

system lksw . Vo agen AG
a gen AG does
⇒ “2.1 Assembly overview - coolant pump, Vol thermostat”,
ksw not
gu
page 264 ed by ara
nte
is
or eo
⇒ “2.2 Removing and installing coolant
au
th pump”, page 267 ra
ss c
⇒ “2.3 Removing and installing thermostat”, page 268
ce
le
un
pt
an
d
⇒ “2.4 Checking thermostat”, page 271

itte
y li
rm
ab
pe
⇒ “2.5 Removing and installing 4/2-way valve with thermostat”,
ility
ot
page 271
wit
, is n
h re
⇒ “2.6 Electric coolant pump”, page 277
hole
spec
es, in part or in w
⇒ “2.7 Removing and installing coolant temperature sender”,
t to the co
page 280
2.1 Assembly overview - coolant pump,
rrectness of i
thermostat
l purpos
⇒ “2.1.1 Assembly overview - coolant pump, thermostat”,

page 264
nform
ercia
⇒ “2.1.2 Assembly overview - coolant pump / thermostat with 4/2-

m
a
way valve ”, page 266
com
tion in
r
2.1.1 Assembly overview - coolant pump, thermostat

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 - Coolant pump
⇒ page 267 .
2 - 15 Nm
3 - O-ring
❑ Renew
4 - Thermostat
⇒ page 268 .
AG. Volkswagen AG d
5 - O-ring agen oes
olksw not
V gu
❑ Renew d by ara
ise nte
or eo
h
6 - Bolt s aut ra
c
s
❑ 13 Nm
ce
e
nl
pt
du
an
7 - Union
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system 265

2.1.2 Assembly overview - coolant pump / thermostat with 4/2-way valve
1 - Coolant pump
⇒ page 267 .
2 - 15 Nm
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - 4/2-way valve with thermo‐
stat
❑ Checking 4/2-way valve
with thermostat ⇒ Vehi‐
cle diagnostic tester
“Function and compo‐ agen
AG. Volkswagen AG d
oes
nent selection”. Volksw not
gu
by ara
❑ The thermostatriis se loca‐
d
nte
ted within theut 4/2-way
ho eo
ra
sa
valve and scannot be ex‐ c
changed individually.
ce
le
un
pt
an
d

itte
y li
⇒ page 271 .
rm
ab
pe
ility
6 - 15 Nm
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.2 Removing and installing coolant pump

equipment required
- VAS 6208-
- V.A.G 1331-
VAS 6362-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
Removing
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
Renew gaskets and seals.

rrectne

ss

o
cial p
f in
Vehicles with supplementary or auxiliary heating

form
mer
atio
– Remove coolant pipes on right ⇒ page 300

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Continuation for all vehicles wage

es n
lks ot g
Vo
– Remove securing bolts -1- for coolant pump -2- eand d by carefully ua
ran
remove coolant pump. ho
ir s tee
ut or
a ac
Installing ss
ce
le
un
pt
an
d
itte
note the following:
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Moisten new O-ring -3- with coolant.
– Insert coolant pump -2- in cylinder block and tighten securing
s
bolts -1- to 15 Nm.
s o
cial p
f inform
mer
Note
atio
om
n
c
i
The coolant pump plug faces downwards.
or
n thi
te
sd
iva
o
pr
c
– Install toothed belt ⇒ page 181 .
um
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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2.3 Removing and installing thermostat
AG.


equipment required
3185-
1331/-
- VAS 6208-
♦ Hose clip pliers - VAS
6340-
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– Disconnect coolant hose from union, loosen hose clip -1- for
this.
– Loosen union securing bolts -arrows- using T-bar and 10 mm AG. Volkswagen AG d
socket - 3185- and unscrew with 5 mm Allen key extension
lksw
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– Turn thermostat -2- approx. 15° clockwise -arrow- and remove
es, in part or in w
from union.
t to the co
– Remove O-ring -1-.
Installing rrectness of i
• Specified torque ⇒ page 264 .

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♦ Renew O-ring.
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must be free of oil and grease when installing.

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– Clean and smoothen sealing surface for O-ring.

– Moisten O-ring with coolant.

– Insert thermostat -3- with O-ring -2- in guides on union -1-.
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– Turn thermostat -1- anticlockwise -arrow-
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– Install charge air pipe. ss c
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– Golf, Golf Plus, Passat: Re-install connecting hoses with
an
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screw-type clips ⇒ page 315
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– Polo: Install connecting hoses with screw-type clips
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⇒ page 355 .
, is n
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spec
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rrectness of i
2.4 Checking thermostat
l purpos
– Heat removed thermostat in water bath.
nform
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Starts to open Fully open Opening travel

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approx. 92 °C approx. 107 °C 1) minimum 7 mm
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2.5 Removing and installing 4/2-way valve

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with thermostat
C py
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Note
The thermostat is located within the 4/2-way valve and cannot be

replaced individually.


equipment required
3185-
1331/-
- VAS 6208-
6340-
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Removing
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Passat 2011, Passat Variant 2011 ⇒ General body repairs, t. C rig
gh ht
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview - pyri by
Vo
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noise insulation
by lksw
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– Removing cowling with radiator fan - V7- .
Note

– Disconnect electrical connector -1- from air mass meter -

G70- .
– Pull hose -3- off air filter housing.
– Loosen bolt -arrow 4-.
intake hose.
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐

nator; Removing and installing alternator .
– Guide alternator with extreme caution past radiator to prevent
damaging it. gen AG
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d a oes
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– Unclip wiring harness from bracket -arrow-.

nform
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at
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c
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for
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– Free wiring harnesses -arrows- and electrical connector -1- at
bracket.


– Free electrical lines and hoses on left air pipe using removal
lever - 80 - 200- .
– Release hose clip -3- and remove left air pipe.
Note
Disregard -item 1, 4-.
– Pull coolant hoses off. Release hose clips -1- for this.
Note
Disregard -items 2, 3, 4-
AG. Volkswagen AG d
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– Remove electrical connector -1- for Hall sender
s au - G40- from ra
c
bracket. s
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nl
pt
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– Unscrew bolts -arrows- and pull front coolant pipe to side away
an
itte
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from 4/2-way valve.
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Note
hole
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es, in part or in w
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– Pull coolant pipe out of connection -C- for 4/2-way valve.

Leave in its installation position.
nf
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orm
m
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– Unscrew bolts -arrows-.

AG. Volkswagen AG d
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– Free coolant hose -3-. Vo lksw
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– Release hose clip -2-. orise nte
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– Disconnect electricalssconnector
a
-1- on charge pressure sender c
- G31- / intake air temperature sender - G42- and remove right
ce
le
un
pt
air pipe.
an
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spec
es, in part or in w
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– Unscrew bolt -1-.

m
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– Press off clip -2- using removal lever - 80 - 200- .
ion in
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– Pull oil dipstick guide tube upwards out of cylinder block and
thi
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Cop py
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– Remove throttle valve module - J338- .

– Pull coolant hoses off connections -A, B and D-.

– Remove securing bolts -3- for 4/2-way valve -2-.
– Pull valve out from cylinder block.
Installing
– Moisten new O-ring -1- with coolant.
AG. Volkswagen AG d
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nl
pt
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– Thread 4/2-way valve in past ancillary bracket in direction of
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oil filter module.
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nf
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– Insert connection -2- of 4/2-way valve with O-ring -1- into cyl‐
m
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atio
inder block with slight rotary motions.
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Cop py
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rig ht
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– Thread coolant pipe into connection -C- for 4/2-way valve.

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

– Tighten securing bolts -3- using T-bar and 10 mm socket -

3185- . Specified torque: 15 Nm.
Specified torque for throttle valve module - J338- ⇒ page 447 .
– Install throttle valve module - J338- ⇒ page 447 .
– Installing charge air pipe ⇒ page 352 .
2.6 Electric coolant pump

G. Volkswagen AG d
⇒ “2.6.1 Removing and installing coolant circulation
wage
n A pump 2 oes
olks not
V178 , Polo”, page 277 by
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⇒ “2.6.2 Removing and installingucoolant
tho circulation pump 2 eo
ra
V178 , Golf, Golf Plus, Golf Cabriolet,
ss
a Passat, Touran”, c
page 278
ce
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un
pt
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2.6.1 Removing and installing coolant circula‐

itte
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ab
tion pump 2 - V178- , Polo
ility
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pyri by
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Prote AG.
Removing

Note
Place a cloth underneath coolant circulation pump 2 - V178- to

absorb escaping coolant.
– Clamp off coolant hoses with hose clamps -3094- and remove:
to do this, loosen hose clips -arrows-.
– Undo bolt -3- and remove coolant circulation pump 2 - V178- .
Note
Disregard -item 1-.

wage
Installing yV
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Installation is carried out in the reverse order; note thehor following:
is tee
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• Specified torque ⇒ page 286 . ss
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nl
pt
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♦ Hose connections and air intake pipes and hoses must be free
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h re
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(ETKA) .
rrectness of i
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nf
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– Check coolant level ⇒ page 259 .
m
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2.6.2 Removing and installing coolant circula‐

thi
te
sd
a
tion pump 2 - V178- , Golf, Golf Plus,

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rp
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Golf Cabriolet, Passat, Touran

f
en
ng
t.
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Special tools and workshop equipment required t. C rig
gh ht
pyri by
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by lksw
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Prote AG.

Removing
noise insulation
AG. Volkswagen AG d
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WARNING
nl
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Danger of injury; the radiator fans can run at any time.

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wit
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time, e.g. because of accumulated heat in the engine

h re
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spec
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– Undo hose clip -2- and push right air duct to right.
rrectness of i
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Note
nf
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Cop py
t. rig
gh ht
pyri by
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by c lksw
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Prote AG.

Note
Place a cloth underneath coolant circulation pump 2 - V178- to

absorb escaping coolant.
– Clamp off coolant hoses with hose clamps -3094- and remove;
to do this, loosen hose clips -3-.
– Undo bolt -1- and remove coolant circulation pump 2 - V178- .
Note
Ignore -arrow-.
Installing
Note
AG. Volkswagen A
of oil and grease before installation. wage
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♦ Secure all hose connections with the correct
ris
ed type of hose clips ran
tee
(same as original equipment) ⇒ Electronic
tho Parts Catalogue or
(ETKA) . au ac
ss
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nl
pt
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– Install air pipe.

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– Installing intake hoses with screw-type clips.
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spec

es, in part or in w
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rrectness of i
noise insulation
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nform
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2.7 Removing and installing coolant temper‐

m
at
ature sender
om
ion
c
in t
or
⇒ “2.7.1 Removing and installing coolant temperature sender G62

his
ate
”, page 280
do
priv
cum
or
⇒ “2.7.2 Removing and installing radiator outlet coolant temper‐

f
en
ng
t.
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ature sender G83 , Golf, Golf Plus, Golf Cabriolet, Passat, Tour‐
Co
op py
an”, page 282
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rig by
py
⇒ “2.7.3 Removing and installing radiator outlet coolant temper‐
co Vo
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ature sender G83 , Polo”, page 283
agen
Prote AG.
2.7.1 Removing and installing coolant temper‐

ature sender - G62-

AG. Volkswagen AG d
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Removing
ility
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• Engine cold
, is n
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hole
– Briefly open filler cap for coolant expansion tank in order to
spec
reduce pressure in cooling system.
es, in part or in w
t to the co
rrectness of i
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2006, Polo, Touran ⇒ General body repairs, exterior; Rep. gr. nform
ercia

m
at

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ion

c
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or
noise insulation
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ate
do
priv
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or
– Pull off crankcase breather hose -1- from cylinder head cover
f
en
ng
by pressing the release buttons.

t.
yi Co
Cop py
. rig
– Unclip and remove plug on the crankcase ventilation hose
ht ht
rig by
py
-1-. co Vo
by lksw
cted agen
Prote
– Free vacuum hoses -arrows- at air pipe.
AG.
– Unscrew bolt -2-, swing air pipe with inlet pipe to rear and re‐
move from turbocharger.
Vehicles with dual clutch gearbox

– Pull off coolant hoses from gear oil cooler by undoing hose
clips -arrows-.

lkswage es n
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4-cylinder commonthrail engine (1.6 l, EA189) - Edition 02.2016 tee o
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– Remove bolt -arrows-.
itte
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– Free electrical wiring and hoses on left air pipe using removal
ility
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lever - 80 - 200- .
wit
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– Loosen hose clip -3- and press left air pipe with coolant pipe
hole
spec
aside.
es, in part or in w
t to the co
rrectness of i
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– Unlock and pull connector -4- off coolant temperature sender
nf
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- G62- .
orm
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Note
or
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♦ Place a cloth under connecting piece to absorb escaping cool‐
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♦ Insert new coolant temperature sender - G62- immediately in‐ Cop py
t. rig
to union to avoid loss of coolant. gh ht
pyri by
Vo
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– Pull off retaining clip -3- and pull coolant temperature sender
Prote AG.
- G62- out of screw connection.

Installing
Note
♦ Renew O-ring.
♦ Insert new coolant temperature sender - G62- immediately in‐
to union to avoid loss of coolant.
– Check coolant level.
2.7.2 Removing and installing radiator outlet

coolant temperature sender - G83- ,
Golf, Golf Plus, Golf Cabriolet, Passat,
Touran
Removing
• Engine cold
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
Note
♦ Place a cloth under coolant temperature sender at the radiator

outlet - G83- to absorb escaping coolant.
to coolant pipe at radiator outlet to avoid loss of coolant.


wage
– Unscrew bolt -2- and nut -3-. olks es n
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– Remove bracket -4- from fuel filter, and lay fuelhofilter
ris -7- aside tee
with fuel hoses -5- and -6- connected. aut or
ac
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– Release and pull connector -2- off radiator outlet coolant tem‐
m
perature sender - G83- .
a
com
tion in
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Installing
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Install in reverse order. In the process, note the following: t. C rig
gh ht
pyri by
Vo
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Prote
Note
AG.
♦ Renew O-ring.
to coolant pipe at radiator outlet to avoid loss of coolant.
2.7.3 Removing and installing radiator outlet

coolant temperature sender - G83- , Po‐
lo
Removing
• Engine cold
– Briefly open filler cap -1- for coolant expansion tank in order
to reduce pressure in cooling system.
Note
Disregard -item 2-.


Note
Place a cloth underneath to catch escaping coolant.
at radiator outlet - G83- -item 3- out of connection of coolant
pipe.
Installing
Note
♦ Renew O-ring. n AG. Volkswagen AG do

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♦ Insert new radiator ir se
doutlet coolant temperature sender - uG83-
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pt
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at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 285
⇒ “3.2 Removing and installing coolant pipes”, page 287
3.1 Assembly overview - coolant pipes

⇒ “3.1.1 Assembly overview - coolant pipes, Golf, Golf Plus, Golf
⇒ “3.1.2 Assembly overview - coolant pipes, Polo”, page 286
3.1.1 Assembly overview - coolant pipes, Golf, Golf Plus, Golf Cabriolet, Passat,
Touran
1 - Grommet
❑ Not available as a sepa‐
rate part
2 - Sleeve
rate part
3 - 2.7 Nm
4 - 40 Nm
5 - Bracket
❑ For coolant circulation agen AG. Volkswagen AG do
pump 2 - V178- Vol
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6 - Front coolant pipe
ho
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7 - O-ring ss
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❑ Renew
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8 - Right coolant pipe

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9 - O-ring
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❑ Renew
h re
ole,
spec
10 - Radiator outlet coolant

temperature sender - G83-

t to the co
11 - Retaining clip
rrectne
12 - 9 Nm
13 - 9 Nm
ss o
14 - 9 Nm
cial p
f inform
15 - Coolant line
mer
atio
m
16 - 9 Nm
o
n
c
i
or
17 - Seal
thi
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sd
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❑ Renew
i
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pr
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ng
18 - Union yi
t.
Co
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19 - 9 Nm
t. C rig
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pyri by
Vo
20 - Retaining clip
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Prote AG.
21 - Coolant temperature sender - G62-
22 - O-ring
❑ Renew
3. Coolant pipes 285

23 - Centre hex stud, 9 Nm

❑
24 - 9 Nm
25 - Left coolant pipe
26 - 9 Nm
AG. Volkswagen AG d
27 - 40 Nm agen oes
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28 - 13 Nm orise nte
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29 - Coolant circulation pump 2 - V178- ss a c
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3.1.2 Assembly overview - coolant pipes, Polo
erm
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ility
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1 - Bolt
ole,
spec
❑ 2.7 Nm
t to the co
2 - Sleeve
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rate part.
3 - Grommet
ss
o
cial p
f
rate part.
inform
mer
4 - Bracket
atio
m
❑ For coolant circulation

o
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pump 2 - V178-
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5 - Bolt
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❑ 40 Nm
en
ng
t.
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6 - Front coolant pipe
C py
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rig ht
❑ Removing and installing py by
co Vo
lksw
⇒ page 287 .
by
cted agen
Prote AG.
7 - O-ring
❑ Renew
8 - Bolt
❑ 9 Nm
9 - Right coolant pipes
⇒ page 297 .
10 - Bolt
❑ 9 Nm
11 - Retaining clip
12 - Radiator outlet coolant
temperature sender - G83-
⇒ page 283 .
13 - O-ring
❑ Renew
14 - Bolt
❑ 9 Nm

15 - Gasket
❑ Renew
16 - Union
17 - O-ring
❑ Renew
18 - Coolant temperature sender - G62-
❑ Removing and installing.
19 - Stud
❑ 9 Nm
20 - Bolt
❑ 9 Nm
21 - Retaining clip
22 - Bolt
❑ 40 Nm
23 - Coolant circulation pump 2 - V178-
3.2 Removing and installing coolant pipes

n AG . Volkswagen AG
⇒ “3.2.1 Removing and installing front coolant
wagepipe, Polo”, does
page 287 Volks not
gu
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⇒ “3.2.2 Removing and installing ut
hofront coolant pipe, Golf,
r eo
Golf Plus, Golf Cabriolet, Passat,
ss
a Touran, vehicles with thermo‐ ra
c
stat”, page 290
ce
e
nl
pt
du
an
⇒ “3.2.3 Removing and installing front coolant pipe, Golf,
itte
Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with 4/2-way y li

erm
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valve”, page 293 ility
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⇒ “3.2.4 Removing and installing right coolant pipes, Polo”, page

h re
hole
297
spec
es, in part or in w
⇒ “3.2.5 Removing and installing right coolant pipe, Golf,

t to the co
Golf Plus, Golf Cabriolet, Passat, Touran”, page 299

⇒ “3.2.6 Removing and installing right coolant pipes, Golf,
rrectness of i
Golf Plus, Golf Cabriolet, Passat, Touran, vehicles with auxiliary

heater”, page 300
l purpos
3.2.1 Removing and installing front coolant

nform
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pipe, Polo
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Removing
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– Remove oil filter bracket with engine oil cooler ⇒ page 236
rrectness of i
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com
tion in
– Country-specific version for cold countries: Disconnect elec‐
r
te o
thi
trical connector -2-.
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agen
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Note
Disregard -item 4-.
– Unclip wiring harness from retainer -arrow-.


bracket.
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is n
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lever - 80 - 200- .
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– Disconnect coolant hoses and free them, loosening hose clips

-1- to do so.
Note

– Remove electrical connector -2- for Hall sender - G40- from

retainer and separate.
– Remove bracket from front coolant pipe.
– Remove coolant hoses, loosening hose clips -1- and -3- to do
so.
– Undo bolts -arrows- and pull front coolant pipe off cylinder
block towards the left.
Installing
Note

(ETKA) .
– Clean or smoothen sealing surface for O-ring.

– Moisten O-ring with coolant and slide onto front coolant pipe.
– Push front coolant pipe into cylinder block.
– Installing intake hoses with screw-type clips ⇒ page 360 . agen
AG. Volkswagen AG d
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– Install charge air pipe ⇒ page 355 . ed byV gu
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pipe, Golf, Golf Plus, Golf Cabriolet,
es, in part or in w
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stat
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♦ Removal lever - 80 - 200- nform

mercia
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te o
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Removing
– Remove oil filter bracket with engine oil cooler ⇒ page 236
– Unscrew bolts -arrows- and remove battery mounting bracket

-1-. wage
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– Remove crankcase breather hose -1- from cylinder head cov‐

er; press release buttons for this.
rrectness of i

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te o
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bracket.
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lever - 80 - 200- . rig ht
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Note
– Remove coolant hoses. To do this, loosen hose clips -1-.
Note


retainer and separate.
so.
– Undo bolts -arrows- and pull front coolant pipe off cylinder
block towards the left.
Installing
Note

(ETKA) .

– Push front coolant pipe into cylinder block. agen
AG. Volkswagen AG d
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– Install air pipe. d by
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s
– Install intake connection.
ce
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pt
– Install battery mounting and battery ⇒ Electrical system; Rep. an
d
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gr. 27 ; Battery; Removing and installing battery . y li

rm
ab
pe
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– Install oil filter bracket with engine oil cooler ⇒ page 236 .
ot
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es, in part or in w
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Passat, Touran, vehicles with 4/2-way
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valve
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♦ Hose clamps, up to 25 mm - 3094- for vehicles with dual clutch

gearbox
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– Drain coolant ⇒ page 259 . d by ara
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or eo
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– Remove air filter housing ⇒ pages au437
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nl
pt
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nf
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m
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– Unscrew bolts -arrows- and remove battery mounting bracket

-1-.
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– Unscrew bolt -2-, swing intake pipe together with intake con‐
spec
nection to rear and pull them off turbocharger.
es, in part or in w
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rrectness of i
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nf
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or c
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bracket.

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lever - 80 - 200- .
– Loosen hose clip -3- and remove left air pipe.
rrectness of i
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Note
nf
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or c
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– Remove coolant hoses. To do this, loosen hose clips -1-.

o
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Note
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bracket.
so.
– Unscrew bolts -arrows- and pull front coolant pipe to left side
away from 4/2-way valve.
Installing
Note

(ETKA) .

– Push front coolant pipe into 4/2-way valve. lkswage es n
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– Install air pipe. ir se
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– Install intake connection. au ac
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– Electrical connections and routing ⇒ Current flow diagrams,
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Electrical fault finding and Fitting locations.
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is n
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gr. 27 ; Battery; Removing and installing battery .
ole,
spec
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3.2.4 Removing and installing right coolant
pipes, Polo ss o
cial p

inform
mer

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♦ Drip tray for workshop hoist - VAS 6208- byV
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Removing cted agen
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– Disconnect electrical connector -2- and free electrical wiring.
gine.
from right coolant pipes, releasing hose clips -1, 3- to do so.
– Undo bolts -arrows- and remove coolant pipes on right.
Installing
Note
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic Parts Catalogue (ET‐
KA) .



Passat, Touran
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cial p
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mer
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Removing
– Pull off engine cover ⇒ page 76 .

AG. Volkswagen AG d
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Golf 2009 ➤ , Golf by Cabriolet
V ol
2012 ➤ , Golf Plus 2009gu ➤ , Passat
ara
2006 ➤ ...
d
4-cylinder common
orise rail engine (1.6 l, EA189) - Edition 02.2016
nte
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th
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– Loosen bolt -1-. s
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– Remove bolt -2- and nut -3-. du
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
noise insulation
l purpos
– Remove front right wheel housing liner: ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
nform
ercia
and installing wheel housing liner .

m
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temperature sender - G83- . p by
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– Clamp off coolant hoses with hose clamps -3094- and remove Prote AG.
from right coolant pipe. To do this, release hose clips
-arrows-.
– Remove nut -1- and bolt -2-, remove right coolant pipe.
Installing
Note
KA) .
– Install front wheel housing liner ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Wheel housing liner; Removing and
noise insulation
– Install fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and

pipes, Golf, Golf Plus, Golf Cabriolet,

AG. Volkswagen AG d
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ut
ss a 4-cylinder common rail engine (1.6 l, EA189)
ra
c - Edition 02.2016
ce
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nl
pt
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Passat, Touran, vehicles with auxiliary
an
itte
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ility
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♦ Hose clamps up to 25 mm - 3094- hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
noise insulation
– Remove front right wheel housing liner: ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing wheel housing liner .
– Loosen nut -2- and remove exhaust pipe for auxiliary heater
-1-.

– Remove bolts -2, 4-.

them. To do this, loosen hose clips -1, 3-.
– Remove right coolant pipes.
Installing
Note
KA) .
– Install exhaust pipe for auxiliary heater ⇒ Auxiliary heater;

Rep. gr. 82 ; Auxiliary heater; Removing and installing exhaust
system .
– Install front wheel housing liner ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Removing and
AG. Volkswagen AG d
agen oes
Golf, Golf Plus, Golf Cabriolet, PassatyV
ol2006,
ksw Passat Variant not
gu
2006, Polo, Touran ⇒ General body ed repairs, exterior; Rep. gr.
b ara
nte
50 ; Noise insulation; Assembly ris
tho overview - noise insulation eo
au ra
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Passat 2011, Passat Variantss 2011 ⇒ General body repairs,
ce
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nl
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4 Coolers, radiator, radiator fan

⇒ “4.1 Assembly overview - radiator, radiator fan”, page 303
⇒ “4.2 Removing and installing radiator”, page 306
⇒ “4.3 Removing and installing radiator cowling with radiator fan”,
page 311
4.1 Assembly overview - radiator, radiator

fan
⇒ “4.1.1 Assembly overview - radiator/radiator fan, Golf, Golf
Plus, Golf Cabriolet, Passat, Touran”, page 303
⇒ “4.1.2 Assembly overview - radiator/radiator fan, Polo”,
page 304
4.1.1 Assembly overview - radiator/radiator fan, Golf, Golf Plus, Golf Cabriolet,
Passat, Touran
1 - Radiator
⇒ page 306 .
❑ After renewing, renew
entire coolant
2 - O-ring
4 - Cap
❑ Check using cooling n AG. Volkswagen AG do
system tester - lkswage es n
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V.A.G 1274- and adapt‐ ed
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⇒ page 257 . s au ac
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5 - Connector
nl
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6 - 5 Nm
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7 - Expansion tank
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❑ Checking cooling sys‐

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tem for leaks with cool‐

hole
spec
ing system tester -

es, in part or in w
V.A.G 1274- and adapt‐

t to the co
er - V.A.G 1274/8-
⇒ page 257 .
rrectness of i

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9 - 5 Nm
10 - 5 Nm
nf
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or
11 - Additional fan for radiator

m
m
atio
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12 - Main fan for radiator

o
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13 - Connector
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14 - Cowling
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4. Coolers, radiator, radiator fan 303

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Connecting coolant hoseVwith
olks plug-in connector to radiator
oes
not
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– Remove old O-ring
or
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h
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– Moisten new
ss O-ring with coolant and insert into coolant hose. c
a a
ce
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nl
– Push coolant hose into connection -1- until it audibly engages.
pt
du
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erm
ab
engaged correctly by pulling hose back.
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4.1.2 Assembly overview - radiator/radiator
rrectness of i
fan, Polo
l purpos
WARNING
nform
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tions:
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hot components.
AG.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers - VAS 6362- or hose clip pliers - VAS
6340- are recommended for installation of spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).

lkswage es n
Golfd b2009
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➤ , Golf Cabriolet 2012 ➤ o,t Golf
gu
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oris
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4-cylinder common rail enginente(1.6 l, EA189) - Edition 02.2016
eo
uth ra
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ss
1 - Clip
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un
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an
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itte
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3 - Expansion tank
wit
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❑ Checking cooling sys‐
ole,
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tem for leaks with cool‐
ing system tester -
t to the co
V.A.G 1274- and adapt‐
er - V.A.G 1274/8-
⇒ page 257 .
rrectne
4 - Cap
s
❑ Check using cooling
s o
system tester - V.A.G
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1274- and adapter for
form
mer
cooling system tester -
atio
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om
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❑ Test pressure 1.4…1.6
i
or
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5 - 5 Nm
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6 - Connector
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7 - Coolant hose
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by
8 - Radiator mounting
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Prote AG.
9 - 5 Nm
10 - Clip
11 - Radiator
⇒ page 307 .
placing
12 - Cowling with radiator fan -
V7-
14 - Charge air cooler
❑ Can only be removed and installed with radiator ⇒ page 307
15 - Lower mounting
❑ Black
16 - Clip
17 - Connector
18 - Radiator fan thermal switch - F18- , 35 Nm
❑ For radiator fan.
❑ Switching temperatures:
• 1st stage on: 92 … 97 °C, off: 84 … 91 °C
• 2nd stage on: 99 … 105 °C, off: 91 … 98 °C
19 - Seal
❑ Renew

20 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser .
4.2 Removing and installing radiator

⇒ “4.2.1 Removing and installing radiator, Golf, Golf Plus, Golf
⇒ “4.2.2 Removing and installing radiator, Polo”, page 307
4.2.1 Removing and installing radiator, Golf, Golf Plus, Golf Cabriolet, Passat,
Touran

equipment required
1331/-
6340-
AG. Volkswagen AG d
agen oes
olksw not
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Removing
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op
– Remove noise insulation: C py
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Golf, Golf Plus, Golf Cabriolet, Passat 2006, Passat Variant cop Vo
by lksw
2006, Polo, Touran ⇒ General body repairs, exterior; Rep. gr. cted agen
Prote AG.


noise insulation
– Remove radiator cowl with radiator fan ⇒ page 311
– Release retaining clip -arrow-.
– Pull off coolant hose -1- from top of radiator.
AG. Volkswagen AG d
agen oes
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– Unlock retaining clip -arrow- for the coolant hose by V pull the
and gu
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ed
coolant hose off the right plug-in connector thof
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– Remove radiator securing bolts -arrows- and take out radiator
upwards.
s
Installing
s o
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form
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Specified torques
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Prote AG.
Component Specified torque
Radiator to charge air cooler 5 Nm
Radiator cowl on radiator 5 Nm
4.2.2 Removing and installing radiator, Polo


equipment required
- VAS 6208-
1331/-
VAS 6362-
♦ Guide rods - 3411-
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Removing
nform
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– Set lock carrier to service position ⇒ General body repairs,

m
at
exterior; Rep. gr. 50 ; Lock carrier; Moving to and back from

om
ion
service position .
c
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– Remove connecting hoses to charge air cooler ⇒ page 355 .

a
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priv
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– Do do this, loosen hose clamps on »hot side« of connecting

f
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hoses.
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– Do do this, loosen hose clamps on »cold side« of connecting

hoses.
– Separate connector for radiator fan.
AG. Volkswagen AG d
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– Remove coolant hoses from radiator at top left,by Vreleasing clips
ol
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-1 and 2 - to do so. rise
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– Drain coolant ⇒ page 259 . ss au ra
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– Disengage fasteners, remove air ducts -1, 2-.
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– Tilt top of radiator slightly backwards.
– Raise radiator, disengage from lower mounting points and
push backwards.

WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
Caution
Danger of damage to refrigerant lines and hoses.

– Place condenser in bonnet lock latch at front and secure with

cable ties to prevent it from falling.
Disconnect charge air cooler from radiator.
Caution
In order to avoid damage to charge air cooler, 2 mechanics

should be used to disconnect charge air cooler from radiator.
AG. Volkswagen AG d
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– Push a wide screwdriver into the by Vlatch on the left. Turn the
o gu
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screwdriver in order to carefully
orised
open the latch of the charge nte
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– Then, pull the charge air cooler on left downwards a little bit.
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Installing
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note the following:

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ion in
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– Vehicles with air conditioner. Fill air conditioning system with

thi
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refrigerant ⇒ Air conditioning systems with refrigerant R134a;

do
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Rep. gr. 00 ; Working with air conditioner service station; Fill‐

rp
cum
fo
ing refrigerant circuit using air conditioner service station .

en
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Golf 2009 ➤ , Golf Cabriolet 2012AG➤. V,oGolf
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4.3 Removing and installing radiator cowl‐ aut
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⇒ “4.3.1 Removing and installing radiator cowl with radiator fan
an
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V7 and radiator fan 2 V177 , Golf, Golf Plus, Golf Cabriolet, Pas‐
erm
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sat, Touran”, page 311
ility
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⇒ “4.3.2 Removing and installing radiator cowl with radiator fan
h re
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V7 , Polo”, page 313
spec
4.3.1 urposes, in part or in wh
Removing and installing radiator cowl
t to the co
with radiator fan - V7- and radiator fan 2
- V177- , Golf, Golf Plus, Golf Cabriolet,
rrectne
Passat, Touran
ss
Removing
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– Open air intake cover by carefully releasing detents -arrows-.
om
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Prote AG.
– Unscrew securing bolts -arrows- for air intake -1- and take
connecting hose -2- out of guide.
– Remove upper securing bolts -upper arrows- of cowling.

noise insulation
– Disconnect connector -1- and free wiring.

– Remove connecting hose on »hot side« from charge air pipe.

To do this, detach hose clips -1-.
– Remove connecting hose on »cold side« from charge air pipe.

To do this, loosen hose clips.
– Remove lower bolts -lower arrows-. agen

AG. Volkswagen AG d
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– Remove cowling together with radiator by V fans downwards. gu
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Vehicles with 2 radiator fans aut
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– Disconnect electrical connector -1- and free electrical wiring.

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– Unscrew nuts -arrows- and remove radiator fan.

Vehicles with one radiator fan
l purpos
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– Unscrew bolts -arrows- and remove radiator fan.

Specified torque -arrows- 6 Nm
Installing
AG. Volkswagen AG d
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4.3.2 Removing and installing radiator cowl
s
ce
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un
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with radiator fan - V7- , Polo
an
d
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Removing
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– Undo bolts -arrows- for air intake -1-. Remove connecting
h re
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hose -2- from air filter.
spec
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rrectne
– Remove connecting hoses to charge air cooler ⇒ page 352 .
ss o
– Disconnect connector for radiator fan ⇒ Item 17 (page 305) .
cial p
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– Disengage cowling with radiator fan - V7- from locking hook

thi
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the mountings and remove downwards.
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Detach radiator fan from fan cowling
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– Remove connector for radiator fan from retainer. cted agen
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– Push pins out of spreader rivets -arrows- ⇒ page 313 .

– Carefully lift up fan ring on back of cowling using a suitable

tool.
– Remove fan ring.
– Unscrew nuts, remove radiator fan.

Installing
– Carefully insert fan shroud together with radiator fan - V7- from
below and then push into all 4 mountings on radiator 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.
AG. Volkswagen AG d
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AG. Volkswagen AG d
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no (1.6 l, EA189) - Edition 02.2016
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21 – Turbocharging/supercharging
eo
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1 Turbocharger
itte
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⇒ “1.1 Assembly overview - turbocharger”, page 315
wit
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⇒ “1.2 Removing and installing turbocharger”, page 321
hole
spec
⇒ “1.3 Renewing vacuum unit for turbocharger”, page 344
es, in part or in w
t to the co
1.1 Assembly overview - turbocharger
⇒ “1.1.1 Assembly overview - turbocharger, Golf, Golf Plus, Golf
rrectness of i
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⇒ “1.1.2 Assembly overview - turbocharger, Polo”, page 318
1.1.1 Assembly overview - turbocharger, Golf,
nf
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Golf Plus, Golf Cabriolet, Passat, Tour‐
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♦ All hose connections are secured.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before installing the turbocharger, fill the oil supply channel
(smaller diameter) with a »splash« of engine oil “to prevent a
dry start up”.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
1. Turbocharger 315

pipe
❑ With flexible joint; do not
bend flexible joint - dan‐
ger of cracking.
2 - Seal olkswage es n
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❑ Renew d b ua
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ho
3- Countersunk bolt
au with dou‐
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ac
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❑ Renew
pt
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❑ 14 Nm
erm
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4 - Union
wit
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❑ With oil supply and re‐
h re
hole
turn line
spec
es, in part or in w
❑ Before installing oil sup‐
t to the co
ply line, ensure that it is
not blocked.
rrectness of i
5 - Seal
❑ Renew
l purpos
6 - Nut
nf
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❑ 24 Nm
orm
m
7 - Heat shield
atio
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8 - Turbocharger
or
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❑ Can only be renewed

iva
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complete with exhaust

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manifold and vacuum

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9 - Retaining ring
AG.
❑ Installation possible in
one position only.
10 - O-ring
❑ Renew
11 - Pulsation damper
12 - Bolt
❑ 9 Nm
13 - Intake connecting pipe
14 - Bolt
❑ 9 Nm
❑ Attached in inlet connection.
15 - O-ring
❑ Renew
16 - Bracket
❑ For electrical cables.
17 - Bolt
❑ 15 Nm
316 Rep. gr.21 - Turbocharging/supercharging

18 - Heat shield
19 - Seal
❑ Renew
20 - Nut
❑ Renew
❑ 24 Nm
21 - Exhaust gas temperature sender 1 - G 235-
22 - Bolt
❑ 14 Nm
23 - Support
❑ Before installing oil supply line, ensure that it is not blocked.
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.
24 - Bolt
❑ 10 Nm
25 - O-rings
❑ Various diameters.
❑ Renew
26 - Banjo bolt
❑ 60 Nm
❑ Renew complete with O-rings.
27 - Oil seals
❑ Renew
28 - Banjo bolt
❑ 30 Nm
AG. Volkswagen AG d
❑ Renew complete with O-rings. lksw
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29 - O-rings rised ara
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❑ Renew aut
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30 - Nut
ce
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❑ 22 Nm
d
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Installation position of O-ring and seals in pulsation damper

h re
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spec
t to the co
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pyri by
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317
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1. Turbocharger
AG.
1 - Damper
❑ With grooves.
2 - O-ring
3 - Seal
❑ With spring.
AG. Volkswagen AG d
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Installation position of exhaust gas temperature sender with an‐
es, in part or in w
gled cable guide
t to the co
Note
rrectness of i
l purpos
When installing the exhaust temperature sender with angled ca‐

ble guide, adhere to dimension -a- of 3 … 5 mm from the turbo‐
charger support threaded connection.
nf
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1.1.2 Assembly overview - turbocharger, Polo

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⇒ “2 Safety instructions”, page 3 t. Cop py
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Note
♦ All hose connections are secured.

♦ Charge air system must be free of leaks.
♦ Before screwing on oil supply line, fill turbocharger at connec‐
tion with engine oil.

1 - Turbocharger
❑ Only renew together
with exhaust manifold
⇒ page 321 .
2 - Vacuum unit
❑ With position sender for n AG. Volkswagen AG do
wage
charge pressure posi‐ olks es n
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tioner - G581- d b ua
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❑ Renew ⇒ page 344 autho
or
ac
ss
3 - Connector
ce
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nl
pt
du
❑ To position sender for
an
itte
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charge pressure posi‐ erm
ab
tioner - G581-
ility
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4 - Heat protection
h re
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spec
es, in part or in w
5 - Seal
t to the co
❑ Renew
6 - 14 Nm
rrectness of i
7 - Connecting pipe
l purpos
❑ To exhaust gas recircu‐

lation cooler
nform
ercia
8 - Exhaust gas temperature

m
at
sender 1 - G 235-
om
ion
c
❑ 45 Nm
in t
or
his
te

a
do
riv
⇒ page 509 .
p
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for
en
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9 - 10 Nm
t.
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. rig
10 - Bracket
t
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11 - Heat shield
by
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12 - 10 Nm
13 - Turbocharger support
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.
14 - O-rings
❑ Renew with banjo bolt.
❑ Renew complete with O-rings.
16 - Oil return pipe
17 - Ribbed bolt
❑ Renew.
❑ 14 Nm
❑ Renew complete with oil seals.
19 - Seal
❑ Renew
1. Turbocharger 319
20 - Oil supply line

❑ Removing and installing - Polo ⇒ page 246 .
21 - Pulsation damper
22 - 9 Nm
Installation position of O-ring and seals in pulsation damper

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wa gen AG does
1 - Damper olks not
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❑ With grooves.
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2 - O-ring ss au ra
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Installation position of exhaust gas temperature sender with an‐ rig ht
py by
gled cable guide
co Vo
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Note


1.2 Removing and installing turbocharger

⇒ “1.2.1 Removing and installing turbocharger, Golf, Golf Cab‐
riolet”, page 321
⇒ “1.2.2 Removing and installing turbocharger, Golf Plus, Tour‐
an”, page 326
⇒ “1.2.3 Removing and installing turbocharger, Passat”,
page 331
⇒ “1.2.4 Removing and installing turbocharger, Polo”, page 338
Caution
If a mechanical fault is discovered on the turbocharger (e.g. a

destroyed compressor impeller), it is not sufficient to just renew
the turbocharger. To avoid any subsequent damage, the fol‐
lowing work must be carried out:
♦ Check air filter housing, air filter element and air inlet ho‐
ses for contamination. AG. Volkswagen AG d
agen oes
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♦ Check the whole charge air path and charge
ed
b air cooler for ua
ran
ris
foreign objects. tho tee
or
u ac
sa
♦ If foreign objects are discovered in
s the charge air system,
ce
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clean the charge air path and, if necessary, renew the

nl
pt
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charge air cooler.
itte
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1.2.1 Removing and installing turbocharger,
, is n
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Golf, Golf Cabriolet
spec
es, in part or in w
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♦ Tool set, 17 mm - T10395-
rrectness of i
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nf
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1. Turbocharger 321
Removing
AG. Volkswagen AG d
– Remove engine cover ⇒ page 76 . olksw
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– Remove air filter housing with bracket ⇒ page 437ris.e d ara
nte
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– With ignition switched off, disconnect earth strap
s a from battery.
u ra
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nl
connecting battery
pt
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c by lksw
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– Detach vacuum line -arrow- from brake booster and vacuum

pump.
– Remove heat shield sleeve from position sender for charge
pressure positioner - G581- .

4-cylinder
en AG. Volkswagencommon
AG rail engine (1.6 l, EA189) - Edition 02.2016
ag does
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– Disconnect electrical d connector
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– Pull vacuum hose
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ce
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pt
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– Separate vacuum hose -3-.
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– Free electrical connector -3- for exhaust temperature sender
1 - G 235- and electrical line.
l purpos
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– Unscrew securing clamp -2- between particulate filter and tur‐

bocharger.
Note
1. Turbocharger 323

AG. Volkswagen AG d
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un
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– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
an
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lation. itte
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Vehicles with supplementary heater or auxiliary heater
ot
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– Loosen coolant lines ⇒ Heating, air conditioning; Rep. gr. 87 ;
h re
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Coolant circuit .
spec
es, in part or in w
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crankcase.
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– Unscrew bolts -1, 2- and banjo bolts -4, 5-, and remove tur‐
Note
Disregard -item 3-.

– Unscrew bolts -arrows- and remove heat shield.
AG. Volkswagen AG d
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– Unscrew nuts -arrows- and pull turbocharger with eexhaust
db
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1. Turbocharger 325
– Carefully remove turbocharger from above in direction of gear‐

box.
Installing
Specified torques:
♦ Assembly overview - turbocharger ⇒ page 315
♦ Coolant lines ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant
circuit .
Caution
Before installing, check whether flexible joint of oil return line

is bent and thus stretched. If this is the case, micro cracks can
have formed and may cause leakage. If necessary, olkswagerenew oil es n
return line of turbocharger before installing.
db
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Removing
– Remove particulate filter ⇒ page 480 .
pipe ⇒ page 437 .
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1 - G 235- and electrical line.
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1. Turbocharger 329
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manifold off cylinder head.

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Specified torques:
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♦ ⇒ “1.1.1 Assembly overview - turbocharger, Golf, Golf Plus,
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have formed and may cause leakage. If necessary, renew oil
– Install in reverse order. In the process, note the following:
Note

line.
(ETKA) .
installing.


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1. Turbocharger 331
olkswagen AG
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Caution

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
perform the following repairs:
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
ed air routing must be cleaned and the charge air cooler must

Removing
pipe ⇒ page 437 .
connecting battery
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– Detach vacuum line -arrow- from brake booster and vacuum
pump.
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pressure positioner - G581- .
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– Pull vacuum hose -2- from turbocharger vacuum unit.

1. Turbocharger 333
– Disconnect connectors -1...4-.

– Place bracket plate with solenoid to one side.
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1. Turbocharger 335

crankcase.
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Note
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– Remove bolts -1…2...3-.

– Remove pendulum support.

– Using tensioning strap - T00038- as - shown-, pull engine to‐

wards assembly mountings.

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Installing
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Specified torques:
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 60
hole
spec
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 134
es, in part or in w
t to the co
♦ ⇒ “1.1.1 Assembly overview - turbocharger, Golf, Golf Plus,
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rrectness of i
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Caution
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or
have formed and may cause leakage. If necessary, renew oil
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line.
(ETKA) .
installing.

gled cable guide
Note


Polo

♦ Tool set, 17 mm - T10395-
♦ Transport guard - T10403-
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♦ Used oil collection and extraction unit , e.g. -V.A.G 1782-

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for soiling.
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1. Turbocharger 339

Removing
connecting battery
– Pull connector -1- off position sender for charge pressure po‐
sitioner - G581- on turbocharger.
– Remove air filter housing with air mass meter and intake hose
⇒ page 438 .
overview - bulkhead . AG. Volkswagen AG d
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erm
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– Unscrew bolt -2-, remove pressure differential sender - G
or
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– On decoupling element in front exhaust pipe, fasten the trans‐

port lock - T10403- -arrow-.
– Unscrew bolts -1- and nuts -2-, remove bracket for particulate
filter.
– Pull particulate filter from mountings -arrows-.
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es, in part or in w
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down backwards from front exhaust pipe.
– Move particulate filter to side and fix using suitable means.
rrectness of i
Right-hand drive vehicles ⇒ page 478
l purpos

– Remove oil supply line together with oil return line (turbo‐
nform
ercia
charger support) ⇒ page 246 .

m
– Pull vacuum line -3- off turbocharger.

com
tion in
r
– Remove pulsations damper with connecting hose to charge

te o
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air pipe.
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1. Turbocharger 341

lation.
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Remove bolts -arrows- from exhaust gas recirculation cooler in

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box.
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Caution AG. Volkswagen AG d

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Before installing, check whether flexible
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♦ Note installation position of exhaust temperature sender 1 - G
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Specified torques:
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♦ ⇒ “1.1.2 Assembly overview - turbocharger, Polo”, page 318 .

iv
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en
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page 245 .
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1. Turbocharger 343
– Observe sequence when installing particulate filter:

-1- loosely.
2. Screw in nuts -2, 4- and bolts -3, 5- loosely by hand
3. Tighten clip -1-

4. Tighten nuts -2, 4-
5. Tighten bolts -3, 5-
1.3 Renewing vacuum unit for turbocharger

AG. Volkswagen AG d
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Hexagon key, extension 10 mm aut - T10422 A- replaces the old ra
s c
hexagon key, extension 10 mm
s - T10422- . Existing keys without
ce
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un
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Special tools and workshop equipment required ab

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♦ Ring spanner 10x12 - T10423-
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♦ Hand vacuum pump - VAS 6213-
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mercia
at
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c
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or
♦ Turbocharger tester - V.A.G 1397A-

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♦ Vehicle diagnostic tester
1. Turbocharger 345
Caution
The special tools indicated, in particular the 10 mm socket in‐

sert - T10422- or 10 mm socket insert - T10422 A- is designed
solely for use according to the following work instructions and
must not be used for other threaded connections. There is a
danger of deformation if high torques are applied.
Note
A spare-parts kit is available ⇒ ETKA (Electronic Parts Cata‐

logue) for replacing the vacuum unit with position sender for
Removing
– Open heat protection mat.
– Open clip -4-.

– Pull connecting hose to turbocharger off air filter housing.
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– Remove crankcase breather connecting pipe-1- from cylinder

wit
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head cover; press release buttons to do this.

h re
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spec

t to the co
– Unscrew bolt -2- (captive bolt).

– Swing air pipe together with intake connection towards rear
rrectne
and pull them off the turbocharger.

– Seal opening in turbocharger with the sealing cap from the
ss
spare-parts kit.
o
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mer
atio
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n
c
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Rep. gr.21 - Turbocharging/supercharging
4-cylinder
en AG. V common
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ag does
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– Remove locking plate.
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c
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Vehicles with proper vacuum advance function:
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Note
To be able to fit special tools, the turbocharger control rod must

be brought into a certain position.
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐

uum pump - VAS 6213- to vacuum unit of turbocharger as
– Set turbocharger tester - V.A.G 1397A- to position »II«.

– Connect vacuum hose to connection »II« of turbocharger test‐
er - V.A.G 1397A- .
1. Turbocharger 347
– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for »vacuum«.
Caution
Using hand vacuum pump - VAS 6213- , generate a vacuum

of 0.8 bar max.
Excessive pressure may damage the vacuum unit. n AG. Volkswagen AG do
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an
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ility
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ot
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, is n
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– Read vacuum value displayed on turbocharger tester - V.A.G
spec
1397A- .
es, in part or in w
t to the co
– Keep the vacuum constant.
– Fit ring spanner 10x12 - T10423- on lock nut -A-.
rrectness of i
– Use ring spanner 10x12 - T10423- to counterhold or loosen
l purpos
lock nut -A-.

– Loosen securing nut -B- from control rod using socket AF
nform
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10 mm - T10422- or socket AF 10 mm - T10422 A- .

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– Allow partial vacuum to escape from the vacuum unit.
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– Unscrew securing nut -B- from control rod using socket AF

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Vehicles with improper vacuum advance function:
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To be able to fit special tools, the turbocharger control rod must
AG.
be brought into a certain position.

– Using suitable tools, push control rod downwards.
– Fit ring spanner 10x12 - T10423- on lock nut -A-.
– Use ring spanner 10x12 - T10423- to counterhold or loosen
lock nut -A-.
– Loosen securing nut -B- from control rod using socket AF
– Unscrew securing nut -B- from control rod using socket AF

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Continuation for all vehicles:ss
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– Unscrew securing bolts -arrows- of vacuum unit.
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– Remove vacuum unit with position sender for charge pressure
erm
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Installing
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Caution
t to the co
Only use new bolts and nuts from the spare-parts kit!
rrectne
– If necessary, remove lower securing nut of the control rod from
ss
the new vacuum unit.
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– Screw locknut by hand onto the control rod as far as possible
mer
in the direction of the vacuum unit.
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– Guide control rod trough adjusting lever on turbocharger.
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– Fit vacuum unit with position sender for charge pressure po‐
i
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sitioner - G581- -A-, and tighten securing bolts.

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– Tighten securing bolts -arrows- to 8 Nm. t. Cop py
rig
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Make sure that the guiding element moves easily along the con‐
trol rod.
– Slowly unscrew lock nut -A- from control rod by hand. Adjust‐
ing lever is resting on the lower »stop«.
– Screw securing nut -B- onto control rod until it lies against ad‐
justing lever.
– Counterhold on securing nut -B- using socket AF 10 mm -
T10422- or socket AF 10 mm - T10422 A- .
– Using ring spanner 10x12 - T10423- , slightly tighten lock nut
-A-.
– Connect connector -arrow- to the position sender for the

charge pressure positioner - G581- and close the heat pro‐
tection mat.
1. Turbocharger 349
AG. Volkswagen
– Connect turbocharger tester w-aV.A.G
gen 1397A- and hand
AG do
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olks
uum pump - VAS 6213- d by to vacuum unit of turbocharger tas
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In this step, the vacuum unit is activated by means of vacuum.
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– Set turbocharger tester - V.A.G 1397A- to position »II«.
om
n
c
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– Connect vacuum hose to connection »II« of turbocharger test‐
thi
te
er - V.A.G 1397A- .
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for »vacuum«.
Caution
Using hand vacuum pump - VAS 6213- , generate a vacuum

of 0.8 bar max.
Excessive pressure may damage the vacuum unit.
During the following procedure for adjusting the control rod,
keep the partial vacuum and thus the voltage constant.
Checking adjustment of vacuum unit:

– Connect vehicle diagnostic tester .
– Select Guided Functions .
– Select function Renew vacuum unit of turbocharger .
– Follow instructions on vehicle diagnostic tester .

– Adjust preload by turning nuts -A- and -B-.

Tightening control rod on turbocharger:
Note
AG. Volkswagen AG d
The control rods are tightened using Guided
olks
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– Read vacuum value displayed ut
hor
on turbocharger tester - V.A.G eo
1397A- , and keep it constant.
ss a ra
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– Observe value displayed on vehicle diagnostic tester : it must

nl
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remain constant.
itte
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– Counterhold on lock nut -A- using ring spanner 10x12 -
ility
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spec
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– Tighten securing nut -B- using socket AF 10 mm - T10422- or
socket AF 10 mm - T10422 A- .
rrectness of i
– Push locking plate onto control rod by hand.
l purpos
– Seal connection between control rod and securing nut with

sealing paint from the spare-parts kit.
nform
ercia
– Remove sealing cap from turbocharger.

m
at
om
– Complete the engine.
ion
c
in t
or
♦ ⇒ Rep. gr. 21 ; Turbocharger; Assembly overview – turbo‐
his
ate
charger; Assembly overview – turbocharger, Polo
do
priv
cum
or
♦ ⇒ Rep. gr. 23 ; Vacuum system; connection diagram – vac‐

f
en
ng
t.
uum system; Connection diagram – vacuum system, Polo
yi Co
Cop py
t. rig
♦ ⇒ Rep. gr. 23 ; Air filter; Assembly overview – air filter housing;
gh ht
yri by
Assembly overview – air filter housing, Polo
op Vo
by c lksw
cted agen
Prote AG.
♦ ⇒ Rep. gr. 10 ; Engine cover; Removing and installing engine
cover
– Continue with the Guided Functions .
1. Turbocharger 351
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 352
⇒ “2.2 Removing and installing charge air cooler”, page 356
⇒ “2.3 Assembly overview - charge-air hose connections”,
page 360
⇒ “2.4 Checking charge air system for leaks”, page 363
2.1 Assembly overview - charge air system

⇒ “2.1.1 Assembly overview - charge air system, Golf, Golf Plus,
Golf Cabriolet”, page 352
⇒ “2.1.2 Assembly overview - charge air system, Passat, Touran”,
page 353
⇒ “2.1.3 Assembly overview - charge air system, Polo”,
page 355
2.1.1 Assembly overview - charge air system,

Golf, Golf Plus, Golf Cabriolet
Note
♦ All hose connections of charge air system are secured by

AG. Volkswagen
spring-type clips, plug-in connectors
lksw or by spring band rings.
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♦ The charge air system must
ris
ed be free of leaks.
ara
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♦ Checking charge air ssystem
au for leaks ⇒ page 363 . ra
c
s
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rm
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es, in part or in w
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tion in
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te o
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1 - Charge air cooler gen AG

. Volkswagen AG
swa does
❑ For removal, set lock y V olk not
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carrier to service posi‐
rised b ara
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tion ⇒ Generalubodytho re‐ eo
ra
pairs, exterior;
ss aRep. gr. c
50 ; Lock carrier; Moving
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le
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to and back from service
an
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2 - Connecting hose
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❑ »Cold« side, bottom
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spec
3 - Screw-type clip, 8 Nm
es, in part or in w
t to the co
4 - To throttle valve module -
J338-
5 - Connecting hose
rrectness of i
❑ »Cold« side, top
l purpos
6 - 5 Nm
nform
ercia
7 - Charge air pressure sender

- G31- with intake air tempera‐
m
a
ture sender - G42-
com
tion in
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8 - Rubber grommet
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10 - Charge air pipe
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11 - Connecting hose Prote AG.
❑ »Hot« side, top

12 - From turbocharger
❑ »Hot« side
14 - Connecting hose
❑ »Hot« side, bottom
15 - Mounting
❑ For charge air cooler.
16 - 10 Nm

Passat, Touran
Note
♦ All hose connections of charge air system are secured by hose

clips. Observe installation instructions when installing
⇒ page 360 .
♦ The charge air system must be free of leaks.
♦ Checking charge air system for leaks ⇒ page 363 .
2. Charge air system 353

Caution
The screw-type clips on the charge air lines must always be

tightened to 5.5 Nm. If the torque is too low or too high, the
charge air hose may slip off the charge air pipe during vehicle
operation.
Assembly of hose connections ⇒ page 360 .

Assembly overview - charge air line (Passat)
1 - 5 Nm
2 - Mounting
❑ For charge air cooler.
❑ For removal, set lock AG. Volkswagen AG d
agen
carrier to service posi‐ Volksw
oes
not
tion ⇒ General body re‐ ed b y gu
ara
pairs, exterior; Rep. gr. thoris nte
eo
50 ; Lock carrier; Moving
s au ra
c
to and back from service
s
ce
le
position .
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4 - Connecting hose
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❑ »Cold« side, bottom.
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5 - Screw-type clip, 5.5 Nm
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spec
es, in part or in w
J338-
t to the co
7 - Connecting hose
❑ »Cold« side, top.
rrectness of i

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ture sender - G42-
nform
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9 - 2 Nm
m
a
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10 - Rubber grommet
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❑ »Hot« side, top.
Prote AG.
❑ »Hot« side.
❑ »Hot« side, bottom.


Polo
Note
♦ The charge air system must be free of leaks.

♦ Checking charge air system for leaks ⇒ page 363 .

❑ Can only be removed to‐
gether with radiator
⇒ page 307 .
2 - Connecting hose
❑ »Cold« side, bottom
3 - Screw-type clip, 8 Nm
J338-
5 - Connecting hose
❑ »Cold« side, top
6 - 5 Nm
ture sender - G42-
. Volkswagen AG
gen AG does
8 - Rubber grommet olks
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❑ »Hot« side
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❑ »Hot« side, bottom

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2.2 Removing and installing charge air cool‐

er
⇒ “2.2.1 Removing and installing charge air cooler, Golf, Golf
Plus, Golf Cabriolet”, page 356
⇒ “2.2.2 Removing and installing charge air cooler, Passat, Tour‐
an”, page 358
⇒ “2.2.3 Removing and installing charge air cooler, Polo”,
page 359
2.2.1 Removing and installing charge air cooler, Golf, Golf Plus, Golf Cabriolet
AG. Volkswagen AG d
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olksw not
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Special tools and workshop d b ara
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equipment required thor eo
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♦ Refractometer - T10007- ss
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6340-
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ility
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♦ Guide rods - T10093-
spec
es, in part or in w
t to the co
- VAS 6208-
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
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pyri by
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by
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Prote AG.
Removing
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing front
bumper .
– Remove air filter ⇒ page 437 .
– Pull connectors off thermal switch and radiator fan.
– Remove radiator ⇒ page 306 .

Note
To prevent damage to the condenser, make sure that the lines

and hoses are not stretched, kinked or bent.
– Remove retaining clamp(s) for refrigerant lines.

– Make a paper template with the specified dimensions.
– Fit the template on the plastic bracket at the front right so that
it rests against the edges at the top and left.
– Mark the intersection on the template -arrow- with a centre
punch.
– Drill a hole into the plastic bracket with a 5-mm drill bit.
– Drill or cut the hole to 16 mm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl
pt
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– Unscrew securing bolt -arrow-.
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itte
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erm
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ility
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
Vo
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by c lksw
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Prote AG.

– Unscrew securing bolts -arrows-.

– Remove charge air cooler downwards.
Installing
note the following:
Specified torques:
Component Nm
Cowling to radiator 5
Radiator to charge air cooler 5
Charge air cooler to condenser 5
2.2.2 Removing and installing charge air cool‐

er, Passat, Touran
Removing
– Removing radiator ⇒ page 306 .
– Remove front bumper cover ⇒ General body repairs, exterior;
bumper .
– Unbolt air ducts on left and right from charge air cooler.
WARNING
Risk of injury caused by refrigerant. . Volkswagen AG

gen AG does
swa
♦ The air conditioner refrigerant circuit must not be opened. by V olk not
gu
d ara
ise nte
or eo
h
aut ra
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Caution
ce
e
nl
pt
du
an
itte
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Danger of damage to condenser, refrigerant lines and hoses.
erm
ab
ility
ot p

wit
, is n
h re
hole
spec
– Unscrew bolt from refrigerant line retaining clamp next to lon‐
es, in part or in w
t to the co
gitudinal member.
– Unscrew bolts -1- for charge air cooler and -2- for condenser.
rrectness of i
– Swing charge air cooler backwards slightly.

l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
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by c lksw
cted agen
Prote AG.

– Unscrew bolt from lower right refrigerant line bracket on

charge air cooler.
– Swing condenser forwards into opening on lock carrier.
– Detach charge air cooler upwards out of lock carrier and re‐
move diagonally downwards.
Installing
Note
(ETKA) .
– Install condenser ⇒ Heating, air conditioning system; Rep. gr.

87 ; Refrigerant circuit; Removing and installing condenser .
– Install front bumper cover ⇒ General body repairs, exterior;
bumper .
– Installing radiator ⇒ page 306 . AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise
2.2.3 Removing and installing charge air cool‐ r nte
tho eo
u ra
er, Polo s a c
s
ce
e
nl
pt
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Charge air cooler is located beneath radiator.

an
itte
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Charge air cooler can only be removed together with radiator

ility
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⇒ page 307 .
wit
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es, in part or in w
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nf
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Prote AG.

2.3 Assembly overview - charge-air hose

connections
⇒ “2.3.1 Hose connections with grooved unions”, page 360
⇒ “2.3.2 Hose connections with plug-in connectors”, page 360
⇒ “2.3.3 Removing and installing charge air pipe hot side”,
page 361
2.3.1 Hose connections with grooved unions
Note
♦ Check all air hoses and pipes for firm seating and leaks before
carrying out tests or repairs.
(ETKA) .
♦ In order to be able to securely attach the air hoses on their
connections, the worm screws of the used hose clips have to
be sprayed with penetrating spray before installing.
Caution
The screw-type clips -A- on the charge air lines must always
be tightened as specified ⇒ page 360 . If the torque is too low
or too high, the charge air hose may slip off the corrugated pipe G. Volkswagen AG d
connection or the charge air pipe when the vehicle is used. lkswagen A oes
n o ot g
yV ua
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Installing air hoses with screw-type clips ss ce
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Specified torques for

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1- Hose clip -a- = 13 mm wide: 5.5 Nm
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2- Hose clip -b- = 9 mm wide: 3 Nm

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t to the co
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2.3.2 Hose connections with plug-in connec‐

o
cial p
f i
tors
nform
mer
atio
om
Caution
c
i
or
n thi
te
sd
a
The seal in the push-fit connector can be damaged if the se‐

iv
o
pr
curing clip is in the locked position when fitting the connector.

um
r
fo
en
ng
This can cause leakage. Observe installation instructions.

t.
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Cop py
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Prote AG.

Removing
– Release push-on connector by pulling securing clip -1-. Pull
hose/pipe-2- off without the use of tools.
Installing
– If renewed, place oil seal in groove of charge air hose. Ensure
the seal is correctly seated
agen
in
AGthe
. Volgroove.
kswagen AG
do w es n
olks ot g
– Lubricate sealing
ed
bysurface and seal with oil.
V ua
ran
ris tee
– Bring retaining
au
tho clip to release position -1-. or
ac
ss
– Push charge air hose into coupling to stop.
ce
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nl
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erm
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– Bring securing clip to locking position -2- and then push charge
wit
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air hose again.
h re
hole
spec
– Check if plug-in connector seats correctly and is properly en‐
es, in part or in w
gaged by pulling hose.
t to the co
rrectness of i
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ate
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by
2.3.3 Removing and installing charge air pipe
cted agen
Prote AG.
»hot« side
Procedure
connecting battery
pipe ⇒ page 438 .

– Loosen clamp -2- on connecting hose to pulsation damper.

Unscrew securing bolt -3- from charge air pipe.
– Unscrew securing bolt -arrow- from charge air pipe. Pull con‐
necting hose from pulsation damper as far as possible.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
nte
– Unclip top coolant
horis
hose on charge air pipe -arrow-. eo
aut ra
ss c ce
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nl
pt
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itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Unclip wiring harness on charge air pipe -arrows-.

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– Remove »hot side« connecting hose -arrow-.
Prote AG.

olkswagen AG
en AG. V
– Remove securing bolts -arrows-
ksw of charge air pipe ones»hot
ag do
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– Remove charge aair
ut pipe.
ho eo
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Installing
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nl
pt
du
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itte
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erm
ab
– First start all securing bolts on charge air pipe. Then tighten.
ility
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Specified torques ⇒ Item 9 (page 353)
wit
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Replace damaged cable ties and clips.
hole
spec
es, in part or in w
t to the co
2.4 Checking charge air system for leaks
rrectness of i
l purpos
♦ Charge air system tester - V.A.G 1687-
nf
ercia
orm
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♦ Adapter - V.A.G 1687/10-

– Remove intake hose -1- from air filter.
– Insert adapter - 1687/10- in intake hose -1- and secure with
clip.
Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure regulating valve -2- and close valves -3-

and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect charge air system tester - V.A.G 1687- to adapter -

1687/10- as shown.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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t to the co
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f inform
mer
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Prote AG.

– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks as follows:
♦ by listening
♦ by feeling
♦ with leak detector spray
♦ or with the ultrasonic tester - V.A.G 1842- .
Note
♦ Slight leaks on the intake side of turbocharger are permissible,

as the intake hoses are not designed for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester - V.A.G 1842-g⇒
en Aoperating
G. V gen AG olkswa
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♦ Depressurise test circuit by detaching
ho from adapter - eo
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agen 2. Charge air system
23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Schematic overview - fuel system”, page 366
⇒ “1.2 Assembly overview - fuel system”, page 371
⇒ “1.3 Filling, bleeding fuel system”, page 383
⇒ “1.4 Checking fuel system for leaks”, page 383
1.1 Schematic overview - fuel system

⇒ “1.1.2 Schematic overview - fuel system, Golf, Golf Plus, Golf
Cabriolet, Touran, Passat 2006 ▶”, page 368
⇒ “1.1.3 Schematic overview - fuel system, Passat 2011▶”, page
369
1.1.1 Schematic overview - fuel system, Polo

To prevent the high-pressure fuel pump from running while it is
empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe the following:
♦ If fuel system components between fuel tank and fuel high-
pressure pump are removed or renewed
♦ If a fuel system pressurisation pump - G 6 -, fuel line or fuel
filter is removed or renewedn AG. Volkswagen A
ge G do
swa es
♦ If the fuel high-pressure
by
Vol
k
pump is removed or replaced
not
gu
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se
– Connect vehicle
tho
ri diagnostic tester . tee
or
au ac
– Perform sfunction
s
“Fuel pump activation (Filling/bleeding fuel
ce
e
system)” in “Guided functions” ⇒ page 383 .

nl
pt
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an
itte
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ab
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es, in part or in w
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366
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Rep. gr.23 - Mixture preparation - injection
agen
Prote AG.
1 - Fuel metering valve - N290-

❑ Do not open.
2 - High-pressure fuel pump
❑ After renewing, a first
fuel filling “must” be per‐
formed (never allow
pump to run while dry)
⇒ page 383 .
⇒ page 410 .
3 - Fuel pressure sender - G
247-
⇒ page 419 .
5 - Fuel pressure regulating
valve - N 276-
❑ Renew
⇒ page 416 .
❑ 80 Nm
6 - Injectors agen
AG. Volkswagen AG d
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❑ Injector, cylinder 1 - d by
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❑ Injector, cylinder 2 - ss a ra
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❑ Injector, cylinder 3 -
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⇒ page 394 .
es, in part or in w
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7 - Fuel return lines
❑ The fuel return lines must not be dismantled. They can only be renewed together with the pressure
retention valve as one unit.
rrectness of i
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then
l purpos
check fuel return lines for leaks.

8 - Pressure retention valve
nf
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❑ The pressure retention valve maintains a residual pressure of approx. 1 bar in the return lines.
rm
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❑ This residual pressure is required for the control function of the piezo injectors.
om
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❑ The pressure retention valve may only be renewed completely together with the fuel return lines.
or
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❑ The pressure retention valve is installed in the fuel return lines just before the metal return line.
iva
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❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
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❑ Check pressure retention valve ⇒ page 392 .
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9 - Fuel tank
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❑ With fuel system pressurisation pump - G6- .
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10 - Fuel pre-heating valve
11 - Fuel filter
❑ Assembly overview ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter
❑ Removing and installing fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and installing fuel filter .
1. Injection system 367

1.1.2 Schematic overview - fuel system, Golf,

Golf Plus, Golf Cabriolet, Touran, Pas‐
sat 2006 ▶ n AG. Volkswagen AG do
lkswage es n
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⇒ “2 Safety instructions”, page 3 d byV ua
ran
ir se tee
⇒ “3.1 Rules for cleanliness”, page 5 autho
or
ac
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nl
empty and to ensure that the engine starts quickly after parts have
pt
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y li
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♦ If fuel system components between fuel tank and fuel high-
ility
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pressure pump are removed or renewed
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spec
filter is removed or renewed
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t to the co
♦ If the fuel high-pressure pump is removed or replaced
rrectness of i
– Perform the function “Fuel pump activation (Filling/bleeding
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fuel system)” in “Guided functions”.
nform
ercia
1 - Fuel tank
m
❑ With fuel system pres‐
at
om
io
surisation pump - G6- .
n
c
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or
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2 - Fuel filter
at
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❑ ⇒ Rep. gr. 20 ; Fuel fil‐

p
cum
or
ter; Assembly overview

f
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- fuel filter
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❑ ⇒ Rep. gr. 20 ; Fuel fil‐
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ter; Removing and in‐ cop Vo
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stalling fuel filter
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Prote AG.

❑ After renewing, a first
fuel filling “must” be per‐
formed (never allow
⇒ page 410 .
⇒ page 410 .
❑ Do not open.
247-
⇒ page 419 .
valve - N 276-
❑ Renew
368 Rep. gr.23 - Mixture preparation - injection

⇒ page 416 .
❑ 80 Nm
8 - Pressure retention valve with fuel return lines
❑ The fuel return lines must not be dismantled. They can only be renewed together with the pressure
❑ This residual pressure is required for the control function of the piezo injectors.
9 - Injectors
❑ Injector, cylinder 1 - N30-
1.1.3 Schematic overview - fuel system, Pas‐

sat 2011▶
empty and to ensure gthat
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lkswagen AG quickly after parts have
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1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6- .
2 - Fuel filter
❑ (Passat 2011▶) ⇒ Rep.
gr. 20 ; Fuel filter; As‐
sembly overview - fuel
filter
fuel filter (Passat
2011▶) ⇒ Rep. gr. 20 ;
Fuel filter; Removing
and installing fuel filter
3 - High-pressure fuel pump lkswage es n
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❑ After renewing, a first ir se
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or
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⇒ page 410 .
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⇒ page 410 .
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⇒ page 419 .
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⇒ page 416 .
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❑ This residual pressure is required for the control function of the injectors.
9 - Injectors

1.2 Assembly overview - fuel system

⇒ “1.2.1 Assembly overview - fuel system, Polo, Golf, Golf Plus,
Golf Cabriolet, Touran, Passat 2006 ►”, page 371
⇒ “1.2.2 Assembly overview - fuel system, Passat 2011▶”,
page 376
1.2.1 Assembly overview - fuel system, Polo,

Golf, Golf Plus, Golf Cabriolet, Touran,
Passat 2006 ►
Caution
To prevent the high-pressure fuel pump from running while it

is empty and to ensure that the engine starts quickly after parts
have been renewed, it is important to observe the following:
♦ If fuel system components between fuel tank and fuel
high-pressure pump are removed or renewed AG. Volkswagen AG d
agen oes
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♦ Basic setting “Checking fuel pre-supply pump” edmust be
b ua
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ris
carried out to bleed fuel system. tho tee
or
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♦ If a fuel pump, fuel line (between fuel tank
s and fuel high-
ce
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pressure pump) or fuel filter is removed or renewed

nl
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♦ Basic setting “Testing fuel pre-supply pump” must be car‐
erm
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ried out »once« before first starting engine.
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, is n
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basic setting “Checking fuel system pressurisation pump”
hole
spec
must be performed »three times« before the engine is
es, in part or in w
started for the first time.
t to the co
♦ Performing first fuel filling after installing high-pressure
pump ⇒ page 410 .
rrectness of i
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1 - Fuel return line
Caution
Gradual introduction of a
new fuel return line. Al‐
ways observe notes
⇒ page 374 !
❑ Flexible
❑ The following compo‐
nent must be renewed
any time the fuel return
line is removed and in‐
stalled: “return line re‐
taining clip”
❑ To fuel tank.
❑ The fuel return line must
not be kinked, damaged
or blocked.
❑ The fuel return lines
must not be dismantled.
❑ Only renew O-ring if
necessary
❑ The pressure retention
valve maintains a resid‐
ual pressure in the re‐ n AG. Volkswagen AG do
turn lines. lkswage es n
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❑ This residual pressure is ir se
d ran
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required for the control utho
or
function of the injectors. ss
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❑ Check pressure reten‐

un
pt
tion valve ⇒ page 392 .

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❑ Cannot be re-installed.
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t to the co
❑ 80 Nm
rrectness of i
❑ Rigid
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4 - Bolt
nform
ercia
❑ 10 Nm
m

a
com
tion in

r
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❑ With fuel metering valve - N290- (do not open).

s
iva
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❑ After renewing, a first fuel filling must be performed (never allow the pump to run while it is still empty)
rp
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⇒ page 383 .
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6 - Bolt
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❑ 20 Nm + turn 180° further p by
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❑ Renew
agen
Prote AG.
7 - Hub
❑ With sender ring

8 - Nut
❑ 95 Nm
❑ Bolts 20 Nm
❑ Renew
10 - Bolt
❑ 20 Nm + turn 45° further
❑ Renew
11 - Bolt
❑ 10 Nm
12 - High-pressure line
❑ 28 Nm
❑ Between high-pressure pump and high-pressure accumulator
❑ Install so that component is not under tension.

agen oes
olksw not
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♦ oThe
ris high-pressure line may be
ed
nte
ut re-used after the following
h eo
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ss checks: c
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♦ Check taper seat of high-pres‐

pt
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sure line for deformation and

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cracks.
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♦ The inside of the line must not be

wit
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deformed, constricted or dam‐

h re
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aged.
spec
es, in part or in w
♦ Corroded lines should no longer

t to the co
be used.
rrectness of i
13 - Fuel pressure sender - G 247-

l purpos
❑ 100 Nm
nform
ercia
m

at
om
ion
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15 - Bolt
in t
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❑ 22 Nm
at
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16 - High-pressure lines
for
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Cop py
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❑ 28 Nm
ht rig
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❑ Between high-pressure accumulator and injectors.
co lksw
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cted agen
Prote
❑ Do not interchange.
AG.
Note
♦ Observe cylinder-specific mark‐

ings when reusing high-pressure
lines.
♦ The high-pressure lines may be
re-used after the following
checks:

♦ Check taper seat of respective

high-pressure line for deforma‐
tion and cracks.
aged.
n AG. Volkswagen A
be used. olks
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17 - Seal thoris tee
or
❑ Renew if damaged ⇒ page 172 . au ac
ss
ce
le
18 - Seal
un
pt
an
d
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❑ Renew if damaged ⇒ page 172 .
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ility
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19 - Injectors
wit
is n
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ole,
❑ The following components and seals/O-rings must be renewed each time on removal/installation: “bolt
spec
for clamping piece”, “copper seal”, “O-ring of injector bore” and “retaining clip for return connection”.
t to the co
❑ The following components must also be renewed when an injector is replaced: “bolt for clamping piece”
❑ Before re-using “high-pressure line”, perform visual check of taper seats for damage such as transverse
rrectne
scores or corrosion; always renew if damaged.
❑ If they are to be re-installed, injectors, high-pressure fuel lines and clamping pieces must always be re-
fitted in their original positions (i.e. on the same cylinder).
ss o
cial p
f
20 - Bolt for clamp
inform
mer
❑ Renew
atio
m
Tighten securing bolts to a maximum of 1 to 2 Nm at first.

o
n
c
i
or
n thi
te
After the high-pressure lines have been fitted. Final specified torque: 8 Nm + turn 180° further.
sd
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21 - O-ring for fuel return lines

en
ng
t.
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❑ The following component must be renewed any time the fuel return line is removed and installed: “return
Cop py
line retaining clip”
ht. rig
rig ht
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❑ Only renew O-ring if necessary
co Vo
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Prote
❑ Observe notes on installing ⇒ page 374 .
AG.
Removing O-ring for fuel return lines

Proceed with extreme caution. Avoid damage to fuel return line.
– Lever old O-ring very carefully off fuel return line.
Do not work with a sharp-edged tool. Preferably use a plastic tool.
Installing O-ring for fuel return lines
Caution
Gradual introduction of a new fuel return line. Always ensure

proper allocation of components when renewing the O-rings.
The new fuel return line can be identified by the indentation
-arrow- in the connecting piece. The new fuel return lines must
always be equipped with the orange O-rings ⇒ Electronic Parts
Catalogue (ETKA) . Other O-rings must not be used since this
will cause leaks and failures.

A - Connection for »new« fuel return line, with indentation

-arrow-, use orange O-ring.
B - Connection for »old« fuel return line, without indentation, use
green O-ring.
Note
Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in fuel return line.
Proceed with extreme caution. Avoid damage to the O-ring and

fuel return line.
– Clean seating surfaces for O-rings on fuel return line very
carefully.
– Carefully push O-ring -1- on its seat -2-.
AG. Volkswagen AG d
agen oes
olksw not
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om
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c
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ate
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en
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.2.2 Assembly overview - fuel system, Pas‐

sat 2011▶
Caution
To prevent the high-pressure fuel pump from running while it

is empty and to ensure that the engine starts quickly after parts
have been renewed, it is important to observe the following:
♦ If fuel system components between fuel tank and fuel
high-pressure pump are removed or renewed
♦ Basic setting “Checking fuel pre-supply pump” must be
carried out to bleed fuel system.
♦ If a fuel pump, fuel line (between fuel tank and fuel high-
pressure pump) or fuel filter is removed or renewed
♦ Basic setting “Testing fuel pre-supply pump” must be car‐
ried out »once« before first starting engine.
♦ If the high-pressure fuel pump is removed or renewed, the
basic setting “Checking fuel system pressurisation pump”
must be performed »three times« before the engine is
started for the first time.
♦ Performing first fuel filling after installing high-pressure
pump ⇒ page 410 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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ab
ility
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wit
is n
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ole,
spec
t to the co
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cial p
f inform
mer
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om
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c
i
or
n thi
te
sd
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caution
Gradual introduction of a
new fuel return line. Al‐
ways observe notes
⇒ page 379 !
❑ Flexible
❑ The following compo‐
nent must be renewed
any time the fuel return
line is removed and in‐
stalled: “return line re‐
taining clip”
❑ To fuel tank.
❑ The fuel return line must
not be kinked, damaged
or blocked.
❑ The fuel return lines
must not be dismantled.
❑ Only renew O-ring if
necessary
❑ The pressure retention
valve maintains a resid‐
ual pressure in the re‐
turn lines.
❑ This residual pressure is
required for the control
function of the injectors.
❑ Check pressure reten‐
tion valve ⇒ page 392 .
2 - Fuel pressure regulating AG. Volkswagen AG d
valve - N 276- agen oes
olksw not
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❑ Cannot isedbe re-installed.
b ara
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❑ Checking
aut
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❑ sRemoving and installing ⇒ page 416 .
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❑ 80 Nm
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4 - Bolt
hole
spec
❑ 10 Nm
es, in part or in w
t to the co

rrectness of i

❑ After renewing, a first fuel filling must be performed (never allow the pump to run while it is still empty)
l purpos
⇒ page 383 .
6 - Bolt
nf
ercia
orm
❑ 20 Nm + turn 180° further

m
atio
m
❑ Renew
o
n in
or c
thi
e
7 - Hub
t
sd
iva
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❑ With sender ring

rp
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f
en
ng

t.
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op
C py
ht. rig
rig ht
py by
co Vo
by lksw
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377
Prote AG.
1. Injection system
8 - Nut
❑ 95 Nm
❑ 20 Nm AG. Volkswagen AG d
agen oes
❑ Renew Volksw not
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db ran
10 - Bolt rise tee
tho or
❑ 20 Nm + turn 45° further au ac
ss
❑ Renew
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le
un
pt
an
d
itte
11 - Bolt
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rm
ab
❑ 10 Nm
pe
ility
ot
wit
, is n
h re
hole
❑ 28 Nm
spec
es, in part or in w
❑ Between high-pressure pump and high-pressure accumulator
t to the co
rrectness of i
Note
l purpos
♦ The high-pressure line may be

checks:
nform
ercia
♦ Check taper seat of high-pres‐

m
a
com
ti
sure line for deformation and
on in
cracks.
r
te o
thi
s
iva
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rp
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um
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en
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ng
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be used. pyri by
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Prote AG.
13 - Fuel pressure sender - G 247-
❑ 100 Nm
15 - Bolt
❑ 22 Nm
16 - High-pressure lines
❑ 28 Nm
❑ Between high-pressure accumulator and injectors.
❑ Do not interchange.
Note
♦ Observe cylinder-specific mark‐

ings when reusing high-pressure
lines.
♦ The high-pressure lines may be
checks:

♦ Check taper seat of respective

high-pressure line for deforma‐
tion and cracks.
aged.
be used.
17 - Gasket
18 - Gasket
19 - Injectors
❑ The following components and seals/O-rings must be renewed each time on removal/installation: “bolt
for clamping piece”, “copper seal”, “O-ring of injector bore” and “retaining clip for return connection”.
❑ The following components must also be renewed when an injector is replaced: “bolt for clamping piece”
❑ Before re-using “high-pressure line”, perform visual check of taper seats for damage such as transverse
scores or corrosion; always renew if damaged.
❑ If they are to be re-installed, injectors, high-pressure fuel lines and clamping pieces must always be re-
fitted in their original positions (i.e. on the same cylinder).
20 - Bolt for clamp
❑ Renew
Tighten securing bolts to a maximum of 1 to 2 Nm at first.
After the high-pressure lines have been fitted. Final specified torque: 8 Nm + turn 180° further.
21 - O-ring for fuel return lines

❑ The following component must
gen AG
. Vobe renewed
lkswagen AG any time the fuel return line is removed and installed: “return
does
line retaining clip”Volkswa not
by gu
❑ Only renewrisO-ring
ed if necessary ara
nte
o eo
❑ Observeaunotes
th
on installing ⇒ page 379 . ra
c
ss
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e
nl
pt
du
an
itte
Removing O-ring for fuel return lines

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erm
ab
ility
Proceed with extreme caution. Avoid damage to fuel return line.

ot p
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– Lever old O-ring very carefully off fuel return line.

h re
hole
spec
Do not work with a sharp-edged tool. Preferably use a plastic tool.

es, in part or in w
t to the co
Installing O-ring for fuel return lines

rrectness of i
Caution
l purpos
Gradual introduction of a new fuel return line. Always ensure

proper allocation of components when renewing the O-rings.
The new fuel return line can be identified by the indentation
nf
ercia
-arrow- in the connecting piece. The new fuel return lines must
rm
m
atio
always be equipped with the orange O-rings ⇒ Electronic Parts

om
Catalogue (ETKA) . Other O-rings must not be used since this

n in
or c
will cause leaks and failures.

thi
te
sd
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A - Connection for »new« fuel return line, with indentation

-arrow-, use orange O-ring.
B - Connection for »old« fuel return line, without indentation, use
green O-ring.
Note
Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in fuel return line.
Proceed with extreme caution. Avoid damage to the O-ring and

fuel return line.
– Clean seating surfaces for O-rings on fuel return line very
carefully.
– Carefully push O-ring -1- on its seat -2-.
. Volkswagen AG
gen AG
1.2.3 Conversion of 0.5 bar low-pressure
yV
olks
wa fuel does
not
gu
system to 6.0 bar low-pressure fuel sys‐
d b ara
e nte
ris
tho eo
tem ss
au ra
c
ce
e
At the time of publication, only the CAYC engine in the (Passat

nl
pt
du
an
2011►) was affected.

itte
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erm
ab
New components
ility
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wit
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♦ 6.0 bar fuel delivery unit (generates the required feed pressure
h re
for the high-pressure pump).

hole
spec
♦ Fuel hoses in engine compartment, 6.0 bar (low-pressure fuel

es, in part or in w
t to the co
system) ⇒ Rep. gr. 20 ; Fuel hoses in engine compartment

♦ Fuel filter 6.0 bar ⇒ Rep. gr. 20 ; Fuel filter; Removing and
installing fuel filter
rrectness of i
♦ Fuel return line (flexible) 6.0 bar with pressure retention valve
l purpos
⇒ Item 1 (page 377)

♦ Testing of the pressure retention valve remains the same for
nform
ercia
all CAY... engines ⇒ page 392 .

m
at
om
♦ Fuel return lines (rigid) 6.0 bar ⇒ Item 1 (page 377)

on
c
in t
or
♦ High-pressure pump without feed flow pump (fuel delivery unit

his
ate
generates the required feed pressure for the high-pressure

do
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pump)
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for
en
ng
t.
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♦ Fuel pressure regulating valve - N 276- 6.0 bar
Co
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Volkswagen AG
4-cylinder scommon
wage
n AG. rail engine (1.6
doesl, EA189) - Edition 02.2016
k not
Vol gu
d by ara
Possible differences in the fuel deliveryocomponents
ris
e in the CAYC nte
engine auth eo
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ab
ility
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1 - Fuel return line for 0.5 bar
wit
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h re
fuel low-pressure system (Po‐
hole
lo, Golf, Touran Passat 2006►)
spec
es, in part or in w
t to the co
❑ Flexible
❑ With pressure retention
valve
rrectness of i
2 - Fuel return line for 6.0 bar
l purpos
fuel low-pressure system

(Passat 2011►)
nf
ercia
orm
m
❑ Flexible
atio
om
❑ With pressure retention
n in
or c
valve
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o
3 - Fuel return lines for 0.5 bar
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fuel low-pressure system (Po‐
f
en
ng
t.
lo, Golf, Touran Passat 2006►)
yi Co
Cop py
❑ Rigid
t. rig
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pyri by
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4 - Fuel return lines for 6.0 bar
c by lksw
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fuel low-pressure system
Prote AG.
(Passat 2011►)
❑ Rigid
Differences: high-pressure pumps with fuel pressure regulating

valve - N 276-

1 - High-pressure pump for 0.5

bar fuel low-pressure system
(Polo, Golf, Touran Passat
2006►)
❑ Fitted with pressurisa‐
tion pump on high pres‐
sure pump
2 - High-pressure pump for 6.0
bar fuel low-pressure system
(Passat 2011►)
❑ Without booster pump.
❑ The 6.0 bar required in
the low-pressure fuel
system is generated by wage
es n
s
the fuel delivery unit ⇒ yV
olk ot g
ua
Rep. gr. 20 ; Fuel deliv‐ ir se
d b ran
tee
ery unit, fuel gauge utho
or
sender; Assembly over‐ ss
a ac
view - fuel delivery unit,
ce
e
nl
pt
fuel gauge sender .
du
an
itte
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erm
ab
ility
valve - N 276- 0.5 bar fuel low-
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pressure system (Polo, Golf,
, is n
h re
Touran Passat 2006►)
hole
spec
es, in part or in w
Note
t to the co
♦ The fuel pressure regulating
valve - N 276- of the 0.5 bar fuel
rrectness of i
low-pressure system looks the
same as that of the 6.0 bar fuel
l purpos
low-pressure system.
nf
♦ Observe the index as per ⇒
ercia
orm
Electronic Parts Catalogue (ET‐
m
atio
m
KA) .
o
n in
or c
thi
e

t
sd
iva
valve - N 276- 6.0 bar fuel low-pressure system (Passat 2011 ►).
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Note
Co
Cop py
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♦ The fuel pressure regulating p by
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valve - N 276- of the 6.0 bar fuel
by lksw
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Prote
low-pressure system looks the
AG.
same as that of the 0.5 bar fuel

low-pressure system.
♦ Observe the index as per ⇒
Electronic Parts Catalogue (ET‐
KA) .

1.3 Filling, bleeding fuel system
Caution
Risk of irreparable damage to high-pressure pump if allowed

to run dry.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. The high-pressure pump must not
be allowed to run while still empty.
swage es n
Note byV
olk ot g
ua
d ran
ir se tee
o
♦ When installing the high-pressure pump, it ais
u essential to en‐
th or
ac
sure that no dirt enters the fuel system. ss
ce
le
un
pt
♦ Only remove sealing plugs immediately prior to installation of
an
d
itte
fuel lines.
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erm
ab
ility
♦ There must be sufficient fuel in the tank.
ot p
wit
is n
h re
ole,
– Switch ignition on.
spec
– Connect vehicle diagnostic tester and carry out guided func‐
t to the co
tion “Actuating fuel pump”.
– After completion of the function start the engine.
rrectne
– After filling fuel system, leave the engine running at moderate
speed for a few minutes and then switch it off again.
ss o
– Checking fuel system for leaks ⇒ page 383
cial p
f inform
– Read out event memory and, if necessary, delete the event
mer
memory entry ⇒ Vehicle diagnostic tester .
atio
om
n
c
– Test drive the vehicle extensively, accelerating to full throttle
i
or
n thi
e
at least once. Then check high-pressure part of fuel system

t
sd
va
again for leakage.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note
C py
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co
If there is any air left in the fuel system, the engine may switch to
by lksw
cted agen
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the backup mode ('emergency running' mode) during the road
AG.
test. Switch off engine and clear event memory. Then continue
road test.
– Read event memory again.
1.4 Checking fuel system for leaks

– Allow engine to idle for a few minutes but do not accelerate.
Then switch off engine again. Fuel system will bleed itself au‐
tomatically.
– Check fuel system for leaks.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
– Road-test the vehicle. Accelerate with full throttle at least
once, then check the high-pressure section again for leaks.

Note
test. Switch off engine and clear event memory. Then continue
road test.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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Cop py
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Prote AG.

2 Vacuum system
⇒ “2.1 Schematic diagram - vacuum system”, page 385
2.1 Schematic diagram - vacuum system

⇒ “2.1.1 Assembly overview - vacuum system, Golf, Golf Plus,
Golf Cabriolet, Touran, Passat”, page 385
⇒ “2.1.2 Schematic diagram - vacuum system, Polo”, page 386
2.1.1 Assembly overview - vacuum agen

AG. Volksystem,
swagen AG
does
Golf, Golf Plus, dGolf
by
V Cabriolet, Touran,
olksw not
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ara
Passat ise nte
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Caution
un
pt
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itte
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Do not kink, twist or crush the vacuum lines when routing. This
erm
ab
ility
may cause breakdowns.
ot p
wit
is n
h re
ole,
spec
t to the co
Note
♦ Blue = vacuum control line for exhaust gas recirculation.
rrectne
♦ Grey = breather line from air filter housing.
s
♦ Green = vacuum control line for turbocharger.
s o
cial p
f i
♦ Red = vacuum supply line for vacuum pump.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Vacuum system 385

1 - Vacuum unit
❑ For changeover for ex‐
haust gas recirculation
cooler.
2 - Non-return valve
cooler changeover valve -
N345- AG. Volkswagen AG d
agen oes
olksw not
❑ Checking changeover ed by
V gu
ara
⇒ page 521 . horis nte
eo
aut ra
4 - Cylinder head cover ss c
ce
e
❑ With integrated vacuum

nl
pt
du
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reservoir
itte
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erm
ab
5 - Vacuum unit
ility
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❑ On turbocharger.
, is n
h re
❑ With position sender for
hole
spec
charge pressure posi‐
es, in part or in w
tioner - G581- .
t to the co
6 - Charge pressure control
solenoid valve - N75-
rrectness of i
7 - Vacuum pump
l purpos
8 - Air filter housing

❑ With union for breather
nf
ercia
o
line.
rm
m
atio
om
n in
or c
thi
te
sd
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
2.1.2 Schematic diagram - vacuum system,

Polo
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
Note
♦ Blue = vacuum control line for exhaust gas recirculation.

♦ Grey = breather line from air filter housing.
♦ Green = vacuum control line for turbocharger.
♦ Red = vacuum line from vacuum pump.

1 - Vacuum unit
❑ For changeover for ex‐
cooler.
2 - Non-return valve
cooler changeover valve -
N345-
❑ Checking changeover
⇒ page 521 .
4 - Cylinder head cover
❑ With integrated vacuum n AG. Volkswagen AG do
wage
reservoir olks es n
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byV ua
d ran
5 - Vacuum unit ir se tee
tho
u or
❑ On turbocharger. ss
a ac
❑ With position sender for
ce
le
un
pt
charge pressure posi‐
an
d
itte
y li
tioner - G581- .
rm
ab
pe
ility
❑ Renew ⇒ page 344
ot
wit
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6 - To intake hose
h re
hole
spec
7 - Vacuum line
es, in part or in w
t to the co
❑ To brake booster
8 - Vacuum pump
rrectness of i
9 - Charge pressure control
solenoid valve - N75-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
g
Vacuum lines can also be removed complete together with brack‐

n
t.
yi Co
et -1- from air filter. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Vacuum system 387

To renew charge pressure control solenoid valve - N75- , pull off

connector and unscrew nuts -1 + 2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 Injectors and fuel rail

⇒ “3.1 Assembly overview - injectors”, page 389
⇒ “3.2 Adapting correction values for injectors”, page 390
⇒ “3.3 Testing jammed-open injectors”, page 390
⇒ “3.4 Check pressure retention valve in fuel return line”,
page 392
⇒ “3.5 Removing and installing injectors”, page 394
⇒ “3.6 Removing and installing fuel rail”, page 398
⇒ “3.7 Removing and installing high-pressure lines”, page 402
3.1 Assembly overview - injectors
Caution

installing the high-pressure lines ⇒ Item 20 (page 374) . Clamp‐
ing jaws are only secured »hand-tight« for setting the injectors
while installing high-pressure lines. Non-observance of these
notes may lead to damage to engine.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
389
by lksw
cted agen
Prote AG.
3. Injectors and fuel rail
1 - Injectors
❑ If they are to be reinstal‐
led, the injectors, high-
pressure lines and
clamping pieces must
only ever be refitted on
the same cylinder.
❑ Before installing, clean
injector bore using
cleaning set - VAS
6811-
2 - Bolt for clamp
❑ Renew
Tighten securing bolts to a
maximum of 1 to 2 Nm at first.
After the high-pressure lines

AG. Volkswagen AG d
have been fitted. Final speci‐ ksw
agen oes
not
l
fied torque: 8 Nm + turn 180° by Vo gu
ara
further. rise
d
nte
tho eo
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3 - High-pressure fitting ss c
ce
e
❑ Counterhold when loos‐

nl
pt
du
an
ening the high-pressure
itte
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lines
erm
ab
ility
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4 - Return lines retaining clip
wit
, is n
h re
❑ Do not reuse, renew
hole
spec
❑ Grease the retaining clip
es, in part or in w
lightly before installing
t to the co
the injector.
5 - Copper washer
rrectness of i
❑ Renew
l purpos
6 - O-ring
❑ Renew
nform
mercia
at
om
ion
3.2 Adapting correction values for injectors
c
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
♦ After renewing the injectors (piezo injectors) “perform adap‐
t. C rig
gh ht
tation of the correction values” ⇒ Vehicle diagnostic tester. pyri by
Vo
co lksw
by
cted agen
♦ “Reading / adapting” correction values. Prote AG.
3.3 Testing jammed-open injectors
Note
♦ Leaky regulating valves in injectors may lead to irregular en‐

gine running or may prevent engine from starting.
♦ To check regulating valves for soiling (and with it higher leak‐
age), in addition to the "classical" return quantity measure‐
ment, checking with vacuum is also possible.
♦ Observe instructions for working on fuel system ⇒ page 5 .


♦ Hand vacuum pump - VAS 6213-
♦ Make an -adapter- from a return line.
AG. Volkswagen AG d
agen oes
olksw not
– Collect escaping fuel with ed bya cleaning cloth.
V gu
ara
ris nte
o
– Open cleaned returnaut line connection of injector to be tested
h eo
ra
using a small screwdriver
ss and long-nose pliers. c
ce
le
un
pt
Always renew clips.

an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
3. Injectors and fuel rail 391

– Pull off return line in direction of arrow.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
WARNING ised b ara
nte
or eo
h
ut ra
♦ The fuel and the fuel lines in the
s fuel system can become
s a c
very hot (danger of scalding)!
ce
e
nl
pt
du
an
♦ The fuel system is also under pressure! Before opening
itte
y li
erm
the system, place cloths around the connections. Then
ab
ility
carefully loosen connection to release the pressure!
ot p
wit
, is n
♦ Wear eye and hand protection when performing any type
h re
hole
of repair work on the fuel system!
spec
es, in part or in w
t to the co
– Undo fuel high-pressure line -2-. To do this, only undo union
rrectness of i
nuts on high-pressure accumulator -1-.
– Connect clean, blow-out adapter to injector to be tested.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
ht. rig
– Use hand-operated vacuum pump - VAS 6213- to generate
rig ht
py by
o Vo
vacuum of approx. -500 mbar. by c lksw
cted agen
Prote AG.
If injectors are OK, pressure remains constant for 30 seconds.
If injectors are defective, the pressure drops within 2 ... 3 s to 0
bar.
Repeat check if necessary, observe pressure loss at hand-oper‐
ated vacuum pump - VAS 6213- .
– Renew injectors ⇒ page 394 .
3.4 Check pressure retention valve in fuel

return line
The pressure retention valve maintains a residual pressure of ap‐
prox. 1 bar in the return lines.
This residual pressure is required for the control function of the
injectors.

♦ Pressure gauge - VAS 6330-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
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spec
es, in part or in w
♦ Adapter - VAS 6330/3-1-
t to the co
♦ Adapter - VAS 6330/3-2-
rrectness of i
l purpos
– Clean return line connection on cylinder 1 (e.g. with cold clean‐

er) before removing.
nf
ercia
– Dry return line connection on No. 1 cylinder.
orm
m
– Cover return line connection on No. 1 cylinder with a cleaning
atio
m
cloth.
o
n in
or c
thi
e
– Pull return line connection off No. 1 cylinder; pull out release
t
sd
iva
clip to do this.
o
r
rp
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o
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f
en
ng
t.
yi Co
op
Note
C py
t. rig
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Vo
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by c
♦ Open the return line connection with a narrow screwdriver and
lksw
cted agen
Prote
long-nosed pliers.
AG.
♦ Adhere strictly to rules of cleanliness. No dirt must be allowed

to enter the disconnected fuel return lines or the open con‐
nections on the injectors.
♦ Always renew clips.

– Install tester for fuel return system - 6330- with adapters -VAS
6330/3-1- and -VAS 6330/3-2- between return line n Aconnection
G. Volkswagen AG d
on injector and return line. wage oes
olks no t gu
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– Start engine. rise nte
tho eo
– Check pressure on pressure gauge. au ra
c
ss
ce
le
♦ Specification: approx. 1.0 bar
un
pt
an
d
itte
y li
If the value does not match the specification, fit a new pressure
rm
ab
retention valve.
pe
ility
ot
wit
, is n
h re
hole
• Observe instructions for working on fuel system ⇒ page 5 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
3.5 Removing and installing injectors

m
a
com
ti
⇒ “3.5.1 Removing”, page 395
on in
r
te o
thi
⇒ “3.5.2 Installing”, page 397
s
iva
do
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cum
fo
en
ng
t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.


equipment required
♦ Puller - T10055-
♦ Assembly sleeve - T10377-
♦ Socket - T40055-
1331-
♦ Ratchet - V.A.G 1331/1-
♦ Support sleeve - T10411-
♦ Injector remover - T10402-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
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3.5.1 Removing
inform
mer

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– Remove noise insulation from cylinder head cover.

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– Pull off connectors -1- at injectors to be removed.

Remove high-pressure line between high-pressure accumulator
and injectors. ⇒ page 402
Note
♦ Open the return line connection with a narrow screwdriver and

long-nosed pliers.
♦ Renew clips.
– To release fuel return line, pull clip out in direction of arrow.
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– Pull fuel return line connections off injectors in direction of ar‐

row.
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– Unscrew securing bolt of clamping piece of injector to be re‐

l purpos
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nf
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Caution
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Proceed very carefully to prevent unnecessary dismantling or

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In some vehicles (e.g. Touran), the plenum chamber bulkhead
op Vo
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must be removed ⇒ General body repairs, exterior; Rep. gr. 50 ;
cted agen
Prote AG.
Plenum chamber bulkhead; Assembly overview - plenum cham‐
ber bulkhead .

– Apply puller - T10055- with injector remover - T10402- -1- and

-2- as shown in illustration and pull injectors out upwards by
tapping gently.
3.5.2 Installing n AG. Volkswagen AG do

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Important instructions for working on fuel system ⇒ page 5 by Vo ot g
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Fitting used injectors utho tee
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• Clean empty injector bores and sealing surfaces in cylinder ss
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head using cleaning set - VAS 6811- before fitting injectors ⇒

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Instructions
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When a used injector is re-fitted, the following must be replaced:
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♦ Copper seal
h re
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♦ O-ring for injector shaft
spec
t to the co
♦ Retaining clip for injector return
♦ O-ring for return line
rrectne
– Spray tip of injector with rust-releasing spray. Wait approx.
5 minutes and wipe off soot particles and oil with a cloth.
ss
– If an injector is very dirty, the tip of the nozzle should also be
o
cial p
f
cleaned with a soft brass wire brush to make it easier to re‐
inform
move the copper seal. Do not apply the wire brush to the bores
mer
in the nozzle.
atio
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Note
t
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It must be ensured that the brass brush does not touch the holes
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in the injection nozzles.
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– To remove the old copper seal from the injector, carefully

clamp the copper seal in a pair of pliers so it is just prevented
from spinning.
– Then carefully pull and twist the injector out of the copper seal
by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Caution
Risk of damage to sealing surface for injector.

♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector shaft in the cylinder head with a
cloth soaked in engine oil or rust solvent.
– Fit renewed clips before fitting the injector. To do this, grease

lightly.
Fitting new injectors:
When a fitting a new injector, the following must be replaced:
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♦ Copper seal lksw
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♦ O-ring for injector return line s au ra
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♦ Retaining clip for injector return

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Continuation for used and new injectors:
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– Use a plastic socket to mount new copper seal.
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– Lubricate all O-rings with engine oil or assembly oil before in‐
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stalling.
spec
es, in part or in w
– Fit new O-rings for injector shaft.
t to the co
– Push clamping piece onto injectors, during this process pay
attention to installation position.
rrectness of i
– Always guide two injectors in pairs carefully into injector bores
l purpos
in cylinder head.
– Tighten bolt for clamp to a maximum of only 1 to 2 Nm at first.
nform
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• Injectors must still be able to move.

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– Install high-pressure lines ⇒ page 402 .

n
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Further assembly in reverse order of removal.

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– Tighten injectors ⇒ page 371

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– Adapt correction values for injectors ⇒ page 390 .
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3.6 Removing and installing fuel rail
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♦ Ratchet - V.A.G 1331/1- orise nte
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♦ Tool insert 17 mm - V.A.G 1331/6-
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♦ Socket - T40055-

♦ Pliers - 3314-
Removing
– Remove engine cover ⇒ page 76 . AG. Volkswagen AG d
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– Unscrew bolt -3- from retainer for high-pressure line. ised b ara
nte
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– Remove fuel high-pressure line -2-. To do this, releases autunion ra
c
nuts on high-pressure pump -4- and high-pressure accumu‐
s
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lator -1-.
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The lifting eye (for engine mounting) must be movable in order to
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unscrew union nut on high-pressure pump; loosen bolts -4- to do

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this.
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– Open cable guide fasteners -arrows- to free wiring harness.


shoulder -arrow B-.
– Carefully pull connectors off glow pin plugs in direction of

-arrow-.
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– Pull off electrical connectors -1 and 4-.

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– Pull off fuel return hose -2-.

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– Disconnect electrical connectors -1, 6 and 7-.

at
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Caution
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♦ Mark allocation of high-pressure lines to cylinders. They

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must always be re-installed on the same cylinders.
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♦ Plug open connections with suitable sealing caps imme‐
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diately.
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– Remove high-pressure lines between high-pressure accumu‐

lator and injectors.

Note
Counterhold on high-pressure union -A- when loosening high-

pressure line.
– After removal, lay high-pressure lines on a clean cloth.

– Remove high-pressure accumulator, first unscrewing the two
bolts. gen AG
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Installation is carried out in the reverse order.
tho When installing, eo
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– Initially tighten securing bolts -arrows- to just max. 1 - 2 Nm.
an
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• It must be possible to move the rail so the hoses can be fitted
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free of tension.
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– Install high-pressure lines ⇒ page 402 .
hole
spec
– Firmly screw lifting eye in ⇒ page 90 .
es, in part or in w
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Note
rrectness of i
♦ Renew retaining clips.
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♦ Observe cylinder-specific markings when reusing high-pres‐

sure lines.
nform
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♦ The high-pressure lines may be re-used after the following

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t
checks:
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♦ Check taper seat of respective high-pressure line for defor‐
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♦ Specified torques:
AG.
⇒ “1.2.1 Assembly overview - fuel system, Polo, Golf, Golf

Plus, Golf Cabriolet, Touran, Passat 2006 ►”, page 371 .
3.7 Removing and installing high-pressure

lines
⇒ “3.7.1 Removing high-pressure lines between high-pressure
accumulator and injectors”, page 404
⇒ “3.7.2 Removing high-pressure line between high-pressure ac‐
cumulator and high-pressure pump”, page 405
⇒ “3.7.3 Installing high-pressure lines”, page 405

lkswage es n
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♦ Ratchet - V.A.G 1331/1-
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♦ Tool insert 17 mm - V.A.G 1331/6-
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♦ Socket - T40055-

♦ Support sleeve - T10411-
3.7.1 Removing high-pressure lines between

high-pressure accumulator and injec‐
tors
AG. Volkswagen AG d
– Remove engine cover ⇒ page 76 . agen oes
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Caution utho eo
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Ensure absolute cleanliness. There should be no dirt in the

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disconnected fuel return lines or the open connections on the
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injectors under any circumstances.
rm
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able methods under all circumstances.
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Used injectors may only be re-installed on the same cylinder.
es, in part or in w
t to the co
Preferable order for disconnecting high-pressure lines cylinder
4-3-2-1
rrectness of i
– To disconnect the high-pressure lines, counterhold the high-
l purpos
pressure fitting -A- on the injectors.

– Remove high-pressure line between high-pressure accumu‐
nform
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lator and injectors.

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– Then only loosen the high-pressure line between high-pres‐
Prote AG.
sure accumulator and high-pressure pump -3-.

3.7.2 Removing high-pressure line between

high-pressure accumulator and high-
pressure pump
Caution
Ensure absolute cleanliness. There should be no dirt in the

disconnected fuel return lines or the open connections on the
injectors under any circumstances.
Protect open fuel connections from dirt entrainment using suit‐
able methods under all circumstances.
Used injectors may only be re-installed on the same cylinder.
– Unscrew bolts -1 and 2-, remove engine lifting eyes -3-.
AG. Volkswagen AG d
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– Unscrew union nuts -1 and 4 -, and remove high-pressure
auth line ra
-2-. ss c
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3.7.3 Installing high-pressure lines rrectness o
cial p
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Caution
mer
atio
om
To position injection lines more easily and stress-free, loosen

n
c
i
or
and shift high-pressure accumulator and injectors slightly if

thi
te
sd
necessary. The lines must never be bent or tensioned. Tension

iva
o
r
would otherwise cause the respective line to break in the long-

p
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term.
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Note
♦ Tools must not be used to align the high-pressure accumulator

element (high-pressure accumulator) / the injectors.
♦ Observe cylinder-specific markings when reusing high-pres‐
sure lines.
♦ The high-pressure lines may be re-used after the following
n AG. Volkswagen A
checks: olks
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♦ Check taper seat of respective high-pressure
ris
ed line for defor‐ ran
tee
mation and cracks. utho or
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ss
♦ The inside of the line must not be deformed, constricted or
ce
le
damaged.
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pt
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♦ Corroded lines should no longer be used.
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ility
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Caution
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spec
t to the co
installing the high-pressure lines ⇒ Item 20 (page 374) . Clamp‐
ing jaws are only secured »hand-tight« for setting the injectors
rrectne
while installing high-pressure lines. Non-observance of these
notes may lead to damage to engine.
ss o
cial p
f inform
– Use a vacuum-type cleaner to remove dirt from taper seat on
mer
high-pressure accumulator.
atio
om
n
– Clean fuel line and head of line using cold cleaning solvent
c
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or
and dry using compressed air. n thi

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– Moisten union nut thread with fuel.

p
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– Fit the injection lines from high-pressure accumulator to injec‐

t.
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op
tor by hand first, only tighten union nuts by hand.
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Next install high-pressure line from high-pressure pump to high- cop Vo
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pressure accumulator. cted agen
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– To install high-pressure line between high-pressure pump and

high-pressure accumulator, slide support sleeve -T10411- on‐
to fuel pressure sender - G 247- .

Note
♦ The lifting eye (for engine mounting) must be movable in order

to fit union nut on high-pressure pump; loosen bolts -4- to do
this.
♦ Support sleeve -T10411- specifies the correct distance be‐
tween fuel pressure sender - G 247- and high-pressure line.
– Only tighten union nuts on high-pressure line from high-pres‐

sure pump to high-pressure accumulator by hand.
The further final assembly follows the sequence described.
Sequence
– Tighten high-pressure lines on high-pressure accumulator and

injector to specified torque ⇒ Item 16 (page 373) .
– To tighten injector lines, use torque wrench - V.A.G 1331- with
ratchet - V.A.G 1331/1- and 17 mm socket - T40055- .
– Tighten high-pressure line -2- between high-pressure pump
and high-pressure accumulator first at high-pressure pump
-4- and then at high-pressure accumulator -1-.
AG. Volkswagen AG d
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– Tighten bolt -3- for retainer for high-pressure line.

♦ Specified torques:
⇒ “1.2.1 Assembly overview - fuel system, Polo, Golf, Golf
Plus, Golf Cabriolet, Touran, Passat 2006 ►”, page 371 .
♦ Firmly screw lifting eye in ⇒ page 90 .
– Remove the support sleeve - T10411 - .
– Tighten high-pressure accumulator to specified torqueVolkswa
⇒ Item 15 (page 373) . swa
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– Tighten bolts for clamps to final tighteningd b torque. ara
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⇒ Item 20 (page 374) thor eo
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– Reconnect connector to fuel pressure
ss sender - G 247- .
ce
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pt
– Press return line connections carefully onto injectors (check
an
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seal for damage before connecting return line). You should
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hear them click into place.
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– Engage pressure retention valve in retainer provided on the
is n
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cylinder head cover.
ole,
spec
t to the co
Note
♦ After renewing the injectors “perform adaption of the correc‐
rrectne
tion values” ⇒ Vehicle diagnostic tester.
s
♦ “Reading / adapting injector correction values”.
s o
cial p
f i
♦ Never allow the high-pressure pump to run dry under any cir‐
nform
cumstances. If the low-pressure section of the fuel system was
mer
also opened (between fuel tank and high pressure pump), the
atio
m
fuel system must be filled ⇒ page 383 .

o
n
c
i
or
n thi
te
sd
a
– Start and run the engine at idling speed for several minutes
iv
o
pr
and then switch off.

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– Switch off ignition.
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– Check the complete fuel system and return line connections
ht
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for leaks.
co lksw
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Prote AG.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
– Then test drive the vehicle, accelerating to full throttle at least
once.
– Then check high-pressure part of fuel system again for leak‐
age.
Note
test. Switch off the engine and erase event memory ⇒ Vehicle
diagnostic tester. Then continue road test.

4 High-pressure pump
⇒ “4.1 Assembly overview - high-pressure pump”, page 409
⇒ “4.2 Removing and installing high-pressure pump”, page 410
4.1 Assembly overview - high-pressure pump

⇒ page 89 .
2 - Bolt
❑ Qty. 2.
❑ Renew
❑ 20 Nm +180°
3 - Hub
❑ Use counterhold -
T10051- to loosen and
tighten.
❑ To remove, use puller - AG. Volkswagen AG d
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4 - High-pressure pump tooth‐ orise nte
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5 - Bolt
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❑ Renew
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❑ Qty. 3.
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❑ 20 Nm
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6 - Nut
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spec
❑ 95 Nm
es, in part or in w
t to the co
7 - Bolt
❑ Renew rrectness of i
❑ 20 Nm +45°
l purpos
8 - High-pressure pump
nform
ercia
Caution
m
Danger of functional im‐

com
tio
pairment due to contam‐

n in
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ination/soiling
thi
s
Note
♦
iva
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⇒ “3.1 Rules for cleanli‐

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ness”, page 5
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pump if allowed to run
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while empty Prote AG.
After
♦ the high-pressure
pump has been installed,
it must be filled with fuel
before engine is started
⇒ page 383 .
4. High-pressure pump 409

❑ After high-pressure pump or fuel pressure regulating valve - N276- is replaced, learned values have to
be re-adapted, see “Guided Functions ” in vehicle diagnostic tester.
❑ Between high-pressure pump and fuel rail
AG. Volkswagen AG d
❑ Do not alter shape. lksw
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❑ Check for damage before re-installing.
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❑ When renewing high-pressure ut
ho pump, also renew high-pressure line. eo
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❑ Removing and installing s⇒ page 402 .
s
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❑ Lubricate thread of union nuts with clean engine oil
pt
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❑ 28 Nm
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10 - Fuel supply hose
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11 - Fuel return hose
hole
spec
es, in part or in w
t to the co
4.2 Removing and installing high-pressure
pump
rrectness of i
l purpos
Caution
nform
ercia
Danger of functional impairment due to contamination/soiling

m
a
♦
com
tion in
r
To prevent the high-pressure fuel pump from running when

te o
thi
empty (very tight tolerances) and to ensure that the engine
s
iva
do
starts quickly after parts have been renewed, it is essential to
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observe the following:

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ng
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♦ If the high-pressure pump is removed or renewed, the fuel C py
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system must be bled before engine is started for the first
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Initial fuel filling procedure ⇒ page 383 .


equipment required
♦ Puller - T40064-
♦ Thrust piece - T40064/1-
1331-
AG. Volkswagen AG d
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ility
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es, in part or in w
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♦ Pliers - 3314- p by
co Vo
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Caution
After renewing high-pressure pump, fuel pressure regulating

valve - N276- or fuel delivery unit, it is essential to reset learnt
values of respective components. Use Guided functions and
start »Basic settings; Resetting learnt values« on ⇒ Vehicle
diagnostic tester, for this. Otherwise there will be problems in

Removing
⇒ page 181 .
shoulder -arrow B- and pull plugs off glow pin plugs.
AG. Volkswagen AG d
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– Separate connector -1- from fuel temperature sender - G81- .

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– Unclip coolant return hose -arrows- and place coolant line to

one side.
2) There are different installation positions for the coolant return hose.

– Unscrew and remove securing bolts -arrows- and place cool‐

ing water return line to one side.
– Remove securing bolts -arrows-.

Caution

support sleeve may be damaged.
– Pull fuel supply line -arrow- off the high-pressure pump.

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spec
es, in part or in w
t to the co
– Unscrew -1, 3, 4-. Separate connector -arrow- from fuel me‐

tering valve - N290- .
rrectness of i
l purpos
nform
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at
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ion
c
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ate
do
priv
cum
for
en
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t.
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– Unscrew bolts -4- and then remove bracket.
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– Pull off fuel return line -2-. s
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es, in part or in w
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– Remove high-pressure fuel line between high-pressure pump

and high-pressure accumulator ⇒ Item 12 (page 373) .
nform
ercia
– Take toothed belt off high-pressure pump ⇒ page 181 .

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– Counterhold hub of high-pressure pump using counterhold -

T10051- and unscrew securing nut -1-.

– Apply puller - T40064- with thrust

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doeand pin -
T40064/2- as shown andVodetach
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pump. If necessary,scounter-hold
db with a 24 mm open-ended ara
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spanner thor eo
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spec
es, in part or in w
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– Unscrew securing bolts -arrows- for high-pressure pump.
rrectness of i
– Remove high-pressure pump.
Installing
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Install in reverse order. Specified torques for fuel system
nf
ercia
⇒ page 371
orm
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Specified torques for toothed belt drive, Golf, Golf Plus, Golf Cab‐
atio
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riolet, Touran, Passat ⇒ page 177

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Specified torque for toothed belt drive, Polo ⇒ page 179

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Specified torques -1, 3, 4- t. C rig
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In illustration 1 = 8 Nm
co Vo
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– Read event memory and erase stored event entry if necessa‐
ry.
– Filling/bleeding high-pressure pump/fuel system ⇒ page 383 .
– Perform the function “Resetting engine control unit program‐
med values” in “Guided functions”.

AG. Volkswagen AG d
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⇒ “5.1 Removingss and installing fuel pressure regulating valve N r ac
a
276 ”, page 416
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nl
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⇒ “5.2 Checking fuel pressure regulating valve N276 ”,
itte
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page 418
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⇒ “5.3 Removing and installing fuel pressure sender G 247 ”, page
wit
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419
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spec
⇒ “5.4 Checking fuel pressure sender G 247 ”, page 421
es, in part or in w
t to the co
⇒ “5.5 Checking fuel metering valve N 290 ”, page 421
⇒ “5.6 Removing and installing pressure differential sender G505
”, page 422
rrectness of i
5.1 Removing and installing fuel pressure
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regulating valve - N 276-
nform
ercia

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i
♦ Torque wrench
on
c
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or
♦ Open-end spanner insert, 36 mm
his
ate
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c
Fuel pressure regulating valve - N 276- -6- is located on high-
um
for
pressure accumulator.
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t.
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It ensures constant pressure in the high pressure accumulator

and in injector lines.
If pressure is too high in the fuel high-pressure circuit, fuel pres‐
sure regulating valve - N 276- opens.
As a result a small amount of fuel from the high-pressure accu‐
mulator will make its way back to fuel tank via the return line.
If pressure is too low in fuel high-pressure circuit, fuel pressure
regulating valve - N 276- closes.
This seals the high-pressure side against the low-pressure side.
Note
The fuel pressure regulating valve - N 276- cannot be re-used.
Caution
After renewing high-pressure pump, fuel pressure regulating

valve - N276- or fuel delivery unit, it is essential to reset learnt
values of respective components. Use Guided functions and
start »Basic settings; Resetting learnt values« on ⇒ Vehicle
diagnostic tester, for this. Otherwise there will be problems in
AG. Volkswagen AG d
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Removing olksw not
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WARNING s aut ra
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nl
♦ Always observe rules for cleanliness and instructions
pt
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when working on fuel system ⇒ page 5 .
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♦ Always follow these rules for cleanliness and instructions
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before starting work and while working on the fuel system.
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spec
es, in part or in w
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– Removing high-pressure accumulator ⇒ page 398 .
– Clean threaded area around fuel pressure regulating valve -
rrectness of i
N 276- (e.g. with standard cleaning solution) before removing.
l purpos
There should be no dirt in the hole on the high-pressure accumu‐

lator element (high-pressure accumulator) under any circumstan‐
nform
ercia
ces.
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at
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Note
c
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or
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ate
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riv
Clean carefully; cleaning solvent must not enter the electrical

p
cum
connector.
for
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ng
t.
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op py
– Dry fuel pressure regulating valve - N 276- .
. C rig
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rig by
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– Loosen regulating valve using 36 mm open-end spanner in‐
co Vo
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cted
sert . Then unscrew and remove by hand.
agen
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– Extract dirt from threads and sealing surfaces. Do not use tools
or other instruments for this purpose.
5. Senders and sensors 417

Note
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Seal off drilling immediately withbyaVosuitable plug to prevent dirt ot gua
l
from entering. ris
ed ran
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Installing ss
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pt
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Note
ab
ility
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♦ The fuel pressure regulating valve - N 276- has a deformable
h re
sealing lip and no separate seal; it can therefore be used only
hole
spec
once.
es, in part or in w
t to the co
♦ Check that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N 276- are not
damaged.
rrectness of i
♦ Check sealing surface of drilling.
l purpos
♦ Lubricate thread and deformable sealing lip of fuel pressure

regulating valve - N 276- with Molybdenum grease.
nform
mercia
– Screw in fuel pressure regulating valve - N 276- by hand.
at
om
ion
c
– To tighten union nut, use a suitable torque wrench with a
in t
or
36 mm open-end spanner insert.
his
ate
do
priv
c
– Install high-pressure accumulator ⇒ page 398 . um
for
en
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t.
♦ Specified torque settings: ⇒ page 371 .
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– Connect vehicle diagnostic tester . Prote
cted AG.
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– Read event memory and erase stored event entry if necessa‐

ry.
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Then test drive the vehicle, accelerating to full throttle at least
once.
– Then check high-pressure part of fuel system again for leak‐
age.
– Read event memory again.
5.2 Checking fuel pressure regulating valve

- N276-
• Engine at operating temperature.
• Air conditioner switched off
Note
♦ A fuel pressure regulating valve - N 276- leaking during start‐

ing will result in an increased return flow rate.
♦ The fuel high-pressure required for starting will not be ach‐
ieved.


wage
– Pull off fuel return line -2-. olks es n
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– Seal open fuel return line connection with a blanking plug
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-1-.
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– Connect fuel return line -2- to suitable hose -3-.
nform
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– Hold the end of this hose -1- in a suitable container -2- to
p by
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measure the return flow rate. Prote
cted AG.
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1) Check with engine running

– Start engine and run at idling speed.
• Specified amount in 30 seconds: ≥75 ml
If the specification is not attained, the fuel pressure regulating
valve - N 276- is defective.
2) Check with engine running
If condition in 1) is met, increase engine speed ≥ 2,000 rpm.
• Return flow rate specification: 0 ml
• Droplets are allowed
• If the specification is not attained, the fuel pressure regulating
3) If it is no longer possible to start engine
Carry out check with starting speed.
• Return flow rate specification: 0 ml
• Droplets are allowed
• If the specification is not attained, the fuel pressure regulating
5.3 Removing and installing fuel pressure

sender - G 247-
The fuel pressure sender - G 247- is located in the high-pressure
accumulator, measures the current fuel pressure in the high-
pressure system and transmits a voltage signal to the diesel direct
injection system control unit - J248- .

If the sender fails, the pressure is regulated by the engine control

unit using a map. In back-up function, the maximum engine speed
is limited to approx. 3,000 rpm.
Removing
Caution
Always read rules for cleanliness and instructions for working

on fuel system ⇒ page 5 .
Follow these instructions before starting work and while work‐
ing on the fuel system.

– Before removal, clean area around thread for fuel pressure
sender, using e.g. a cold cleaning solvent. No dirt must enter
the bore in the high-pressure accumulator.
Note
Clean carefully; cleaning solvent must not enter the electrical

connector.
– Dry fuel pressure sender - G 247- .

– Pull electrical connector off fuel pressure sender - G 247- .
. Volkswage n AG n AG d
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– Unscrew fuel pressure sender - G 247-
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– Use suction device to extract dirthofrom
ris high-pressure accumu‐ nte
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lator bore (threads and sealing aut
surface). Do not use tools or ra
c
ss
other instruments for this purpose.
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un
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Note
ab
ility
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Seal off high-pressure accumulator hole immediately with a suit‐

h re
able plug to prevent dirt from entering.

ole,
spec
t to the co
Installing
rrectne
Note
♦ Check that sealing surfaces (deformable sealing lip) and

ss
threads on fuel pressure sender - G 247- are undamaged.

o
cial p
f inform
♦ Also check sealing surface of fuel rail bore.

mer
atio
m
♦ The thread on the fuel pressure sender - G 247- has a special

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c
lubricating coating. The thread must be kept free of oil and

i
or
n thi
grease.
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– Screw in fuel pressure sender - G 247- by hand.

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– Tighten sender. Specified torque ⇒ Item 13 (page 373) . C py
t. rig
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– After installation, run engine at moderate speed for several
p by
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by lksw
minutes and then switch off. Prote
cted AG.
agen

– Read event memory.
– Then test drive the vehicle with at least one full acceleration.
Check high pressure part of fuel system again for leaks.

– Read event memory.
5.4 Checking fuel pressure sender - G 247-

Note
♦ Fuel pressure sender - G 247- -1- is located in fuel rail. It

measures the current fuel pressure in the high-pressure sys‐
tem and transmits a voltage signal to the engine control unit -
J623- .
♦ If it is not possible to start engine, but with connector removed
engine start is OK, fuel pressure sender - G 247- is faulty.
♦ With connector removed, a substitute value is taken from con‐
trol unit for starting. If engine start is not possible with con‐
nector removed, the problem is not on fuel pressure sender -
G 247- .
♦ In the event of sender failure, pressure regulation is controlled
using a map from the engine control unit.
♦ In back-up function, the maximum engine speed is limited to
approx. 3,000 rpm.
– Disconnect electrical connector -1- on fuel pressure sender -

G 247- .
– Perform check as described.
♦ Perform electrical checks on fuel pressure sender - G 247-
using the »Guided fault finding«.
lkswage es n
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ab
5.5 Checking fuel metering valve - N 290-

ility
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– With engine running, remove connector from fuel metering

h re
hole
valve - N 290- -11-.

spec
es, in part or in w
t to the co
Note
rrectness of i
Valve is closed without power.

l purpos
♦ If engine stalls: fuel metering valve - N290- OK.

nf
ercia
♦ If engine continues running: renew high-pressure pump

or
⇒ page 410 .
m
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n in
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cted agen
421
Prote AG.
5. Senders and sensors
5.6 Removing and installing pressure differ‐

ential sender - G505-
⇒ “5.6.1 Differentiating criteria”, page 422
⇒ “5.6.2 Removing and installing pressure differential sender G
505 , Golf, Golf Plus, Golf Cabriolet, Touran, Passat”, page 424
505 , Polo”, page 425
505 , Polo, right-hand drive”, page 426
5.6.1 Differentiating criteria
Note
♦ Pressure differential sender - G 505- determines charge status

of particulate filter.
♦ Different measurement methods are used.
♦ The component retains the same designation.
Method 1 (differential-pressure measurement)

The pressure differential sender - G 505- is connected via two
pipes to the measuring points upstream and downstream of the
particulate filter.
Assembly overview - Lambda probe ⇒ Item 15 (page 473) .
AG. Volkswagen AG d
agen oes
olksw not
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
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rig ht
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Prote AG.

1 - Pressure differential sender

- G 505- with 2 pipe systems
2 - Exhaust gas feed agen
AG. Volkswagen AG d
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erm
ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Method 2 (relative-pressure measurement)

Pressure differential sender - G 505- is connected via one pipe to
the particulate filter.
Assembly overview - Lambda probe

1 - Pressure differential sender

- G 505- with 1 pipe systems
2 - Fresh air feed
AG. Volkswagen AG d
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es, in part or in w
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rrectness of i
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com
tion in
r
te o
thi
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iva
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5.6.2 Removing and installing pressure differ‐ Cop py
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ential sender - G 505- , Golf, Golf Plus, pyri by
Vo
co lksw
by
Golf Cabriolet, Touran, Passat
cted agen
Prote AG.
Removing
– Before pulling off, spray two hoses of pressure differential
sender - G 505- with solvent.

– Pull electrical connector -2- off the pressure differential sender

- G 505- .
– Unscrew bolt -4- ⇒ Item 3 (page 473) .
– Carefully pull hoses off connections in a straight line (the con‐
nections on the pressure differential sender - G 505- can easily
break off).
– Unscrew bolt -3- ⇒ Item 1 (page 473) and remove pressure
differential sender - G 505- .
Installing
– When installing, note the following:
• Specified torque for pressure differential sender - G 505- bolt,
see assembly overview - Lambda probe
Note
♦ Before installing, blow out hoses of pressure differential send‐

er - G 505- to particulate filter with compressed air (hoses can
become obstructed or may ice up due to condensation).
G. Volkswagen AG d
♦ Make sure that hoses are securely fitted and seal properly.
lksw
agen
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♦ If the pressure hoses on the particulate filter have edbeen de‐ ara
nte
ris
tached, tighten them to 45 Nm. ut
ho eo
ra
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ss
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Adaptation must be performed after renewing pressure differen‐
e
nl
pt
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tial sender - G 505- and/or particulate filter. (The procedure is also
an
itte
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described under Guided Functions).
erm
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ility
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Select the correct vehicle in Guided Fault Finding.
wit
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hole
5.6.3 Removing and installing pressure differ‐
spec
es, in part or in w
ential sender - G 505- , Polo
t to the co
rrectness of i
Note
l purpos
♦ Pressure differential sender - G 505- determines charge status

of particulate filter. nf
ercia
o
♦ Different measurement methods are used.
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atio
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♦ The component retains the same designation.

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Method 1 (differential-pressure measurement)

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particulate filter. C py
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Assembly overview ⇒ Item 3 (page 477)
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cted agen
Method 2 (relative-pressure measurement)
Prote AG.
Pressure differential sender - G 505- is connected via one pipe to

the particulate filter.
Removing

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– Pull connector -2- from pressure differential ssender
au
t
- G 505- . or
ac
s
– Pull hoses carefully and straight from unions (unions break off
ce
le
un
pt
pressure differential sender - G 505- very easily).
an
d
itte
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erm
ab
– Unscrew bolt -3-, remove pressure differential sender - G
ility
ot p
505- .
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is n
h re
Installing
ole,
spec
t to the co
rrectnes
Note
s o
cial p
f inform
♦ Before installing, blow out hoses of pressure differential send‐
mer
er - G 505- to particulate filter with compressed air (hoses can
atio
m
become obstructed or may ice up due to condensation).

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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t.
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op
C py
ht. rig
rig ht
py by
Select correct vehicle in guided fault finding.
co Vo
by lksw
cted agen
Prote AG.
5.6.4 Removing and installing pressure differ‐

ential sender - G 505- , Polo, right-hand
drive
particulate filter.
Assembly overview - Lambda probe ⇒ Item 8 (page 479) .
Pressure differential sender - G 505- determines charge status of
particulate filter.
Removing

– Pull electrical connector -2- from pressure differential sender

- G 505- .
– Pull hoses carefully and straight from unions (unions break off
pressure differential sender - G 505- very easily).
– Unscrew nut -1-, remove pressure differential sender - G 505- .
Installing

agen oes
olksw not
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♦ Before installing,
orise
blow out hoses of pressure differentialntesend‐
e
er - G 505-
aut to particulate filter with compressed air (hosesorcan
h
a
becomes obstructed or may ice up due to condensation). c
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Select correct vehicle in guided fault finding.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
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Cop py
t. rig
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cted agen
Prote AG.

6 Lambda probe
⇒ “6.1 Assembly overview - Lambda probe”, page 428
⇒ “6.2 Removing and installing Lambda probe”, page 432
6.1 Assembly overview - Lambda probe

⇒ “6.1.1 Assembly overview - lambda probe, Golf, Golf Plus,
Touran, Passat 2006►”, page 428
⇒ “6.1.2 Assembly overview - lambda probe, Golf Cabriolet, Pas‐
sat 2011►”, page 430
⇒ “6.1.3 Assembly overview - lambda probe, Polo”, page 431
6.1.1 Assembly overview - lambda probe, Golf, Golf Plus, Touran, Passat 2006►
1 - Bolt for exhaust gas pres‐

sure sensor 1 - G450-
❑ 8 Nm
⇒ page 422 .
❑ Pressure lines to partic‐
ulate filter 45 Nm
2 - Measuring lead for pressure
differential sender - G505-
3 - Particulate filter
AG. Volkswagen AG d
❑ Adaptation must be car‐ lksw
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not
ried out after renewing
d by Vo gu
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particulate filter.
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4 - Exhaust gassstemperature
a c
sender 3 - G495-
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⇒ page 509 .
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ility
❑ 45 Nm
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5 - Lambda probe 1 before cat‐

h re
hole
alytic converter - GX10-

spec
es, in part or in w
❑ with lambda probe -

t to the co
G39- and lambda probe

heater - Z19-
❑ New Lambda probes
rrectness of i
are coated with an as‐

l purpos
sembly paste
❑ In the case of a used
lambda probe grease
nform
ercia
only the thread with

m
high-temperature paste
a
com
tio
n in
r
Catalogue (ETKA) .
te o
thi
s
iva
❑ Assembly paste or high-

do
r
rp
temperature paste must

um
fo
en
g
not get into the slots in

n
t.
yi Co
the Lambda probe. t. Cop py
rig
gh
ht
pyri by
Vo
co lksw
❑ 50 Nm
by
cted agen
Prote AG.
6 - Exhaust gas temperature sender 4 - G648-
❑ 45 Nm

7 - Nut
Exhaust gas temperature sender 1 - G235- -1-

Removing and installing exhaust gas temperature sender 1 -
G235- ⇒ page 432 .
G. Volkswagen AG d
Connectors on plenum chamber bulkhead
lksw
agen
A
oes
not
Vo gu
by
1 - Electrical connector for charge
rised pressure control solenoid valve ara
nte
- N75- ut
ho eo
ra
s a c
2 - Electrical connector for
s exhaust temperature sender 4 - G648-
ce
le
un
pt
3 - Electrical connector for exhaust temperature sender 1 - G235-
an
d
itte
y li
erm
ab
4 - Electrical connector for Lambda probe - G39-
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Lambda probe 429

6.1.2 Assembly overview - lambda probe, Golf Cabriolet, Passat 2011►
1 - Bolt for exhaust gas pres‐

sure sensor 1 - G450-
❑ 8 Nm
⇒ page 422 .
❑ Pressure lines to partic‐
ulate filter 45 Nm
2 - Measuring lead for pressure
differential sender - G505-
❑ Adaptation must be car‐
ried out after renewing
particulate filter.
sender 3 - G495-
⇒ page 432 .
❑ 45 Nm
5 - Lambda probe 1 before cat‐
alytic converter - GX10-
❑ with lambda probe -
heater - Z19-
❑ New Lambda probes
are coated with an as‐
sembly paste
Lambda probe grease
only the thread with AG. Volkswagen AG d
high-temperature paste agen oes
olksw not
V
⇒ Parts catalogue d by gu
ara
rise nte
❑ Assembly paste or high- utho eo
ra
temperature paste must ss a c
ce
le
un
pt
the Lambda probe.

an
d
itte
y li

erm
ab
ility
❑ 50 Nm
ot p
wit
is n

h re
ole,
spec

❑ 45 Nm
t to the co
rrectne
Exhaust gas temperature sender 1 - G235- -1-

Removing and installing exhaust gas temperature sender 1 -
ss
G235- ⇒ page 432 .

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
430
AG.
Rep. gr.23 - Mixture preparation - injection
Connectors on plenum chamber bulkhead

1 - Electrical connector for charge pressure control solenoid valve
- N75-
4 - Electrical connector for Lambda probe - G39-
n AG. Volkswagen A
6.1.3 Assembly
Vol
ksw overview - lambda
age G do
es n probe, Polo
ot g
by ua
ed ran
oris tee
h
1 - Exhaustutgas temperature or
ac
sa
sender 4 - G648-
s
ce
le
un
pt

an
d
itte
⇒ page 432 .
y li
erm
ab
ility

ot p
wit
sender 1 - G235-
is n
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ole,

spec
⇒ page 432 .
t to the co

sender 3 - G495-
rrectne
⇒ page 432 .
s
4 - Differential pressure sender

s o
- G505-
cial p
f inform

mer
⇒ page 422 .
atio
m
❑ 45 Nm
o
n
c
i
or
n thi
e
5 - Lambda probe - G39- with

t
sd
va
lambda probe heater - Z19-

i
o
pr
cum
r
fo

en
ng
t.
yi
⇒ page 432 .
Co
Cop py
t. rig
❑ New Lambda probes yri
gh by
ht
are coated with an as‐ cop Vo
by lksw
sembly paste
cted agen
Prote AG.
lambda probe, grease
only the thread with
Catalogue (ETKA) .
❑ Assembly paste or high-
temperature paste must
the Lambda probe
❑ 55 Nm
6. Lambda probe 431

6.2 Removing and installing Lambda probe

⇒ “6.2.1 Removing and installing lambda probe 1 before catalytic
converter GX10 , Golf, Golf Plus, Golf Cabriolet, Passat, Touran”,
page 432 en AG. V
olkswagen AG
ag does
ol probe 1 before catalytic ksw not
⇒ “6.2.2 Removing and installing lambda
yV gu
db ara
converter GX10 , Polo”, page 433
ris
e nte
tho eo
au ra
6.2.1 Removing and installing lambda probe 1 ss c
ce
le
before catalytic converter - GX10- , Golf,

un
pt
an
d
itte
Golf Plus, Golf Cabriolet, Passat, Tour‐
y li
rm
ab
an
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
Removing
en
ng
t.
yi Co
op
– Remove engine cover ⇒ page 76 . C py
t. rig
gh ht
yri by
– Detach electrical connector -4- of Lambda probe - G39- . op Vo
by c lksw
cted agen
Prote AG.

– Unscrew Lambda probe - G39- -3- using tool from Lambda

probe open ring spanner set - 3337- .
Installing
When installing, note the following:
Note
♦ New Lambda probes are coated with an assembly paste; the

paste must not get into the slots in the Lambda probe.
♦ 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. For high-temperature paste
refer to ⇒ Parts catalogue .
♦ When installing, the Lambda probe's electrical wiring connec‐
tion must always be re-attached in the same locations to
prevent the Lambda probe cables from coming into contact
with the exhaust pipe.
♦ For specified torque see:

⇒ “6.1.1 Assembly overview - lambda probe, Golf, Golf Plus,
Touran, Passat 2006►”, page 428
6.2.2 Removing and installing lambda probe 1

before catalytic converter - GX10- , Polo
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
lksw not
♦ Lambda probe open ring spanner set - 3337- byV
o gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Pull off engine cover ⇒ page 76 .

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Lambda probe 433

– Detach electrical connector -4- of Lambda probe - G39- .

– Unscrew Lambda probe - G39- -2- using tool from Lambda
probe open ring spanner set - 3337- .
Installing
Note
♦ New Lambda probes are coated with an assembly paste; the

paste must not get into the slots in the Lambda probe.
♦ 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. For high-temperature paste
refer to ⇒ Parts catalogue .
♦ When installing, the Lambda probe's electrical wiring connec‐
tion must always be re-attached in the same locations to
prevent the Lambda probe cable from coming into contact with
. Volkswagen AG
the exhaust pipe. swa
gen AG does
k not
Vol gu
d by ara
e
• Specified torque ⇒ page 431hor.is nte
eo
ut ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7 Air filter
⇒ “7.1 Assembly overview - air filter housing”, page 435
⇒ “7.2 Removing and installing air filter housing”, page 437
7.1 Assembly overview - air filter housing

⇒ “7.1.1 Assembly overview - air filter housing, Golf, Golf Plus,
⇒ “7.1.2 Assembly overview - air filter housing, Polo”, page 436
7.1.1 Assembly overview - air filter housing, Golf, Golf Plus, Golf Cabriolet, Tour‐
an, Passat
1 - Intake hose
❑ To turbocharger.
⇒ page 438 .
2 - Air mass meter - G70-
3 - O-ring
4 - Vacuum hose
❑ To charge pressure
control solenoid valve -
N75- agen
AG. Volkswagen AG d
oes
lksw not
❑ Vacuum hose schemat‐ by Vo gu
ara
ic diagram ⇒ page 385 . rise
d
nte
tho eo
u
5 - 2 Nm ss a ra
c ce
e
6 - Air filter upper part

nl
pt
du
an
itte
y li

erm
ab
ility
❑ Bolted to lock carrier.

ot p
wit
, is n
8 - 2 Nm
h re
hole
spec
9 - Connecting hose
es, in part or in w
t to the co
10 - Water drainage pipe

11 - Air filter lower part
rrectness of i
12 - 8 Nm
l purpos
13 - Filter element
14 - 2 Nm
nf
ercia
orm
15 - Connecting pipe
m
atio
m
❑ From cylinder head cov‐

o
n in
or c
er
thi
te
sd
a
❑ For crankcase ventila‐

iv
o
r
rp
cu
tion
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Air filter 435

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 ris ➤ , Passat 2006 ➤ ...
ed
nte
o eo
4-cylinder common rail engine (1.6 l, EA189) - Edition
aut
h
02.2016 ra
ss c
ce
e
7.1.2 Assembly overview - air filter housing, Polo
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
❑ With captive bolt, 9 Nm
h re
hole
spec
2 - Clip
es, in part or in w
t to the co
3 - Heater for crankcase
breather
❑ For vehicles in cold cli‐
rrectness of i
mate zones
l purpos
4 - Vacuum hose
❑ From charge pressure
nform
control solenoid valve - ercia
N75-
m
at
om
⇒ “2.1.1 Assembly over‐
ion
c
view - vacuum system,
in t
or
his
e
Golf, Golf Plus, Golf

at
do
riv
Cabriolet, Touran, Pas‐

p
cum
sat”, page 385
for
en
ng
t.
yi Co
5 - Spring-type clip . Cop py
rig
ht ht
rig
6 - Intake hose py by
co Vo
by lksw
❑ To turbocharger. cted agen
Prote AG.
7 - Hose
❑ For crankcase ventila‐
tion.
❑ Press release buttons to
remove.
8 - 2 Nm
9 - Air mass meter - G70-
10 - O-ring
11 - 8 Nm
12 - Air filter upper part
13 - Hose
❑ For preheating
❑ For vehicles in cold climate zones
14 - Filter element
❑ To remove, turn 1/4 turns anti-clockwise
15 - 8 Nm
16 - Rubber bush
17 - Air filter lower part
❑ Bolted to lock carrier.
19 - 2 Nm
20 - Air intake hose
❑ Intake connecting pipe
21 - Water drainage pipe
❑ Note installation position.

22 - Rubber bush
7.2 Removing and installing air filter hous‐

ing
⇒ “7.2.1 Removing and installing air filter housing, Golf, Golf Plus,
⇒ “7.2.2 Removing and installing air filter housing, Polo”,
page 438
7.2.1 Removing and installing air filter hous‐

ing, Golf, Golf Plus, Golf nCabriolet, Tour‐
AG. Volkswagen AG d
an, Passat yV
olkswage oes
not
gu b ara
ed
Removing horis nte
e
t or
au ac
– Open intake system cover
ss by carefully releasing fasteners
-arrows-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– Remove securing bolts -arrows- for intake system -1- and take
s o
cial p
connecting hose -2- out of guide. f inform

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Press locking lugs -1- and -3- in and pull connecting hose -4-
off air filter housing -2-.
– Disconnect connector from air mass meter - G70- -1- and pull
off vacuum line -2-.
7. Air filter 437

– Loosen threaded connection on air filter housing -3-.
– Open clamp -4- and pull off hose to turbocharger.

– Remove entire air filter housing.
Remove intake hose
Note
As it is difficult to gain access to clip on intake hose beneath, it is

better to remove intake connecting pipe from turbocharger.
– Remove crankcase breather hose -3-.

– Pull vacuum hose -2- off intake hose -1- and move to side.
Unclip bracket.
– Completely undo bolt -4- (make sure bolt is captive).
– Swivel intake connecting pipe to the right and remove together
with intake hose -1-. Volkswa AG. gen AG
agen does
Install intake hose y Volksw not
gu
edb ara
Installation is carried out in the reverse horisorder. When installing, nte
eo
note the following: s aut ra
c
s
ce
e
nl
pt
du
an
– When mounting intake connecting pipe on turbocharger, it

itte
y li
erm
must be ensured that intake connecting pipe is correctly seat‐

ab
ility
ed on the bolt of the turbocharger. -arrow-.

ot p
wit
, is n
Installing
h re
hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
7.2.2 Removing and installing air filter hous‐

rm
m
atio
m
ing, Polo
o
n in
or c
thi
e
Removing
t
sd
iva
o
r
rp
cu

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

– Release catches -arrows-, remove air duct -1-.
– Unclip bracket -arrows- together with vacuum hoses from air

filter housing.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Disconnect electrical connector -3-. s
ce
le
un
pt
– Remove intake hose, loosening hose clip -2- to do so.
an
d
itte
y li
rm
ab
– Remove air hose; loosening hose clip -1- to do so if there is
pe
ility
one.
ot
wit
, is n
h re
– Unscrew bolt -4- and remove air filter housing.
hole
spec
Remove intake hose
es, in part or in w
Note t to the co
rrectness of i

l purpos

nform
ercia

m
a
com
tio
n in
r
Unclip bracket.
te o
thi
s
iva
do

r
rp
cum
fo
en
g
– Swivel intake connecting pipe to the right and remove together

n
t.
yi Co
with intake hose -1-. Cop py
t. rig
gh ht
yri
Install intake hose p by
co Vo
by lksw
cted agen
Installation is carried out in the reverse order. When installing, Prote AG.
note the following:
7. Air filter 439

– When mounting intake connecting pipe on turbocharger, it

must be ensured that intake connecting pipe is correctly seat‐
ed on the bolt of the turbocharger. -arrow-.
Installing
In the process, note the following:
Note
♦ A clean air filter housing is essential.

♦ In order to avoid functional problems, you should cover the
critical air-conducting components such as air mass meter, air
pipes etc. with a clean cloth when blowing out the air filter
housing with compressed air.
♦ Use a silicone-free lubricant when installing air hoses.
(same as original equipment) ⇒ Electronic Parts Catalogue n AG. Volkswagen AG do
(ETKA) . o lkswage es n
ot
yV gu
db ara
ir se nte
– Check air intake hose for salt residue, dirt and leaves
ut
ho and, if eo
necessary, clean. ss
a ra
c
ce
le
– Check air duct leading from lock carrier to air filter housing for
un
pt
an
d
dirt and leaves. Clean if necessary.

itte
y li
erm
ab
Further installation is carried out in the reverse order.
ility
ot p
wit
is n
h re
– Guide water drainage pipe -arrow- between gearbox and
ole,
body.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
– Check under the wing to see whether the water drainage pipe
sd
iva
o
r
has been installed correctly.

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

8 Intake manifold
⇒ “8.1 Assembly overview - intake manifold”, page 441
⇒ “8.2 Removing and installing intake manifold”, page 443
⇒ “8.3 Removing and installing throttle valve module J338 ”, page
447
8.1 Assembly overview - intake manifold

⇒ “8.1.1 Assembly overview - intake manifold, vehicles with intake
manifold flap V157 ”, page 441
⇒ “8.1.2 Assembly overview - intake manifold with attachments,
vehicles without intake manifold flap ”, page 442
8.1.1 Assembly overview - intake manifold, vehicles with intake manifold flap -
V157-
AG. Volkswagen AG d
1 - Intake manifold lkswagen oes
not
o
❑ With intake yV gu
ed b manifold ara
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flap motor
tho
ris - V157- eo
au ra
Gradual introduction:
ss Intake c
ce
le
manifold flap motor - V157-

un
pt
discontinued
an
d
itte
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erm
ab
❑ Must not be dismantled.

ility
ot p
wit
2 - 9 Nm
is n
h re
ole,
3 - Gasket
spec
❑ Renew
t to the co
4 - Connecting pipe
❑ To cylinder head/ex‐
rrectne

cooler.
ss
5 - Clamp 5 Nm
o
cial p
f in
❑ Renew
form
mer
atio
6 - Gasket
om
n
c
❑ Renew
i
or
n thi
te
sd
a
7 - 9 Nm
iv
o
pr
cum
r
fo
8 - Throttle valve module -

en
ng
t.
J338-
yi Co
Cop py
t. rig
9 - 10 Nm
gh ht
pyri by
Vo
o
by c lksw
10 - 10 Nm Prote
cted AG.
agen
11 - 10 Nm
12 - Clip
❑ For oil dipstick tube
13 - Oil dipstick tube
14 - Gasket
❑ Renew
❑ Individual seals can also be installed.
8. Intake manifold 441

8.1.2 Assembly overview - intake manifold with attachments, vehicles without in‐
take manifold flap olks
wage es n
ot
yV gu
db ara
rise nte
1 - Guide tube tho eo
au ra
c
ss
❑ For oil dipstick.
ce
le
un
pt
an
2 - Seal itte
d
y li
rm
ab
❑ Renew
pe
ility
ot
3 - Gasket
wit
, is n
h re
❑ Renew
hole
spec
es, in part or in w
4 - 8 Nm
t to the co
6 - 9 Nm
rrectness of i
❑
l purpos
7 - Intake manifold
nform
ercia
⇒ page 443 .
m
a
com
t
8 - Bracket
ion in
r
❑ For exhaust gas recircu‐

te o
thi
lation cooler change‐
s
iva
do
r
over valve - N345- .

rp
cum
fo
en
g
9 - 9 Nm
n
t.
yi Co
Cop py
t.
rig
gh ht
yri by
cooler changeover valve - op Vo
by c lksw
N345- cted agen
Prote AG.
11 - Gasket
❑ Renew
12 - 9 Nm
13 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler.
14 - Clamp, 5 Nm
❑ Renew
15 - Connection
❑ For exhaust gas recirculation.
16 - 8 Nm
17 - Seal
❑ Renew
18 - Throttle valve module - J338-
❑ With throttle valve potentiometer - G69- .
19 - 8 Nm
20 - 9 Nm
21 - Clip

8.2 Removing and installing intake manifold

Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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un
pt
an
d
itte
y li
rm
ab
♦ Pliers - 3314-
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio

n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
noise insulation
Removing high-pressure accumulator ⇒ page 398 .

Caution

support sleeve may be damaged. olkswage es n
o
yV t gu
db ara
ir se nte
tho eo
– Unclip vacuum lines -arrow- and lay to sside.
au ra
c
s
Polo
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Unclip coolant return hose -arrows- and place coolant line to
ss
one side.
o
cial p
f inform
The arrangement of the coolant return hose can vary.
mer
atio
Golf, Golf Plus, Golf Cabriolet, Passat
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew the securing bolt -arrows- and place the coolant re‐
turn line to the side.
Touran
– Remove securing bolts -arrows-.

– Disconnect connector -3- from intake manifold flap motor -

V157- (if there is one).
wage es n
– Pull connector -2- off throttle
yV
olkvalve
s module - J338- . ot g
b ua
ed ran
– Remove bolt -3- from
ho dipstick
ris connection. tee
t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove exhaust gas recirculation connecting pipe.

– To do this, open clip -1-.
– Unscrew securing bolts from intake manifold from the outside
to the inside in diagonal sequence with hexagon key extension
- T10405- .
– Carefully remove intake manifold.
Installing
• Always renew seals.
– Tighten intake manifold bolts from inside outwards, alternately
and diagonally.
– Install air pipe.
– Install high-pressure accumulator ⇒ page 398 .
Note
♦ An intake manifold without an intake manifold flap - V157- ⇒

Electronic Parts Catalogue (ETKA) can also be used as a re‐
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8.3 Removing and installing throttle valve

module - J338-
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9 Engine control unit

⇒ “9.1 Removing and installing engine control unit”, page 449
9.1 Removing and installing engine control

unit
⇒ “9.1.1 Removing and installing engine control unit J623 , Golf”,
page 449
⇒ “9.1.2 Removing and installing engine control unit J623 with
protective housing, Golf, Golf Cabriolet”, page 450
⇒ “9.1.3 Removing and installing engine control unit J623 , Golf
Plus, Touran”, page 453
protective housing, Golf Plus, Touran”, page 454
⇒ “9.1.5 Removing and installing engine control unit J623 , Polo”,
page 456
protective housing, Polo”, page 457
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9. Engine control unit 449

– Push connector locking devices in -direction of arrow- and pull

off connector.
Installing
– Fit connectors to engine control unit and slide locking devices

to stop in direction of -arrow-.
– Insert engine control unit into retaining frame and press re‐
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pulled off connector.


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unit -arrows-.
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off -arrows-.

– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

unit - J623- , Golf Plus, Touran
trol unit”.
Removing
– Remove wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing wiper arms .
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Plenum chamber bulkhead; Assembly overview
- plenum chamber bulkhead .
– Loosen securing bolts -arrows- of control unit cover.
– Then remove securing nuts for control unit bracket -arrows-.
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9. Engine control unit
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
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– Push engine control unit onto control unit bracket until it en‐
gages in catches.
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– Tighten securing bolts -arrows- to 10 Nm.
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trol unit”.
Removing
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Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

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output (600 °C).
– Set two-stage switch for volume of air -3- to position 3.
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– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.
– Tighten securing bolts -arrows- to 10 Nm.

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shear-head bolts using pliers.

– Pull retainer -1- and protective housing -2- off engine control
unit -3- in -direction of arrow-.
nector.
Installing
– Fit connectors and lock in position.
– Push the protective housing over the engine control unit.
– Install retainer for protective housing using new shear-head
bolts.
– Tighten shear-head bolts evenly until head shears off.
– Insert engine control unit into mounting bracket on plenum

chamber bulkhead until it audibly engages in catches -1-.
– Insert wiring into wiring guide -1- and close guide.
– If engine control unit has been renewed, clear learnt values
and adapt engine control unit Vehicle diagnostic tester “Gui‐
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– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Plenum chamber bulkhead; Assembly

Passat 2006►
trol unit”.
♦ Grip pliers
Removing

– Remove bolts -1-.

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26 – Exhaust system
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⇒ “1.2 Aligning exhaust system free of stress”, page 469
an
d
itte
y li
rm
ab
⇒ “1.3 Installation position of clamp”, page 471
pe
ility
ot
wit
1.1 Assembly overview - silencers
, is n
h re
hole
spec
⇒ “1.1.1 Assembly overview - silencer, Golf, Touran, Passat 2011
es, in part or in w
►”, page 464
t to the co
⇒ “1.1.2 Assembly overview - silencer, Passat 2006►”,
page 466
rrectness of i
⇒ “1.1.3 Assembly overview - silencer, Polo”, page 467
l purpos
⇒ “1.1.4 Separating exhaust system”, page 467
nform
1.1.1 Assembly overview - silencer, Golf,
ercia
Touran, Passat 2011 ►

m
a
com
tion in
r
te o
thi
s
iva
Note do
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cum
fo
en
g
♦ After working on the exhaust system, ensure that the system

n
t.
yi Co
is not under tension and that there is sufficient clearance to Cop py
. rig
t
gh ht
yri by
cop Vo
by lksw
tained to the bodywork and the support rings are evenly loa‐ cted agen
Prote AG.
ded.
464 Rep. gr.26 - Exhaust system

Golf 2009 ➤ , Golf Cabriolet 2012 ➤ ,eGolf Plus
.Volksw2009
agen A➤
G do, Passat 2006 ➤ ...
g n AG
4-cylinder common ol swa engine (1.6 l, EA189)
krail - Edition
es n
ot g 02.2016
V y ua
db ran
rise tee
1 - 25 Nm tho or
au ac
❑ Renew ss
ce
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nl
pt
2 - Retaining rings
du
an
itte
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erm
ab
ility
ot p
3 - Silencer
wit
, is n
h re
❑ Golf Cabrio: to remove,
hole
remove diagonal strut
spec
-A-
es, in part or in w
t to the co
4 - 25 Nm
5 - Tunnel cross-piece
rrectness of i
Specified torque for tunnel
l purpos
cross members:
Golf, Golf Plus, Golf Cab‐
nf
ercia
o
rio, Passat 2006, Passat
rm
m
Variant 2006, Polo, Tour‐
atio
m
an ⇒ General body re‐

o
n in
or c
pairs, exterior; Rep. gr.
thi
te
50 ; Tunnel cross mem‐
sd
iva
o
r
bers; Assembly overview

rp
cu
o
m
- tunnel cross members
f
en
ng
t.
yi Co
op py
Passat 2011, Passat t. C rig
gh ht
Variant 2011 ⇒ General yri
p by
o Vo
body repairs, exterior;
c by lksw
cted agen
Rep. gr. 66 ; Tunnel
Prote AG.
cross members; Assem‐

bly overview - tunnel
cross members
6 - Mounting
7 - Double clamp
❑ Not shown
❑ Aligning exhaust sys‐
tem free of tension ⇒ page 469 .
Diagonal struts only on Golf Cabrio

Specified torque of diagonal struts -A- ⇒ Rep. gr. 42 ; Running
gear ⇒ page 465
1. Exhaust pipes, silencers 465

AG. Volkswagen AG d
1.1.2 Assembly overview - silencer, Passat Volksw
agen oes
not
2006► by gu
d ara
ise nte
or eo
h
aut ra
ss c
Note
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nl
pt
du
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itte
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erm
ab
is not under tension and that there is sufficient clearance to
ility
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hole
spec
ded.
es, in part or in w
t to the co
rrectness of i
1 - From front exhaust pipe
l purpos
2 - Clamp
nform
ercia
❑ Before tightening, align

cold exhaust system
m
at
free of tension
om
io
⇒ page 469
n
c
in t
or
his
e
❑ Tighten bolted connec‐

at
do
riv
tions evenly.
p
cum
or
❑ Specified torques: M8 =
f
en
ng
t.
yi
25 Nm, M10 = 40 Nm.
Co
Cop py
t. rig
3 - Front silencer
gh ht
pyri by
Vo
o
by c lksw
4 - Mounting cted agen
Prote AG.
5 - 25 Nm
❑ Renew
6 - Separating point
❑ Marked by impressions
on exhaust pipe.
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, with a
clamp for connecting.
❑ Cut through exhaust
pipe at right angles at
separating point
-arrow A- using e.g.
body saw - V.A.G 1523-
(wear eye protection)
❑ When installing, posi‐
tion repair double clamp
at side markings -arrows B-.
❑ Evenly tighten threaded connections of clamping sleeve (repair double clamp)
❑ Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm
❑ Before tightening, align cold exhaust system free of tension ⇒ page 469
7 - Retaining ring
8 - Rear silencer

1.1.3 Assembly overview - silencer, Polo
1 - Exhaust pipe with silencer

❑ Separating point
❑ Marked by indentation
on exhaust pipe.
❑ As standard, exhaustlkswage es n
o ot g
pipe and esilencer
d byV are in‐ ua
ran
stalledhoras a single com‐
is tee
ponent.
aut For repairs, ex‐ or
ac
haust pipe and silencer
ss
ce
e
are supplied with a

nl
pt
du
an
clamp separately.
itte
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erm
ab
❑ Cut through separating
ility
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point on connecting pipe
wit
at right angles using e.g.
, is n
h re
pneumatic sabre saw -
hole
spec
V.A.G 1523A- (wear eye
es, in part or in w
protection).
t to the co
❑ Position double repair
clamp at side marks
when installing.
rrectness of i
❑ Tighten bolts of repair
l purpos
double clamp evenly,

specified torque: M8 =
25 Nm, M10 = 40 Nm. nform
ercia
❑ Before tightening, align

m
at
cold exhaust system

om
ion
free of tension
c
in t
or
⇒ page 469
his
ate
do
riv
2 - Retaining ring
p
cum
for
en
g
❑ 23 Nm
n
t.
yi Co
op
C py
t. rig
gh ht
yri by
3 - 20 Nm cop Vo
by lksw
cted agen
Prote AG.
4 - Tunnel cross-piece
1.1.4 Separating exhaust system

♦ Body saw e.g. -V.A.G 1523 A-
♦ or

♦ Chain-type pipe cutter - VAS 6254-
♦ Eye protection
Procedure
In order to separate exhaust pipe and silencer, there is a sepa‐
ration point in the exhaust pipe marked with indentations.
wage es n
WARNING
yV
olks ot g
ua
b
ed ran
ris tee
Wear eye protection.
tho
or
au ac
ss
ce
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nl
pt
du
– Cut through exhaust pipe at right angles using body saw at

an
itte
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separating point -arrow 1-.

erm
ab
ility
ot p
– Position double clamp -4- on side markings -arrow 2- and

wit
, is n
-arrow 3- when installing.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Install double clamp so that the bolt ends do not protrude be‐
orm
yond bottom of double clamp.

m
atio
om
n in
• Bolted connection faces right.

or c
thi
te
– Tighten bolt connections of double clamp evenly to 23 Nm.

sd
iva
o
r
rp
cu
Before tightening, align cold exhaust system free of tension

o
m
f
en
ng
⇒ page 469 .
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.2 Aligning exhaust system free of stress

⇒ “1.2.1 Aligning exhaust system free of tension, Golf, Golf Cab‐
riolet, Golf Plus, Touran, Passat”, page 469
⇒ “1.2.2 Aligning exhaust system free of tension, Polo”,
page 469
1.2.1 Aligning exhaust system free of tension,

Golf, Golf Cabriolet, Golf Plus, Touran,
Passat
• Engine must be cold.
– Loosen bolts -3 and 4- on front clamp -1-.
– Align front clamp -1- to marking -A- on front exhaust pipe -2-
(-arrow- points forwards).
• Dimension -a- = ⇒ page 471
• The bolts must be on the right and the ends of the bolts must
not protrude beyond the lower edge of the clamp.
– Push rear silencer forwards into clamp until dimension -a- =

15…17 mm is attained between mountings for body and rear
silencer. -Arrow- points in direction of travel.
– Align rear silencer horizontally.
– Tighten clamp bolts in this position. Mounting position and
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
1.2.2 Aligning exhaust system free of tension,
ce
le
un
pt
an
d
Polo
itte
y li
rm
ab
pe
ility

ot
wit
, is n

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
Prerequisite
do
r
rp
cum
fo
• The exhaust system is cold.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
469
by lksw
cted agen
Prote 1. Exhaust pipes, silencers
AG.
Procedure
– Loosen threaded connections of the front clamp.
– Align clamp on front exhaust pipe under consideration of di‐
mension -a-. Dimension -a- = 5 mm.
AG. Volkswagen AG d
agen oes
olksw not
– Align clamp so that bolt ends do not protrude beyond lower d b y V gu
ara
edge of clamp -arrow-. horise nte
eo
ut ra
a
– Tighten front threaded connection of clamp slightly. ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Then align exhaust system with mountings under considera‐
rrectne
tion of dimension -a-. The -arrow- points forwards. Dimension
-a- = 3 … 7 mm.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Then evenly tighten securing nuts -arrows- of foremost clamp.
cop Vo
by lksw
cted
Specified torque: M 8 = 25 Nm, M10 = 40 Nm.
agen
Prote AG.
– Once clamp has been tightened, check fitting dimensions and

correct if necessary.

1.3 Installation position of clamp
Note
Gradual introduction of clamp with continuous clip.
Specified torque and mounting dimensions of clamping sleeve.

Clamp -A- with 2 individual clips.
Specified torque: 25 Nm.
Installation dimensions -a- 5 mm (only for front clamp)
Clamp -B- with continuous clip.
Specified torque: 35 Nm.
Installation dimensions -a- 6.6 mm (only for front clamp)
Installation dimension -a- for vehicles with marking on front ex‐

haust pipe
1 - Clamp
AG. Volkswagen AG d
2 - Front exhaust pipe agen oes
olksw not
byV gu
ara
a - Installation dimension rised
nte
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A - Marking ss a ra
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pt
du
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itte
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erm
ab
ility
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Installation position of front clamp

hole
spec
es, in part or in w
– Install clamp so that end of bolt -arrow- does not extend be‐
t to the co
yond lower edge of clamp.

• Threaded connection faces right
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
Installation position of rear clamp

do
priv
cum
or
– Install clamp so that end of bolt -arrow- does not extend be‐
f
en
ng
t.
yond lower edge of clamp.
yi Co
Cop py
ht. rig
• Threaded connection faces to rear. rig ht
py by
co Vo
by lksw
Specified torques: M8 = 25 Nm, M10 = 40 Nm. Prote
cted AG.
agen

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Golf 2009aut ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 ➤ r a, Passat
c
2006 ➤ ...
s
4-cylinder
s common rail engine (1.6 l, EA189) - Edition 02.2016
ce
e
nl
pt
du
an
itte
y li
2 Emission control
erm
ab
ility
ot p
wit
⇒ “2.1 Assembly overview – emission control”, page 472
, is n
h re
hole
⇒ “2.2 Removing and installing particulate filter”, page 480
spec
es, in part or in w
t to the co
2.1 Assembly overview – emission control
⇒ “2.1.1 Assembly overview - front exhaust pipe with particulate
rrectness of i
filter, Golf, Golf Plus, Golf Cabriolet, Passat, Touran”, page 472
l purpos
⇒ “2.1.2 Assembly overview - front exhaust pipe with catalytic

converter, Golf, Golf Plus, EU3 and EU4 vehicles”, page 474
nf
ercia
or
filter, Polo, left-hand drive”, page 476
m
m
atio
m

o
n in
or c
filter, Polo, right-hand drive”, page 478
thi
te
sd
iva
2.1.1 Assembly overview - front exhaust pipe
o
r
rp
cu
o
m
f
with particulate filter, Golf, Golf Plus,
en
ng
t.
yi Co
op
Golf Cabriolet, Passat, Touran
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ Removing and installing exhaust manifold ⇒ page 315 .

ded.
adapted using vehicle diagnostic tester : Guided functions;
Adapting pressure differential sender - G 505- .


- G 505-
2 - Connector
3 - 10 Nm
4 - Shield
5 - Lambda probe - G 39-
❑ 50 Nm
❑ Grease only thread with
- G 052 112 A3- .
❑ The high-temperature
paste - G 052 112 A3-
must not get into the
slots on the probe body.
❑ To remove use Lambda
probe open ring span‐
ner set - 3337- .
sender 4 - G 648-
⇒ page 512 .
❑ 60 Nm
7 - Gasket
❑ Renew agen
AG. Volkswagen AG d
oes
olksw not
❑ Note installationd byposi‐
V gu
ara
tion. orise nte
e h
ut or
8 - Clamp, 7 Nm
ss
a ac
ce
e
nl

pt
du
an
sender 3 - G 495-
itte
y li
erm
ab
❑ 45 Nm
ility
ot p
❑ Tightening
wit
, is n
h re
⇒ page 506 .
hole
spec
10 - 25 Nm
es, in part or in w
t to the co
11 - Mounting
rrectness of i
l purpos
❑ With oxidation catalytic converter and front exhaust pipe.

❑ After replacing the particulate filter, set to “0” via adaption of ash mass calibration. ⇒ Vehicle diagnostic
nf
ercia
tester “Guided functions”.

orm

m
atio
om
n in
13 - 25 Nm
or c
thi
te
14 - Bracket
sd
iva
o
r
rp
cu
❑ Renewing particulate filter bracket with riveted stud bolts ⇒ Electronic Parts Catalogue (ETKA) .
o
m
f
en
ng
❑ This is the only way to apply the necessary tightening torque.

t.
yi Co
Cop py
. rig
15 - Control line, 45 Nm
ht ht
rig by
copy Vo
lksw
16 - Bracket
by
cted agen
Prote AG.
❑ Bolted to diesel particulate filter
17 - Clip
❑ Renew
2. Emission control 473

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf aPlus
ut
h o
2009 ➤ , Passat 2006 ➤ ... eo
ra
ss - Edition 02.2016 c
ce
le
un
pt
an
d
18 - Bracket
itte
y li
erm
ab
❑ Bolted to cylinder head.
ility
ot p
wit
19 - 25 Nm
is n
h re
ole,
20 - 3 Nm
spec
21 - 3 Nm
t to the co
22 - 8 Nm
rrectne
23 - 25 Nm
ss o
Installation position of clamp cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Position double clamp -a- = 5 mm from marking on front ex‐

haust pipe of particulate filter.
– Install clamp so that bolt ends do not protrude beyond lower
edge of clamp -arrow-.

with catalytic converter, Golf, Golf Plus,
EU3 and EU4 vehicles
Note

the bodywork.
♦ If necessary, loosen double and single clamps and align si‐
lencers and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly loaded
⇒ page 469 .
♦ Removing and installing exhaust manifold with turbocharger
⇒ page 326 .
♦ The flexible joint in the front exhaust pipe must not be bent
more than 10° - otherwise it can be damaged.
♦ Renew seals, gaskets and self-locking nuts.

Note
♦ EU3 vehicles have a catalytic converter instead of a particulate

filter.
♦ The following components are not installed on EU3 vehicles.
♦ Pressure differential sender - G 505- ⇒ Item 1 (page 477)

♦ Exhaust temperature sender 3 - G 495-
♦ Exhaust temperature sender 4 - G 648- ⇒ Item 5 (page 477)
♦ Lambda probe - G 39- ⇒ Item 6 (page 477)
♦ Bracket ⇒ Item 16 (page 477)
1 - Catalytic converter
2 - Gasket
❑ Renew
❑ Note installation posi‐
tion.
3 - Clip
❑ 7 Nm
4 - Mounting
5 - 25 Nm
6 - Bracket
AG. Volkswagen AG d
❑ Renew agen oes
olksw not
y V gu
❑ Particulate filter bracket ise
d b ara
nte
with riveted stud boltstho⇒
r eo
Electronic Parts Cata‐
ss au ra
c
logue (ETKA) .
ce
le
un
pt
❑ This is the only way to

an
d
itte
y li
apply the necessary

erm
ab
tightening torque.
ility
ot p
wit
7 - 25 Nm
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
The flexible joint in the front exhaust pipe must not be bent more
ng
t.
yi Co
than 10° - otherwise it can be damaged. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

If the catalytic converter is to be re-installed, a transportation lock

for decoupling element - T10404- -arrow- must always be secured
to the decoupling element in the front exhaust pipe.

with particulate filter, Polo, left-hand
drive
Note lkswage es n
o ot g
byV ua
ed ran
♦ After working on the exhaust system, ensurehthat oris the system tee
is not under tension and that there is sufficient
s au clearance to
t or
ac
the bodywork. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
⇒ page 469 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Removing and installing exhaust manifold with turbocharger
rrectness of i
⇒ page 326 .
l purpos
♦ The flexible joint in the front exhaust pipe must not be bent
more than 10° - otherwise it can be damaged.
nf
ercia
♦ Renew seals, gaskets and self-locking nuts. orm

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


- G 505-
2 - 3 Nm
3 - Control lines
4 - Clips
sender 4 - G 648- , 45 Nm
❑ Lubricate thread of
sender using high-tem‐
perature paste - G 052
112 A3-
6 - Lambda probe - G 39- , 50
Nm
- G 052 112 A3- .
paste - G 052 112 A3-
ner set - 3337- .
7 - Heat shield
8 - 9 Nm
⇒ page 480 . n AG. Volkswagen A ge G do
swa es n
10 - Gasket yV
olk ot g
ua
edb ran
❑ Renew horis tee
t or
au
❑ Note installation posi‐ ac
ss
tion.
ce
le
un
pt
an
d
11 - Clip
itte
y li
rm
ab
❑ 7 Nm
pe
ility
ot
wit
12 - 25 Nm
, is n
h re
hole
13 - 25 Nm
spec
es, in part or in w
14 - Bracket
t to the co
❑ Bolted to cylinder head

15 - Exhaust gas temperature sender 3 - G 495- , 45 Nm
rrectness of i
❑ Lubricate thread of sender using high-temperature paste - G 052 112 A3-

l purpos
❑ To remove, use tool set - T10395/6 - .

16 - Bracket
nform
ercia
17 - 25 Nm
m
a
com
tion in
18 - 45 Nm
r
te o
thi
❑ For control line

s
iva
do
r
rp
19 - Bracket
um
fo
en
ng
t.
❑ For pressure differential sender - G 505- .
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Installation position of clamp

– Position double clamp at distance -a- = 5 mm from marking on
front exhaust pipe.

with particulate filter, Polo, right-hand
drive
Note

the bodywork.
⇒ page 469 .
♦ Removing and installing exhaust manifold with turbocharger.
⇒ page 321
wage e
♦ The flexible joint in the
y Vfront exhaust pipe must not bet bent
olks s no
gu
more than 10° - otherwise
ise
db it can be damaged. ara
nte
r
ho e
♦ Renew seals,s agaskets
ut and self-locking nuts. or
ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
478
agen
Prote AG.
Rep. gr.26 - Exhaust system
1 - Lambda probe - G 39-

❑ 50 Nm
- G 052 112 A3- .
paste - G 052 112 A3-
ner set - 3337- .
2 - Gasket
❑ Renew
❑ Note installation posi‐
tion.
3 - Clamp, 7 Nm
4 - Exhaust gas temperature AG. Volkswagen AG d
agen
sender 4 - G 648- Volksw
oes
not
gu
by ara
❑ 45 Nm rise
d
nte
ho eo
❑ aLubricate thread of
ut ra
c
s sender using high-tem‐
s
ce
e

nl
pt
du
an
112 A3-
itte
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erm
ab
❑ Tightening
ility
ot p
⇒ page 509 .
wit
, is n
h re

hole
sender 3 - G 495-
spec
es, in part or in w
❑ 45 Nm
t to the co
❑ Lubricate thread of
sender using high-tem‐
rrectness of i
112 A3-
l purpos
❑ Tightening
⇒ page 509 .
nform
ercia
6 - Pressure differential sender - G 505- bracket

m
at
om
7 - Clips
ion
c
in t
or
8 - Control lines
his
ate
do
riv
9 - Differential pressure sender - G 505-

p
cum
for

en
ng
t.
yi Co
op py
10 - 4.5 Nm t. C rig
gh ht
pyri by
11 - 25 Nm
co Vo
by lksw
cted agen
Prote AG.
12 - 25 Nm
13 - Bracket
❑ Bolted to cylinder head

Installation position of clamp

– Position double clamp at distance -a- = 5 mm from marking on
front exhaust pipe.
2.2 Removing and installing particulate filter

⇒ “2.2.1 Removing and installing particle filter, Golf, Golf Plus,
⇒ “2.2.2 Removing and installing particulate filter, Polo, left-hand
drive”, page 487
⇒ “2.2.3 Removing and installing particulate filter, Polo, right-hand
drive”, page 494
2.2.1 Removing and installing particle filter,

Golf, Golf Plus, Golf Cabriolet, Touran,
Passat
Note
Volkswagen AG
♦ After working on the exhaust system, ensure that the
swa system
gen AG
.
does
is not under tension and that there is sufficientbyclearance
Vo lk
to not
gu
the bodywork. If necessary, loosen doublerisclamp and align
ed ara
nte
silencer and exhaust pipe so that sufficient
ut clearance is main‐
ho eo
ra
tained to the bodywork and the supports rings are evenly loa‐
s a c
ded.
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nl
pt
du
an

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ab

ility
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spec
es, in part or in w
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♦ Torque wrench - V.A.G horis
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ab
ility
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es, in part or in w
t to the co
rrectness of i
♦ Ratchet wrench 13 mm - T10384-
l purpos
nf
ercia
orm
m
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n in
or c
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Prote AG.
♦ Transportation lock - T10404-
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .

– Disconnect connector for Lambda probe - G 39- -3- and con‐

nector for exhaust gas temperature sender 4 - G 648- -2-.

495- -1- (secured behind bracket).
– Pull connector out of retainers and guide wiring out of retainers
on plenum chamber bulkhead -2- and on turbocharger.
– Separate connector at pressure differential sender - G 505-

-2- .
– Unscrew bolts -3 + 4-.
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ab
ility
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spec
es, in part or in w

t to the co

– Open clips on hoses from differential pressure sender at pipes
rrectness of i
of particle filter, pull off hoses and remove pressure differential

sender.
l purpos
nf
ercia
orm
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or c
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t.
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rig ht
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482
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agen
Prote AG.

bocharger.
– Remove Lambda probe with Lambda probe open ring spanner
set - 3337- .
– Remove exhaust temperature sender 3 - G 495-
⇒ Item 9 (page 473) . With tool set - T10395/6-
– Only loosen bolt -1-.

noise insulation
– Unscrew exhaust gas temperature sender 4 - G 648-

-item 1- from exhaust pipe downstream of particulate filter.
Note
AG. Volkswagen AG d
-Item 2- should be disregarded.
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– In vehicles withthan
o auxiliary heater, remove the brackets fortee
r
o
the coolant lines
au leading to the auxiliary heater from the cylin‐ r ac
ss
der block or transfer gearbox and the oil sump.
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nl
pt
du
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itte
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erm
ab
ility
ot p
– Remove securing bolts -1- and remove cover from cylinder

wit
block for right drive shaft.

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
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te
sd
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Loosen securing nuts -1- above particulate filter bracket using

ratchet wrench - T10384- . Unscrew nuts -2-.
Renewing particulate filter bracket with riveted stud bolts ⇒ Elec‐
tronic Parts Catalogue (ETKA) .
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
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– Unscrew bolts -2- and -3- for pendulum support. ss a c
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nl
pt
du
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itte
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Caution
erm
ab
ility
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hole
♦ Secure the flexible joint with the transportation lock -
spec
T10404- .
es, in part or in w
t to the co
rrectness of i
l purpos
Transportation lock - T10404- -arrow-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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cted agen
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– Loosen clamp nuts -1- and push clamp to rear.

Remove front tunnel cross-piece -arrows- for underbody.
AG. Volkswagen AG d
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tho eo
au ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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– Unscrew nuts -1- and -2-, and remove rear tunnel cross-piece.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Remove particulate filter and turn it until exhaust pipe hangs

p
cum
or
downwards.
f
en
ng
t.
yi Co
op
– Unhook rear part of exhaust system from rubber mountings.
C py
t. rig
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yri by
– Push rear part of exhaust system as far forwards and down‐ cop Vo
by lksw
wards as possible.
cted agen
Prote AG.
– Unscrew nuts -arrows- from underbody cover.

– Unscrew clamping washers -2- and -3-.
– Guide heat shield -1- for transmission tunnel past exhaust
pipes and remove.
Note
To remove the particle filter, the engine must be swung forwards

and/or rearwards by a second mechanic.

– Observe the following points here:

• The air conditioning compressor -2- may not touch the refrig‐
erant line -1- -arrow-.
• The alternator may not touch the refrigerant line.
• The pressure pipe may not touch the radiator.
– Carefully remove particulate filter by turning 180° on its own

axis.
Installing
• Specified torques for pendulum support ⇒ page 60
• Specified torque for bolts for drive shaft heat shield -1- ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐
moving and installing drive shaft heat shield .
Specified torque for tunnel cross members:
Golf, Golf Plus, Golf Cabrio, Passat 2006, Passat Variant agen AG. Volkswagen AG doe
2006, Polo, Touran ⇒ General body repairs, exterior; Rep. ksw
Vol gr.
s no
t gu
50 ; Tunnel cross members; Assembly overview - tunneld by cross ara
se nte
ri
members tho eo
u ra
sa c
Passat 2011, Passat Variant 2011 ⇒ General s body repairs,
ce
le
exterior; Rep. gr. 66 ; Tunnel cross members; Assembly over‐

un
pt
an
d
view - tunnel cross members

itte
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erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
♦ Renew all seals, self-locking nuts and clip for particulate filter.
t to the co
♦ Reinstall all cable ties in the same locations when installing.
♦ Renewing particulate filter bracket with riveted stud bolts ⇒
rrectne
♦ This is the only way to apply the necessary tightening torque.
ss o
cial p

inform
mer
atio
om
n
c
i
or
n thi
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

Observe sequence when installing particulate filter:

-1- loosely.
2. Screw in bolts and nuts -2 … 5- loosely by hand
3. Tighten clip -1-

4. Tighten nuts and bolts -2- and -5-
– Install heat shield for centre tunnel.
Check correct position of cables. They are held in position to‐

gether on the heat shield by clip -A-.
AG. Volkswagen AG d
agen oes
– Install noise insulation: yV
olksw not
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d b ara
e
Golf, Golf Plus, Golf Cabriolet, Passat 2006,horis Passat Variant nte
eo
2006, Polo, Touran ⇒ General body repairs,
s aut exterior; Rep. gr. ra
c
50 ; Noise insulation; Assembly overview
s - noise insulation
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le
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noise insulation
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– Install pendulum support ⇒ page 60 .
h re
ole,
– Aligning exhaust system free of stress ⇒ page 469 .
spec
t to the co
If particulate filter or pressure differential sender - G 505- is ex‐
changed, pressure differential sender - G 505- must be adapted
using vehicle diagnostic tester : Guided functions; Adapting pres‐
sure differential sender - G 505- .
rrectne
2.2.2 Removing and installing particulate fil‐ ss o
cial p
f
ter, Polo, left-hand drive
inform
mer

atio
om
n
c

i
or
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te
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pr
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t.
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rig ht
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Prote AG.

AG. Volkswagen AG d
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Golf 2009se➤ d , Golf Cabriolet 2012 ➤ , Golf Plus
b ar2009
an ➤ , Passat 2006 ➤ ...
ri tee
4-cylinder
tho common rail engine (1.6 l, EA189) - Edition o 02.2016
au ra
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Transport guard - T10403-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Engine and gearbox jack - VAG 1383A-

– Turn wheels to straight-ahead position.

– Remove cover -2- and unscrew plastic nuts -1-.
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tho
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a ac
ss
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un
pt
an
d
itte
– Unscrew bolt -1- from universal joint and pull universal joint off
y li
rm
in direction of arrow. ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ -1- Separate exhaust gas temperature sender 1 - G 235- con‐

m
nector
com
tion in
r

te o
thi
nector
s
iva
do
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rp
cum

fo
en
ng
nector
t.
yi Co
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.
♦ -4- Separate Lambda probe - G 39- connector
t rig
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by
cted agen
Prote AG.

AG. Volkswagen AG d
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Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009
autho
➤ , Passat 2006 ➤ ... eo
ra
4-cylinder common rail engine (1.6 l, EA189) - Edition
ss 02.2016 c
ce
le
un
pt
an
d
– Separate connector to pressure differential sender - G 505-
itte
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-2-.
rm
ab
pe
ility
– Unscrew pressure differential sender - G 505-
ot
wit
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⇒ Item 2 (page 477) .
h re
hole
spec
– Pull lines out of retainers on engine and remove heat shield
es, in part or in w
from particulate filter; if necessary remove cable ties.
t to the co
– Unscrew Lambda probe - G 39- using Lambda probe open ring
spanner set - 3337- ⇒ Item 6 (page 477) .
rrectness of i
– Unscrew exhaust temperature sender 3 -G 495- using span‐
l purpos
ner - T10395/6- ⇒ Item 15 (page 477) .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Remove securing clamp -1- between particulate filter and tur‐ C py
t. rig
bocharger.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Open bracket -B- of hydraulic lines -A-.

– Remove pendulum support -arrows-.

Item -1- must not be loosened.
– Place engine and gearbox jack engine and gearbox jack - VAG
1383A- below subframe.
– Fix subframe in position ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Fixing subframe in position .
– Loosen anti-roll bar from top of coupling rod ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐
ling anti-roll bar .
– Lower subframe with engine and gearbox jack - VAG 1383A- ;
steering remains on subframe.
The hydraulic steering circuit must not be opened for this.
– Lower on the right side max. 10 cm -movement arrow-.
. Volkswagen AG
does gen AG
– To prevent the hydraulic lines being
Vol
ksoverstretched,
wa lower on not
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ed
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Note
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nl
pt
du
an
itte
Secure subframe with steering rack to underbody of vehicle using
y li
erm
ab
tensioning strap - T00038- , so that the hydraulic lines are not
ility
ot p
stressed.
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
m

o
n in
c

or
thi
te
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a
– Disregard -item 2-.

iv
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ng
t.
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Cop py
t. rig
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pyri by
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o
by c lksw
cted agen
Prote AG.

– Unscrew exhaust gas temperature sender 4 - G 648-

-item 1- from exhaust pipe downstream of particulate filter.
– Unscrew bolts -1- and then nuts -2-.

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agen
Note Volksw
oes
not
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d by ara
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ut
hor eo
ra
than 10° - otherwise it can be damaged. ss a c
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pt
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itte
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pe
ility
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If the particulate filter is to be re-installed, a transportation lock -
hole
spec
T10403- -arrow- must always be secured to the decoupling ele‐
es, in part or in w
ment in front exhaust pipe.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
– Loosen securing bolts -arrows- of clamping sleeve, then push
iva
do
r

rp
cum
fo
en
ng
t.
– Detach front exhaust pipe from mounting brackets. Cop
yi Co
py
t. rig
Carefully remove front exhaust pipe with particulate filter together yri
gh by
ht
with pressure differential sender - G 505- above lowered sub‐
op Vo
by c lksw
frame.
cted agen
Prote AG.

– Remove particulate filter by turning 180° around its own axis.

Installing
Specified torque for subframe ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Subframe; Assembly overview - subframe .
Note
♦ Before installing subframe with steering rack ensure that seal

on steering rack contacts the assembly plate without kinks.
Ensure opening to footwell is correctly sealed. Otherwise wa‐
ter could leak in and/or there will be more noise.
♦ Renew seals, self-locking nuts and clip for particulate filter.
Check fitting position of seal -arrow- (steering donut).

note the following:
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Observe
au sequence when installing particulate filter: or a
t
c
ss
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e

nl
pt
du
-1- loosely.
an
itte
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ab
2. Screw in bolts and nuts -2 … 5- loosely by hand

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3. Tighten clip -1-

hole
spec

es, in part or in w
t to the co

rrectness of i
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nf
ercia
orm
m
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om
n in
or c
thi
te
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t.
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Specified torque for bolts for drive shaft heat shield -1- ⇒ Running
installing drive shaft heat shield . . Volkswage n AG n AG d
wage oes
– Aligning exhaust system free of stressy V⇒olkpage
s 469 . not
gu
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oris eo
th
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ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
2.2.3 Removing and installing particulate fil‐
es, in part or in w
t to the co
ter, Polo, right-hand drive
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ -T 10403-

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olksw not
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Golf 2009 ➤ , Golf Cabrioletara
nte 2012 ➤ , Golf Plus 2009 ➤ , Passat 2006 ➤ ...
autho
4-cylinder common
eo
r a rail engine (1.6 l, EA189) - Edition 02.2016
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
rrectness o
cial p
f i
♦ Engine and gearbox jack - VAG 1383A-
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Turn wheels to straight-ahead position.
– Remove cover -2- and unscrew plastic nuts -1-.

AG. Volkswagen AG d
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olksw not
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Golf 2009 ➤ , Golf Cabriolet 2012 ➤ u, thGolf Plus 2009 ➤ , Passat 2006 ➤ ...
o eo
ra
a
4-cylinder common rail engine (1.6 sl, EA189) - Edition 02.2016
s c
ce
e
nl
pt
du
– Unscrew bolt -1- from universal joint and pull universal joint off
an
itte
y li
in direction of arrow.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Disconnect connectors -1- for exhaust temperature sender 1

- G 235- .
m
at
om
ion
– Disconnect connectors -2- for Lambda probe - G 39- .
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew Lambda probe - G 39- -1- using Lambda probe open

ring spanner set - 3337- .
bocharger.
– Disconnect connector -2- to pressure differential sender - G

505- .
– Unscrew pressure differential sender - G 505- -1-.
– Disconnect connector -3- to pressure differential sender - G
505- .
– Pull lines from retainers and remove cable ties if necessary.
than 10° - otherwise it can be damaged.


– Open bracket -B- of hydraulic lines -A-.
– Remove pendulum support -arrows-.

Item -1- must not be loosened.
– Place engine and gearbox jack - VAG 1383A- below subframe.
– Fix subframe in position ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Fixing subframe in position .
– Loosen anti-roll bar from top of coupling rod ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐
ling anti-roll barolk.swage es n
o
V t gu
by a
– Lower subframe
ris
ed with engine and gearbox jack - VAG
ran 1383A- ;
tee
steering
utho remains on subframe. or
a ac
ss
The hydraulic steering circuit must not be opened for this.
ce
le
un
pt
an
d
– Lower on the right side max. 10 cm -movement arrow-.

itte
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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pr
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fo
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ng
t.
yi Co
Cop py
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co
497
by lksw
cted agen
Prote 2. Emission control
AG.
– To prevent the hydraulic lines being overstretched, lower on

the left side max. 7 cm.
Note
Secure subframe with steering rack to underside of vehicle with

tensioning strap - T00038- .
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o ot g
byV ua
d ran
ir se tee
tho
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a ac
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le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Unscrew exhaust gas temperature sender 3 - G 495- using -
es, in part or in w
T10395/6- ⇒ Item 5 (page 479) from front exhaust pipe.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove right underbody panel.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Remove cover from connector for exhaust temperature sender

4 - G 648- .


648- .
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– Unscrew bolts -1- and then nuts -2-. agen oes
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– Remove particulate filter bracket. orise nte
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Note
un
pt
an
d
itte
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ab
ility
than 10° - otherwise it can be damaged.
ot p
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is n
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ole,
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t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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o
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fo
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t.
yi Co
Cop py
ht. rig
– Loosen securing bolts -arrows- of clamping sleeve, then push rig ht
py by
Vo
co lksw
by
cted agen
Prote AG.
– Detach front exhaust pipe from mounting brackets.
Carefully remove front exhaust pipe with particulate filter together
with pressure differential sender - G 505- above lowered sub‐
frame.

– Remove particulate filter by turning 180° around its own axis.

Installing
Note
♦ Before installing subframe with steering rack ensure that seal

on steering rack contacts the assembly plate without kinks.
Ensure opening to footwell is correctly sealed. Otherwise wa‐
ter could leak in and/or there will be more noise.
♦ Renew seals, self-locking nuts and clip for catalytic converter.
Check fitting position of seal -arrow- (steering donut).

note the following:
– Renew gasket/seals ⇒ Item 2 (page 479) .
lkswage es n
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byV ua
d ran
ir se tee
tho
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ss
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le
un
pt
an
d
itte
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Installation sequence for particulate filter
rm
ab
pe
ility
♦ 1. Particulate filter mounting -1- on turbocharger, clamp -2-
ot
wit
, is n
(only positioning)
h re
hole
spec
♦ 2. Bracket on cylinder block with nuts -4- + -6- (only position‐
es, in part or in w
ing). Bolts -5- + -7- also (positioning)
t to the co
♦ 3. Tightening clamp -2- to turbocharger 7 Nm
♦ 4. Tightening left nut -6- to crankcase 25 Nm rrectness of i
♦ 5. Tightening right nut -4- to crankcase 25 Nm

l purpos
♦ 6. Tightening left bolt -7- of bracket to diesel particulate filter

25 Nm
nform
ercia
♦ 7. Tightening right bolt -5- of bracket to diesel particulate filter

m
a
com
ti
25 Nm
on in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Specified torque for bolts for drive shaft heat shield -1- ⇒ Running . Cop py
t rig
gh ht
yri by
installing drive shaft heat shield . cop Vo
by lksw
cted agen
Prote
Specified torque for exhaust gas temperature sender
AG.
⇒ page 509 .
– Aligning exhaust system free of stress ⇒ page 469 .

2.3 Removing and installing catalytic con‐

verter
⇒ “2.3.1 Removing and installing catalytic converter, Golf, Golf
Plus, EU3 vehicles”, page 501
2.3.1 Removing and installing catalytic con‐

verter, Golf, Golf Plus, EU3 vehicles
♦ Ratchet wrench 13 mm - T10384-
lkswage es n
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ss
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le
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pt
an
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
♦ Transportation lock - T10404-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp

um
fo
en
ng
t.
yi
Removing
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Loosen bolt -2- and remove clamp. cted agen
Prote AG.

– Unscrew securing bolt -1- from upper bracket of catalytic con‐

verter.
– Unscrew bolts (if any) -arrows- and remove heat shield for right
drive shaft.
Caution

♦ Secure decoupling element.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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Transportation lock - T10404- -arrow- ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Undo clamping sleeve nuts -1- and push clamping sleeve to‐
wards rear.
nform
ercia
– Unscrew nuts -arrows- and remove tunnel cross-piece at front.

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

– Unscrew nuts -1- and -2-, and remove rear tunnel cross-piece.
– Remove bolts -arrows- of bracket.
– Unscrew securing nuts -1- above catalytic converter bracket

using ratchet wrench - T10384- ; unscrew nuts -2-.
wage
e
olks s no
yV t gu
– Remove catalytic converter bracket. edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unscrew bolts -2- and -3- for pendulum support.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis
2012 ➤ , Golf Plus 2009 ➤ , Passat e2006 ➤ ...
ut or
4-cylinder commonss a rail engine (1.6 l, EA189) - Edition 02.2016 ac
ce
le
un
pt
– Push engine/gearbox assembly with engine support device -
an
d
itte
3300 A- forwards by measurement -a-.
y li
erm
ab
ility
• Dimension -a- = 35 mm
ot p
wit
is n
– Remove particulate filter and turn it until exhaust pipe hangs
h re
ole,
downwards.
spec
– Unhook rear part of exhaust system from rubber mountings.
t to the co
– Push rear part of exhaust system as far forwards and down‐
wards as possible.
rrectness o
cial p
f in
– Unscrew nuts -arrows- from underbody cover.
form
mer
atio
– Unscrew clamping washers -2- and -3-.
om
n
c
i
– Guide heat shield -1- for transmission tunnel past exhaust
or
n thi
e
pipes and remove.

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove particulate filter by turning it 180° around its own axis

through the tunnel.
Installing
• Specified torques for catalytic converter ⇒ page 474 .
• Specified torques for pendulum support ⇒ page 60
• Specified torque for bolts for drive shaft heat shield ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly
overview - drive shaft .
Specified torque for tunnel cross members:
Golf, Golf Plus, Golf Cabrio, Passat 2006, Passat Variant
50 ; Tunnel cross members; Assembly overview - tunnel cross
members
exterior; Rep. gr. 66 ; Tunnel cross members; Assembly over‐
view - tunnel cross members
Note
♦ Renew seals, self-locking nuts and clip for catalytic converter.

♦ Fit cable tie in same place when installing.

lkswage es n
Golf 2009 ➤ d by, VGolf Cabriolet 2012 ➤ , Golf Plus
o ot g
ua2009 ➤ , Passat 2006 ➤ ...
r
ir se 4-cylinder common rail engine (1.6 l,anEA189) tee - Edition 02.2016
tho
u or
a ac
ss
– Observe sequence when installing catalytic converter:
ce
e
nl
pt
du
an
1. Locate catalytic converter filter on turbocharger and se‐
itte
y li
cure clip -1- loosely
erm
ab
ility
ot p
2. Screw bolts -2 … 5- in loosely by hand
wit
, is n
• It should still be possible to move catalytic converter
h re
and bracket. hole
spec
es, in part or in w
3. Tighten clip -1-
t to the co
4. Tighten bolts -2- and -5-
5. Tighten bolts -3- and -4-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Exhaust gas temperature regulation

⇒ “3.1 Assembly overview - exhaust gas temperature regulation”, AG. Volkswagen AG d
page 506 lksw
agen oes
n o ot g
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⇒ “3.2 Removing and installing parts of exhaust gas temperature
ris
ed
b ran
tee
regulation”, page 509 ut
ho
or
a ac
ss
3.1 Assembly overview - exhaust gas tem‐
ce
e
nl
pt
du
perature regulation
an
itte
y li
erm
ab
ility
ot p
wit
, is n
3.1.1 Assembly overview - exhaust gas temperature regulation, Golf, Golf Plus,
h re
hole
Golf Cabrio, Touran, Passat
spec
es, in part or in w
t to the co
1 - Turbocharger
rrectness of i
2 - Control pipe
❑ 45 Nm
l purpos
nform
ercia
4 - Nut
m
❑ 9 Nm
at
om
ion
c
5 - Bracket
in t
or
his
te
❑ Bolted to diesel particu‐

a
do
riv
late filter.
p
cum
for
en
ng
6 - Hose
t.
yi Co
Cop py
. rig
7 - Bracket
t
gh ht
pyri by
Vo
o
❑ For pressure differential
c by lksw
cted agen
sender - G505- . Prote AG.
❑ Illustration does not

show version installed in
vehicle.
- G505-
⇒ page 422 .
9 - Bracket
10 - Bolt
❑ 4.5 Nm
11 - Bolt
❑ 8 Nm
sender 3 - G495-
⇒ page 511 .
❑ The thread of the ex‐
haust gas temperature sender is coated and must not also be coated with high-temperature paste.
❑ 45 Nm, observe procedure ⇒ page 511 .
13 - Lambda probe 1 before catalytic converter - GX10-
❑ with lambda probe - G39- and lambda probe heater - Z19-


❑ The thread of the exhaust gas temperature sender is coated and must not also be coated with high-
temperature paste.
❑ 60 Nm
❑ Coat thread with high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
3.1.2 Assembly overview - exhaust gas temperature regulation, Polo (LHD)
1 - Turbocharger
2 - Control pipe
❑ 45 Nm
4 - Nut
❑ 9 Nm
AG. Volkswagen AG d
agen oes
5 - Bracket olksw not
byV gu
ara
d
❑ Bolted to diesel particu‐
orise nte
late filter. aut
h eo
ra
ss c
6 - Hose
ce
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nl
pt
du
an
7 - Bracket
itte
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erm
ab
❑ For pressure differential

ility
ot p
sender - G505- .
wit
, is n
❑ Illustration does not

h re
hole
show version installed in

spec
vehicle.
es, in part or in w
t to the co

- G505-
rrectness of i

⇒ page 422 .
l purpos
9 - Bracket
nform
ercia
10 - Bolt
❑ 4.5 Nm
m
at
om
ion
11 - Bolt
c
in t
or
his
e
❑ 8 Nm
at
do
priv

um
for
en
g
sender 3 - G495-
n
t.
yi Co
op
C py
ht. rig
⇒ page 515 .
rig ht
py by
co Vo
by lksw
❑ The thread of the ex‐ Prote
cted AG.
agen
haust gas temperature sender is coated and must not also be coated with high-temperature paste.
❑ 45 Nm, observe procedure.
13 - Lambda probe 1 before catalytic converter - GX10-
❑ with lambda probe - G39- and lambda probe heater - Z19-
3. Exhaust gas temperature regulation 507

❑ The thread of the exhaust gas temperature sender is coated and must not also be coated with high-
temperature paste.
❑ 60 Nm
3.1.3 Assembly overview - exhaust gas temperature regulation, Polo (RHD)
1 - Catalytic converter
2 - Lambda probe 1 before cat‐ olks
wage es n
ot g
alytic converter - GX10- by V ua
ed ran
❑ with lambda probe - oris tee
th or
ss
au ac
heater - Z19-
ce
e
nl
pt
du
an
itte
y li
⇒ page 432 .
erm
ab
ility
ot p
wit
sender 3 - G495-
, is n
h re
hole
spec
⇒ page 517 .
es, in part or in w
t to the co
haust gas temperature
sender is coated and
rrectness of i
must not also be coated
with high-temperature
l purpos
paste.
❑ 45 Nm
nf
ercia

rm
m
atio
sender 4 - G648-
om
n in
c

or
thi
⇒ page 518 .
te
sd
iva

r
rp
cu
o
haust gas temperature

f
en
ng
t.
sender is coated and
yi Co
op
must not also be coated
C py
t. rig
gh
with high-temperature
ht
pyri by
Vo
o
paste. by c lksw
cted agen
Prote AG.
❑ 60 Nm
sender 1 - G235-
⇒ page 509 .
❑ 45 Nm, observe procedure.
7 - Turbocharger

3.2 Removing and installing parts of ex‐

haust gas temperature regulation
⇒ “3.2.1 Removing and installing exhaust gas temperature sender
1 G235 ”, page 509
3 G495 ”, page 511
4 G648 ”, page 512
4 G648 , Polo, left-hand drive”, page 514
3 G495 , Polo, left-hand drive”, page 515
AG. Volkswagen AG d
3 G 495 , Polo, right-hand drive”, page 517
lkswagen oes
n o ot g
yV ua
⇒ “3.2.7 Removing and installingrexhaust
ise
db gas temperature sender ran
tee
4 G 648 , Polo, right-hand drive”,
utho page 518 or
a ac
ss
3.2.1 Removing and installing exhaust gas
ce
le
un
pt
temperature sender 1 - G235-
an
d
itte
y li
erm
ab
Removing
ility
ot p
wit
is n
– Disconnect electrical connector -3- for exhaust temperature
h re
ole,
sender 1 - G235- and free electrical line.
spec
t to the co
rrectne
s
s o
cial p
noise insulation
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note
You access the threaded connection from above using the span‐
ner from tool set - T10395/7- .
– Unscrew exhaust temperature sender 1 - G235- -item 1- from

exhaust manifold.
Note
wage es n
Ignore -arrows-. byV
olks ot g
ua
d ran
ir se tee
o
Installing auth or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ Coat threads of exhaust temperature sender with high-tem‐
h re
hole
perature paste ⇒ Electronic Parts Catalogue (ETKA) .
spec
es, in part or in w
♦ Fit all cable ties in the original position when installing.
t to the co
Installation position of exhaust gas temperature sender -G235- .
rrectness of i
l purpos
WARNING
The torque wrench - V.A.G 1331- must be set to 28 Nm in this

nform
ercia
case.
m
at
om
Extending the torque wrench - V.A.G 1331- with the spanner

ion
c
from tool set - T10395/7- allows the correct torque of 45 Nm to

in t
or
be achieved.
his
ate
do
priv
cum
for
en
ng
Lubricate thread of sender using high-temperature paste - G 052

t.
yi Co
op
112 A3- .
C py
t. rig
gh ht
pyri by
Vo
co lksw
– Screw exhaust gas temperature sensor 1 - G 235- in by hand.
by
cted agen
Prote AG.
– Then apply tightening torque using torque wrench - V.A.G
1331- together with wrench from tool set - T10395/7- .

• Angled shaft must have a distance -a- = 3 … 5 mm to bolting

of turbocharger support.

temperature sender 3 - G495-
♦ Tool set, 17 mm - T10395-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
♦ Torque wrenchs- V.A.G 1331-
s c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia
– Remove Lambda probe - G39- ⇒ page 432 .

m

com
tion in

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

– Unscrew exhaust gas temperature sender 3 - G495- -item 1-

using tool from 17 mm tool kit - T10395- .
Note
Installing
Note
Fit all cable ties in the original position when installing.
Caution
Loose exhaust gas temperature senders cause malfunctions.

♦ Threads of exhaust temperature sender -G495- and -
G648- are coated. Do NOT additionally coat with high-
temperature paste and always adhere to the prescribed
tightening torque.
Installation position of temperature sender -G495- -item 1-:

• Angled end to left-hand side of vehicle. n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
• Angle -α- to marking -arrow- = approx. 17°.ised b ran
or tee
th or
au ac
WARNING ss ce
e
nl
pt
du
an
itte
y li
erm
case.
ab
ility
ot p

wit
, is n

h re
hole
be achieved.
spec
es, in part or in w
t to the co
– Screw exhaust temperature sender 1 - G 495- in by hand.

rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
temperature sender 4 - G648- cted agen
Prote AG.

♦ Tool set, 17 mm - T10395-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
♦ Torque wrench - V.A.G 1331- ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
Removing
in t
or
his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


using tool from 17 mm tool set - T10395- .
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
by ara
d
rise nte
Disregard -item 2-. utho eo
ra
s a c
s
ce
e
Installing
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
tightening torque.
rrectness of i
l purpos

nform
ercia
⇒ “3.1 Assembly overview - exhaust gas temperature regula‐

tion”, page 506 .
m
at
om
ion
c
in t
or
his
ate
temperature sender 4 - G648- , Polo,
do
priv
cum
or
left-hand drive
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
♦ Tool set, 17 mm - T10395- cop Vo
by lksw
cted agen
Prote AG.

Removing
Note
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
using tool from 17 mm tool set - T10395- .
Note t to the co
rrectness of i
l purpos
Disregard -item 2-.

nf
ercia
Installing
orm
m

atio
om
n in
c
or
thi
e
⇒ “3.1 Assembly overview - exhaust gas temperature regula‐

t
sd
iva
tion”, page 506 .

o
r
rp
cu
o
m
f
en
ng
t.
yi
Caution
Co
Cop py
t. rig
gh ht
yri by
cop Vo
by lksw
cted agen
Prote
AG.

tightening torque.

temperature sender 3 - G495- , Polo,
left-hand drive

♦ Tool set, 17 mm - T10395- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
Removing
ht
pyri by
Vo
o
by c lksw
– Remove Lambda probe - G39- ⇒ page 432 .
cted agen
Prote AG.

using tool from 17 mm tool kit - T10395- .
Note
Installing
Note
Fit all cable ties in the original position when installing.
Caution

tightening torque.

lkswage es n
Vo ot g
Golf d 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf
by ua Plus 2009 ➤ , Passat 2006 ➤ ...
ran
ir se
tho 4-cylinder common rail enginetee(1.6 or l, EA189) - Edition 02.2016
au ac
ss
Installation position of temperature sender -G495- -item 1-:
ce
le
un
pt
an
d
• Angled end to left-hand side of vehicle.
itte
y li
rm
ab
pe
• Angle -α- to marking -arrow- = approx. 17°.
ility
ot
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
t to the co
case.
rrectness of i
be achieved.
l purpos
nform
ercia
– Screw exhaust temperature sender 1 - G 495- in by hand.

m
a
com
tio
n in
r

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

temperature sender 3 - G 495- , Polo,
right-hand drive

Specified torque for exhaust temperature sender 3 - G 495- up‐

stream of particulate filter (right-hand drive)
Use torque wrench - V.A.G 1331- with spanner from tool set -
T10395/6- to tighten.
WARNING

case.
be achieved.

temperature sender 4 - G 648- , Polo,
right-hand drive
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Specified torque for exhaust temperature sender 4 - G 648- down‐

stream of particulate filter
Use torque wrench - V.A.G 1331- with spanner from tool set -
T10395/6- to tighten.
WARNING

case.
Extending the torque wrench - V.A.G 1331- with the spanner from
tool set - T10395/6- allows the correct torque of 45 Nm to be ach‐
ieved.
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4 Exhaust gas recirculation

⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 520
⇒ “4.2 Checking changeover for exhaust gas recirculation cooler”,
page 521
⇒ “4.3 Removing and installing exhaust gas recirculation cooler”,
page 522
⇒ “4.4 Checking exhaust gas recirculation cooler for leaks”, page
527
4.1 Assembly overview - exhaust gas recirculation

AG. Volkswagen AG d
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1 - Bolt byV gu
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❑ 9 Nm ut
ho eo
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s a c
2 - Exhaust gas recirculation s
ce
le
pipe
un
pt
an
d
itte
❑ With flexible joint; do not
y li
erm
ab
bend flexible joint - dan‐
ility
ot p
ger of cracking.
wit
is n
h re
3 - Bolt
ole,
spec
❑ 9 Nm
t to the co
4 - Gasket
❑ Renew
rrectne
5 - Vacuum line
❑ Do not alter shape.
ss o
❑ Vacuum hose schemat‐
cial p
f i
ic diagram ⇒ page 385 .
nform
mer
6 - Bolt atio
om
❑ 9 Nm
n
c
i
or
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e
7 - Gasket
t
sd
iva
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pr
❑ Renew
um
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pipe
. C rig
ht ht
rig by
❑ With flexible joint; do not copy Vo
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bend flexible joint - dan‐ cted agen
Prote AG.
ger of cracking.
9 - Bolt
❑ 9 Nm
10 - Clip
❑ 4 Nm
cooler
❑ With integrated exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer -
G212- .
❑ Checking changeover ⇒ page 521 .
❑ Check exhaust gas recirculation cooler for leaks ⇒ page 527 .
12 - Bolt
❑ 9 Nm

13 - Gasket
❑ Renew
14 - Gasket
❑ Renew
15 - Exhaust gas recirculation pipe
❑ With flexible joint; do not bend flexible joint - danger of cracking.
16 - Nut
❑ 22 Nm
17 - Bolt
❑ 9 Nm
18 - Gasket
❑ Renew
4.2 Checking changeover for exhaust gas

AG. Volkswagen AG d
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recirculation
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♦ Hand vacuum pump
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pt
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Procedure
nf
ercia
– Remove heat shield sleeve.

rm
m
atio
m
– Detach vacuum hose from vacuum unit and connect hand

o
n in
c
vacuum pump - VAS 6213- in its place.

or
thi
te
sd
a
– Operate hand vacuum pump to create a vacuum.

iv
o
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rp
cu
o
• The linkage of the changeover for the exhaust gas recircula‐

f
en
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t.
tion cooler moves -arrows-.
yi Co
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If linkage does not move or only moves in jerks:
gh ht
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♦ Vacuum actuator is defective. cted agen
Prote AG.
♦ Changeover flap for exhaust gas recirculation is tight.
Note
Reinstall heat shield sleeve in the same location when assem‐

bling.
4. Exhaust gas recirculation 521

4.3 Removing and installing exhaust gas re‐

circulation cooler
⇒ “4.3.1 Removing and installing exhaust gas recirculation cooler,
Golf, Golf Plus, Golf Cabriolet, Touran, Passat”, page 522
⇒ “4.3.2 Removing and installing exhaust gas recirculation cooler,
Polo”, page 525
AG. Volkswagen AG d
4.3.1 Removing and installing exhaust gas re‐ Vol
ksw
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circulation cooler, Golf, Golf Plus, rGolf
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db ara
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Cabriolet, Touran, Passat ho eo
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Caution
an
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ab
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ot
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tions:
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
hot components.
nform
ercia
If the exhaust gas recirculation cooler is to be removed or re‐

m
a
newed
com
tion in
r
– First, in the “selection of functions and components ” of a

te o
thi
⇒ Vehicle diagnostic tester test pump 2 for coolant circulation
s
iva
do
- V178- .
r
rp
cum
fo
en
g
If coolant circulation pump 2 - V178- is not OK, this may be the

n
t.
yi Co
op
cause of the faulty exhaust gas recirculation cooler. C py
t. rig
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♦ Drip tray for workshop hoist - VAS 6208- AG. Volkswagen AG d

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or eo
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un
pt
an
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itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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Removing gh ht
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– Remove engine cover ⇒ page 76 . Prote
cted AG.
agen

for this.
– Open clip -3- and pull intake hose off air mass meter - G70- .
– Unscrew bolt -2-, swing intake hose with intake line to rear and
pull off of turbocharger.

– Unscrew bolts -arrows-, loosen hose clip -1- and remove pul‐
sation damper -2-.
– Unscrew bolts for pipes -A- of exhaust gas recirculation and

remove pipes.
– In vehicles with an auxiliary heater, remove the brackets for
the coolant lines leading to the auxiliary heater from the cylin‐
der block or transfer gearbox and the oil sump.
– Remove oil supply line together with oil return line (turbo‐
charger support) ⇒ page 246 .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
ut ra
– Place drip tray for workshop hoist - VAS 6208- beneath
ss a
en‐ c
gine.
ce
le
un
pt
an
d
– Pinch off coolant hoses -1- and -3- with hose clamps -3094-
itte
y li
erm
and remove from exhaust gas recirculation cooler; loosen
ab
ility
hose clamps for this.
ot p
wit
is n
h re
ole,
spec
– Remove vacuum hose -4- from vacuum unit and free.
t to the co
– Unscrew bolts -arrows- and remove exhaust gas recirculation
cooler.
rrectne
Installing
ss o
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
♦ Renew gaskets, seals and self-locking nuts.

t
sd
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pr
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fo
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ng

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op py
♦ Secure hose connections with hose clips corresponding to the
t. C rig
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standard equipment ⇒ Electronic Parts Catalogue . p by
o Vo
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cted agen
♦ Fit heat shield sleeve in the same place when installing. Prote AG.
– Installing support for turbocharger with oil supply line, inlet

connection and pulsation damper ⇒ page 315 .
– Check coolant level and top up as needed ⇒ page 261 .

AG. Volkswagen AG d
agen oes
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y V gu
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Golf
orise 2009 ➤ , Golf Cabriolet 2012 ➤ , GolfanPlus tee 2009 ➤ , Passat 2006 ➤ ...
h
aut 4-cylinder common rail engine (1.6
or
acl, EA189) - Edition 02.2016
ss
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nl
4.3.2 Removing and installing exhaust gas re‐
pt
du
an
itte
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circulation cooler, Polo
erm
ab
ility
If the exhaust gas recirculation cooler is to be removed or re‐ ot p
wit
, is n
newed
h re
hole
spec
– First, in the “selection of functions and components ” of a
es, in part or in w
⇒ Vehicle diagnostic tester test pump 2 for coolant circulation
t to the co
- V178- .
If coolant circulation pump 2 - V178- is not OK, this may be the
rrectness of i
cause of the faulty exhaust gas recirculation cooler.
l purpos

nform
ercia

m
at
om
ion
c
in t
or
Note
his
ate
do
priv
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or

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en
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Prote AG.
Unclip bracket.


– Loosen hose clip -1- and remove pulsation damper -2-.
– Remove turbocharger support
⇒ “4.2.1 Removing and installing oil supply line, Polo”,
page 246 .
– Release front left wheel housing liner at bottom.
– Unscrew bolts of coolant pipes on right ⇒ page 297 .
– Remove coolant pipes from exhaust gas recirculation cooler.
– Collect escaping coolant with drip tray for workshop hoists -
VAS 6208- .
– Catch leaking engine oil with used oil collection and extraction
unit - V.A.G 1782- .
– Pull vacuum line off vacuum unit ⇒ Item 5 (page 520) .
– Disconnect electrical connector from electrical actuator of ex‐
haust gas recirculation valve - N18- for exhaust gas recircu‐
lation cooler.
– Clamp off coolant supply line and return lines using hose clips
up to 25 mm - 3094- at exhaust gas recirculation cooler
⇒ page 520 .
– Disconnect coolant supply line and return lines from exhaust
gas recirculation cooler.
AG. Volkswagen AG d
agen
– Collect escaping coolant with drip tray for workshop hoists - Volksw
oes
not
gu
VAS 6208- . ed by ara
nte
ris
o eo
– Unscrew bolts ⇒ Item 12 (page 520) and remove exhaustaugas
th
ra
recirculation cooler. ss c
ce
le
un
pt
Installing
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ Renew the seals, gaskets and self-locking nuts ⇒ Electronic
Parts Catalogue (ETKA) .
rrectne
♦ Checking engine oil level ⇒ page 227 .
s
♦ Replenish coolant ⇒ page 261 . s o
cial p
f in
♦ Install particulate filter ⇒ page 480 .
form
mer
atio
m

o
n
c
i
or
(ETKA) .
thi
te
sd
va

i
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fo
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Adapting pressure differential sender - G 505- . C py
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by c lksw
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Prote AG.

4.4 Checking exhaust gas recirculation

cooler for leaks
Note
A pressure of 0.8 bar is applied to the exhaust side of the exhaust

gas recirculation cooler. While doing this, the pressure in the
cooling system is measured.

♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/11-

♦ Adapter - V.A.G 1687/15- for exhaust pipes of 60 mm and
65 mm in diameter
♦ Adapter - V.A.G 1687/16- for exhaust pipes of 55 mm in di‐
ameter
♦ Y junction - VAS 691 005/1-
AG. Volkswagen AG d
agen oes
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♦ Test adapter - VAS 691 005/5-

♦ Turbocharger tester - V.A.G 1397A-
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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Prote AG.

Test prerequisite:
• Coolant temperature must be at least 40 °C.
Connecting turbocharger tester - V.A.G 1397A- :
– Screw test adapter - VAS 691 005/5- onto coolant expansion
tank.
– Push Y junction - VAS 691 005/1- onto test adapter - VAS 691
005/5- .
– Close valve -1- for connection »C« and open valve -2- for con‐
nection »A«.
– Connect hose from connection »A« of Y junction to connection
»II« of turbocharger tester - V.A.G 1397A- .
Volkswagen AG
– Switch turbocharger tester - V.A.G 1397A- to position »II« a(rel‐
gen AG
.
does
ksw
ative pressure test) and turn it on. The »II« must be
by
Vvisible.
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nl
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erm
ab
ility
ot p
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, is n
Connecting tester - V.A.G 1687- :
h re
hole
spec
– If fitted, unclip wire to exhaust flap control unit -1-.
es, in part or in w
t to the co
– Loosen clamp -2- on exhaust pipe, and push it towards rear.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
– On vehicles without a tunnel cross-piece, use a tensioning

t
sd
iva
strap -2- to tie up exhaust pipe -1-.

o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Connect adapter - V.A.G 1687/11- with hose -A- to exhaust

pipe (engine side). Secure hose with hose clips.
Use hose -A- for exhaust pipes of 55 mm in diameter = hose
- V.A.G 1687/16- .
Use hose -A- for exhaust pipes of 60 mm and 65 mm in diam‐
eter = hose - V.A.G 1687/15- .
– Connect charge air system tester - V.A.G 1687- to adapter -
V.A.G 1687/11- .
Prepare charge air system tester - V.A.G 1687- as follows:

– Completely unscrew pressure regulating valve -2-, and close
valves -3- and -4-.
• To turn the pressure regulating valve -2-, the knob must be
pulled upwards.
– Connect compressed air -1- to charge air system tester -
V.A.G 1687- .
– Open valve -3-.

– Using pressure regulating valve -2-, adjust pressure to 0.8 bar.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.8 bar.

agen oes
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A small amount of air escapes
ed by through the valves and enters arthe
an
engine. Therefore athoholding pressure test is not possible.
ris tee
or
au ac
ss
ce
le
un
pt
an
d
Reading turbocharger tester - V.A.G 1397A- :

itte
y li
erm
ab
• Observe turbocharger tester about 5 minutes.

ility
ot p
wit
is n
• The pressure indicated by the turbocharger tester must not

h re
ole,
rise more than 0.025 bar.

spec
– If the pressure on the turbocharger tester rises above

t to the co
0.025 bar, compressed air is leaking from the exhaust side into
the cooling system. The exhaust gas recirculation cooler has
a leak. Renew exhaust gas recirculation cooler.
rrectnes
Note
s o
cial p
f inform
A vacuum can develop due to the cooling of the coolant. A vac‐

mer
uum is indicated by a »minus« symbol on the turbocharger tester .

atio
m
»Negative« values do not indicate a leak. If you are uncertain,

o
n
c
equalise the pressure in the cooling system and repeat the test.
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Cleaning Y junction - VAS 691 005/1- :
Note
The Y junction - VAS 691 005/1- must be cleaned after performing

the leakage test to remove any moisture which may have entered.
– Insert cleaning nozzle -D- into hose on connection -A- of Y

junction .
– Fit test adapter - VAS 691 005/5- onto hose of connection
-B-.
– Push compressed air hose onto connection -C-.
– Open valve and blow air through hose for about 15 seconds.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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gh ht
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530
Prote AG.
AG. Volkswagen AG d
agen oes
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Golf 2009 ➤ , Golf d by Cabriolet 2012 ➤ , Golf Plus 2009
V gu ➤ , Passat 2006 ➤ ...
ara
e
is4-cylinder common rail engine (1.6 l, EA189) nte
hor e o - Edition 02.2016
aut ra
ss c
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28 – Glow plug system
un
pt
an
d
itte
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rm
ab
pe
ility
1 Glow plug system
ot
wit
, is n
h re
hole
⇒ “1.1 Removing and installing glow plugs”, page 531
spec
es, in part or in w
⇒ “1.2 Checking glow plugs”, page 533
t to the co
⇒ “1.3 Removing and installing Hall sender G40 ”, page 533
⇒ “1.4 Removing and installing engine speed sender G 28 ”, page
rrectness of i
535
l purpos
1.1 Removing and installing glow plugs
nform
ercia

m
a
♦ 10 mm jointed spanner - 3220-
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
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by c lksw
cted agen
Prote AG.
♦ Pliers - 3314-
Removing
– Clean glow plug channel in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
opening, let it work in briefly and blow out with compressed air.
♦ Then clean glow plug opening using a cloth moistened with oil.
1. Glow plug system 531

Caution

connecting the heater-element connectors.
Otherwise the whole wiring harness will need to be renewed.
Do not squeeze the pliers - 3314- too firmly when pulling off
glow plug connectors, because otherwise the support sleeve
may be damaged.
– Pull connector -B- off pressure differential sender - G 505- and

fuel pressure sender - G 247- -C-.
– Unscrew securing bolts (Golf, Golf Plus, Passat) of coolant line
-arrows- from intake manifold and set line down in front of in‐
take manifold.
– Open cable guide fasteners to free wiring harness.
AG. Volkswagen AG d
agen oes
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ara
ed
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aut ra
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Position pliers - 3314- with groove -arrow A- on support sleeve spec

shoulder -arrow B- and pull plugs off glow pin plugs.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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rig ht
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Prote AG.
532 Rep. gr.28 - Glow plug system

AG. Volkswagen AG d
agen oes
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rise nte
tho eo
au ra
ss c
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
– Unscrew securing nut of fuel return line from intake manifold,
wit
is n
open clamp -arrow- and pull line off high-pressure accumula‐
h re
ole,
tor.
spec
– Remove entire fuel return line and set it down in front of intake
t to the co
manifold.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
– To loosen glow plugs use special tool U/J extension and
or
n thi
e
10 mm socket - 3220-
t
sd
iva
o
pr
cum
Installing
r
fo
en
ng
t.
yi
– To tighten glow plugs use special tool U/J extension and
Co
Cop py
10 mm socket - 3220- with a suitable torque wrench.
t. rig
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– Then tighten glow plugs to specified torque.
c by lksw
cted agen
Prote AG.
♦ Specified torque: 18 Nm
– Fit glow plug connectors onto glow plugs and ensure they are
properly seated.
– Open cable guide fasteners to free wiring harness.
– Secure wiring harness in cable guide again.
– Further installation is carried out in the reverse order.
– Clear engine control unit event memory.
1.2 Checking glow plugs

Checking
The glow plug system is monitored by the engine control unit's
self-diagnosis system.
The necessary checks are performed with Guided fault finding.
1.3 Removing and installing Hall sender -

G40-
Removing
– Remove fuel filter with bracket ⇒ Rep. gr. 20 ; Fuel filter;
1. Glow plug system 533


– Remove vibration damper ⇒ page 88 .
– Pull connector -1- only off radiator outlet coolant temperature
sender - G83- , open clips -arrows- and remove toothed belt
guard.
Polo
– Remove engine bracket ⇒ page 105 .
During further work, toothed belt must be removed from idler pul‐
ley and high-pressure pump.
Note
2 versions of tensioning roller are fitted. They are interchangea‐

ble. On making adjustments, first check which tensioning roller is
fitted ⇒ page 181 .
Removing toothed belt from idler pulley and high-pressure pump

⇒ page 181 .
AG. Volkswagen AG d
agen oes
ksw
– Disconnect connector -1- for Hallbysender
Vol
- G40- and pull con‐ not gua
nector out of retainer. ris
ed ran
tee
ho
ut or
– Detach plug from its retainer.
ss
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
en
ng
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Prote AG.
534 Rep. gr.28 - Glow plug system

– Remove webs and repair aperture cover -arrows- with a

screwdriver.
– Remove Hall sender - G40- from cylinder head and guide its
plug through repair aperture in toothed belt guard.
Installing
♦ Seal repair aperture in toothed belt guard with rubber plugs as
specified in ⇒ Electronic Parts Catalogue (ETKA) .
– Fit toothed belt and adjust valve timing ⇒ page 181 .
Polo
– Install engine bracket ⇒ page 105 .
1.4 Removing and installing engine speed

sender - G 28-
♦ Hexagon key extension, 4 mm - T10370-
AG. Volkswagen AG d
agen oes
olksw not
V gu

D3E801B26A2-4-Cylinder Common Rail Engine (1 6 L EA189)

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D3E801B26A2-4-Cylinder Common Rail Engine (1 6 L EA189)

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Copyright:

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D3E801B26A2-4-Cylinder Common Rail Engine (1 6 L EA189)

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Service

Polo 2010 ➤ , Touran 2003 ➤

4-cylinder common rail engine (1.6 l, EA189)

Service Department. Technical Information

23 - Mixture preparation - injection

28 - Glow plug system

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Copyright © 2016 Volkswagen AG, Wolfsburg D3E801B26A2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4.4 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 t to the co

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

1.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

2.3 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

3.1 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

4 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

4.1 Assembly overview - radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

2.3 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

1.3 Filling, bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

7.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531

1.1 Engine number, engine data

1.1.1 Engine number

number”. If more than 999,999 engines were produced with the

1.1.2 Engine data

Engine code CAYA CAYA CAYB CAYC CAYC

Manufac‐ Golf 04.09 06.09 06.09

Golf 04.09 06.09 06.09

Polo 05.09 05.09 07.09 07.09

Emissions fulfil EU5 EU4 EU5 EU5 EU3

Torque Nm at 195/ 195/ 230/ 250/ 250/

Particulate filter yes no yes yes no

2 Rep. gr.00 - Technical data

The fuel line is under pressure.

Wear eye protection and protective clothing to avoid eye inju‐

ries and skin contact. Before loosening hose connections,

wrap a cloth around the connection. Then release pressure by

necting electrical wiring of injection and glow plug system or

♦ Observe prescribed procedures when disconnecting bat‐

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;