Engine BLG Bmy BWK Repair Manual Eng

Service
Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Tiguan 2008 ➤
Touran 2003 ➤
4-cylinder direct-injection engine (1.4 l, EA 111,
turbocharger, supercharger)
Engine ID BLG BMY BWK
Edition 08.2017
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg K0058993820

Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , Touran 2003 ➤
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 08.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 16
2 Removing and installing engine (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 28
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.1 Assembly overview - parts l and ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2 Assembly overview - part I, belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3 Assembly overview - part II, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.4 Removing and installing poly V-belt (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . 36
1.5 Removing and installing poly V-belt (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.6 Removing and installing control housing (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.7 Removing and installing valve timing housing (Tiguan, Touran) . . . . . . . . . . . . . . . . . . . . 44
1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 50
2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3 Removing and installing crankshaft seal on belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.5 Removing and installing crankshaft sealing flange on flywheel end . . . . . . . . . . . . . . . . . . 58
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.4 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.5 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Contents i
1.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.4 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . . 94
1.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.7 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Engine oil, oil capacities, engine oil specification (engine codes BLG, BMY) . . . . . . . . . . 121
1.2 Engine oil, oil capacities, engine oil specification (engine code BWK) . . . . . . . . . . . . . . . . 121
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.1 Assembly overview - parts of cooling system, body side (engine codes BLG, BMY) . . . . 131
1.2 Assembly overview - parts of cooling system, body side (engine code BWK) . . . . . . . . . . 132
1.3 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 133
1.4 Coolant hose schematic diagram (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Coolant hose schematic diagram (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.6 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.7 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.8 Removing and installing radiator fan V7 and radiator fan 2 V177 (engine codes BLG, BMY)
. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 142
1.9 Removing and installing radiator (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . . . . . 142
1.10 Removing and installing radiator and radiator fan V7 (engine code BWK) . . . . . . . . . . . . 144
1.11 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.12 Removing and installing coolant pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.13 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.2 Releasing pressure in high-pressure area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.1 Fuel tank - assembly overview (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.2 Draining fuel tank (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.3 Removing and installing fuel tank (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.4 Assembly overview - fuel tank (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.5 Draining fuel tank (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.6 Removing and installing fuel tank (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.7 Assembly overview - fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.8 Draining fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.9 Removing and installing fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.2 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
ii Contents
3.3 Removing and installing fuel delivery unit (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . 181
3.4 Removing and installing fuel gauge sender G (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . 183
3.5 Checking fuel pumps (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.6 Removing and installing fuel delivery unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.7 Removing and installing fuel gauge sender G (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.8 Checking fuel pump (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.9 Removing and installing fuel delivery unit (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.10 Removing and installing fuel gauge sender G (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.11 Removing and installing suction-jet pump (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.12 Removing and installing fuel gauge sender 2 G169 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 215
3.13 Checking fuel pump (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.14 Removing and installing fuel pump control unit J538 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 223
4 Repairing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.2 Removing and installing accelerator module (Golf, Golf Plus, Tiguan) . . . . . . . . . . . . . . . . 225
4.3 Removing and installing accelerator module (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.1 Assembly overview (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.2 Checking fuel tank breather (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.3 Checking fuel tank breather (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.4 Assembly overview (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5.5 Checking fuel tank breather (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.2 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.3 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.5 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.6 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.7 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.1 Assembly overview - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.2 Removing and installing compressor (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . 255
2.3 Removing and installing compressor (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . 263
2.4 Removing and installing drive unit seal for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.2 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3.3 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.4 Removing and installing charge air cooler (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . 281
3.5 Removing and installing charge air cooler, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.1 Assembly overview - parts l and II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.2 Assembly overview - part I, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
1.3 Assembly overview - part II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.4 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
1.5 Checking vacuum reservoir for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.6 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
1.7 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
1.8 Removing and installing regulating flap control unit J808 and throttle valve module J338
........................................................................ 298
Contents iii
1.9 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

1.10 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.11 Checking fuel pressure in high-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.12 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
1.13 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.14 Renewing Teflon seal and support washer on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.15 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
1.16 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.17 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
2 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.1 Removing and installing engine control unit J623 (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.2 Removing and installing anti-theft engine control unit J623 (Golf) . . . . . . . . . . . . . . . . . . . . 321
2.3 Removing and installing engine control unit J623 (Golf Plus, Touran) . . . . . . . . . . . . . . . . 323
2.4 Removing and installing anti-theft engine control unit J623 (Golf Plus, Touran) . . . . . . . . 324
2.5 Removing and installing engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . 326
2.6 Removing and installing anti-theft engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . 328
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
1.1 Assembly overview - catalytic converter and attachments (engine codes BLG, BMY) . . . . 330
1.2 Assembly overview - catalytic converter and attachments (engine code BWK) . . . . . . . . . . 332
1.3 Assembly overview - silencer with mountings (engine codes BLG, BMY) . . . . . . . . . . . . . . 333
1.4 Assembly overview - silencer with mountings (engine code BWK) . . . . . . . . . . . . . . . . . . 334
1.5 Removing and installing front exhaust pipe (engine code BWK) . . . . . . . . . . . . . . . . . . . . 334
1.6 Separating centre and rear silencers (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . 335
1.7 Separating centre and rear silencers (engine codes BWK) . . . . . . . . . . . . . . . . . . . . . . . . 337
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.2 Problem solution for Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
1.5 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
iv Contents
00 – Technical data
1 Technical data
(VRL010627; Edition 08.2017)
Engine number ⇒ page 1
Engine data ⇒ page 1
1.1 Engine number

– Detach hose from activated charcoal filter at hose clip
-arrow-.
Engine code and engine number can be found on the sticker

-arrow- on the control housing.
The engine code is also on the vehicle data sticker and on the
crankcase above the gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter.
Note
♦ Vehicles for certain export countries have no type plate. Fitting

locations for vehicle data sticker and identification plate:
♦ Golf, Golf Plus ⇒ Maintenance ; Booklet 38
♦ Touran ⇒ Maintenance ; Booklet 18.1
♦ Tiguan ⇒ Maintenance ; Booklet 24.1
1.2 Engine data

Engine code BLG BMY BWK
Manufactured
Golf 11.05► 02.06► ---
Golf Plus 11.05► 02.06► ---
Touran 11.05► 02.06► ---
Tiguan --- --- 10.07►
Exhaust emission stan‐ EU4 EU4 EU4
dard
Displace‐ cm3 1390 1390 1390
ment
Power kW at rpm 125/6000 103/6000 110/5800
1. Technical data 1
Engine code BLG BMY BWK

Torque Nm at rpm 240/1750-4500 220/1500-4000 240/1750-4000
Bore ∅ mm 76.5 76.5 76.5
Stroke mm 75.6 75.6 75.6
Compression ratio 10 10 10
RON min. 95 unleaded 95 unleaded 95 unleaded
Injection, ignition Motronic MED 9.5.10 Motronic MED 9.5.10 Motronic MED 17
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Type of mixture formation Homogeneous Homogeneous Homogeneous
Charging Turbocharger and mechan‐ Turbocharger and me‐ Turbocharger and me‐
ical supercharger chanical supercharger chanical supercharger
2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1 Removing and installing engine
(Golf, Golf Plus, Touran)
Removing engine ⇒ page 3 .
Securing engine to assembly stand ⇒ page 13 .
Installing engine ⇒ page 13 .
Specified torques ⇒ page 15
Assembly mountings ⇒ page 16
Additional information and assembly work for vehicles with air
conditioner ⇒ page 16 .
1.1 Removing engine
Note
♦ Crankcases were installed with different size threaded holes.

♦ Check these holes before dismantling/assembling and install
the respective engine support.
♦ The engine support - T40075- can continue to be used if con‐
verted as described in the respective work sequence.
♦ The fitting of engine support - T40075- and engine support -
T40075A- on the crankcase is described in the respective
work sequence.
Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill a hole with a 13.0 mm bit.
– Identify engine support with an -A- behind tool designation.
1. Removing and installing engine (Golf, Golf Plus, Touran) 3

Special tools and workshop

equipment required
♦ Engine support - T40075- with adapters /4, /5, /6 or engine

support - T40075A- (not illustrated) with adapters /4, /5, /6
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine and gearbox support - VAS 6095-
♦ Drip tray for workshop hoist - VAS 6208-
4 Rep. gr.10 - Removing and installing engine

♦ Pliers for spring-type clips - VAS 5024A-

♦ Stepladder - VAS 5085-
♦ Torque wrench (40 to 200 Nm) - V.A.G. 1332-
♦ Guide pins - T10093-
Note
The battery earth must be disconnected for the remaining proce‐

dure. Therefore, first check whether a coded radio is fitted. Then
obtain anti-theft coding first if necessary.
Engine cover panel ► November 2006

– Release vacuum hose on vacuum reservoir -arrow- and pull it

off.
– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
Engine cover panel, November 2006 ►
– Pull vacuum hose off -arrow-.

rection of -arrow-.
– Unbolt heat shield over turbocharger -arrows-.

– Remove air filter ⇒ page 297 .
– Open and close expansion tank cap to release pressure in
cooling system.
– Drain coolant ⇒ page 136 .
Note
Pull coolant hoses off engine with spring-type clip pliers - VAS
5024A- .
– Release hose guides -arrows- and remove coolant hose -1-

from coolant reservoir.
– Remove hose -2- from activated charcoal filter system

solenoid valve 1 - N80- to activated charcoal filter.

– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 180 .
– Remove securing bolts -arrows- of engine splash protection.

– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
The engine is removed downwards together with the gearbox.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Remove battery and battery holder ⇒ Electrical system; Rep.
gr. 27 ; Removing and installing battery .
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
WARNING
Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.
– Pull vacuum and breather hoses off engine.

– Pull connectors off thermal switch and radiator fan.
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Removing and installing anti-theft engine control unit (Golf) ⇒
page 321 .
– Removing and installing anti-theft engine control unit (Golf
Plus, Touran) ⇒ page 323 .

– Open all line guide fasteners -arrows-.

– Remove wiring from engine control unit.
– Secure lines/wiring to engine with a cable tie.
Golf, Golf Plus only
– Remove hoses for activated charcoal filter -arrows-.
– Pull activated charcoal filter -1- upwards out of bracket.
– Unbolt bracket -arrows-.

Continued for all vehicles
– Remove wiring for Lambda probe after catalytic converter -
G130- and for alternator from cable guides -arrows-.

– Pull connector off Lambda probe after catalytic converter -

G130- and remove.
– Open hose clip -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from catalytic converter -arrows-.
– Unbolt exhaust pipe together with flexible joint -arrows-.
– Loosen securing bolts of double clamp -arrows- and pull ex‐

haust pipe to rear.

– Disconnect pendulum support -arrows-.

– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
– Remove strut -1-.
– Detach slave cylinder -arrows- and place to one side. Do not

open pipes.
– Remove hydraulic clutch slave cylinder: ⇒ 6-speed manual
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism
Note
Do not depress clutch pedal.
– Remove poly V-belt ⇒ page 36 .

– Remove air conditioner compressor ⇒ Heating, air condition‐
ing system; Rep. gr. 87 .
Note
The air conditioning system lines must not be opened.
– Secure air conditioner compressor to lock carrier.

– Ensure that lines are not kinked.
– Observe additional information and installation work ⇒ page
16 .
– Remove right drive shaft, and unscrew left drive shaft from
gearbox and tie up: ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
exterior; Rep. gr. 50 ; Body - front; Lock carrier service posi‐
tion
Work sequence with engine support - T40075-
Engine support - T40075- with adapters -/4-, -/5- and -/6- is re‐
quired to lower engine with gearbox.

– Screw adapter T40075/4 into crankcase to stop.

– Position engine support - T40075- with adapters -/5- and -/6-
on crankcase.
– Secure engine support - T40075- hand-tight to crankcase us‐

ing bolt -1-.
– Tighten all bolts on engine support - T40075- to 20 Nm.

– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
Work sequence with engine support - T40075A-
Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐

– Screw adapter T40075A/4 into crankcase to stop.

– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.
– Secure engine support - T40075A- hand-tight to crankcase

using bolt -1-.
– Tighten all bolts on engine support - T40075A- to 20 Nm.
– Unbolt engine side of assembly mounting from above

-arrows-.

– Unbolt gearbox side of assembly mounting from above

-arrows-.
Note
♦ To remove securing bolts use a stepladder - VAS 5085- .

♦ When lifted out, the engine/gearbox assembly must be care‐
fully guided to prevent damage to the bodywork.
– Carefully lower engine and gearbox.
1.2 Securing engine to assembly stand

Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
Procedure
– Unbolt gearbox.
– Secure engine on engine and gearbox support - VAS 6095- .
1.3 Installing engine

Installation is carried out in the reverse order. When installing,
note the following:
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
– Check clutch release bearing for wear and renew if necessary.

– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
– When swinging engine in, ensure that there is clearance be‐
tween drive shafts.
Align engine mountings as follows:

♦ There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ On gearbox end, ensure that edges of support arm -2- and
gearbox bracket -1- are parallel.
– Install pendulum support.
Note
Specified torques for assembly mountings ⇒ page 16 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

shafts .
– Install air conditioning system compressor ⇒ Heating, air con‐
ditioning system; Rep. gr. 87 .
– Install poly V-belt ⇒ page 36 .
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐
box 02S; Rep. gr. 30 ; Repairing clutch mechanism .
– Attach selector mechanism ⇒ 6-speed manual gearbox 02S;
Rep. gr. 34 ; Repairing selector mechanism .
– Install engine splash protection.
– Add coolant ⇒ page 136 .
– Install air filter ⇒ page 297 .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

– Place vacuum hose -2- onto vacuum reservoir union -1-.
Note
Ensure that the vacuum hose is locked onto the union -2-.
– Push engine cover panel down at points -1- in direction of

-arrow- until it engages.

– Fit vacuum hose onto connection -arrow-.
– Connect vehicle diagnostic tester .
– Erase learnt values, and adapt engine control unit to regulating
flap control unit and throttle valve module ⇒ Vehicle diagnostic
tester “Guided Function”.
– Carry out vehicle system test ⇒ Vehicle diagnostic tester
“Guided fault finding”.
– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Perform road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.
1.4 Specified torques

Bolted connection Specified torque
Nuts and bolts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Note

1.5 Assembly mountings

Specified torques
Note
Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.
Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further
B 1) = 40 Nm + 90° (1/4 turn) further
C 1) = 60 Nm + 90° (1/4 turn) further

1) Renew
Gearbox mounting
A 2) = 40 Nm + 90° (1/4 turn) further
B 2) = 60 Nm + 90° (1/4 turn) further

2) Renew
Pendulum support
A 3) = 40 Nm + 90° (1/4 turn) further
B 3) = 100 Nm + 90° (1/4 turn) further

3) Renew
1.6 Additional information and assembly

work for vehicles with air conditioner
Note
To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:

– Remove retaining clamp(s) for refrigerant lines.

sition .

2 Removing and installing engine

(Tiguan)
Removing engine ⇒ page 18 .
Securing engine to assembly stand ⇒ page 25 .
Installing engine ⇒ page 25 .
Specified torques ⇒ page 27
Assembly mountings ⇒ page 27
Additional information and assembly work for vehicles with air
conditioner ⇒ page 28 .
2.1 Removing engine

equipment required
♦ Engine support - T40075 A- with adapters /4, /5, /6

♦ Engine and gearbox support - VAS 6095-
♦ Drip tray for workshop hoist - VAS 6208-

Note
The engine support - T40075- can continue to be used if convert‐

ed as described in the respective work sequence.
Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill a hole with a 13.0 mm bit.
– Identify engine support with an -A- behind tool designation.
♦ Hose clamp pliers - VAS 6340-
2. Removing and installing engine (Tiguan) 19

♦ Stepladder - VAS 5085-

♦ Guide pins - T10093-
Note


rection of -arrow-.

cooling system.
Note
Pull coolant hoses off engine with hose clip pliers - VAS 6340- .
– Release hose guides -arrows- and remove coolant hose -1-

from coolant reservoir.
– Remove hose -2- from activated charcoal filter system

solenoid valve 1 - N80- to activated charcoal filter.

– Seal lines so that fuel system is not contaminated by dirt.
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
sition .
The engine is removed downwards together with the gearbox.
– Remove battery and battery holder ⇒ Electrical system; Rep.
gr. 27 ; Removing and installing battery .
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
WARNING
– Pull vacuum and breather hoses off engine.

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Removing and installing plenum chamber
cover
– Removing and installing anti-theft engine control unit ⇒
page 328 .

– Open all line guide fasteners -arrows-.

– Remove wiring from engine control unit.
– Secure lines/wiring to engine with a cable tie.

– Disconnect connector for Lambda probe after catalytic con‐
verter - G130- .
– Remove Lambda probe after catalytic converter - G130- -1-.
– Remove both drive shafts ⇒ Repairing drive shafts; Rep. gr.
40 ; Removing and installing drive shafts .
– Remove securing bolts -1- and -2- for exhaust pipe mounting.
– Remove exhaust pipe mounting downwards.

– Loosen securing nuts of double clamp -arrows- and slide it

forwards on exhaust pipe -1-.
– Unscrew nuts -arrows- and pull exhaust pipe backwards.

– Push exhaust pipe backwards out of mounting -1-.

– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐
shaft and final drive; Rep. gr. 39 ; Removing and installing
propshaft .
– Push propshaft aside.
– Lower subframe ⇒ Subframe, anti-roll bar, suspension links;
Rep. gr. 40 ; Lowering subframe .
– Remove exhaust pipe forwards.
– Remove gearbox carrier from bevel box ⇒ 6-speed manual
gearbox 0A6; Rep. gr. 34 ; Removing and installing bevel box .
– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 0A6; Rep. gr. 34 ; Repairing selector mechanism .
– Remove hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed

manual gearbox 0A6; Rep. gr. 30 ; Assembly overview - hy‐
draulic system .
Note
Do not depress clutch pedal.

Note


– Observe additional information and installation work ⇒ page
16 .
exterior; Rep. gr. 50 ; Body - front; Lock carrier service posi‐
tion
Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐
– Screw adapter T40075A /4 into the crankcase to stop.

– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.
– Secure engine support - T40075A- hand-tight to crankcase

using bolt -1-.
– Tighten all bolts on engine support - T40075A- to 20 Nm.

– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .

– Unbolt engine side of assembly mounting from above

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

-arrows-.
Note
♦ To remove securing bolts use a stepladder - VAS 5085- .

♦ When lifted out, the engine/gearbox assembly must be care‐
fully guided to prevent damage to the bodywork.
– Carefully lower engine and gearbox.
2.2 Securing engine to assembly stand

carry out repairs.
Procedure
– Unbolt gearbox.
– Secure engine on engine and gearbox support - VAS 6095- .
2.3 Installing engine

note the following:
Caution

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

– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.

– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.

♦ On gearbox end, ensure that edges of support arm -1- and
gearbox bracket -2- are parallel.
– Install gearbox carrier for bevel box ⇒ 6-speed manual gear‐
box 0A6; Rep. gr. 34 ; Removing and installing bevel box .
– Install exhaust pipe.
Note
First tighten securing nuts hand-tight.
– Install exhaust pipe mounting and tighten securing bolts -1-

and -2- to 25 Nm.
Specified torques for exhaust pipe ⇒ page 332 .
– Install subframe ⇒ Subframe, anti-roll bar, suspension links;
Rep. gr. 40 ; Removing and installing subframe .
– Install propshaft ⇒ Rear propshaft and final drive; Rep. gr.
39 ; Removing and installing propshaft .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
shafts .
– Attach selector mechanism ⇒ 6-speed manual gearbox 0A6;
Rep. gr. 34 ; Repairing selector mechanism .
– Install hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed
manual gearbox 0A6; Rep. gr. 30 ; Assembly overview - hy‐
draulic system .

– Install pendulum support.
Note
Specified torques for engine/gearbox assembly mountings ⇒

page 27
– Install air conditioning system compressor ⇒ Heating, air con‐

ditioning system; Rep. gr. 87 .
– Install poly V-belt ⇒ page 38 .
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

– Connect vehicle diagnostic tester .
– Erase learnt values, and adapt engine control unit to regulating
flap control unit and throttle valve module ⇒ Vehicle diagnostic
tester “Guided Function”.
– Carry out vehicle system test ⇒ Vehicle diagnostic tester
“Guided fault finding”.
– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.
2.4 Specified torques

Bolted connection Specified torque
Nuts and bolts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Note
2.5 Assembly mountings

Specified torques

Note
Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.
Engine mounting
A 4) = 20 Nm + 90° (1/4 turn) further
B 4) = 40 Nm + 90° (1/4 turn) further
C 4) = 60 Nm + 90° (1/4 turn) further

4) Renew
Gearbox mounting
A 5) = 60 Nm + 90° (1/4 turn) further
B 5) = 40 Nm + 90° (1/4 turn) further

5) Renew
Pendulum support
A Bolt M10 6) = 50 Nm + 90° (1/4 turn) further
A Bolt M12 6) = 60 Nm + 90° (1/4 turn) further
B Bolt M10 6) = 50 Nm + 90° (1/4 turn) further
B Bolt M12 6) = 60 Nm + 90° (1/4 turn) further
C 6) = 100 Nm + 90° (1/4 turn) further

6) Renew
2.6 Additional information and assembly

work for vehicles with air conditioner
Note

To facilitate removing and installing engine without opening re‐

frigerant circuit:


sition .

13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦ If metal shavings or larger quantities of metal particles or other

deposits (caused for example, by partial seizure of the conrod
bearings) are found in the engine oil when making repairs,
clean the oil passages thoroughly and renew the oil filter in
order to prevent further damage from occurring later.
♦ All bearing and running surfaces must be oiled before assem‐
bly.
Assembly overview - parts l and ll ⇒ page 30 .

Assembly overview - part I, belt drive ⇒ page 31 .
Assembly overview - part II, cylinder block ⇒ page 33 .
Removing and installing poly V-belt (engine codes BLG, BMY) ⇒
page 36 .
Removing and installing poly V-belt (engine code BWK) ⇒ page
38 .
Removing and installing valve timing housing (Golf, Golf Plus) ⇒
page 40 .
Removing and installing valve timing housing (Touran, Tiguan) ⇒
page 44
Removing and installing ancillary bracket ⇒ page 48 .
Note

carry out repairs.
1.1 Assembly overview - parts l and ll
30 Rep. gr.13 - Crankshaft group

1.2 Assembly overview - part I, belt drive
1. Dismantling and assembling engine 31

1 - 40 Nm + 1/4 turn (90°) fur‐

ther
❑ To loosen and tighten
securing bolt, counter‐
hold supercharger shaft
with spanner.
❑ Renew
2 - Pulley
❑ For supercharger
3 - 23 Nm
4 - Tensioning element
❑ For supercharger poly
V-belt
❑ Relieve tension with
spanner.
❑ Lock with locking pin -
T10060 A- .
5 - 8 Nm
6 - Coolant pump with magnet‐
ic clutch for supercharger -
N421-
❑ Removing and installing
⇒ page 146
coolant pump pulley ⇒
page 151 .
7 - 23 Nm
❑ For poly V-belt.
❑ Relieve tension using
16 mm open-end span‐
ner - T10241- .
❑ Lock with locking pin - T10060 A- .
Note
♦ Vehicles with a manual gearbox:

idler roller installed instead of
tensioning element.
♦ Specified torque for securing
bolt: 40 Nm.
9 - 23 Nm
10 - Alternator
11 - Pulley
❑ For crankshaft
❑ With diamond coated washer
❑ Contact surfaces must be free of oil and grease.
12 - Securing bolt
❑ Renew
❑ Removing and installing crankshaft pulley ⇒ page 55
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.

❑ Secure belt pulley against turning with counterhold - 3415- .
❑ Turning further can be done in several stages.
❑ The turning further angle can be measured with a commercial protractor.
13 - 40 Nm + 1/4 turn (90°) further
❑ Renew
❑ Removing and installing with vehicle raised
14 - Air conditioner compressor
15 - 23 Nm
❑ For poly V-belt.
❑ Relieve tension with spanner.
❑ Lock with 4 mm Allen key.
17 - Poly V-belt
❑ Mark direction of rotation before removing.
Caution
When installing poly V-
belt, observe direction of
rotation and make sure it
is properly seated on pul‐
leys and tensioning ele‐
ments.
❑ Removing and installing (engine codes BLG, BMY) ⇒ page 36 .

❑ Removing and installing (engine code BWK) ⇒ page 38 .
18 - Poly V-belt
❑ Mark direction of rotation before removing.
Caution
ments.
1.3 Assembly overview - part II, cylinder block

1 - Cylinder head with

camshaft housing
⇒ page 108
❑ Do not rework sealing
surface.
❑ With integrated
camshaft bearings.
❑ Remove sealant
residue.
❑ Coat with
AMV 188 001 02 before
fitting.
❑ When installing, insert
vertically from above so
that dowel pins fit into
holes in cylinder head.
2 - Cylinder block
❑ Dismantling and assem‐
bling cylinder block ⇒
page 50 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 71 .
3 - Ancillary bracket
❑ For tensioning element
and air conditioner com‐
pressor
⇒ page 48
4 - Cover
5 - Sprocket
❑ For oil pump drive and
timing chain.
6 - 20 Nm + 1/4 turn (90°) further
❑ Renew
7 - Sprocket
❑ Lock sprocket using counterhold tool -T10172- .
8 - Drive chain
❑ Before removing, mark direction of rotation (installation position).
9 - 25 Nm
10 - Mounting pin
❑ Specified torque: 8 Nm
11 - Chain tensioner with tensioning rail
❑ For oil pump drive.
12 - Spring
13 - Sump
❑ Removing and installing ⇒ page 124
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant D 176 600 A2

14 - 13 Nm
15 - Piston
❑ For drive chain tensioner
16 - Compression spring
17 - Chain tensioner
18 - 9 Nm
19 - Valve timing housing
❑ Removing and installing (Golf, Golf Plus) ⇒ page 40
❑ Removing and installing (Touran, Tiguan) ⇒ page 44
❑ Install with sealant D 176 501 A1.
❑ When installing, install two -M6x80- studs in camshaft housing and cylinder block as guides.
❑ To guide valve timing housing, secure sump in position with two bolts.
20 - 10 Nm
21 - Pulley
❑ Note tightening sequence ⇒ page 55 .
22 - Securing bolt
❑ Renew
23 - Bearing bush
24 - O-ring
❑ Renew
25 - 50 Nm
26 - Seal
27 - 40 Nm + 1/4 turn (90°) further
❑ Lock sprockets using counterhold - T10172- .
❑ Bolt with left-hand thread.
❑ Renew
28 - 50 Nm + 1/4 turn (90°) further
❑ Renew
29 - Tensioning rail
30 - Camshaft adjuster
❑ Must not be dismantled.
31 - Timing chain

32 - Sprocket
❑ For exhaust camshaft
❑ Lock sprockets using counterhold -T10172- .
33 - Slide rail
❑ For timing chain
34 - Guide pin
35 - Bearing bush
1.4 Removing and installing poly V-belt (en‐

gine codes BLG, BMY)
Special tools and workshop equipment required
♦ Locking pin - T10060 A-
♦ 16 mm open-end spanner - T10447-
♦ 4 mm Allen key
Removing
Note
♦ Vehicles with an automatic gearbox, two tensioning elements

must be slackened to remove poly V-belt.
♦ Vehicles with a manual gearbox, idler roller installed instead
of upper tensioning element.


– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Wheel housing liner; Removing and in‐
stalling front wheel housing liner .
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt, swing tensioning element in

-direction of arrow- from below using 16 mm open-end span‐
ner.
– Lock tensioning element with a 4 mm Allen key -1-.
– To slacken poly V-belt, swivel tensioning element in direction

of -arrow- from above using 16 mm open-end spanner -
T10447- .
– Lock tensioning element using locking pin - T10060 A- .
– Remove poly V-belt -2-.
Installing
Caution
Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
When installing poly V-belt, observe direction of rotation and
make sure it is properly seated on pulleys and tensioning ele‐
ments.
– Fit poly V-belt first over crankshaft pulley. Finally, push belt
onto tensioning roller.
Further assembly is basically the reverse of the removal proce‐
dure.
After completing repairs always:
– Start engine and check belt running
1.4.1 Poly V-belt routing

Belt drive with air conditioner compressor

1 - Pulley - cooling system pump
2 - Crankshaft pulley
3 - Tensioning pulley
4 - Tensioning roller or idler roller
5 - Alternator pulley
6 - Air conditioner compressor pulley
7 - Poly V-belt
Belt drive for supercharger
Note
♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .
1 - Supercharger pulley
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt
1.5 Removing and installing poly V-belt (en‐

gine code BWK)

♦ 16 mm open-end spanner - T10447-
♦ 4 mm Allen key
Removing
Note
Two tensioning elements must be slackened to remove poly V-

belt.

– Drain coolant; to do this, pull hose -2- off.
Item -1- can be disregarded.
– Release retaining clip and pull right connection (as seen in
direction of travel) off radiator.
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt, swing tensioning element in

-direction of arrow- from below using 16 mm open-end span‐
ner.
– Lock tensioning element with a 4 mm Allen key -1-.

– To slacken poly V-belt, swivel tensioning element in direction

of -arrow- from above using 16 mm open-end spanner -
T10447- .
– Remove poly V-belt -2-.
Installing
Caution
Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
When installing poly V-belt, observe direction of rotation and
make sure it is properly seated on pulleys and tensioning ele‐
ments.
– Fit poly V-belt first over crankshaft pulley. Finally, push belt
onto tensioning roller.
dure.
Add coolant ⇒ page 136 .
1.5.1 Poly V-belt routing

Belt drive with air conditioner compressor
1 - Pulley - cooling system pump
2 - Crankshaft pulley
5 - Alternator pulley
6 - Air conditioner compressor pulley
7 - Poly V-belt
Belt drive for supercharger
Note
♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .
1 - Supercharger pulley
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt
1.6 Removing and installing control housing (Golf, Golf Plus)


equipment required
♦ Support - 10-222A-
♦ Adapter - 10 - 222 A /8-
♦ Counter-hold tool - 3415-
♦ Pin - 3415/1-
♦ Sealant D 176 501 A1
1.6.1 Removing

– Remove engine splash protection.

pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Mark the direction of rotation of the poly V-belt and remove
belt ⇒ page 36 .
– Turn crankshaft in direction of engine rotation to TDC No. 1
cylinder ⇒ page 79 .
– Remove coolant pump ⇒ page 146 .
– Remove air conditioner compressor from bracket with refrig‐
erant lines still connected ⇒ Heating, air conditioning; Rep.
gr. 87 .
– Remove bracket for tensioning element and air conditioner
compressor.
– Remove alternator.
– Install support device - 10 - 222 A- with adapter - 10 - 222 A /
8- as shown and hook into lifting eye.
– Take up weight of engine and remove securing bolts

-arrows-.
– Remove sump ⇒ page 124 .
– Now remove pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .

– Remove Allen head bolt for control housing and hexagon bolts
indicated by -arrows-.
– Remove valve timing housing.
Note
Note that crankshaft bearing bush remains in sealing flange.
1.6.2 Installing
Note
♦ From model year 2009, a diamond coated washer is installed.

The washer prevent the crankshaft from being turned when
the securing bolt is tightened.
♦ Install a diamond coated washer -7- when a washer was not
fitted as original equipment ⇒ Electronic Parts Catalogue “ET‐
KA”.
♦ The washer is fitted -7- between the bearing bush -5- and the
crankshaft sprocket.
♦ Note that all contact surfaces from the securing bolt to the
crankshaft sprocket must be free of oil and grease.
– Clean sealing surfaces carefully. They must be free of oil and

grease.
1 - Securing bolt
2 - Crankshaft belt pulley
3 - Diamond coated washer (clipped onto crankshaft belt pulley)
4 - Crankshaft oil seal
5 - Bearing bush
6 - O-ring
7 - Diamond coated washer
Note
♦ The valve timing housing is still sealed to the engine with a

seal and also sealant D 176 501 A1.
♦ The sealant D 176 501 A1 is used to prevent leaks between
the valve timing housing and the joints -1- and -2-.
♦ Sealant spots must have a diameter of 10 mm and a thickness
of approx. 1 mm.

♦ Do not apply sealant until directly before the valve timing

housing is fitted.
– Apply sealant D 176 501 A1 to the joints camshaft housing/

cylinder head -1- and cylinder head/cylinder block -2-.
– Fit new gasket onto dowel pins.
– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
– Tighten valve timing housing securing bolts evenly and diag‐
onally.
Ensure that valve timing housing is not canted.
Specified torque:
M6 bolt to 10 Nm
M10 bolt to 50 Nm

Install crankshaft belt pulley ⇒ page 55 .
dure.
1.7 Removing and installing valve timing housing (Tiguan, Touran)


equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /22- ( adapter - 10 - 222 A /26- must only
be used for Touran vehicles from November 2006 ►)
♦ Pin - 3415/1-
1.7.1 Removing


housing liner .
– Mark direction of rotation of poly V-belt and remove belt.
Removing and installing (engine codes BLG, BMY) ⇒ page 36 .
Removing and installing (engine code BWK) ⇒ page 38 .
cylinder ⇒ page 79 .
– Remove coolant pump ⇒ page 146 .
– Remove air conditioner compressor from bracket with refrig‐
erant lines still connected ⇒ Heating, air conditioning; Rep.
gr. 87 .
– Remove ancillary bracket.
– Remove alternator.
– Fit support bracket - 10 - 222 A- with adapter - 10 - 222 A /22-
(vehicles as of November 2006 ►: adapter - 10 - 222 A /26- )
as shown in illustration, and hook it into lifting eye.
– Take up weight of engine and remove securing bolts

-arrows-.

- 3415- and -3415/1- .

– Remove Allen head bolts for valve timing housing and

hexagon bolts indicated by -arrows-.
Note
Note that crankshaft bearing bush remains in sealing flange.
1.7.2 Installing
Note

KA”.

grease.
1 - Securing bolt
5 - Bearing bush
6 - O-ring
Note
♦ The valve timing housing is still sealed to the engine with a

seal and also sealant D 176 501 A1.
♦ The sealant D 176 501 A1 is used to prevent leaks between
the valve timing housing and the joints -1- and -2-.
♦ Sealant spots must have a diameter of 10 mm and a thickness
of approx. 1 mm.

♦ Do not apply sealant until directly before the valve timing

housing is fitted.
– Apply sealant D 176 501 A1 to the joints camshaft housing/

cylinder head -1- and cylinder head/cylinder block -2-.
– Fit new gasket onto dowel pins.
– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
– Tighten valve timing housing securing bolts evenly and diag‐
onally.
Ensure that valve timing housing is not canted.
Specified torque:
M6 bolt to 10 Nm
M10 bolt to 50 Nm

Install crankshaft belt pulley ⇒ page 55 .
dure.
1.8 Removing and installing bracket for an‐

cillaries
Removing
Golf, Golf Plus, Touran


Tiguan
– Remove poly V-belt.
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
ing system; Rep. gr. 87
Note

– Unscrew securing bolts -1- and remove bracket.

Installing
– Fit ancillary bracket to cylinder block.
– Tighten securing bolts -1- to 25 Nm.

Specified torque for tensioning element ⇒ Item 13 (page 33)
dure.

2 Removing and installing sealing

flanges and flywheel or drive plate
Assembly overview ⇒ page 50
Removing and installing engine speed sender - G28- (engine
codes BLG, BMY, BWK) ⇒ page 51 .
Removing and installing crankshaft seal on belt pulley end ⇒ page
53
Removing and installing crankshaft pulley ⇒ page 55
Removing and installing crankshaft sealing flange on flywheel
end ⇒ page 58
2.1 Assembly overview
Note
Repairing clutch ⇒ Repairing clutch; Rep. gr. 30 ; Removing and

installing clutch .
1 - Securing bolt
crankshaft pulley ⇒
page 55
❑ Renew
❑ Contact surface for se‐
curing bolt must be free
of oil and grease.
❑ Secure pulley against
turning with counterhold
3415.
❑ The turning further an‐
gle can be measured
with a commercial pro‐
tractor.
2 - Pulley
❑ With diamond coated
washer
❑ Contact surfaces must
be free of oil and grease.
❑ Secure against turning
with counterhold 3415
when removing and in‐
stalling.
poly V-belt (engine
codes BLG, BMY) ⇒
page 36 .
poly V-belt (engine code
BWK) ⇒ page 38 .
3 - Seal
⇒ page 53
4 - Bearing bush

5 - O-ring
❑ Renew
6 - Cylinder block
7 - 60 Nm + 1/4 turn (90°) further
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold - T10044- .
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
10 - 12 Nm
❑ Renew
11 - Sealing flange with sender wheel and oil seal
❑ Removing and installing engine speed sender - G28- (not shown) ⇒ page 51 .
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Removing and installing crankshaft sealing flange on flywheel end ⇒ page 58
2.2 Removing and installing engine speed sender - G28-
2. Removing and installing sealing flanges and flywheel or drive plate 51


equipment required

♦ Guide pin - T10341-
♦ Insert tool - T10370-
Removing
– Remove compressor.
Removing and installing compressor (engine codes BLG, BMY)
⇒ page 255 .
Removing and installing compressor (engine code BWK) ⇒ page
263 .

– Pull off connector -1- from engine speed sender - G28- .

– Remove gasket -2- from cylinder block and remove engine
speed sender - G28- with socket - T10370- .
Installing
– Install engine speed sender - G28- and tighten securing bolt
to 5 Nm.
dure.
2.3 Removing and installing crankshaft seal on belt pulley end

equipment required
♦ Seal puller - 3203-

♦ Torque wrench - V.A.G 1332-
♦ Assembly sleeve - T10117/2-
♦ Assembly tool - T10053-
Removing


pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
– Removing and installing crankshaft pulley ⇒ page 55 .
tool -3415- and -3415/1- .
– Remove centre bolt and remove crankshaft pulley.
– Screw inner part of oil seal extractor - 3203- three turns (ap‐
prox. 5 mm) out of outer part and lock using knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Remove bearing bush from crankshaft journal and clean con‐
tact surfaces of crankshaft sprocket and bearing bush.
Installing
Note

KA”.

grease.
1 - Securing bolt
5 - Bearing bush
6 - O-ring

– Push bearing bush onto crankshaft journal.
– Fit sleeve -T10117/2- onto bush and slide oil seal onto bush.
– Remove sleeve -T10117/2- from bush.
– Using assembly tool - T10053- , drive in oil seal into valve tim‐
ing housing as far as it will go with even blows of hammer.
dure.
Removing and installing crankshaft pulley ⇒ page 55
2.4 Removing and installing crankshaft pulley


equipment required


♦ Pin - 3415/1- (not illustrated)
♦ Locating bolt - T10340-
♦ Dial gauge - VAS 6079-
♦ Dial gauge adapter - T10170-
Removing
Only Tiguan with all-wheel drive
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
drive shafts .
– Loosen pulley securing bolt. Hold pulley with counterhold -
3415- and -3415/1- .
Installing
– Tighten pulley hand-tight using a new securing bolt.

cylinder.

– Unscrew plug from crankcase.

– Screw locking pin - T10340- to stop into crankcase.
– Tighten locking pin - T10340- to 30 Nm.
Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
Note
♦ Always use a new bolt.
Specified torque: 150 Nm + 1/2 turn (180°) further.

Hold pulley with counterhold - 3415- and -3415/1- .
– Unscrew locking pin - T10340- from crankcase.

– Screw plug into crankcase.
Specified torque: 30 Nm
– Install poly V-belt.
dure.
2.5 Removing and installing crankshaft sealing flange on flywheel end


equipment required

♦ Insert tool, 24 mm - V.A.G 1332/11-
♦ Hexagon bolts (Qty. 3) M6×35 mm
♦ Feeler gauge
♦ Depth gauge
2.5.1 Pressing sealing flange with sender

wheel off crankshaft
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
Procedure
– Remove flywheel or drive plate as applicable.

– Set engine to TDC No. 1 cylinder ⇒ page 79

– Remove engine speed sender - G28- -arrow-.
– Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using three M6×35 mm bolts.
– Screw three M6×35 mm bolts into threaded holes -arrows- of

sealing flange.
– Screw bolts alternately (max. 1/2 turn (180°) for each bolt) into
sealing flange and press sealing flange together with sender
wheel off crankshaft.
2.5.2 Pressing sealing flange with sender

wheel onto crankshaft
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.

Assembly tool - T10134-

A - Clamping surface
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)
2.5.3 A - Assemble seal with sender wheel on

assembly tool - T10134- .
– Screw in hexagon nut -B- to just before clamping surface -A-
of threaded spindle.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on
hexagon nut -B- -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.
– Remove securing clip -arrow- from new sealing flange.
Note
Do not remove the sender wheel from the sealing flange or turn
it.

– 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.
– Push sealing lip support ring -A- downwards in direction of ar‐

row until it lies on flat surface.
– Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
– Place sealing flange with front side on assembly tool - T10134-

so that locating pin -A- can be inserted in sender wheel hole
-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 the 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.
2.5.4 B - Fitting assembly tool - T10134- with

sealing flange to 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).
– To guide sealing flange, screw two M6 × 35 mm bolts -A- into

cylinder block.

2.5.5 C - Screwing assembly tool - T10134- on

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft flange -A-.
– Push guide pin for petrol engines (red knob) -F- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
Note
The guide pin for diesel engines (black knob) -D- must not be
inserted 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-.
2.5.6 D - Pressing sender wheel onto

crankshaft 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.
2.5.7 E - Checking sender wheel installation

position on crankshaft

♦ Ruler - T40100-

– 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.
– Turn Allen head bolt of Assembly tool - T10134- out of
crankshaft flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange.

– Measure the distance »a« between crankshaft flange and
sender wheel.
Note
If the engine and gearbox support - VAS 6095- does not provide
the necessary space, the ruler - T40100- should be placed on the
crankshaft flange and the distance determined with a feeler
gauge.
If dimension »a« is too small:

– Re-press sender wheel ⇒ page 65 .
If dimension »a« is achieved:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.
– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install sump ⇒ page 124 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to 60
Nm +1/4 turn (90°).
2.5.8 f) Re-pressing sender wheel

– 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 64
If dimension »a« is still too small:
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 64 .

3 Crankshaft
Pulling needle bearing out of and driving into crankshaft ⇒
page 68 .
Crankshaft dimensions ⇒ page 70 .
1 - 50 Nm and 1/4 turn (90°)

further
❑ Only tighten to 50 Nm
when measuring
crankshaft radial clear‐
ance. Do not turn fur‐
ther.
❑ Renew
2 - Bearing cap
❑ Do not interchange
bearing caps (mark po‐
sitions).
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
3 - Crankshaft
❑ Axial clearance (new):
0.07 ... 0.24 mm
❑ Wear limit: 0.26 mm
Check radial clearance with
Plastigage
❑ New: 0.03…0.05 mm
❑ Do not rotate crankshaft
when checking radial
clearance
❑ Pulling needle bearing
out of and driving into
crankshaft ⇒ page
68 .
❑ Crankshaft dimensions ⇒ page 70 .
4 - Sealing flange with sender wheel and oil seal
❑ With engine speed sender - G28- (not illustrated).
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 58 .
5 - 12 Nm
❑ Renew
6 - Thrust washers
❑ For bearing cap 3.
3. Crankshaft 67
❑ Note fixing arrangement
7 - Bearing shell
❑ In cylinder block
8 - Sprocket
❑ For oil pump drive and timing chain.
9 - Bearing shell
❑ In bearing cap.
❑ Do not interchange used bearing shells (mark).
3.2 Pulling needle bearing out of and driving

into crankshaft
Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-
♦ Drift - VW 207 C-

Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Installing
Note
The needle bearing must always be renewed after the gearbox

has been separated from the engine.
Condition:
• The front edges of the inner puller must not be chipped.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .
3. Crankshaft 69
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

renewed because it will be damaged when it is pulled out again.
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐

box; Installing gearbox .
3.3 Crankshaft dimensions

Honing Crankshaft Conrod
dimension in mm main journal ∅ journal ∅
Basic dimension -0.022 -0.022
54.00 47.80
-0.037 -0.037
Stage I -0.022 -0.022
53.75 47.55
-0.037 -0.037
Stage II --- -0.022
47.30
-0.037

4 Dismantling and assembling pistons

and conrods
Checking piston ⇒ page 72 .
Checking cylinder bores ⇒ page 73 .
Separating new conrod ⇒ page 73 .
Removing and installing pistons ⇒ page 74 .
Removing and installing oil spray jets ⇒ page 75 .
Note
All bearing and running surfaces must be oiled before assembly.
1 - Retaining ring
2 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install us‐
ing drift - 10 - 14- .
3 - Piston
❑ Checking ⇒ page
72
❑ Mark installation posi‐
tion and cylinder num‐
ber.
Caution
Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring

clamp.
4 - Compression rings
❑ Offset gaps by 120°
❑ Remove and install
compression rings with
piston ring pliers.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap ⇒
page 72 .
❑ Checking ring-to-groove
clearance ⇒ page
72 .
5 - Oil scraper rings
❑ Carefully remove and
install 3-part oil scraper rings by hand.
❑ Checking ring gap ⇒ page 72 .
4. Dismantling and assembling pistons and conrods 71

❑ Ring-to-groove clearance not measurable.
6 - Conrod bolt
❑ M7×0.75: 20 Nm + 1/4 turn (90°) further.
❑ M8×1: 30 Nm + 1/4 turn (90°) further.
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
7 - Conrod bearing cap
❑ Due to the cracking method used to separate the bearing cap from the conrod in manufacture, the caps
only fit in one position and only on the appropriate conrod.
❑ Markings -A-: mark with cylinder number
❑ Markings -B-: mark paired conrods and conrod bearing caps
8 - Bearing shell
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
Checking radial clearance with Plastigage:
❑ New: 0.020 ... 0.060 mm
❑ Do not rotate crankshaft when checking radial clearance.
9 - Connecting rod
❑ Renew as set only.
❑ Markings -A-: mark with cylinder number
❑ Markings -B-: mark paired conrods and conrod bearing caps
❑ Separating new conrod ⇒ page 73 .
Caution
The conrod must be re‐
installed in exactly the
same position as it was
previously installed.
If new conrods are fitted,
then the choice of posi‐
tion is arbitrary.
❑ Guided axially by piston.
4.2 Checking piston

♦ External micrometer 75-100 mm - VAS 6071-
Checking piston
– Measure pistons approx 12 mm from the lower edge of skirt,
at 90° to the piston pin axis. Difference between actual and
nominal diameter max. 0.04 mm.
Piston ∅
Basic dimension mm 76.4601)
• 1) Measure approx. 12 mm from bottom of piston skirt

Checking piston ring gap

– Push ring squarely from above down into cylinder bore to ap‐
prox. 15 mm from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20 … 0.40 1.0
2nd compression ring 0.40 … 0.60 1.0
Oil scraper ring 0.20 … 0.80 ---7)
7) No wear limit details available
Checking ring-to-groove clearance

Clean annular groove before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.04 … 0.08 0.15
2nd compression ring 0.02 … 0.06 0.15
Oil scraper ring Cannot be measured
4.2.1 Checking cylinder bores

♦ Cylinder gauge - VAS 6078- (50…100 mm)
Checking cylinder bores
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.08 mm.
Cylinder bore ∅
Basic dimension mm 76.51
Note
Do not measure cylinder bores when cylinder block is mounted

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

On new conrods it is possible that the breaking point is not fully
separated. If the conrod bearing cap cannot be removed by hand,
proceed as follows:
– Mark cylinder allocation of conrod ⇒ Item 9 (page 72) .

– Gently clamp conrod, as shown in illustration, in a vice with

soft aluminium jaws.
Note
♦ To prevent damage to the conrod, only clamp conrod in lightly.

♦ Conrod is clamped below the dashed line.
– Unscrew the two bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.
4.4 Removing and installing pistons

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

Removing
– Remove cylinder head ⇒ page 108 .
– Mark piston installation position and corresponding cylinder
number ⇒ Item 3 (page 71) .
– Mark conrod installation position and corresponding cylinder
and conrod bearing cap ⇒ Item 7 (page 72) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
Note

If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installing
Install in reverse order of removal, observing the following:
Note
Renew bolts that are tightened with turning further angle.
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position ⇒ Item 3 (page 71) .
– Install conrod bearing cap, observing installation position ⇒
Item 7 (page 72) .
– Install cylinder head ⇒ page 108 .
Specified torques
♦ ⇒ “4.1 Assembly overview”, page 71
4.5 Removing and installing oil spray jets

Removing
– Unscrew bolts -arrows-.
– Remove oil pump ⇒ page 126 .
Note
♦ The crank web of the respective cylinder must be positioned

so that the socket - T10545- can be inserted in the pressure
relief valve as close to vertical as possible.
♦ Furthermore, the corners of the socket - T10545- and of the
pressure relief valve must engage well.
– Turn crankshaft via vibration damper securing bolt in direction

of engine rotation until the respective bolt is accessible.

– Unscrew pressure relief valve -1- using Torx bit T40 -

T10545- .
– Remove oil spray jets -2-.
Installing
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Check clearance of oil jets after reinstallation of pistons.
♦ Bent oil spray jets must be renewed.
1- Pressure relief valve - 27 Nm

2- Oil spray jet
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
– Install oil pump ⇒ page 126 .
– Install bolts -arrows-.

15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head, all the contact

surfaces between the support elements, roller rocker arms
and the cams must be oiled before installing the camshaft
housing.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
♦ All bearing and running surfaces must be oiled before assem‐
bly.
♦ Dismantling and assembling intake manifold ⇒ page 288

Checking valve timing ⇒ page 79 .
Adjusting valve timing ⇒ page 82
Checking timing chain ⇒ page 88
Removing and installing timing chain and drive chain for oil pump
⇒ page 94
Removing and installing camshaft housing ⇒ page 103 .
Removing and installing cylinder head ⇒ page 108 .
Checking compression ⇒ page 111 .
1. Cylinder head 77
1 - 8 Nm
2 - High-pressure pump
❑ For fuel supply.
❑ With fuel pressure regu‐
lating valve - N276- .
⇒ page 307
3 - Wiring guide
❑ Bolt to camshaft hous‐
ing with 8 Nm torque.
4 - To air filter
5 - 10 Nm
6 - Hall sender - G40-
❑ With O-ring
❑ Renew O-ring if dam‐
aged.
❑ Problem solution if con‐
nector has slipped ⇒
page 340
7 - Stud, 6 Nm
8 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ Tighten from inside out‐
wards.
9 - Camshaft case
⇒ page 103
❑ Remove sealant
residue.
❑ Carefully clean sealing
surfaces. They must be oil and grease free.
❑ Coat with D 154 103 A1 before fitting
❑ When installing, carefully fit onto dowel pins.
10 - 20 Nm
11 - Lifting eye
12 - Exhaust turbocharger
13 - Oil pressure switch - F1- , 25 Nm
❑ Checking ⇒ page 128
❑ If seal is leaking, nip open and renew.
14 - Cylinder head gasket
❑ Renew
❑ Metal gasket.
❑ After renewing, renew entire coolant.
15 - Cylinder head
❑ Check for distortion ⇒ page 79 .
❑ Sealing surfaces to camshaft housing must be oil and grease free.
❑ After renewing, renew entire coolant.
78 Rep. gr.15 - Cylinder head, valve gear

16 - Guide pin
17 - Dowel pin
18 - Oil strainer
❑ Inserted into cylinder head
❑ Renew
19 - Support element
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface
20 - Roller rocker fingers
❑ Check roller bearing for ease of movement.
❑ When installing, secure to supporting element using securing clip.
21 - Seal
Note
Note the different sealing types

when removing and installing the
camshaft housing ⇒ page 103 .
❑ Renew
❑ Qty. 4
❑ Inserted into cylinder head.
22 - Cylinder head bolt
❑ Renew
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 108 .
23 - Roller tappet
❑ Lightly coat contact surface with engine oil.
24 - O-ring
❑ Renew
❑ Moisten with oil before inserting.
Checking cylinder head for distortion

Check with straightedge 500 mm - VAS 6075- and feeler gauge.
Max. permissible distortion: 0.05 mm
1.2 Checking valve timing
1. Cylinder head 79

equipment required
♦ Spark plug socket - 3122 B-

♦ Puller - T10094 A-
♦ Camshaft clamp - T10171 A-
Note
The mounting points for securing the camshaft clamp were mod‐
ified. A new special tool designated camshaft clamp - T10171 A-
has been introduced. Previous camshaft clamp - T10171- can
continue to be used if processed as described in the following.

– Place template -1- onto camshaft clamp - T10171- as shown.

– Mark camshaft clamp - T10171- at mark -2- using a centre
punch.
– Drill through camshaft clamp - T10171- using a 7 mm bit.
– Deburr hole on both sides.
– Additionally mark tool designation -T10171- with an »A«.
Test sequence
– Remove spark plug from No. 1 cylinder. Use puller -T10094
A- and spark plug socket and extension 3122 B ⇒ page
341
– Unscrew coolant pipe securing bolts.
– Remove oil pressure switch using jointed wrench 24 mm -
T40175- .
– Screw dial gauge adapter -T10170- into spark plug hole to

stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC No. 1
cylinder. Note position of small needle on dial gauge.
The bores -arrows- in the camshafts must be as illustrated. If

necessary, turn crankshaft one turn (360°) further.
Note
♦ If crankshaft is turned more than 0.01 mm past TDC, then turn

crankshaft back 45° against engine direction of rotation. Then
turn crankshaft in direction of engine rotation to TDC No. 1
cylinder.
♦ Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.
♦ If the chain tensioner is defective, the timing chain may jump
when being turned back.
Caution
Before using camshaft clamp - T10171 A- you must check that

the pins on the tool project by at least 7 mm.
If this is not the case, the camshaft clamp is defective and must
be renewed.
Do not use any kind of hammer to position the camshaft clamp.
1. Cylinder head 81
– Insert camshaft clamp -T10171 A- to stop in camshaft open‐

ings.
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
tion “TOP” -arrow 3- must be readable from above.
If camshaft clamp -T10171 A- cannot be fitted into camshaft
openings to stop, then timing is incorrect and must be readjusted
⇒ page 82 .
Timing is OK if camshaft clamp -T10171 A- can be fitted into
camshaft openings to stop.
dure. During this procedure, observe the following:
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
1.3 Adjusting valve timing

equipment required



♦ Counter-hold tool - T10172-
♦ Pin - T40011-

♦ Locating bolt - T10340-
1. Cylinder head 83

Procedure
Removing and installing valve timing housing (Golf, Golf Plus) ⇒
page 40 .
Removing and installing valve timing housing (Touran, Tiguan) ⇒
page 44 .
– To turn crankshaft, reinstall bearing bush, crankshaft pulley
-2- and crankshaft bolt -3- and securely tighten crankshaft bolt
(use counterhold 3415).
– Remove spark plug from No. 1 cylinder. Use puller -T10094
A- and spark plug socket and extension 3122 B ⇒ page
341
– Screw dial gauge adapter - T10170- into spark plug hole to

stop.
– Screw dial gauge -VAS 6079- and extension -T10170/1- in to
– Then turn crankshaft back 45° opposite direction of engine ro‐
tation.
– Press tensioning guide rail -1- in direction of arrow and lock

piston with locking pin -T40011- .
– Mark direction of rotation of timing chain -3- using coloured felt

tip marker pen.
Note
Camshaft adjuster centre bolt -2- has a left-hand thread.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .
– Install camshaft adjuster -1- again.

– Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt
-4- to 50 Nm (use counterhold -T10172- ).
Caution

be renewed.
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be pushed into holes in camshaft to stop.
Note
Do not push camshafts axially whilst turning.
– Screw an M6 bolt hand-tight into corresponding bore

-arrows- (but do not tighten) to secure camshaft clamp -
T10171 A- .
Note
Note that there are different securing points for the camshaft
clamp - T10171 A- .
– Remove camshaft sprocket bolts. It is absolutely necessary to

use counterhold -T10172- for this.
Note
Do not use camshaft clamp - T10171 A- as a counterhold.
– Remove one camshaft sprocket.

– Place timing chain over camshaft sprockets, observing chain
direction of rotation, and install camshaft sprocket again.
– Tighten camshaft bolts until camshaft sprockets can still just
be turned on camshafts.
– Tension timing chain by removing locking pin - T40011- .
1. Cylinder head 85

cylinder. Permissible deviation from TDC No. 1 cylinder:
±0.01 mm.
Note
If crankshaft is turned more than 0.01 mm past TDC, then turn

crankshaft back 45° against engine direction of rotation. Then turn
crankshaft in direction of engine rotation to TDC No. 1 cylinder.
Only Tiguan with all-wheel drive

drive shafts .
– Unscrew plug -arrow- from crankcase.

Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
– Hold camshaft sprockets -1- and -5- in this position with coun‐
terhold -T10172- then tighten bolt -2- (left-hand thread) to 40
Nm and bolt -4- to 50 Nm.
Note
Crankshaft cannot move, and timing chain -3- must remain ten‐
sioned on both sides when tightening camshaft bolts.
– Remove camshaft clamp -T10171 A- .

– Unscrew locking pin - T10340- from crankcase.

– Rotate crankshaft two full turns in direction of engine rotation
to TDC No. 1 cylinder. Permissible deviation from TDC No. 1
cylinder: ± 0.01 mm.
Caution

be renewed.
– Insert camshaft clamp -T10171 A- to stop in camshaft open‐

ings.
If camshaft clamp -T10171 A- cannot be fitted:
– Repeat adjustment.
If camshaft clamp -T10171 A- can be fitted

– Remove camshaft clamp -T10171 A- , hold camshaft sprock‐

ets with counterhold -T10172- and tighten bolts -2- (left-hand
thread) and -4- a 1/4 turn (90°) further with a rigid wrench.
Note
Camshaft adjuster centre bolt -2- has a left-hand thread.
Note
Camshaft sprockets cannot move on camshaft whilst tightening.

1. Cylinder head 87
Note
The locking pin - T10340- remains in the crankcase until the

crankshaft pulley is installed.
♦ Installing valve timing housing (Golf, Golf Plus) ⇒ page 43 .

♦ Installing valve timing housing (Touran, Tiguan) ⇒ page 47
♦ Install crankshaft belt pulley ⇒ page 55 .
♦ Install poly V-belt.
♦ Removing and installing (engine codes BLG, BMY) ⇒ page
36 .
♦ Removing and installing (engine code BWK) ⇒ page 38 .
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
1.4 Checking timing chain

♦ Torque wrench - VAS 6583-
♦ Tester for checking elongation of chain links - T10550-
♦ Camshaft clamp - T10550/1-

♦ Indicator - T10550/2-
♦ Scale sleeve - T10550/3-
• The engine oil temperature must be at least 40°C ⇒ Vehicle
diagnostic tester.
• The engine must necessarily not be at »TDC« position.
– Remove right front wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres .

– Remove noise insulation ⇒ Body, front; Rep. gr. 50 ; Noise

insulation; Assembly overview - noise insulation .
– Remove front right wheel housing liner: ⇒ General body re‐
housing liner .
Removing poly V-belt (engine codes BLG, BMY) ⇒ page 36 .
Removing poly V-belt (engine code BWK) ⇒ page 38 .
– Pull coolant hoses -1- off charge air pipe -2-, and clamp them
off using hose clips up to 40 mm - 3093- .
Vehicles with auxiliary/supplementary heater:
– Open hose clips, and pull coolant hoses off coolant pipes -1-.
– Remove auxiliary/supplementary heater with exhaust pipe
and coolant hoses still connected ⇒ Auxiliary heater, supple‐
mentary heater; Rep. gr. 82 ; auxiliary/supplementary heater;
Removing and installing auxiliary/supplementary heater .
Continued for all vehicles:

– Pull off securing clip on charge air cooler in
-direction of arrow-.
– Pull charge air hose -arrow- off charge air cooler.
– Remove securing bolt -arrow- for charge air pipe -1-.
1. Cylinder head 89
– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– Unclip bracket -2- on subframe for electric wire to oil level and
oil temperature sender - G266- .
– Unscrew securing bolt -arrow- for charge air pipe -1-.
– Lift off engine cover at points -1- and pull it forwards in direction
of -arrow-.
– Remove air filter housing ⇒ page 297 .
– Pull off fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing release tabs.

– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.
– Unscrew hose clip -1- on charge air pipe.

– Open hose retainer -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3- and pull off con‐
nector from charge air pressure sender - G31- with intake air
temperature sender 2 - G299- .
– Remove bracket -4-.
– To do this, unscrew bolts -arrows-.

– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
– Remove charge air pipe downwards.
– Release connector -2- and pull off.
1. Cylinder head 91
Disregard item -1-.
– Remove bolts for both camshaft covers -3-.

– Unclip wiring harness -1-.
– Pull coolant pipe -2- and wiring harness -1- away from cylinder
head.
– Lever both camshaft covers -3- out of cylinder head.
– The hole in the left exhaust camshaft -left arrow- must be po‐
sitioned as shown in the illustration.
– If necessary, turn crankshaft in direction of engine rotation.
– Insert camshaft clamp - T10550/1- to stop in camshaft open‐

ings.
– The locking pin -arrow A- must engage in hole -arrow B- in
exhaust camshaft.
– Inscription “TOP” must be readable from above.

– Bolt on camshaft clamp - T10550/1- hand-tight.

– Use one bolt of the camshaft covers for this purpose -arrow-.
– Screw indicator - T10550/2- into hole in sump.

– Align centring point vertically so that the tip faces upwards.
– Tighten centring point with knurled nut.
– Position scale sleeve - T10550/3- on belt pulley.
Caution
There is a risk of injury caused by trapping fingers.

The scale sleeve - T10550/3- is equipped with magnets.
Proceed with great care when joining the components.
Note that the components are drawn together quickly by the
magnetic force.
– Align scale sleeve - T10550/3- with indicator - T10550/2- as

shown in illustration.
– Apply torque wrench - VAS 6583- with a suitable socket to

crankshaft bolt.
– Push torque wrench - VAS 6583- clockwise and maintain a
torque of 40 Nm on it.
– Set scale sleeve - T10550/3- and indicator - T10550/2- to »0«.
1. Cylinder head 93
– Switch setting of torque wrench - VAS 6583- , and push it

slowly anti-clockwise.
– Maintain a torque of 40 Nm on torque wrench - VAS 6583- .
– Read value on the scale.
– If the chain skips during the test, renew timing chain ⇒ page
94 .
– If the chain skips, it can be heard and felt clearly.
Evaluation of the test
– If a chain elongation of up to 28° has been determined during
the test, the timing chain is OK.
– If a chain elongation of 29° and more has been determined,
the timing chain is not OK and must be renewed ⇒ page
94 .
Assemble in reverse order of dismantling. During this procedure,
observe the following:
Note
♦ The scale sleeve - T10550/3- is equipped with magnets.

♦ Do not use any levers for removing the scale sleeve -
T10550/3- from the belt pulley!
– Turn scale sleeve - T10550/3- towards right by approx. 45° so

that indicator - T10550/2- is not positioned within range of
scale.
– Grasp behind scale sleeve - T10550/3- with both hands.
– Press thumbs against bolt of belt pulley, and pull off scale
sleeve - T10550/3- .
– Renew oil seals for camshaft sealing cover and oil them before
fitting.
Specified torques
♦ ⇒ “1.7 Removing and installing air filter”, page 297
♦ ⇒ “2.1 Assembly overview”, page 114
♦ ⇒ “3.1 Assembly overview - charge air system”, page 275
♦ ⇒ “2.1 Assembly overview - supercharger”, page 254
♦ ⇒ “1.2 Assembly overview - part I, belt drive”, page 31
♦ ⇒ Body, front; Rep. gr. 50 ; Noise insulation, Assembly
overview - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
1.5 Removing and installing timing chain and chain drive for oil pump


equipment required

♦ Pin - T40011-
1. Cylinder head 95

Removing

off.
rection of -arrow-.

rection of -arrow-.
– Remove coolant hoses and line/wiring guides -arrows-.

– Unscrew securing bolts and remove camshaft sealing
covers -1-.
– Remove spark plug from No. 1 cylinder. To do this, use puller
- T10094 A- and spark plug socket and extension - 3122 B- ⇒
page 341 .

– Screw dial gauge adapter - T10170- into spark plug hole to

stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
The bores -arrows- in the camshafts must be as illustrated. If

necessary, turn crankshaft one turn (360°) further.
Note
♦ If crankshaft is turned more than 0.01 mm past TDC, then turn

crankshaft back 45° against engine direction of rotation. Then
turn crankshaft in direction of engine rotation to TDC No. 1
cylinder.
♦ Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.
Caution

be renewed.
– Insert camshaft clamp - T10171 A- to stop in camshaft open‐

ings.
1. Cylinder head 97
– Screw an M6 bolt hand-tight into corresponding bore

-arrows- (but do not tighten) to secure camshaft clamp -
T10171 A- .
Note
Note that there are different securing points for the camshaft
clamp - T10171 A- .
– Remove the control housing (Touran, Tiguan) ⇒ “1.7 Remov‐

ing and installing valve timing housing (Tiguan, Touran)”, page
44
– Remove the control housing (Golf, Golf Plus) ⇒ “1.6 Removing
and installing control housing (Golf, Golf Plus)”, page 40 .
– Pull cover -1- off sprocket for oil pump.
– Press tensioning rail in -direction of arrow- by hand and lock

piston of chain tensioner with locking pin - T40011- .
– Mark direction of rotation of timing chain -3- using coloured felt

tip marker pen.
Note
Camshaft adjuster securing bolt -2- has a left-hand thread.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .

– Hold oil pump sprocket with counterhold - T10172- and loosen

securing bolt -1-.
– Use a screwdriver on bolt -2- to release tensioning spring -1-

then remove tensioning spring -1-.
– Unscrew securing bolt -3- and remove chain tensioner.
– Mark direction of rotation of oil pump drive chain -2- using felt-
tip marker.
– Remove securing bolt for sprocket -1- and remove

sprockets -1- and -3- together with drive chain for oil pump
-2-.
Installing
• The crankshaft must be positioned at TDC No. 1 cylinder.
– Push sprocket -1- in -direction of arrow- onto crankshaft jour‐

nal as far as the stop.
Caution
Cast lug -2- on sprocket -1- must seat in groove -3- on

crankshaft journal.
1. Cylinder head 99
– Mark position of sprocket and crankshaft to cylinder block us‐

ing a felt-tip marker.
– Place oil pump drive chain -3- onto sprocket -1- while posi‐
tioning sprocket -2- on oil pump drive shaft.
Note
♦ Note running direction mark on oil pump drive chain.

♦ Oil pump drive sprocket only fits on oil pump drive shaft in one
position -arrow-.
– Hold oil pump drive sprocket with counterhold - T10172- .

– Tighten new securing bolt -1- to 20 Nm + 1/4 turn (90°) further.
– Position chain tensioner on oil pump drive chain and tighten

securing bolt -3- to 8 Nm.
– Lever tensioning spring -1- onto bolt -2- using a screwdriver.
Note
♦ Note marks -arrows-.

♦ The crankshaft must remain stationary.
– Tighten sprocket -3- hand-tight with new securing bolt.

– Place timing chain -1- on crankshaft sprocket -4-, exhaust

camshaft sprocket -3-, and tighten camshaft adjuster -2- hand-
tight using a new securing bolt.
Note
♦ Note running direction mark on timing chain -1-.

♦ Ensure guide sleeve is installed between inlet camshaft and
camshaft adjuster.
♦ Camshaft adjuster securing bolt -2- has a left-hand thread.
Timing chain must lie on guide rail -1- and crankshaft sprocket
-arrow-.
– Install chain tensioner -1- and tighten securing bolts -2- to

9 Nm.
– Tension timing chain by pulling locking pin - T40011- out of
chain tensioner.
– Check marks on crankshaft sprocket and cylinder block; they
must align.
– Tighten securing bolt -2- to 40 Nm and bolt -4- to 50 Nm (use

counterhold -T10172- ).
Note
♦ Securing bolts -2- and -4- are only tightened 90° further once
timing has been checked.
♦ The camshaft adjuster securing bolt -2- has a left-hand thread.
1. Cylinder head 101

– Unscrew bolt -arrow- and remove camshaft clamp - T10171

A- from camshaft housing.
– Check valve timing ⇒ page 79
If valve timing is OK:
– Hold camshaft wheels with counterhold -T10172- and tighten

bolts -2- (left-hand thread) and -4- a 1/4 turn (90°) further with
a rigid wrench.
Note
Camshaft adjuster securing bolt -2- has a left-hand thread.
Note
Camshaft sprockets cannot move on camshaft whilst tightening.
– Install oil pump wheel cover -1-.

– Install valve timing housing (Touran, Tiguan) ⇒ “1.7 Removing
and installing valve timing housing (Tiguan, Touran)”, page
44 .
– Install valve timing housing (Golf, Golf Plus) ⇒ “1.6 Removing
and installing control housing (Golf, Golf Plus)”, page 40 .
– Install crankshaft pulley ⇒ “2.4 Removing and installing
crankshaft pulley”, page 55 .
Removing and installing (engine codes BLG, BMY) ⇒ “1.4 Re‐
moving and installing poly V-belt (engine codes BLG, BMY)”,
page 36 .
Note



dure.
1.6 Removing and installing camshaft housing


equipment required

♦ Pin - T40011-


1.6.1 Removing
Note
♦ The camshafts are mounted in the camshaft housing on this

engine. Before removing the camshaft housing, first remove
the valve timing housing.
♦ Removing and installing valve timing housing (Golf, Golf Plus)
⇒ page 40 .
♦ Removing and installing valve timing housing (Touran,
Tiguan) ⇒ page 44 .
♦ The camshaft housing sealing surface cannot be reworked.
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.
– With ignition switched off, disconnect battery earth strap.
– Remove coolant hoses and line/wiring guides -arrows-.
– Unscrew securing bolts and remove camshaft sealing
covers -1-.
– Remove turbocharger ⇒ page 238 .
– Remove valve timing housing ⇒ page 40 .
– Turn crankshaft to TDC No. 1 cylinder. Then, turn crankshaft
back 45° against direction of engine rotation, and remove
camshaft sprockets with timing chain ⇒ page 82 .
– Unbolt camshaft sealing covers.
– Pull connectors off fuel pressure sender for low-pressure -
G410- and off high-pressure pump.
– Unscrew earth cable from camshaft housing.
– Remove ignition coils. Use puller -T10094 A- for this purpose
⇒ page 341 .
– Remove cable guide with wiring harness from camshaft hous‐
ing.
WARNING


– Pull connector and fuel supply line -arrows- off high-pressure

pump.
– Remove wiring guide -2- and take clip -4- off high-pressure
line.
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
– Loosen union nuts -3- and -1- of high-pressure line.

– Disconnect connector off Hall sender - G40- .
– Pull out oil dipstick.
– Loosen camshaft housing bolts from outside to inside, alter‐
nately and diagonally and remove.
– Carefully lift camshaft housing off.
1.6.2 Installing
Condition
• The pistons cannot be positioned at TDC.
– Remove sealant residues from cylinder head and camshaft
housing with a rotating brush, e.g. a hand drill with a plastic
brush (wear eye protection).
grease.
– Also prevent dirt and residual sealant from entering cylinder
head.
Caution

be renewed.

– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be pushed into holes in camshaft to stop.
– Secure camshaft clamp -T10171 A- hand-tight with an M6 bolt
(do not tighten).
Sealing on cylinder head with no sealing ring in area of spark plug
recess
Caution
No sealant is applied in area of the oil strainer -1-.
– Apply thin, even coat of sealant on clean camshaft housing

sealing surface. See yellow area in illustration.
Note
Sealant cannot be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
Sealing on cylinder head with sealing ring in area of spark plug

recess
– Place new seals into grooves in cylinder head.
Caution
No sealant is applied in area of the oil strainer -1-.
– Apply thin, even coat of sealant on clean camshaft housing

sealing surface. See yellow area in illustration.
– Do not apply sealant in area of -arrows-.
Note
Sealant cannot be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
Caution
Ensure that all roller rocker fingers contact valve stem ends
-1- correctly and that they are clipped into their respective sup‐
port elements -2-.
Proceed with extreme caution when fitting the camshaft hous‐
ing onto the cylinder head in order to prevent the roller rocker
fingers from sliding down!

– When fitting camshaft housing onto cylinder head, first fit

camshaft housing at angle shown in illustration onto dowel
pins -arrows-.
– Then, carefully lower camshaft housing in

-direction of arrow- towards cylinder head.
Note
Ensure that no oil residue can drip onto sealing surfaces.
– Evenly tighten new camshaft housing securing bolts from in‐

side to outside alternately and diagonally.
Ensure that camshaft housing is not canted. Specified torque: 10
Nm + 1/4 turn (90°) further.
Note
After installing the camshaft housing, wait about 30 minutes for

the sealant to dry.
– Adjust valve timing ⇒ page 82 .

♦ Install turbocharger ⇒ page 238 .
♦ Install crankshaft belt pulley ⇒ page 55 .
♦ Attaching fuel lines ⇒ page 307
1.7 Removing and installing cylinder head


equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8- (Golf, Golf Plus)
♦ Adapter - 10 - 222 A /22- (Touran, Tiguan)
♦ Bracket - T10358-
Removing
Remove following components:
♦ Removing and installing valve timing housing (Golf, Golf Plus)
⇒ page 40 .
♦ Removing and installing valve timing housing (Touran,
Tiguan) ⇒ page 44
♦ Remove thermostat housing from cylinder head.
♦ Remove timing chain and drive chain for oil pump ⇒ page
94 .
♦ Remove turbocharger ⇒ page 238 .
♦ Remove regulating flap control unit - J808- and throttle valve
module - J338- ⇒ page 298 .

♦ Removing intake manifold ⇒ page 288 .

– Unscrew securing bolt for gearbox and attach bracket -
T10358- as shown.
– Attach hooks of support bracket - 10 - 222 A- to bracket -
T10358- as shown.
– Turn spindle until the hooks are lightly tensioned.
– Unhook hook -1- from left lifting eye and push spindle onto left
side of support bracket - 10 - 222 A- .
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.
– Loosen cylinder head bolts in sequence given and then re‐

move completely.
– Carefully remove cylinder head.
Installing
Condition
• The pistons cannot be positioned at TDC.
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Now carefully clean sealing surfaces of cylinder head and
cylinder block. When doing this, ensure that surfaces are not
scored or scratched (if sand paper is used, grade must not be
less than 100).
– Carefully remove metal particles, emery residue and cloths.
– Set no. 1 cylinder piston to top dead centre and then turn
crankshaft back slightly.
– Fit new cylinder head gasket. Inscription (Part No.) must be
readable.
– Fit cylinder head. When doing this, observe centring pins in
cylinder block.
– Insert new cylinder head bolts and tighten hand-tight.

– Tighten cylinder head in sequence as follows:

Specified torque/turning further angle
Stage Specified torque
1 30 Nm
2 Turn 90° further using rigid
wrench
wrench
wrench
– Install supporting elements in cylinder head and fit respective
roller rocker finger onto respective valve stem end or support‐
ing element.
– Install camshaft housing.
dure.
1.8 Checking compression


equipment required

♦ Compression tester - V.A.G 1763-
Prerequisites for check
• The engine oil temperature must be at least 30 °C.
Procedure
– Remove ignition coils. Use puller -T10094 A- for this purpose.
– Remove spark plugs using spark plug socket 3122 B ⇒
page 341 .
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er; fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
– Check compression using compression tester - V.A.G 1763- .
Note

How to use the test unit is described in the respective operating

instructions.
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New: 10 … 15 bar
Wear limit: 7 bar
Maximum permissible difference between all cylinders: 3 bar
– Insert spark plugs with spark plug spanner 3122B and tighten
to 25 Nm.
dure.
– Read fault memory, rectify any faults and then erase fault
memory: ⇒ Vehicle diagnostic tester “Guided fault finding”.
The readiness code must be generated if the fault memory has
been erased.

2 Repairing valve gear

Checking camshaft axial clearance ⇒ page 115 .
Reworking valve seats ⇒ page 116 .
Checking valve guides ⇒ page 117
Renewing valve stem seals ⇒ page 118
1 - 40 Nm and 1/4 turn (90°)

further
❑ Left-hand thread
❑ Renew
2 - Camshaft adjuster
❑ Must not be dismantled.
⇒ page 82
3 - Camshaft sprocket
❑ Note position when in‐
stalling timing chain.
4 - O-ring
❑ Renew if damaged
❑ Before installing, coat
lightly with engine oil.
5 - Inlet camshaft control valve
1 - N205-
6 - 10 Nm
7 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ Tighten from inside out‐
wards.
8 - Camshaft case
⇒ page 103
❑ Remove sealant
residue.
❑ Coat with D 154 103 A1
before fitting
❑ When installing, fit verti‐
cally from above onto studs and dowel pins.
9 - 10 Nm
10 - Sealing cover
❑ For inlet camshaft
❑ For exhaust camshaft
11 - Roller rocker fingers
❑ Check roller bearing.

❑ When installing, secure to supporting element using securing clip.
12 - Cotters
13 - Valve stem seal
❑ Renew
14 - Support element
❑ Check oil spray holes.
❑ With hydraulic valve clearance compensation.
❑ Before installing, check camshaft axial clearance ⇒ page 115 .
15 - Valve guide
16 - Valve springs
❑ To remove and install with cylinder head removed, use valve spring tool - 3362- .
❑ With cylinder head installed ⇒ page 118 .
17 - Cylinder head
❑ Reworking valve seats ⇒ page 116 .
❑ Reworking sealing surface ⇒ page 115 .
18 - Valves
❑ Do not rework; only lapping-in is permitted.
❑ Valve dimensions ⇒ page 116
19 - Exhaust camshaft
❑ Do not interchange with inlet camshaft.
❑ Checking axial clearance ⇒ page 115 .
❑ Coat with oil before inserting (also axial bearing shoulder).
20 - Guide bush
21 - Inlet camshaft
❑ With cam for high-pressure pump -arrow-.
❑ Before removing, remove and renew bucket tappet for high-pressure pump.
❑ Do not interchange with exhaust camshaft.
❑ Checking axial clearance ⇒ page 115 .
❑ Coat with oil before inserting (also axial bearing shoulder).
22 - 50 Nm + 1/4 turn (90°) further
Reworking cylinder head sealing surface

Cylinder head reworking dimension: a = at least 108.25 mm
Note
When the sealing surface has been reworked, the valves must be
set deeper by the same amount (valve seat inserts reworked) or
valves will contact pistons. When doing this, ensure that the per‐
missible minimum dimension is maintained ⇒ page 116 .
2.2 Checking camshaft axial clearance
2. Repairing valve gear 115


♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Perform measurements with camshaft housing removed and cap
fitted.
Checking camshaft axial clearance
Wear limit: max. 0.40 mm
Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Outlet valve

∅a mm 29.5 26.0
∅b mm 5.973 5.953
c mm 100.9 100.5
α ∠° 45 45
2.3 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 117 .
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.
Note

If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
– Measure distance between end of valve stem and upper edge

of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance and minimum dimension.
Minimum dimension: inlet valve 7.6 mm, exhaust valve 7.6 mm
Measured distance minus minimum dimension
= max. permissible reworking dimension.
Example:
-Measured distance 8.0 mm
Minimum dimension 7.6 mm
=Max. permissible reworking dimension8) 0.4 mm
8) The max. permissible reworking dimension is shown as dimension “b” in the
illustrations for reworking valve seats.
Reworking inlet valve seat

a = 28.7 mm diameter
b = max. permissible reworking dimension1
c = 1.5 … 1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
9) Calculating max. permissible reworking dimension ⇒ page 116 .
Reworking exhaust valve seat
a 25.0 mm ∅
b = max. permissible reworking dimension1
c = approx.1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
10) Calculating max. permissible reworking dimension ⇒ page 116 .
2.4 Checking valve guides

♦ Dial gauge
Test sequence

– Insert new valve into guide. The end of the valve stem must
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: 0.8 mm
If the amount of sideways play is exceeded:
– Renew cylinder head.
2.5 Renewing valve stem seals

♦ Spark plug socket - 3122B-
♦ Valve stem pliers - VAS 6770-
♦ Valve spring tool - 3362- with thrust piece - 3362/1-

♦ Valve stem seal fitting tool - 3365-
♦ Pressure hose - VW 653/3-
Removing
(With cylinder head installed)
– Remove camshaft housing ⇒ page 103 .
– Remove roller rocker fingers and place onto a clean surface.
When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Remove spark plugs with spark plug spanner -3122B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Attach valve spring tool - 3362- with thrust piece - 3362/1- .
– Now screw pressure hose -VW 653/3- into spark plug hole.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals using valve stem pliers - VAS 6770- .
Installing

– Place plastic sleeve supplied on respective valve stem. This

will prevent damage to new valve stem seal.
– Place new valve stem seal in valve stem seal fitting tool -
3365- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
– Install camshaft housing ⇒ page 106 .
♦ Install fuel lines ⇒ page 307

17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the conrod bear‐
ings are damaged. To prevent this from causing further
damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renewing oil filter
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 124 .
Engine oil, oil capacities, engine oil specification (engine codes

BLG, BMY) ⇒ page 121
Engine oil, oil capacities, engine oil specification (engine code
BWK) ⇒ page 121
Removing and installing sump ⇒ page 124 .
Removing and installing oil pump ⇒ page 126 .
Checking oil pressure and oil pressure switch ⇒ page 128
1.1 Engine oil, oil capacities, engine oil

specification (engine codes BLG, BMY)
Oil capacities
With oil filter 3.6 l
Engine oil specifications
⇒ Maintenance ; Booklet 38
Changing engine oil: ⇒ Maintenance ; Booklet 38 “Engine oil:
Drain or extract”.
1.2 Engine oil, oil capacities, engine oil

specification (engine code BWK)
Oil capacities
With oil filter 4.0 l
Engine oil specifications
⇒ Maintenance ; Booklet 24.1
Changing engine oil: ⇒ Maintenance ; Booklet 24.1 “Engine oil:
drain or extract”
1. Removing and installing parts of lubrication system 121

1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page
124 .
2 - Engine oil cooler
Note
♦ To remove:
♦ Drain coolant ⇒ page 136 .
♦ Remove coolant pipe ⇒ Item 4
(page 122) .
♦ Remove engine oil cooler.
♦ Install in reverse order of re‐
moval.
3 - O-ring
❑ Renew
4 - Coolant pipe
❑ For oil cooler.
❑ Specified torque, brack‐
et to crankcase: 20 Nm.
5 - 8 Nm
6 - Sealing cover
❑ Renew seal if damaged.
7 - Seal
8 - Oil filter cover, 25 Nm
❑ With bypass valve
opening pressure: 2.50 bar.
❑ With non-return valve.
9 - Filter element
10 - Valve
11 - Valve timing housing
❑ Install with sealant D 176 501 A1.
❑ Removing and installing valve timing housing (Golf, Golf Plus) ⇒ page 40 .
❑ Removing and installing valve timing housing (Touran, Tiguan) ⇒ page 44
❑ When installing, install two -M6x80- studs in camshaft housing and cylinder block as guides.
❑ To guide valve timing housing, secure oil sump in position with two bolts.
12 - 10 Nm
13 - Securing bolt
❑ Renew
❑ Secure pulley against turning with counterhold 3415.
14 - Pulley
122 Rep. gr.17 - Lubrication

❑ Contact surfaces of pulley must be free of oil and grease.
❑ Removing and installing poly V-belt (engine codes BLG, BMY) ⇒ page 36 .
❑ Removing and installing poly V-belt (engine code BWK) ⇒ page 38 .
❑ Secure pulley against turning with counterhold -3415- .
15 - Seal
16 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
17 - Seal
18 - Sprocket
❑ For oil pump drive.
19 - 20 Nm + 1/4 turn (90°) further
❑ Renew
20 - Sprocket
❑ For oil pump.
❑ Lock with counterhold -T10172- .
21 - Drive chain
❑ For oil pump.
❑ Before removing, mark direction of rotation (installation position).
22 - 10 Nm
23 - Oil level and oil temperature sender - G266-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
24 - Oil drain plug, 30 Nm
❑ With captive seal
❑ Renew
25 - 13 Nm
❑ Loosen and tighten flywheel end bolts only with Allen key, long reach 5 mm -T10058- .
26 - 40 Nm
27 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant D 176 600 A1
28 - 14 Nm + 1/4 turn (90°) further
29 - Oil pump
Caution
The oil supply line must
be renewed on the tur‐
bocharger if a new oil

pump or oil suction pipe

is fitted.
❑ with oil suction pipe

❑ Specified torque oil suction pipe: 9 Nm
30 - 5 Nm
31 - Oil separator
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched zone: engine oil can be added
c - Area from min. mark up to hatched field: top up, max. 0.5 l of
engine oil!
1.4 Removing and installing sump

♦ Hand drill with plastic brush

♦ Scraper
♦ Safety glasses
♦ Silicone sealant D 176 600 A1
Removing


– Disconnect front exhaust pipe from catalytic converter ⇒ page
330 .
– Pull 3-pin connector off oil level and oil temperature sender -
G266- -1-.
– Drain engine oil.
– Unbolt sump sealed with liquid gasket.

– On the gearbox side, two screws may not be immediately ac‐
cessible. If the screw heads cannot be reached with a bit -
T10058- , turn the crankshaft in the engine direction until the
screws are accessible. The flywheel is provided with recesses.
Remove sump. Loosen sump with light blows of a rubber-
headed hammer if necessary.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump with a rotating brush, e.g.

an electric drill with plastic brush attachment (wear eye pro‐
tection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Check the expiry date of the sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted as guides into the cylinder block flange
at two positions.
– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

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

The sealing compound bead cannot be thicker, or excessive seal‐

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

– Tighten oil sump bolts to 13 Nm.
Specified torque for oil pan securing bolts to gearbox: 40 Nm
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.
1.5 Removing and installing oil pump
Caution
The oil supply line must be renewed on the turbocharger if a

new oil pump or oil suction pipe is fitted.

Removing
– Hold oil pump sprocket with counterhold - T10172- .
– Loosen sprocket securing bolt.
Note
Do not remove bolt completely.

– Press chain tensioner in direction of arrow with a screwdriver.

– Remove sprocket securing bolt.
– Take sprocket off oil pump and out of chain.
– Loosen oil pump securing bolts -arrows- and remove them.

– Remove oil pump from cylinder block.
Installing
Caution
The oil supply line must be renewed on the turbocharger if a

new oil pump or oil suction pipe is fitted.
– Install oil pump and tighten securing bolts to 14 Nm + 1/4 turn

(90°) further.
Specified torque oil suction pipe: 9 Nm
– Press chain tensioner in direction of arrow with a screwdriver.

– Insert sprocket in chain and fit sprocket onto oil pump shaft.
– Observe installation position of sprocket on oil pump shaft

-arrow-.
– Fit sprocket securing bolt.
– Hold sprocket with counterhold - T10172- .

– Apply torque wrench (5…50 Nm) - V.A.G. 1331- as shown in

illustration.
– Tighten securing bolt to 20 Nm +1/4 turn (90°) further.
1.6 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527B-
♦ Adapter set - V.A.G 1594C-
♦ 10 mm jointed spanner - T40175-

Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test sequence
The oil pressure switch is located on the gearbox side beneath
the two camshaft covers.
– Pull connector off oil pressure switch - F1- -arrow-.
– Remove oil pressure switch - F1- using hinged lever, 24 mm -

T40175- and screw into oil pressure tester - V.A.G 1342- .
– Screw tester into cylinder head in place of oil pressure switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- .
– If LED lights up, renew oil pressure switch -F1- .
If LED does not light up:
– Start engine and increase speed slowly. At 0.3 to 0.7 bar the
LED must light up; otherwise renew oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C; the oil pressure should be at least 2.0 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.

19 – Cooling
1 Removing and installing parts of cool‐
ing system
Caution
♦ Observe the following points during all installation work, in

particular in the engine compartment, due to the space
limitations:
sitions.
Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.
♦ Hose clip pliers - VAS 6340- or spring-type clip pliers - VAS
5024A- are recommended for use in installing 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).
Test for leaks in cooling system using cooling system tester -

V.A.G 1274 B- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
Assembly overview - parts of cooling system, body side (engine
codes BLG, BMY) ⇒ page 131 .
Assembly overview - parts of cooling system, body side (engine
code BWK) ⇒ page 132
Assembly overview - parts of cooling system, engine side ⇒ page
133 .
Coolant hose schematic diagram (engine codes BLG, BMY) ⇒
page 135 .
Coolant hose schematic diagram (engine code BWK) ⇒ page
135 .
Draining and filling with coolant ⇒ page 136 .
Checking cooling system for leaks ⇒ page 140 .
Removing and installing radiator fan - V7- and radiator fan 2 -
V177- (engine codes BLG, BMY) ⇒ page 142 .
Removing and installing radiator (engine codes BLG, BMY) ⇒
page 142 .
Removing and installing radiator and radiator fan - V7- (engine
code BWK) ⇒ page 144 .
Removing and installing coolant pump pulley ⇒ page 151 .
130 Rep. gr.19 - Cooling

Removing and installing coolant pump ⇒ page 146 .

Removing and installing coolant circulation pump - V50- ⇒
page 155 .
1.1 Assembly overview - parts of cooling system, body side (engine codes BLG,
BMY)
1 - Radiator/cooler
⇒ page 142
❑ After renewing, renew
entire coolant.
2 - O-ring
3 - Upper coolant hose
❑ To connection on cylin‐
der head.
❑ Connection diagram for
coolant hoses ⇒ page
135
4 - Expansion tank
❑ Check cooling system
for leaks using cooling
system tester - V.A.G
1274 B- and adapter for
cooling system tester -
V.A.G 1274/8-
5 - Connector
6 - Sealing cover
❑ Check using cooling
V.A.G 1274/9-
❑ Pressure relief valve
must open at pressure
of 1.4 to 1.6 bar
7 - 5 Nm
8 - Plastic inserts
❑ For securing bolts.
9 - Bracket
10 - Cowling
11 - 5 Nm
12 - Radiator fan 2 - V177-
13 - Connector
14 - Radiator fan - V7-
❑ With radiator fan control unit - J293- .
15 - Bracket
❑ For connector.
16 - Lower coolant hose
❑ To connection for thermostat.
1. Removing and installing parts of cooling system 131

17 - Retaining clip
18 - Radiator outlet coolant temperature sender - G83-
19 - 5 Nm
1.2 Assembly overview - parts of cooling system, body side (engine code BWK)
1 - Radiator/cooler
⇒ page 144
❑ After renewing, renew
entire coolant.
2 - O-ring
3 - Union
❑ To remove, pull out re‐
taining clip.
4 - Spring-type clip
❑ Remove and install with
hose clip pliers - VAS
6340- .
5 - Coolant hose
135
6 - Upper coolant hose
❑ To connection on cylin‐
der head.
135
7 - Expansion tank
❑ Check cooling system
for leaks using cooling
V.A.G 1274/8-
8 - Connector
9 - Sealing cover
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
❑ Pressure relief valve must open at pressure of 1.4 to 1.6 bar
10 - 5 Nm
11 - Plastic inserts
❑ For securing bolts.
12 - Bracket
13 - 5 Nm
14 - Cowling with radiator fan - V7-
❑ With radiator fan control unit - J293- .

Note
The radiator fan - V7- and the cowl‐

ing may only be renewed complete.
WARNING
Heat shields must be in‐
stalled to prevent dam‐
age to radiator fan due to
heat radiated by exhaust
system.
❑ Specified torque for heat shields: 3 Nm.

15 - Bracket
❑ For connector.
16 - Connector
17 - Retaining clip
❑ Connection diagram for coolant hoses ⇒ page 135
19 - Hose guide
20 - Radiator outlet coolant temperature sender - G83-
❑ Connection diagram for coolant hoses ⇒ page 135
22 - Union
❑ To remove, pull out retaining clip.
1.3 Assembly overview - parts of cooling

system, engine side
Thermostat side

1 - Union
2 - O-ring
❑ Renew
3 - Compression spring
4 - Plunger
❑ Do not cant when in‐
stalling
5 - Thermostat 2
❑ Starts to open at 96 °C
6 - Radiator outlet coolant -
G62-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
7 - Retaining clip
❑ Check for firm seating
8 - Thermostat housing
9 - Seal
❑ Renew
10 - Thermostat 1
❑ Starts to open at 80 °C
11 - To expansion tank
❑ Coolant hose schematic
diagram (engine codes
BLG, BMY) ⇒ page
135 .
❑ Coolant hose schematic
diagram (engine code
BWK) ⇒ page 135 .
12 - Union
13 - Coolant pipe
❑ To remove, remove thermostat housing ⇒ Item 8 (page 134) .
❑ To remove, remove supercharger ⇒ page 255 .
❑ Coolant hose schematic diagram (engine codes BLG, BMY) ⇒ page 135 .
❑ Coolant hose schematic diagram (engine code BWK) ⇒ page 135 .
14 - Coolant pipe
❑ To remove, remove thermostat housing ⇒ Item 8 (page 134) .
❑ To remove, remove supercharger ⇒ page 255 .
15 - 5 Nm
16 - From bottom of radiator.
17 - To top of radiator

1.4 Coolant hose schematic diagram (engine codes BLG, BMY)
1 - Expansion tank
2 - Intake manifold
3 - Heat exchanger for heater
6 - Radiator/cooler
7 - Coolant circulation pump -
V50-
⇒ page 155
⇒ page 238
9 - Cylinder head/cylinder
block
❑ If renewed, refill system
with fresh coolant.
10 - Auxiliary heater
❑ Optional equipment
1.5 Coolant hose schematic diagram (engine code BWK)

1 - Expansion tank
2 - Intake manifold
3 - Heat exchanger for heater
6 - Radiator/cooler
7 - Coolant circulation pump -
V50-
⇒ page 155
⇒ page 238
9 - Cylinder head/cylinder
block
❑ If renewed, refill system
with fresh coolant.
10 - Auxiliary heater
❑ Optional equipment
1.6 Draining and adding coolant


equipment required
♦ Refractometer - T10007 A-
♦ Coolant system charge unit - VAS 6096-
Draining
WARNING
Hot steam may escape when expansion tank is opened. Wear

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.
– Open filler cap on coolant expansion tank.

Engine codes BLG, BMY

– Pull off retaining clip -arrow- and remove coolant hose from
radiator.
Engine code BWK
– Detach spring-type clip and pull off coolant hose -2-.

Disregard item -1-.
Note
Please observe disposal instructions!
Filling
Caution
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been spec‐
ified by Volkswagen. Distilled water fulfils all requirements.
Therefore, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Use ONLY refractometer - T10007A- for determining current
anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐

ever, be increased only to a maximum of -48°C. Otherwise,

the cooling effect will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant at this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixing ratios (use only distilled water for mixing):

Frost Amount of anti- Coolant ad‐ Distilled wa‐
protection to freeze ditive 11) ter 11)
-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l
11) The quantity of coolant can vary depending upon vehicle equipment.
– Press connection against radiator and slide retaining clip

-arrow- into groove.
– Install engine splash protection.
With cooling system charge unit - VAS 6096-
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system
charge unit VAS 6096 .
Without cooling system charge unit - VAS 6096-
– Fill with coolant up to max. mark on expansion tank.

With or without cooling system charge unit - VAS 6096-
– Fit expansion tank cap.
– Turn off heater controls.
Vehicles with no auxiliary heater
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Run engine until radiator fan - V7- cuts in.
Vehicles with auxiliary heater
Caution
Do not switch auxiliary heater on until the cooling circuit has

been filled as described below.

– Connect vehicle diagnostic tester as follows:

– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary/supplementary heater” and “03 - Final control diag‐
nosis” one after the other.
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- .
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed of approx. 2,000
rpm for about 1 minute.
– Run engine until radiator fan - V7- cuts in.
WARNING
Hot steam may escape when expansion tank is opened. Wear

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.
– Check coolant level and top up as needed. The coolant level

must be at the max. marking when the engine is at normal
operating temperature, and between the min. and max. mark‐
ings when the engine is cold.
1.7 Checking cooling system for leaks

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

♦ Adapter for cooling system tester - V.A.G 1274/9-

• Engine at operating temperature.
Test sequence
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
– Open cap on coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Use hand pump on tester to create a pressure of about 1.0 bar.
WARNING
Risk of scalding! Before disconnecting cooling system tester -

V.A.G 1274 B- from connecting hose or connector - V.A.G
1274 B/1- , always relieve existing pressure. To do this, press
pressure relief valve on cooling system tester - V.A.G 1274 B-
until pressure gauge displays value of »0«.
If the pressure drops:

– Find leaks and rectify.
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Use hand pump on cooling system tester to create a pressure
of max. 1.6 bar.
The pressure relief valve must still remain closed.
If the pressure relief valve opens prematurely:

– Renew sealing cap.

– Increase pressure to over 1.6 bar.
The pressure relief valve must open.
If the pressure relief valve does not open:
– Renew sealing cap.
1.8 Removing and installing radiator fan -

V7- and radiator fan 2 - V177- (engine
codes BLG, BMY)
Removing radiator fan
– Remove engine cover.
– Remove upper securing bolts of cowling -arrows-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Noise insulation .
– Separate connector -1- and unscrew lower cowling securing

bolts -arrows-.
– Remove cowling downwards.
– Separate electrical connector -1- and free wiring.

– Unscrew nuts -arrows- and remove fan.
Installing radiator fan
note the following:
Specified torques:
Component Nm
Radiator fan to cowling 10
Cowling to radiator 5
1.9 Removing and installing radiator (engine codes BLG, BMY)


equipment required
Removing
sition .
– Pull coolant hoses off radiator.
– Remove radiator securing bolts and remove radiator with fan
downwards.
Note


– Unbolt condenser from radiator and secure to lock carrier.

Installing
note the following:
Filling with new coolant ⇒ page 136 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
1.10 Removing and installing radiator and radiator fan - V7- (engine code BWK)

equipment required
Removing


– Remove bracket -1- by unscrewing securing bolts -arrows-.
– Push securing clip at charge air cooler in direction of -arrow-

and pull hose -arrow- off.
– Also remove second hose from charge air cooler.
– Disconnect connector -1-.

– Release retaining clip and pull connection -arrow- off radiator.

– Also pull off connection at bottom of radiator.
sition .

– Unscrew securing bolts -arrows- and remove cowling upwards

together with radiator fan - V7- .
Note
The radiator fan - V7- and the cowling may only be renewed com‐
plete.
– Remove securing bolt -arrow-.
– Unscrew bolts -arrows- and remove radiator downwards.

Installing
note the following:
Specified torques:
Component Nm
Radiator to charge air cooler 5
1.11 Removing and installing coolant pump
Note
Coolant pump seal is bonded in position. If the seal is damaged,

the coolant pump must be renewed.


equipment required
♦ 16 mm open-end spanner - T10241- (not shown)
♦ Bit - T10451- (not shown)
Removing

– Pull off hose -1- from pressure pipe.

pressure pipe.
– Unscrew hose clip -1- on charge air pipe.

– Open hose clip -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3-.
– To do so, remove bolts -arrows-.

– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
– Removing poly V-belt (engine codes BLG, BMY) ⇒ page 36 .
– Removing poly V-belt (engine code BWK) ⇒ page 38 .


– Remove securing bolt -arrow- for charge air pipe -1-.
– Unscrew securing bolt for charge air pipe -arrow- and remove
charge air pipe -1- downwards.
Tiguan
– Remove front exhaust pipe ⇒ page 334 .
Note
The front exhaust pipe is only unbolted at the attaching points and
placed down on the subframe.
Only vehicles with auxiliary heater

– Remove coolant hoses for auxiliary heater.
– Carefully press locking lugs on noise insulation housing for

supercharger -arrows- outwards.
– Pull off front housing with noise insulation.

– Release tension from supercharger poly V-belt by swinging

tensioning element using open-end spanner, 16 mm -
T10241- .
– Unscrew securing bolts -arrows- for tensioning element and

remove tensioning element.
– Tightly hold compressor shaft with a spanner -1-.
– Remove securing bolt -2- for pulley and remove pulley and
supercharger poly V-belt -3-.
– Loosen bolts for coolant pump with magnetic clutch for super‐
charger - N421- -arrows- with the bit - T10451- .
– Remove coolant pump with magnetic clutch for supercharger
- N421- from cylinder block.
Installing
Note
Coolant pump seal is bonded in position. If the seal is damaged,

the coolant pump must be renewed.

note the following:
– Insert coolant pump with magnetic clutch for supercharger -
N421- into cylinder block.
– Tighten securing bolts to 8 Nm.
– Place poly v-belt on the magnetic clutch for supercharger -
N421- .

– Bolt on supercharger pulley with poly-v-belt and new securing

bolt.
Specified torques:
Assembly overview - part I, belt drive ⇒ page 31 .
Assembly overview - supercharger ⇒ page 254
Assembly overview - charge air system ⇒ page 275
– Install poly V-belt (engine codes BLG, BMY) ⇒ page 36 .
– Install poly V-belt (engine code BWK) ⇒ page 38 .
1.12 Removing and installing coolant pump pulley

equipment required
♦ Bit XZN 10 - T10154-

Removing


Engine code BWK
– Pull retaining clip in direction of -arrow- and pull charge air

hose -1- out of charge air pipe.
– Unscrew securing bolt for charge air pipe -arrow-.

– Release vacuum hose from vacuum reservoir -arrow- and pull

off.
rection of -arrow-.


rection of -arrow-.
– Pull hose -1- from pressure pipe.

pressure pipe.
– Unscrew hose clip -1- at charge air pipe.
– Open hose clip -2- and pull hose out.

– Unscrew securing bolt for charge air pipe -3- and pull connec‐
tor off charge air pressure sender - G31- with intake air tem‐
perature sender 2 - G299- .
Note
Charge air pressure sender - G31- with intake air temperature

sender 2 - G299- is installed on rear of charge air pipe.

– Loosen securing bolts -1- for coolant pump pulley.
WARNING
As the poly V-belt is still tensioned, the pulley securing bolts

must not yet be removed.

– Unscrew securing bolts -1- and pull pulley from coolant pump.
Installing
– Position pulley on coolant pump and tighten securing bolts

-1- hand-tight.
– Tighten securing bolts to 24 Nm.
Further installation is carried out in reverse order of removal.
When installing, note the following:
Specified torques:
Assembly overview - part I, intake manifold ⇒ page 288 .
Note



1.13 Removing and installing coolant circulation pump - V50-


equipment required
Removing
Engine code BWK

– Remove spring-type clips -arrows- and pull coolant hoses off.

– Pull connector -1- off and remove securing bolt -2-.
– Remove coolant circulation pump - V50- .
Installing
note the following:
Specified torque for securing bolt: 10 Nm.

20 – Fuel supply system

1 Safety precautions
Safety precautions when working on fuel supply system ⇒ page
158 .
Releasing pressure in high-pressure area ⇒ page 158 .
1.1 Safety regulations for working on fuel

supply
Caution

sitions.
When removing and installing fuel gauge sender - G- or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
Remove fuel pump fuse. Fuse assignment ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations
WARNING
Fuel system is under pressure! Wear eye protection and gloves

to avoid injuries and skin contact. Wrap a cloth around the
connection before loosening hose connections. Then release
pressure by carefully pulling hose off connection.
♦ Even before work starts, the extraction hose of a fume extrac‐

tion system which is switched on must be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.2 Releasing pressure in high-pressure

area
WARNING
The injection system consists of a high-pressure section (max‐

imum approx. 120 bar) and a low-pressure section (approx.
6 bar).
Prior to opening the high-pressure section, e.g. when removing
the high-pressure pump, fuel rail, injectors, a fuel line, or the
fuel pressure sender - G247- , the fuel pressure in the high-
158 Rep. gr.20 - Fuel supply system

pressure area must be reduced to a residual pressure of ap‐

prox. 6 bar. The appropriate procedure is described as follows.
– Pull electrical connector off fuel pressure regulating valve -

N276- -arrow-.
– Run engine at idling speed for approx. 10 seconds.
Note
♦ When the engine is idling and the electrical connector is pulled

off the fuel pressure regulating valve - N276- , the pressure in
the high-pressure system will drop to approx. 6 bar.
♦ Once the high-pressure in the high-pressure area is reduced,
open the system immediately as the pressure will rise again
due to warming.
– Switch off ignition.
WARNING
The fuel lines are pressurized! Wear protective goggles and

protective clothing to avoid injury and contact with the skin.
Before opening the high-pressure section, wrap a cloth around
the connection.
– Wrap a clean cloth around the connection and carefully open

to release residual pressure of approx. 6 bar. Catch the es‐
caping fuel.
– After completing work, read fault memory of engine control
unit, erase all fault entries that have been created by pulling
off connector.
Note
If the fault memory was cleared, the readiness code must be gen‐
erated ⇒ Vehicle diagnostic tester.“Guided functions”.
1. Safety precautions 159

2 Fuel tank
158 .
Observe rules for cleanliness ⇒ page 180 .
Assembly overview - fuel tank (Golf, Golf Plus) ⇒ page 160
Draining fuel tank (Golf, Golf Plus) ⇒ page 161
Removing and installing fuel tank (Golf, Golf Plus) ⇒ page
164
Assembly overview - fuel tank (Touran) ⇒ page 165
Draining fuel tank (Touran) ⇒ page 167
Removing and installing fuel tank (Touran) ⇒ page 170 .
Assembly overview - fuel tank (Tiguan) ⇒ page 171 .
Draining fuel tank (Tiguan) ⇒ page 173
Removing and installing fuel tank (Tiguan) ⇒ page 176 .
2.1 Fuel tank - assembly overview (Golf, Golf Plus)
1 - Sealing cover
2 - Securing bolt
3 - Earth connection
❑ Ensure firm seating
4 - 10 Nm
5 - Wiring guide
6 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
⇒ page 164
7 - 25 Nm
❑ Renew
8 - Clamping washer
9 - Securing strap
❑ Observe installation po‐
sition
10 - Heat shield
11 - Fuel filter
❑ Installation position: ar‐
row indicates direction
of flow.
12 - Supply line
❑ To fuel rail
13 - Breather line

❑ Clipped onto side of fuel tank.
14 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
15 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 184 .
❑ Note installation position on fuel tank ⇒ page 161
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 183
❑ Clean strainer if soiled
16 - Locking ring 110 Nm
❑ Remove and install using wrench - T10202- .
17 - Supply line
❑ black
18 - Return line
❑ blue
19 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
Installation position of fuel delivery unit

Marking -3- on sender points opposite to direction of travel.
Return line (blue or with blue mark) -1-
Black supply line -2-
2.2 Draining fuel tank (Golf, Golf Plus)

2. Fuel tank 161

♦ Fuel extraction unit - VAS 5190-
♦ Special wrench - T10202-

– Note safety precautions before beginning work ⇒ page 158 .
Emptying fuel tank if it is more than 3/4 full ⇒ page 162 .
Emptying fuel tank if it is less than 3/4 full ⇒ page 163
2.2.1 Emptying fuel tank if it is more than 3/4

full
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At a distance of -a- = 1180 mm from the end of the hose, mark
extraction hose with insulating tape -arrow-.

– Remove filler cap from fuel tank filler neck.

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank as much as possible through fuel filler neck.

– Carefully pull out extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel.
♦ If work must be performed on fuel pump or fuel tank sender,
proceed as follows:
2.2.2 Emptying fuel tank if it is less than 3/4 full

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat .
– Remove cover from fuel delivery unit.
WARNING
Fuel supply line is pressurised. Wear protective goggles and

Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.
2. Fuel tank 163

– Open locking ring using key - T10202- .

– Raise fuel delivery unit.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 181 .
2.3 Removing and installing fuel tank (Golf,

Golf Plus)
Removing
theft code.
– With the ignition switched off, disconnect battery earth strap.
– Unscrew securing bolts and remove tank flap unit.
– Drain fuel tank and clean fuel filler neck and surrounding area.

– Pull connector as well as supply and return lines -1 and 2- off

flange.
– Remove rear right wheel.
– Remove rear right wheel housing liner ⇒ General body re‐
housing liner; Rear wheel housing liner .
– Unbolt filler pipe from body -arrows-.

– Disconnect all rear exhaust system retainers from body. Then
support lowered exhaust system on body with wire.
WARNING
– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note
Press in securing ring to release the fuel lines.
– Unscrew securing strap and securing bolts. When doing this,

support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
– Lower fuel tank.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
♦ Install breather lines and fuel lines free of kinks.
♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
2.4 Assembly overview - fuel tank (Touran)
2. Fuel tank 165

1 - Sealing cover
2 - Securing bolt
3 - Tank flap unit
⇒ General body re‐
pairs, exterior; Rep. gr.
55 ; Tank flap unit; Re‐
moving and installing fu‐
el tank flap unit .
5 - 11 Nm
6 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
⇒ page 170
7 - 20 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
Note
To secure the securing straps for

the fuel tank, only bolts with loose
washers must be used. If different
bolts are used, the securing straps
might twist during tightening.
8 - Heat shield
9 - Securing strap
Note

10 - Supply line
❑ black
11 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
12 - Breather line
13 - Activated charcoal filter
❑ Location: on fuel tank.
14 - Breather line

❑ With fuel gauge sender - G- ⇒ page 183
❑ Checking fuel pump
❑ Note installation position on fuel tank ⇒ page 167
❑ Removing and installing fuel gauge sender - G- ⇒ page 183
❑ Following installation, adapt fuel pump control unit - J538- to engine control unit ⇒ Vehicle diagnostic
tester “Guided Function”
16 - Seal
17 - Union nut, 80 Nm
❑ Remove and install using union nut tool - 3217- .
❑ Position union nut tool - 3217- on the three rounded pins
18 - Supply line
❑ black
19 - Return line
❑ blue
Installation position of fuel delivery unit

Marking on sender must align with the marking on fuel tank
-arrows-.
Return line (blue or with blue mark) -2-
Black supply line -3-
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
2.5 Draining fuel tank (Touran)

2. Fuel tank 167

♦ Key for union nut - 3217-


full
Caution

part of the body.
– At a distance of -a- = 1200 mm from the end of the extraction
hose, mark hose with insulating tape -arrow-.


filler neck.
Note
-arrow-.

Note

proceed as follows:

WARNING

off connection.
Note
2. Fuel tank 169

– Open locking ring using union nut tool - 3217- .

2.6 Removing and installing fuel tank

(Touran)
• The fuel tank must be filled no more than 1/2 way up.
Note
If necessary, empty fuel tank using fuel extractor - VAS 5190- ⇒

page 167 .

Removing
theft code.

– Fold rear seat bench forwards.
– Pull 5-pin connector -1- off flange.
– Unbolt filler neck from body -arrows-.

– Disconnect all rear exhaust system retainers from body. Then
support lowered exhaust system on body with wire.
WARNING
– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note
– Unscrew securing strap and securing bolts. When doing this,

support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
– Lower fuel tank.
Installing
the following:
♦ To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. If different bolts are used, the
securing straps might twist during tightening.
♦ After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Erase programmed values and adapt fuel pump control unit -
J538- to engine control unit ⇒ Vehicle diagnostic tester “Guid‐
ed functions”.
2.7 Assembly overview - fuel tank (Tiguan)
2. Fuel tank 171

1 - Sealing cover
2 - Securing bolt
4 - Breather line
❑ To activated charcoal fil‐
ter
5 - Locking ring 110 Nm
ing wrench - T10202- .
⇒ page 209
❑ Checking fuel pump ⇒
page 215 .
❑ Note installation posi‐
tion on fuel tank ⇒
page 173
❑ With fuel gauge sender
- G-
fuel gauge sender - G-
⇒ page 212
7 - Supply line
❑ black
❑ Clipped onto side of fuel
tank.
8 - Fuel gauge sender 2 - G169-
❑ With suction-jet pump
9 - 3.5 Nm
10 - Bracket for fuel pump control unit - J538-
11 - Fuel pump control unit - J538-
12 - Seal
13 - Fuel tank
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
14 - 20 Nm + 1/4 turn (90°) further
❑ Renew

Note

15 - Securing strap
❑ Observe installation position
16 - 20 Nm + 1/4 turn (90°) further
❑ Renew
17 - Clamping washer
18 - Heat shield
19 - Breather line
20 - Breather line
21 - 8 Nm + 1/4 turn (90°) further
❑ Renew
22 - Tank flap unit
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
Installation position of flange for fuel delivery unit and fuel gauge
sender 2 - G169-
Fuel delivery unit -3-:
The lug -1- points in direction of travel.
Fuel gauge sender 2 - G169- -2-:
The lug -1- points in direction of travel.
Note
The arrows on the locking rings may be disregarded.
2.8 Draining fuel tank (Tiguan)

2. Fuel tank 173



full
Caution

part of the body.
– At a distance of -a- = 1200 mm from the end of the extraction
hose, mark hose with insulating tape -arrow-.


filler neck.
Note
-arrow-.

Note

proceed as follows:

WARNING

off connection.
Note
2. Fuel tank 175


2.9 Removing and installing fuel tank

(Tiguan)
Removing
theft code.

– Pull connector -1- and fuel line -2- off right flange (in direction
of travel).
– Release connector -arrow- on fuel pump control unit - J538-

using assembly tool - T10118- and pull it off.
– Pull connector -1- off left flange (in direction of travel).

2. Fuel tank 177


– Remove rear exhaust system with centre and rear silencers.

– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.
39 ; Removing and installing propshaft .
WARNING
– Disconnect fuel line -1- (black) and breather line -2- (white) at
connecting point.
– If an auxiliary heater is fitted, also separate fuel line -3-.
Note

– Disconnect breather lines -1- from activated charcoal filter and

fuel tank filler neck -3-.
– Unclip cable -2- from bracket.
– Remove tank flap and fuel tank filler neck cap.
– Disconnect earth cable at fuel tank filler neck.

– Unbolt filler neck from body -arrows-.
– Remove securing bolt -1-.

– Unscrew securing strap and securing bolts -arrows-. When
doing this, support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
Installing
– With the aid of a second mechanic, guide the filler neck in be‐
tween rear axle and body. Then place fuel tank on engine and
gearbox jack - V.A.G 1383 A- .
– Raise fuel tank slowly up to installation position and secure it

in place.
Note
To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. If different bolts are used, the se‐
curing straps might twist during tightening.
Tighten new securing bolts for securing straps -arrows- and new
bolt -1- to 20 Nm + 1/4 turn (90°) further.
– Tighten securing bolts -arrows- for fuel tank filler neck to 8 Nm

+ 1/4 turn (90°) further.
Further installation is carried out in reverse order of removal. Dur‐
ing this procedure, observe the following:
♦ Check earth connection on fuel tank and body to filler neck.
♦ After installing fuel tank, check that supply and breather lines
are still clipped onto fuel tank.
2. Fuel tank 179

3 Removing and installing parts of fuel

supply system
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew crimp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of crimp-type or screw-type clips is not permis‐
sible.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.

158 .
Observe crash fuel shut-off ⇒ page 181 .
Removing and installing fuel delivery unit (Golf, Golf Plus) ⇒ page
181 .
Removing and installing fuel gauge sender G (Golf, Golf Plus) ⇒
page 183
Checking fuel pumps (Golf, Golf Plus) ⇒ page 184
Removing and installing fuel delivery unit (Touran) ⇒ page
195 .
Removing and installing fuel gauge sender G (Touran) ⇒ page
197 .
Checking fuel pump (Touran) ⇒ page 198 .
Removing and installing fuel delivery unit (Tiguan) ⇒ page
209 .
Removing and installing fuel gauge sender G (Tiguan) ⇒ page
212 .
Removing and installing suction-jet pump (Tiguan) ⇒ page
212
Removing and installing fuel gauge sender 2 - G169- (Tiguan) ⇒
page 215 .
Checking fuel pump (Tiguan) ⇒ page 215 .
Removing and installing fuel pump control unit - J538- (Tiguan)
⇒ page 223
3.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.

♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.
3.2 Crash fuel shut-off

Function
Crash fuel shut-off system reduces the risk of a vehicle burning
in event of a crash in that the fuel pump is switched off. The sys‐
tem also improves the starting characteristics of the engine. When
door is opened, the fuel pump is activated for 2 seconds to build
up pressure in the fuel system.
When opening fuel system:
Observe safety precautions ⇒ page 158 .
3.3 Removing and installing fuel delivery

unit (Golf, Golf Plus)
Removing
Condition
• The fuel tank must be filled no more than 1/2 way up.
Note
If necessary, drain fuel tank using fuel extractor - VAS 5190- .

3. Removing and installing parts of fuel supply system 181


theft code.
– Fold rear bench seat forwards.
– Remove cover from fuel delivery unit -arrows-.
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
WARNING

– Pull off connector -arrow-.
– Pull fuel lines -1- and -2- off the flange.
Note
♦ Press in securing ring to release the fuel lines.

♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
– Open locking ring using key - T10202- and raise flange slightly.
– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
♦ If delivery unit is to be renewed, drain old delivery unit before

disposal.
♦ Observe disposal regulations!
Installing
– Renew seal.

– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Coat inner side of seal with fuel.
– When inserting fuel delivery unit, ensure that fuel gauge
sender is not bent.
– Press sealing flange down against spring pressure, and move

sealing flange to installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
– Tighten sealing flange.
• Specified torque: 110 Nm
– Reconnect supply line-1- (black).

– Reconnect fuel return line -2- (blue or blue marking).
– Reconnect connector -arrow-.

– Ensure push-fit couplings and electrical connectors are se‐
cured properly by pulling.
Further assembly is performed in the reverse order of removal.
During this procedure, observe the following:
♦ Observe installation position of fuel feed line to auxiliary heater

⇒ Auxiliary heater; Rep. gr. 82 ; Fuel feed Thermo Top V .
♦ The -arrow- on the cover points forwards.
3.4 Removing and installing fuel gauge

sender G (Golf, Golf Plus)

Removing
– Remove fuel delivery unit ⇒ page 181 .
– Pull fuel gauge sender - G- slightly to side and upwards at the
same time.
– If the sender cannot be released in this way, the retaining tabs

-arrows- must also be pushed to the side slightly.
– Note colour co-ordination of cables for reinstallation.
– Release electrical connectors -1 to 3- and pull them off. Then

bend back locking lugs of connectors.
Installing
– Connect connectors -1…3-. Observe colour co-ordination.

– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
– Install fuel delivery unit ⇒ page 181 .
3.5 Checking fuel pumps (Golf, Golf Plus)
Note

After removing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.

equipment required
♦ Pressure gauge - VAS 6550-

♦ Remote control - V.A.G 1348/3A-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Multimeter - V.A.G 1715-
♦ Measuring container, capacity 2 litres
3.5.1 Checking function and voltage supply

Test conditions:
• Battery voltage at least 11.5 V.
• Fuse for Fuel pump control unit - J538- OK.
• Fuel pump control unit - J538- OK.
Test sequence

Note
Function of fuel pump is checked using final control diagnosis.

driver footwell.
– Switch ignition on.
– Press buttons on display one after the other for Vehicle
self-diagnosis , Engine electronics and Final con-
trol diagnosis .

for fuel pump electronics.
The fuel pump must now run slowly up to maximum speed.
Note
The fuel pump runs very quietly.

If fuel pump does not run:
– Pull connector off fuel pump control unit - J538- .
– Check voltage supply between contacts -1- and -6- using mul‐
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
Voltage supply not OK:
– Locate and rectify open circuit referring to current flow diagram
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
Voltage supply OK:

fuel delivery unit.
– First check that the connector -arrow- is fitted securely by

pulling the connector without pressing the catch. If connector
was not inserted correctly, repeat functional check of fuel
pump.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.
WARNING

off connection.
Note


– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump defective, renew fuel delivery unit ⇒ page 181 .
3.5.2 Checking fuel pressure
WARNING


off connection.
– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.
Note
Press in securing ring to release fuel line.
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 189 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
If no fault is found:
– Pressure limit valve in fuel filter is defective. Renew fuel filter.
If specification is not obtained
– Check fuel pressure upstream of fuel filter; proceed as follows:
– Pull fuel supply line -arrow- off fuel filter.

– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
– Start engine and run at idling speed.
– Slowly close cut-off tap -A-. Pressure must rise to at least

7.0 bar. When 7.0 bar is reached, open shut-off tap again im‐
mediately.
If pressure has risen:
– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐
tive. Renew fuel filter.
If pressure does not rise:
3.5.3 Checking holding pressure

• Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 187 .
Test sequence
pressure.
– Watch pressure drop on pressure gauge. Pressure must re‐
main above 3.0 bar for 10 minutes.
If the pressure drops further:
pressure.

– After pressure has built up, close cut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
flow.
If the pressure does not drop now:
Note
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.
– Check fuel pipe to high-pressure pump for leaks.

– Renew high-pressure pump ⇒ page 307 .
If the pressure drops again:
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel supply line to fuel filter for leaks.
If no fault is found on the fuel line:
– Check pressure retention valve in fuel delivery unit. Proceed
as follows:

pressure.

– After pressure has built up, close cut-off tap -A-.

– Pressure retention valve in fuel pump defective; renew fuel
delivery unit ⇒ page 181 .
If the pressure does not drop:
– Pressure retention valve in fuel filter is OK, pressure limiting
valve in fuel filter is defective. Renew fuel filter.
3.5.4 Checking fuel delivery rate
Note
When driving characteristic problems occur when the fuel tank is

a approx. 1/4 filled, then check fuel delivery rates with approx. 1/
4 filled tank or less.

fuel delivery unit.

pulling the connector without pressing the catch. The connec‐
tor can cause a fault if it has not been fitted correctly.
unit for damage.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
WARNING

off connection.
fuel with a cloth.
Note

adapter - VAS 6550/2- . Hold adapter - VAS 6550/1- in a mea‐
suring container.
WARNING
Danger of spraying! Wear protective goggles and protective

clothing to avoid injury and contact with the skin. Hold contain‐
er in front of open connection of pressure tester.
– Operate remote control - V.A.G 1348/3A- . Then slowly close

shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of
shut-off tap.
– Drain measuring container.

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect multimeter - V.A.G 1715-
to outputs -1 and 5- of test instrument/DSO adapter 5-pin -
VAS 5565- .
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.
– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm3/60 s
**) Voltage at fuel pump with engine not running and pump run‐
ning.
Reading example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 1200 cm3/60 s.
– Check fuel lines for possible restrictions (kinks) or blockages.
– Remove cap from fuel filler neck and repeat check. If fuel de‐
livery rate is now reached, check fuel tank breather.
If reading again does not match specification:
– Check fuel filter (proceed as follows):
WARNING

off connection.


suring container.
shut-off tap.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained
– Remove fuel delivery unit and check filter strainer for soiling.
Only if still no fault has been detected:
– Renew fuel delivery unit.
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Measure current draw of fuel pump ⇒ page 194 .
3.5.5 Checking current consumption

fuel delivery unit.

unit for damage.


– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Measure current draw of fuel pump.
• Specification: max. 9 amps
Note
♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.
If the current draw is exceeded:


unit (Touran)
Note


Removing
Caution
Condition:
• Fuel tank must be filled no more than 3/4. This ensures
that the fill level is below the flange of the fuel delivery unit.
Note
♦ If necessary, drain fuel tank using fuel extractor - VAS 5190- .

♦ Note safety precautions before beginning work ⇒ page 158 .
♦ Observe rules for cleanliness ⇒ page 180 .

theft code.
– Release carpet under rear bench seat and fold it back ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Luggage compartment
trims; Removing and installing luggage compartment floor .
– Remove cover -1- with fuel pump control unit -J538- -2- from
fuel delivery unit.
WARNING

– Pull connector -1- and fuel lines -2- and -3- off flange.
Note
– Fit union nut tool - 3217- on the three rounded ribs of the union
nut and unscrew union nut from flange. When doing this, press
union nut tool - 3217- firmly onto union nut.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
Note
♦ When inserting fuel delivery unit, ensure that fuel gauge

sender is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Note installation position of fuel delivery unit flange: mark on
flange must align with mark on fuel tank -arrows-.
♦ Do not interchange supply and return lines.
♦ After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
♦ Following installation, adapt fuel pump control unit - J538- to
engine control unit ⇒ Vehicle diagnostic tester “Guided Func‐
tion”.

sender G (Touran)
Removing

– Pull fuel gauge sender - G- slightly to side and upwards at the

same time.
– If the sender cannot be released in this way, the retaining tabs

-arrows- must also be pushed to the side slightly.
– Note colour co-ordination of cables for reinstallation.
– Release electrical connectors -1 to 3- and pull them off. Then

bend back locking lugs of connectors.
Installing:
– Connect connectors -1…3-. Observe colour co-ordination.

– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
3.8 Checking fuel pump (Touran)
Note


equipment required


Test conditions
• Battery voltage at least 11.5 V
• Fuse for Fuel pump control unit - J538- OK.
Note


driver footwell.
– One after other, press following buttons on display: “Vehicle
self-diagnosis”, “,01 - Engine electronics” and “Final control
diagnosis”.
Note

– Release carpet under rear bench seat and fold it back ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Luggage compartment
trims; Removing and installing luggage compartment floor .
– Pull connector off fuel pump control unit - J538- .

– Check voltage supply between contacts -1- and -6- using mul‐
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
cations.
Voltage supply OK:
fuel delivery unit.

pump.
unit for damage.
WARNING

off connection.
Note


– Fit union nut tool - 3217- on the three rounded ribs of the union
nut and unscrew union nut from flange. When doing this, press
union nut tool - 3217- firmly onto union nut.
connected.
WARNING

off connection.
fuel with a cloth.
Note
Press in securing ring to release fuel line.

pressure.
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
– Pressure limit valve in fuel filter is defective. Renew fuel filter.
– Check fuel pressure upstream of fuel filter; proceed as follows:


– Slowly close cut-off tap -A-. Pressure must rise to at least

7.0 bar. When 7.0 bar is reached, open shut-off tap again im‐
mediately.
If pressure has risen:
– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐
tive. Renew fuel filter.
If pressure does not rise:

Test sequence
pressure.


pressure.
flow.
Note
engine side.

– Check fuel supply line to fuel filter for leaks.
If no fault is found on the fuel line:
– Check pressure retention valve in fuel delivery unit. Proceed
as follows:

pressure.

– After pressure has built up, close cut-off tap -A-.

– Pressure retention valve in fuel pump defective; renew fuel
delivery unit ⇒ page 195 .
If the pressure does not drop:
– Pressure retention valve in fuel filter is OK, pressure limiting
valve in fuel filter is defective. Renew fuel filter.
Note


fuel delivery unit.

unit for damage.


– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
WARNING

off connection.
fuel with a cloth.
Note

suring container.
WARNING
Danger of spraying! Wear protective goggles and protective

clothing to avoid injury and contact with the skin. Hold contain‐
er in front of open connection of pressure tester.

shut-off tap.


tery voltage. Therefore, also connect multimeter - V.A.G 1715-
to outputs -1 and 5- of test instrument/DSO adapter 5-pin -
VAS 5565- .
age at fuel pump.

ning.
Reading example:
– Check fuel filter (proceed as follows):
WARNING

off connection.


suring container.
shut-off tap.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained
– Remove fuel delivery unit and check filter strainer for soiling.
Only if still no fault has been detected:
– Renew fuel delivery unit.
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):

fuel delivery unit.

unit for damage.


5565- .
Note
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.


unit (Tiguan)
Note


3.9.1 Removing
Caution
Condition:
• Fuel tank must be filled no more than 1/2. This ensures
that the fill level is below the flange of the fuel delivery unit.
Note
If necessary, drain fuel tank using fuel extractor - VAS 5190- .

theft code.
WARNING

– Check that the connector is fitted securely by pulling the con‐

nector without pressing the catch.
Note
Check the contacts on the connectors for damage.
– Pull connector -1- and fuel line -2- off right flange (in direction
of travel).

– Release connector -arrow- on fuel pump control unit - J538-

using assembly tool - T10118- and pull it off.

– Slightly raise fuel delivery unit and remove seal out from aper‐
ture in fuel tank.
– Release fuel hoses on delivery unit -arrows- and pull delivery

unit out of fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
3.9.2 Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
Note
♦ Fuel hoses are allocated to respective unions.

♦ Ensure plug-in connectors are secured properly by pulling.
♦ When inserting the fuel delivery unit, ensure that the fuel
gauge sender - G- is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Note installation position of flange for fuel delivery unit: tab
-1- must point in direction of travel. The fuel delivery unit flange
can only be installed in this position.


sender G (Tiguan)
♦ Welding wire (2 mm thick)
– Bend an 80 mm long welding wire as shown.
Dimension -a- = 10 mm
Dimension -b-: 70 mm
Removing
– Release connectors of wiring for fuel gauge sender -2-, and
pull off.
– Press welding wire -1- in direction of -arrow- into recess be‐

neath sender.
– At the same time, push fuel gauge sender -2- from guides in
direction of -arrow-.
Installing
– Insert fuel sender into guides on fuel delivery unit and press
downwards until it engages.
– Reconnect connector and check that it has engaged correctly.
3.11 Removing and installing suction-jet

pump (Tiguan)

Note
♦ On vehicles with all-wheel drive, a suction-jet pump must

pump the fuel from the area of fuel gauge sender 2 - G169- to
the fuel pump due to the shape of the fuel tank.
♦ The fuel delivery unit must first be removed to remove the
suction-jet pump.
♦ Checking is only necessary when the engine stops due to lack
of fuel, even though the fuel gauge shows that the tank is still
1/4 full.
3.11.1 Removing
– Remove left cover (as seen facing direction of normal travel)
from fuel gauge sender 2 - G169- .
– First check that the connector is fitted securely by pulling the
connector without pressing the catch. The connector can
cause a fault if it has not been fitted correctly.
– Pull connector -1- off left flange.


– Slightly raise flange and remove seal out from opening in fuel
tank.
– Pull flange together with fuel gauge sender 2 - G169- out of
fuel tank.
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
3.11.2 Installing
Caution
When installing do not bend fuel gauge sender 2 - G169- float

arm.
– Install flange together with fuel gauge sender 2 - G169- in fuel

tank. The lug on the flange points in direction of travel.
– Place fuel lines in right chamber of fuel tank ensuring they are
not kinked.
– Place a new flange seal dry into aperture in fuel tank and
moisten only inside (contact to flange) with fuel.
– Note installation position of fuel gauge sender 2 - G169- ⇒
page 173
– Check for correct position of seal.
– Tighten locking ring using wrench - T10202- .
– Reconnect connector -1- and check it is secured properly by

pulling.
Further assembly is performed in the reverse order of removal.


sender 2 - G169- (Tiguan)
– Removing and installing suction-jet pump (Tiguan) ⇒ page
212
♦ Welding wire (2 mm thick)
– Bend an 80 mm long welding wire as shown.
Dimension -a- = 10 mm
Dimension -b-: 70 mm
Removing
– Release connectors for lines for fuel gauge sender 2 -
G169- -2- and pull off.
– Press welding wire -1- in direction of -arrow- into recess be‐

neath sender.
– At the same time, push fuel gauge sender 2 - G169- -2- from
guides in direction of -arrow-.
Installing
– Insert fuel gauge sender 2 - G169- into guides and press down
until it engages.
– Reconnect connector and check that it has engaged correctly.
3.13 Checking fuel pump (Tiguan)
Note


equipment required

Check function and voltage supply ⇒ page 216 .
Checking holding pressure ⇒ page 219 .
Checking fuel delivery rate ⇒ page 220 .
Checking current draw ⇒ page 222 .

• Battery voltage at least 11.5 V
• Fuse for fuel pump on fuse holder OK ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.

Test sequence
Note

driver footwell.
– Press buttons on display one after the other for Vehicle
self-diagnosis , Engine electronics and Final con-
trol diagnosis .

Note

– Remove right (in direction of travel) cover from fuel delivery
unit.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
– First ensure that 5-pin wiring connection -1- is secure by

pump.
– Now pull off connectors -1-.
unit for damage.


– Connect multimeter - V.A.G 1715- to contacts -1- and -5- of
adapters - VAS 5565- .
– Actuate fuel pump with final control diagnosis.
• The voltage must rise up to battery voltage during final control
diagnosis.
cations.
Voltage supply OK:
connected.

Test conditions:
• Function of fuel pump has been checked ⇒ page 216 .
Test sequence
WARNING

off connection.
– Pull off supply line (metal coupling) -2- and catch escaping fuel
with a cloth.


pressure.
– Renew left flange with pressure limiting valve, suction jet pump
and fuel filter.
Note
Pressure limiting valve and fuel filter are integrated into fuel gauge
sender 2 - G169- with suction-jet pump and cannot be renewed
individually.
– Repeat check.

Test sequence
pressure.
pressure.
flow.
Note
engine side.



– Check fuel line to flange for leaks.
If no fault is detected on »external« fuel lines, search for leak in
fuel tank. Proceed as follows:
– Open flanges on left and right. Ensure all hose connections
are fitted correctly and do not leak.
– First renew left flange with pressure limiting valve and fuel fil‐
ter. Repeat pressure retention test. If leak is still present, non-
return valve in fuel pump leaks, renew fuel delivery unit.
Note

Test conditions
• Voltage supply OK.
unit.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.

unit for damage.


– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
– Pull off supply line (metal coupling) -2- and catch escaping fuel
with a cloth.
Note

suring container.
WARNING
Danger of spray when shut-off tap is opened. Wear eye pro‐

tection and protective clothing to avoid injuries and skin con‐
tact. Hold container in front of open connection of pressure
tester.

shut-off tap.


tery voltage. Therefore, connect multimeter - V.A.G 1715- to
wires -1- and -5- of adapter - VAS 5565- in addition.
age at fuel pump.

ning.
Reading example:
– Open flanges on left and right. Ensure all hose connections
are fitted correctly and do not leak. Check sieve in fuel delivery
unit and fuel tank for coarse soiling.
– First renew left flange with pressure limiting valve and fuel fil‐
ter. Repeat delivery rate check. If fuel delivery is still insuffi‐
cient, fuel pump defective, renew fuel delivery unit.
If the fuel delivery rate has been attained but a fault is still sus‐
pected in the fuel supply system (e.g. intermittent failure of fuel
supply system):

unit.


unit for damage.

5565- .
Note
♦ If the fuel system malfunction is intermittent, you can perform
the check during a road test, but a 2nd person is necessary.

3.14 Removing and installing fuel pump con‐

trol unit - J538- (Tiguan)
Note
The fuel pump control unit - J538- is installed on the fuel tank.

♦ Commercially available flat-bladed screwdriver (blade width
120 mm)
Fuel pump control unit - J538- fitting location
1 - Bracket for fuel pump control unit - J538-
2 - Fuel pump control unit - J538-
3 - Connector
Removing
unit.

– Pull off connector -1-.
– Slide screwdriver -2- into bracket recess -1- directly above

plug.
– Swivel screwdriver in direction of -arrow-.
– Press screwdriver down in direction of -arrow- and pull control

unit out of bracket at plug at same time.
– Pull connector off control unit.
Installing
– Reconnect plug -3- to control unit -2-.

– Slide control unit -2- into bracket -1- until it engages.

4 Repairing electronic power control

(EPC)
Removing and installing accelerator module (Golf, Golf Plus,
Tiguan) ⇒ page 225 .
Removing and installing accelerator module (Touran) ⇒ page
226 .
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
❑ Openings -A- for re‐
lease tool.
❑ To remove, remove
dash panel cover and
pedal cluster cover.
accelerator module
(Golf, Golf Plus, Tiguan)
⇒ page 225 .
accelerator module
(Touran) ⇒ page 226 .
3 - 10 Nm
4 - Protective cap
4.2 Removing and installing accelerator

module (Golf, Golf Plus, Tiguan)
4. Repairing electronic power control (EPC) 225

♦ Release tool - T10238-
♦ Release tool - T10240- (for right-hand drive)
Procedure
– Remove pedal cluster cover.
– Pull connector off accelerator module.
– Pull off protective cap in upper area of accelerator module.
– Remove securing bolt.
– To remove accelerator module, push release tool - T10238-
(for right-hand drive models) -T10240- into openings provided
to stop.
– Pull out accelerator pedal module vertically.
Install in reverse order of removal.
4.3 Removing and installing accelerator

module (Touran)

♦ Release tool - T10269-
♦ Release tool - T10297- (for right-hand drive)
Removing
– Remove steering column cover -arrows-.
– Pull connector off accelerator module.
– Pull off cover cap in upper area of accelerator module.
– Remove securing bolt.
– To remove accelerator module, push release tool - T10269-

(for right-hand drive models -T10297- ) into openings provided
to stop.
– Pull out accelerator pedal module vertically.
4. Repairing electronic power control (EPC) 227

Installing
– Push wiring guide -1- and electrical connector -2- onto accel‐
erator module.
– Press accelerator pedal module onto retaining pins -6-.
– Insert centring pin -7- into hole in underbody.
– Secure accelerator module with bolt -3-, specified torque
10 Nm and fit cap -4-.
– Install steering column trim.

5 Activated charcoal filter system

Assembly overview (Golf, Golf Plus) ⇒ page 229
Checking fuel tank breather (Golf, Golf Plus) ⇒ page 230
Note
♦ The fitting location for the activated charcoal filter in the Touran
is on the fuel tank.
♦ Assembly overview - fuel tank (Touran) ⇒ page 165
Checking fuel tank breather (Touran) ⇒ page 231

Assembly overview (Tiguan) ⇒ page 232
Checking fuel tank breather (Tiguan) ⇒ page 233
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew crimp-type clips with spring-type clips.
♦ Spring-type clip pliers - VAS 5024A- are recommended for in‐
stallation of spring-type clips.
5.1 Assembly overview (Golf, Golf Plus)
5. Activated charcoal filter system 229


❑ Location: on right in en‐
gine compartment.
2 - Pressure retention valve
with connecting hose
3 - Connection hose
❑ From fuel tank
4 - 10 Nm
solenoid valve 1 - N80-
❑ Fitting location: behind
intake manifold
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve is activated
(pulsed) by engine con‐
trol unit - J623- .
6 - Connection hose
❑ To intake manifold
7 - Bracket
❑ For activated charcoal
filter.
8 - Breather hose
9 - Sealing grommet
5.2 Checking fuel tank breather (Golf, Golf

Plus)
♦ Hand operated vacuum pump - VAS 6213-

♦ Adapter set - V.A.G 1318/17-

• Ignition must be switched off.
Test sequence
– Pull off breather line -1-. To do this, press release button.
– Then connect hand vacuum pump - VAS 6213- using adapter
set - V.A.G 1318/17- to the activated charcoal filter line.
– Operate hand vacuum pump - VAS 6213- several times. There
must be no development of vacuum.
If vacuum builds up:
– Check breather hose ⇒ Item 8 (page 230) on activated char‐
coal filter for soiling and clean if necessary.
If vacuum does not build up:
– Hold breather fitting ⇒ Item 8 (page 230) closed and operate
vacuum pump again several times. Vacuum must build up.
– Renew activated charcoal filter.
5.3 Checking fuel tank breather (Touran)


Test sequence

– First disconnect white breather hose at hose connection -2-.
– Then connect hand vacuum pump - VAS 6213- to hose -1- as

shown.
If vacuum builds up:
– Check breather hose -3- on activated charcoal filter -2- for
soiling, and clean if necessary.
– Hold breather hose -3- shut and operate vacuum pump again
several times. Vacuum must build up.
– Renew activated charcoal filter -2-.
Note
The fuel tank will have to be removed in order to remove and

install the activated charcoal filter ⇒ page 170 .
5.4 Assembly overview (Tiguan)


❑ Location: in rear right
wheel housing.
2 - Connection hose
❑ To remove, pull off at se‐
curing ring.
3 - From fuel tank
4 - Breather line
ter solenoid valve 1 -
N80-
❑ Clipped onto fuel tank.
5 - Breather line
❑ From activated charcoal
filter
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit
7 - Connection hose
8 - 10 Nm
5.5 Checking fuel tank breather (Tiguan)


Test sequence

– Pull off breather line -1-. To do this, press release button.
– Then connect hand vacuum pump - VAS 6213- as shown to

breather line.
– Detach hose -1- from activated charcoal filter.
– Seal breather hole and connection on activated charcoal filter

-arrows-, and operate vacuum pump several times again. Vac‐
uum must build up.
– If vacuum does not build up, renew activated charcoal filter.

21 – Turbocharging/supercharging
1 Exhaust turbocharger
Note
♦ Secure all hose connections with hose clips which conform to

production standard.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. The seals and sealing
surfaces must be oiled lightly for plug-in connectors ⇒ page
276 .
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ It is recommended that spring-type clips should be installed
using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- .
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed and do not rev up immediately. This ensures that
the turbocharger is fully primed with oil.
Assembly overview - turbocharger ⇒ page 235 .

Removing and installing turbocharger ⇒ page 238 .
Checking turbocharger vacuum unit ⇒ page 244 .
Removing and installing vacuum unit for turbocharger ⇒ page
246 .
Adjusting vacuum unit for turbocharger ⇒ page 247 .
1.1 Assembly overview - turbocharger

Part I ⇒ page 236
Part II ⇒ page 237
1. Exhaust turbocharger 235

1.2 Part I
236 Rep. gr.21 - Turbocharging/supercharging

1 - Charge pressure control

solenoid valve - N75-
2 - 10 Nm
3 - 7 Nm
4 - Turbocharger air recircula‐
tion valve - N249-
❑ To remove, pressure
pipe must be removed ⇒
page 241 .
5 - O-ring
⇒ page 238
❑ Checking turbocharger
vacuum unit ⇒ page
244 .
vacuum unit for tur‐
bocharger ⇒ page
246 .
❑ Adjusting vacuum unit
for turbocharger ⇒ page
247 .
7 - Connection hose
8 - Connection hose
1.3 Part II

1 - 8 Nm
2 - Coolant pipe
3 - O-ring
❑ Renew
4 - Stud, 20 Nm
❑ Coat with high-tempera‐
ture paste.
⇒ page 238
❑ Checking turbocharger
vacuum unit ⇒ page
244 .
vacuum unit for tur‐
bocharger ⇒ page
246 .
❑ Adjusting vacuum unit
for turbocharger ⇒ page
247 .
6 - Seal
❑ Renew
7 - 25 Nm
❑ Renew studs and fas‐
tening nuts.
❑ Coat studs with high-
temperature paste.
Screw the studs into cylinder
head until they project only
25 mm.
Observe tightening sequence:

items -A- to -I-.
8 - Coolant pipe
9 - Seal
❑ Renew
10 - 8 Nm
11 - Oil return pipe
12 - Banjo bolt, 30 Nm
13 - Seal
❑ Renew
14 - Oil supply pipe
Caution
Oil supply line must be
renewed when installing
a new turbocharger.
15 - Banjo bolt, 30 Nm
1.4 Removing and installing turbocharger


Removing
Caution
If a mechanical fault is found on the turbocharger, e.g. a de‐

stroyed compressor impeller, just renewing the turbocharger
is not enough. To prevent this from causing further damage,
perform the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the
charged air routing must be cleaned and the charge air cooler
must be renewed, if necessary.
Note




off.
rection of -arrow-.

rection of -arrow-.

cooling system.
Tiguan
– Remove radiator fan - V7- together with cowling ⇒ page 144 .
Note
– Pull off connecting hoses -1- and coolant hoses -3-.

– Unscrew bracket -2- and securing nuts -4- from turbocharger.

– Unscrew securing bolt -2- and remove upper coolant pipe.
Note
The lower coolant pipe can only be removed following the removal
of the catalytic converter.
– Unscrew bolts -1- and remove pressure pipe

.

Tiguan

G130- and remove.

– Unbolt exhaust pipe to rear silencer -arrows-.

haust pipe to rear.
– Also pull out exhaust pipe together with flexible joint.
Vehicles with all-wheel drive
– The exhaust pipe is only loosened, not removed.
– Remove catalytic converter downwards.
– Unscrew securing bolts for tensioning element -arrows- and

remove it.
Note

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
– Removing cowling with both radiator fans ⇒ page 142 .
– Unscrew securing bolt -arrow- for oil return pipe -2- from tur‐
bocharger.

– Pull oil return pipe downwards.

– Unbolt charge air hose -1- from turbocharger.
– Unscrew banjo bolts for oil supply pipe -arrows- from tur‐
bocharger and crankcase.
– Remove oil supply pipe.

– Unscrew all securing nuts from exhaust manifold -1-.
– Pull exhaust manifold out upwards with turbocharger.
Note
The turbocharger can only be renewed together with the exhaust

manifold.
Installing
Caution
Oil supply line must be renewed when installing a new tur‐

bocharger.

note the following:
♦ Renew studs and fastening nuts.

♦ Screw the studs into cylinder head until they project only
25 mm.
♦ Coat studs with high-temperature paste.
♦ Observe tightening sequence and specified torques: items
-A- to -I- ⇒ page 237 .
♦ Renew seals, gaskets and self-locking nuts.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
free of oil and grease before assembly.
♦ Install exhaust system and align it free of stress.
♦ When installing air pipes with plug-in connector, ensure that
securing clip -arrow- audibly engages into retaining lug -A-.
Fitting hose connections with plug-in connectors ⇒ page 276
Specified torques:


Assembly overview - catalytic converter and add-on parts ⇒ page
330
Note


1.5 Checking vacuum unit for turbocharger


– Check retaining clip -1- is seated correctly on vacuum unit

linkage.
Securing nut -2- must be locked with sealing paint.
– Pull hose -arrow- off vacuum unit.
– Fit hose -2- onto vacuum unit connection.

– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
stop in direction of -arrow-.

– Operate hand vacuum pump - VAS 6213- until a pressure of

700 mbar is displayed on pressure gauge.
Linkage of vacuum unit -1- must move in direction of -arrow-.
If pressure of 700 mbar is displayed:
Vacuum unit is OK.
If pressure drops abruptly:
– Renew vacuum unit ⇒ page 238 .
1.6 Removing and installing vacuum unit for

turbocharger
Removing
off.
rection of -arrow-.

– Pull hose -1- from pressure pipe and unscrew securing bolts
-2- for pressure pipe.
– Remove pressure pipe.
– Pull hose -arrow- from vacuum unit.

– Remove sealing paint from securing nut -2-.
– Pull off retaining clip -1- and loosen securing nut -2- on vacuum
unit linkage.
– Unscrew knurled nut from vacuum unit stud.
– Unscrew securing bolts -arrows- for vacuum unit and remove

vacuum unit from turbocharger.
Installing
note the following:
♦ Linkage must be adjusted after installing vacuum unit ⇒ page
247 .
♦ Specified torque for vacuum unit to turbocharger: 10 Nm
1.7 Adjusting vacuum unit for turbocharger
Note

The vacuum unit must be adjusted only if the linkage has been
loosened.

equipment required
♦ Pressure regulating valve - VAS 6342-

♦ Dial gauge set, 4-part - VAS 6341-
♦ Turbocharger tester - V.A.G 1397A-
♦ Dial gauge extension, 30 mm - VAS 6341/3- (not shown)
♦ Flat pickup - VAS 6341/4- (not shown)
Procedure
off.

rection of -arrow-.

cooling system.
– Now drain coolant.
Note
– Pull off connecting hoses -1- and coolant hoses -3-.

– Remove bolts and securing nuts -4- from turbocharger.
– Unscrew securing bolt -2- and remove upper coolant pipe.
Note
The lower coolant pipe can only be removed following the removal
of the catalytic converter.
– Unscrew bolts -1- and remove pressure pipe.



Tiguan

G130- and remove.
– Remove catalytic converter downwards.
– Pull hose -arrow- from vacuum unit on turbocharger.
Checking vacuum unit adjustment ⇒ page 244 .
Continuation if the vacuum unit has been renewed or the linkage
loosened
– Remove sealing paint from lock nut -2-.
– Pull off retaining clip -1- and loosen lock nut -2- on vacuum
unit linkage.
– Adjust bypass flap -2- on vacuum unit linkage -1- via knurled
screw, so that bypass flap can just be turned by hand.

– Turn knurled nut 2 turns further.

– Tighten lock nut hand-tight.
– Connect hand vacuum pump - VAS 6213- , turbocharger tester

- V.A.G 1397A- to connection -II- and pressure control valve -
VAS 6342- as shown in illustration.
– Close pressure control valve - VAS 6342- at lever -2-.
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
pressure gauge in direction of -arrow-.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position -II-.
– Secure universal dial gauge bracket - VW 387- to turbocharg‐

er.
Note
The dial gauge linkage and the vacuum unit linkage must align.
– Secure dial gauge - VAS 6341/1- with dial gauge extension,

30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to uni‐
versal dial gauge bracket - VW 387- .
– With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm
preload.
– Operate hand vacuum pump - VAS 6213- until a pressure of
800 mbar is displayed on turbocharger tester - V.A.G 1397A- .
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 0 mbar.
– Repeat this procedure approx. 3-5 times.
Note
This procedure is intended to prevent the vacuum unit bypass flap

or linkage from jamming.

Note
The values in mm refer to the read value (includes 1 mm preten‐

sion).

pressure reading drops to 0 mbar.
– Set dial gauge - VAS 6341/1- to 0.
Note
♦ The following measurements must be performed in continuous

sequence. Do not allow the pressure to drop to 0 between
measurements.
♦ Do not knock against linkage throughout the entire measure‐
ment procedure.
– Operate hand vacuum pump - VAS 6213- until turbocharger

tester - V.A.G 1397A- indicates 500 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Operate vacuum pump - VAS 6213- until turbocharger tester
- V.A.G 1397A- indicates 800 +/- 5 mbar.
pressure reading drops to 500 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5.5 +/- 0.25 mm.
– Correct setting if the result (average) is not 5.5 +/- 0.25 mm,
tighten lock nut hand-tight and repeat measurement.
– If the result (mean value) is 5.5 +/- 0.25 mm, tighten the lock
nut to 9 Nm and secure with sealing paint.
– Secure retaining clip to vacuum unit linkage.
note the following:

♦ If renewed, place seal in groove of charge air hose. Ensure
seal is correctly seated in groove.
♦ Lightly moisten seal with engine oil.
♦ Bring retaining clip to release position -arrow-.
Specified torques:


Removing and installing parts of exhaust system ⇒ page 330

2 Compressor
Assembly overview - supercharger ⇒ page 254
Removing and installing compressor (engine codes BLG, BMY)
⇒ page 255 .
Removing and installing compressor (engine code BWK) ⇒ page
263 .
Removing and installing drive unit seal for supercharger ⇒
page 271
2.1 Assembly overview - supercharger
1 - Housing with noise insula‐

tion
❑ For silencer.
2 - Silencer
❑ For intake air.
3 - Intake hose
❑ Secure with spring-type
clips
4 - 7 Nm
❑ Self-tapping bolt
❑ The securing bolt may
only be tightened using
a power-operated
screwdriver if the screw‐
driver speed is max.
500 rpm and a max.
specified torque of 7 Nm
is set.
5 - 7 Nm
6 - 7 Nm
a power-operated
500 rpm and a max.
is set.
7 - O-ring
❑ Renew
8 - Pressure pipe
9 - Noise insulation
10 - Housing
❑ For noise insulation.
11 - Silencer
❑ For charge air.
❑ With seal
❑ Renew seal between supercharger and intake silencer.
12 - Pulley

13 - 8 Nm
14 - Coolant pump with magnetic clutch for supercharger - N421-
15 - Poly V-belt
Caution
ment.
16 - 23 Nm
❑ For supercharger poly V-belt.
❑ Relieve tension using 16 mm spanner.
❑ Lock with locking pin - T10060 A- .
18 - 40 Nm + 1/4 turn (90°) further
❑ To loosen and tighten securing bolt, counterhold supercharger shaft with spanner.
❑ Renew
19 - Compressor
❑ Removing and installing drive unit seal for supercharger ⇒ page 271
20 - 25 Nm
2.2 Removing and installing compressor (engine codes BLG, BMY)
2. Compressor 255

equipment required

Removing
off.
rection of -arrow-.


rection of -arrow-.
– Detach spring-type clip from intake hose -arrow-.

– Remove securing bolt on silencer ⇒ Item 4 (page 254) .

– Remove securing bolt for charge air pipe -2-.
drive shafts .
2. Compressor 257
– Unbolt exhaust pipe to front silencer -arrows-.

haust pipe to rear.
– Also pull out exhaust pipe together with flexible joint.


– Slacken supercharger poly V-belt by swinging tensioning ele‐

ment in direction of -arrow- with 16 mm spanner.

2. Compressor 259
– Opens clips for hose guides -2- and push hoses to one side.
– Carefully press locking lugs on noise insulation housing
-arrows- outwards.
– Unscrew securing bolts -1- for supercharger and remove su‐

percharger together with intake silencer.
Removing intake silencer for charge air:
– Pull intake silencer for charge air -2- together with pressure
pipe in direction of -arrow-.
Installing
Caution
When installing poly V-belts, observe direction of rotation and

make sure they are properly seated on pulleys and tensioning
elements.
Note
♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 254) .

♦ Before installing, lightly moisten O-rings with engine oil.
♦ The pressure pipe can only be pushed in one position into the
intake silencer for charge air (note locating element).

– Push intake silencer for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
– Press intake silencer for charge air -2- against crankcase to
allow both dowel sleeves -3- to sit in holes.
– Turn guide pins - T10341- hand-tight to stop in both lower

threaded holes.
– Renew oil seal -1- and ensure it is correctly seated in the
groove.
– Push supercharger together with intake silencer onto guide
pins - T10341- and tighten upper securing bolts hand-tight.
– Remove guide pins - T10341- .
– Tighten lower securing bolts hand-tight.
– Tighten securing bolts -1- evenly in diagonal sequence.
– Install poly V-belt -3- for compressor along with belt pulley.
Specified torque for new securing bolt -2-: 40 Nm + 1/4 turn (90°)
further.
– Hold supercharger shaft with 16 mm spanner -1-.
– Install tensioner.
2. Compressor 261
– Tighten bolts -arrows- to 23 Nm.
– Hold tensioner using a 16 mm spanner and pull out pin -

T10060 A- .
– Position housing with noise insulation onto supercharger.
Note
Ensure correct position of noise insulation in housing.
– Press housing together with noise insulation against super‐

charger until locking lugs -arrows- click into place.
Perform further installation in reverse order, paying attention to
the following:
♦ Renew securing bolt for supercharger pulley. Specified torque

40 Nm + 1/4 turn (90°) further.
Specified torques:
330

Note


2.3 Removing and installing compressor (engine code BWK)
2. Compressor 263

equipment required

Removing
rection of -arrow-.

– Detach spring-type clip from intake hose -arrow-.

– Remove securing bolt for charge air pipe -2-.
drive shafts .
2. Compressor 265


– Remove bevel box ⇒ 6-speed manual gearbox 0A6; Rep. gr.
34 ; Removing and installing bevel box .


– Slacken supercharger poly V-belt by swinging tensioning ele‐

ment in direction of -arrow- with 16 mm spanner.

2. Compressor 267
– Opens clips for hose guides -2- and push hoses to one side.
– Carefully press locking lugs on noise insulation housing
-arrows- outwards.
– Unscrew securing bolts -1- for supercharger and remove su‐

percharger together with intake silencer.
Removing intake silencer for charge air:
– Pull intake silencer for charge air -2- together with pressure
pipe in direction of -arrow-.
Installing
Caution
When installing poly V-belts, observe direction of rotation and

make sure they are properly seated on pulleys and tensioning
elements.
Note
♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 254) .

♦ Before installing, lightly moisten O-rings with engine oil.
♦ The pressure pipe can only be pushed in one position into the
intake silencer for charge air (note locating element).

– Push intake silencer for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
– Press intake silencer for charge air -2- against crankcase to
allow both dowel sleeves -3- to sit in holes.
– Turn guide pins - T10341- hand-tight to stop in both lower

threaded holes.
– Renew oil seal -1- and ensure it is correctly seated in the
groove.
– Push supercharger together with intake silencer onto guide
pins - T10341- and tighten upper securing bolts hand-tight.
– Remove guide pins - T10341- .
– Tighten lower securing bolts hand-tight.
– Tighten securing bolts evenly and diagonally.
– Install poly V-belt -3- for compressor along with belt pulley.
Specified torque for new securing bolt -2-: 40 Nm + 1/4 turn (90°)
further.
– Hold supercharger shaft with 16 mm spanner -1-.
– Install tensioner.
2. Compressor 269
– Tighten bolts -arrows- to 23 Nm.
– Hold tensioner using a 16 mm spanner and pull out pin -

T10060 A- .
– Position housing with noise insulation onto supercharger.
Note
Ensure correct position of noise insulation in housing.
– Press housing together with noise insulation against super‐

charger until locking lugs -arrows- click into place.
Perform further installation in reverse order, paying attention to
the following:
♦ Renew securing bolt for supercharger pulley. Specified torque

40 Nm + 1/4 turn (90°) further.
Specified torques:
330


2.4 Removing and installing drive unit seal

for supercharger
♦ Gearbox support - T10108-
♦ Extractor hook - T20143-
♦ Repair kit for supercharger ⇒ Electronic parts catalogue (ET‐
KA)
Note
All components in the repair kit must be used!
Removing
– Remove supercharger.
Engine codes BLG, BMY ⇒ page 255 .
Engine code BWK ⇒ page 263 .
– Secure compressor on the gearbox support - T10108- with 2
bolts-arrow-.
2. Compressor 271
– Pry off the circlip -1- with a slot-head screwdriver -2-.
– Pull out the seal -1- with the puller hooks - T20143/1- .
Installing
– Put together assembly cone -T10208/5- and assembly sleeve

-T10208/4- .
– Slide the new seal -1- onto the assembly sleeve in the
-arrow direction- -T10208/5- -T10208/4- via the assembly
cone.
– Pull down the assembly cone - T10208/5- from the assembly

sleeve in the -arrow direction- -T10208/4- .

– Slide the assembly sleeve - T10208/4- onto the compressor

shaft.
– Using the thrust piece - T10208/2- , press in the seal via the
assembly sleeve - T10208/4- up to the stop.
– Press in the new circlip -1- up to the stop also using the as‐
sembly tool - T10208/2- .
Changing the compressor fluid
– Undo the securing bolts for the drive unit according to the
specified sequence -A- to -H-.
– Turn the gearbox support - T10108- until the shaft points to
the floor.
2. Compressor 273
– Unscrew the securing bolts and remove the drive unit -1-.
– Drain compressor oil completely from drive unit.
– Collect the escaping fluid in a suitable container.
– Turn the gearbox support - T10108- until the pair of gears point
upwards.
– Remove sealant residues from compressor and drive unit with
a rotating brush, e.g. a hand drill with a plastic brush (wear eye
protection).
– Carefully clean sealing surfaces. They must be free of oil and
grease.
– Dirt and sealant residues must not be allowed to enter the
space.
Caution
Add only the oil specified in repair set ⇒ Electronic parts cat‐
alogue (ETKA) .
– Fill the space -arrow- with new oil (44 ml) from the repair set.
Note
Sealant must not be applied too thickly, otherwise excess sealant

may enter the space and cause damage.
Do not apply sealant until directly before the drive unit is fitted.
– Apply sealant to the sealing surface on the compressor.
Bead of sealant must be 2 to 3 mm thick and must run along inside

edge in area of bolt holes.
– Tighten the new securing bolts for the drive unit to “12 Nm”
according to the specified sequence -A- to -H-.
– Install supercharger.
Engine codes BLG, BMY ⇒ page 255 .
Engine code BWK ⇒ page 263 .

3 Charge air system
Note
♦ It is recommended that the spring-type clips should be in‐

stalled using the spring-type clip pliers - VAS 5024A- or the
hose clip pliers - VAS 6340- .
free of oil and grease before assembly. The seals and sealing
surfaces must be oiled lightly for plug-in connectors ⇒ page
276 .
♦ Charge air system must be free of leaks.

Checking charge air system for leaks ⇒ page 277
Removing and installing charge air cooler (Golf, Golf Plus,
Touran) ⇒ page 281
Removing and installing charge air cooler (Tiguan) ⇒ page
283
3.1 Assembly overview - charge air system
3. Charge air system 275

1 - Intercooler
(Golf, Golf Plus, Touran)
⇒ page 281
(Tiguan) ⇒ page 283
2 - 5 Nm
3 - Bearings
❑ For charge air cooler.
4 - Seal
5 - Charge air hose
6 - Intake manifold connection
❑ With seals.
7 - Throttle valve module -
J338-
❑ Cleaning ⇒ page 302
❑ If renewed, erase learnt
values and adapt en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester “Guided func‐
tions”.
8 - 7 Nm
9 - Hose clamp
10 - Charge air hose
11 - 10 Nm
12 - Charge air pipe
13 - Charge air pressure
sender - G31- with intake air
temperature sender 2 - G299-
14 - 5 Nm
❑ To turbocharger
16 - Charge air pipe
3.2 Fitting hose connections with plug-in

connectors
Caution
The seal for the push-on coupling can be damaged if the re‐
taining clip is in the locked position during installation. This
would result in leaking. Observe installation instructions.
Removing:

– Release plug-in connector by pulling out retaining clip

-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place seal in groove of charge air hose. Make sure
that the seal is correctly seated in the groove all around the
complete circumference and that it is not twisted.
– Lubricate sealing surface and seal with oil.
– Bring retaining clip to release position -1-.

– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if plug-in connector seats correctly and is properly en‐
gaged by pulling hose.
3.3 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-

♦ Engine bung set - VAS 6122- (not shown)

off.
rection of -arrow-.

rection of -arrow-.
– Press hose locking mechanism and pull hose for crankcase
breather -1- off intake connecting pipe.
– Also pull crankcase breather hose off valve timing housing.
Caution
Crankcase breather hose must be pulled off during leak test to

prevent damage to engine.
– Seal intake connecting pipe with a bung from engine bung set
- VAS 6122- .
– Remove spring-type clips -2- from intake hose and remove
intake hose.

– Renew spring-type clips -arrows- with screw-type clips from

charge air system tester - V.A.G 1687- .
– Slide adapter - V.A.G 1687/6- into intake hose -2- and secure
hose to intake connecting pipe with screw-type clips -1- from
charge air system tester - V.A.G 1687- .
Prepare charge air system tester - V.A.G 1687- as follows:
– Unscrew pressure regulating valve -2- and close valves -3-

and -4-.
– Connect charge air system tester - V.A.G 1687- as shown.

– Connect pressure hose -1- (compressed air supply) 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 by hearing, touching,
with commercially available leak detector spray or using ultra‐
sonic tester - V.A.G 1842- .
Note
♦ Slight leaks in the area of the intake connecting pipe

-arrows- 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- ⇒ operating
instructions
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/6- before removing adapter.
♦ Hose connections and hoses must be free of oil and grease
before assembly.
♦ After testing compression, secure intake hoses again with
spring-type clips.
Note



3.4 Removing and installing charge air cooler (Golf, Golf Plus, Touran)


equipment required
Removing
sition .
– Pull coolant hoses off radiator.
– Remove radiator securing bolts and remove radiator with fan
downwards.
Note


– Remove securing bolts -arrows-.

– Remove securing bolts from side bearing.
– Remove charge air cooler downwards.
Installing
note the following:
Specified torques:
Component Nm
Charge air cooler to condenser 5
3.5 Removing and installing charge air cooler, Tiguan

equipment required


Removing
– Remove bracket -1- by unscrewing securing bolts -arrows-.

– Also remove second hose from charge air cooler.
– Disconnect connector -1-.


– Release retaining clip and pull connection -arrow- off radiator.

– Also pull off connection at bottom of radiator.
sition .
– Unscrew securing bolts -arrows- and remove cowling upwards

together with radiator fan - V7- .
Note
The radiator fan - V7- and the cowling may only be renewed com‐
plete.
– Remove securing bolt -arrow-.
– Unscrew bolts -arrows- and remove radiator downwards.

– Remove securing bolts -arrows-.

– Remove securing bolts from side bearing.
– Remove charge air cooler downwards.
Installing
note the following:
Specified torques:
Component Nm
Charge air cooler to condenser 5

24 – Mixture preparation - injection

1 Injection system
Assembly overview - parts l and II, intake manifold ⇒ page
287 .
Assembly overview - fuel rail with injectors ⇒ page 292 .
Checking vacuum reservoir for leaks ⇒ page 294 .
Assembly overview - air filter ⇒ page 296 .
Removing and installing air filter ⇒ page 297 .
Removing and installing regulating flap control unit - J808- and
throttle valve module - J338- ⇒ page 298 .
Cleaning throttle valve module - J338- ⇒ page 302 .
Assembly overview - high-pressure pump ⇒ page 302 .
Checking fuel pressure in high-pressure section ⇒ page 303 .
Removing and installing high-pressure pump ⇒ page 307
Removing and installing injectors ⇒ page 311 .
Renewing Teflon seal and support washer on injector ⇒ page
314
Safety precautions ⇒ page 317 .
Comply with rules for cleanliness ⇒ page 180 .
Technical data ⇒ page 319 .
General notes on injection
♦ The engine control unit - J623- is capable of self-diagnosis.
Before carrying out repairs and fault finding, read fault mem‐
ory. Also the vacuum hoses and connections must be checked
(unmetered air).
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
not permissible.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched off
via the fuel pump relay. The system also improves the starting
characteristics of the engine. When door is opened, the fuel
pump is activated for 2 seconds to build up pressure in the fuel
system.
1.1 Assembly overview - parts l and II, in‐

take manifold
Assembly overview - part II, intake manifold ⇒ page 290 .
1. Injection system 287

1.2 Assembly overview - part I, intake manifold
288 Rep. gr.24 - Mixture preparation - injection

1 - Intake air temperature

sender 3 - G520- with intake
manifold pressure sender 3 -
G583-
2 - 3 Nm
3 - 7 Nm
a power-operated
500 rpm and a max.
is set.
4 - Intake connecting pipe
5 - Seal
❑ Renew
6 - Regulating flap control unit
- J808-
⇒ page 298
❑ If renewed, erase learnt
values and adapt en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester “Guided func‐
tions”.
7 - 7 Nm
a power-operated
driver speed is max. 500 rpm and a max. specified torque of 7 Nm is set.
8 - Intake connecting pipe
9 - Intake manifold connection
10 - 7 Nm
❑ The securing bolt may only be tightened using a power-operated screwdriver if the screwdriver speed is
max. 500 rpm and a max. specified torque of 7 Nm is set.
11 - 3 Nm
12 - Intake manifold pressure sender - G71-
13 - O-ring
❑ Renew
14 - Intake manifold
❑ To remove: Removing and installing regulating flap control unit - J808- and throttle valve module - J338-
⇒ page 298 .
15 - 20 Nm
16 - Fuel pressure sender - G247- , 22 Nm
❑ Checking fuel pressure in high-pressure section ⇒ page 303 .
17 - 80 Nm

18 - Intake manifold lower part

❑ To remove and install: use Holder for 5/16 inch bits - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 290
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
intake manifold ⇒ page 298 .
❑ On renewal, erase learnt values and adapt intake manifold flap potentiometer - G336- to engine control
unit - J623- ⇒ Vehicle diagnostic tester “Guided function”.
❑ Before removing and installing, lock vacuum actuator using a 2.5 mm drill bit.
❑ After installing a new lower part of intake manifold, remove retaining clip for vacuum positioning element.
❑ After installing, check function of intake manifold flap using hand-operated vacuum pump - VAS 6213-
19 - Seal
❑ Renew
❑ Observe installation position
20 - 2.2 Nm
21 - Intake manifold flap potentiometer - G336-
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
functions”.
22 - 2.2 Nm
23 - Vacuum actuator
❑ For intake manifold flap
24 - 20 Nm
25 - Throttle valve module - J338-
❑ Cleaning ⇒ page 302
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
functions”.
26 - 7 Nm
27 - Pressure pipe
❑ Before installing, lightly coat seal with clean engine oil.
❑ From turbocharger
28 - Retaining clip
29 - 7 Nm
Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
1.3 Assembly overview - part II, intake manifold

1 - Union
2 - Fuel hose
clips
3 - Connecting pipe
4 - Fuel hose
❑ Low pressure
❑ To high-pressure pump
5 - Clamp
6 - Connection hose
ter solenoid valve 1 -
N80-
8 - Connection hose
9 - To pressure pipe.
10 - Connecting pipe
11 - Connection hose
❑ To intake manifold con‐
nection.
12 - 8 Nm
13 - Fuel line
❑ High pressure
❑ Specified torque for
union nuts: 18 Nm.
14 - Union
❑ To intake connecting pipe.
16 - Non-return valve
❑ For crankcase ventilation.
18 - Charge pressure control solenoid valve - N75-
❑ To turbocharger
21 - Union
22 - 5 Nm
❑ To turbocharger
24 - Union
25 - Union

❑ To charge pressure control solenoid valve - N75- .
28 - Union
❑ Connected to valve timing housing.
29 - Vacuum hose
❑ From vacuum reservoir
30 - Vacuum hose
❑ To vacuum positioning element
31 - Vacuum hose
❑ To intake manifold flap valve - N316-
32 - Vacuum hose
33 - Non-return valve
❑ Ensure correct installation position before installing
Note
♦ The valve is one-directional.

♦ Wrong position may result in
complaints about driving be‐
haviour.
34 - Intake manifold flap air flow control valve - N316-

35 - Union
❑ For vacuum hoses.
36 - Union
37 - Vacuum hose
38 - Fuel hose
❑ To lower part of intake manifold
❑ For fuel return line.
1.4 Assembly overview - fuel rail with injectors

1 - O-ring
❑ Renew
❑ Before installing, moist‐
en lightly with clean en‐
gine oil.
2 - Spring element
❑ Renew each time after
removing lower part of
intake manifold.
❑ Ensure proper seating
on injector.
3 - Injector, cylinder 4 - N33-
❑ Injector, cylinder 1 -
N30-
N31-
N32-
❑ With Teflon seal and
support washer.
❑ After removing injector,
Teflon seal and support
washer must be re‐
newed ⇒ page 314 .
injectors ⇒ page 311 .
4 - Vacuum hose
5 - Return line
❑ From high-pressure
pump.
❑ Blue or with blue mark‐
ing
clips
6 - 20 Nm
7 - Pressure limiting valve
❑ Renew removed valve.
❑ Before installing lightly moisten O-rings with clean engine oil.
❑ Press in by hand using an 8 mm hexagon key.
8 - Intake manifold lower part
❑ To remove and install: use Holder for 5/16 inch bits - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 294
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
intake manifold ⇒ page 298 .

Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
Checking function of intake manifold flap

– After installing a new lower part of intake manifold, remove
retaining clip -arrow- for vacuum positioning element.
– Connect hand vacuum pump - VAS 6213- as shown in illus‐
tration.
– Generate a vacuum, and check function of vacuum unit on
lever arm.
Note
When the intake manifold is removed, the function of intake man‐

ifold flap can be checked simultaneously.
1.5 Checking vacuum reservoir for leaks

Test conditions
Perform visual check if all vacuum hoses on intake manifold are
not damaged and connected properly.
Test sequence
Vacuum reservoir is integrated into engine cover panel.

– Pull vacuum hose -arrow- off vacuum reservoir.


– Connect hand vacuum pump - VAS 6213- to connection.
– Screw in knurled screw on hand vacuum pump - VAS 6213- .
– Operate hand vacuum pump until a vacuum of 0.3 bar is at‐
tained on pressure gauge.
Note
Due to the high volume in the vacuum reservoir, 20 strokes may

be necessary to generate a pressure of 0.3 bar.
– Observe pressure approx. 3-5 minutes.

If pressure of 0.3 bar is displayed:
Vacuum reservoir is OK.
If pressure drops:
– Renew engine cover panel with vacuum reservoir.
Note



1.6 Assembly overview - air filter

Removing and installing air filter ⇒ page 297 .

1 - 1.6 Nm
2 - Air filter upper part
3 - Vacuum hose
Caution
To avoid damage to the
connection and vacuum
hose, do not use sharp-
edged tools to remove
the hose.
❑ From camshaft housing.
4 - Spring-type clip
ing spring-type clip pli‐
ers - VAS 5024A- .
5 - Intake hose
6 - Cover
7 - Intake air guide
8 - Air filter lower part
❑ With captive securing
bolt.
❑ Specified torque: 8Nm
❑ With intake connection.
9 - Water drain hose
❑ When installing, arrows
on lower part of air filter
and water drainage
hose must align.
10 - O-ring
❑ Renew
11 - Filter element
1.7 Removing and installing air filter

Removing
– Pull coolant hose upwards out of brackets -arrows-.
– Press fastener -1- and pull intake air duct cover out upwards.

– Press fastener -arrows- and pull intake air duct upwards.

– Release spring-type clip -1- and pull intake hose off air filter.
– Loosen securing bolt -2- and pull air filter housing upwards
from locating pins -arrows-.
Installing
the following:
– Push air filter housing onto locating pins -arrows- from above.
– Tighten new securing bolt -2- to 8 Nm and slide spring-type

clip -1- with intake hose onto air filter connection.
1.8 Removing and installing regulating flap

control unit - J808- and throttle valve
module - J338-
Note
To remove throttle valve module - J338- , regulating flap control

unit - J808- must first be removed.

Removing regulating flap control unit - J808-

– Release vacuum hose from vacuum reservoir -arrow- and pull
off.
rection of -arrow-.

rection of -arrow-.
– Remove securing bolts -1-.

– Detach spring-type clips and pull off hose -2- on activated

charcoal filter system solenoid valve 1 - N80- and pressure
pipe -3-.
– Unscrew securing bolt for pressure pipe -3- on turbocharger
and pull pressure pipe -3- off.
– Pull off all connectors and hose connections on intake con‐

necting pipe -4- and regulating flap control unit - J808- .
– Unscrew intake connecting pipe securing bolts -arrows- and

pull intake connecting pipe upwards with regulating flap con‐
trol unit - J808- .
– Unscrew securing bolts -arrows-.

Removing throttle valve module - J338-
– Detach coolant hose -1- from hose clips.

– Pull connector -2- off intake air temperature sender 3 - G520-

with intake manifold pressure sender 3 - G583- .
– Remove charge air hose -3- from throttle valve module - J338-
and charge air pipe.
– Unscrew securing bolts -arrows- and pull throttle valve module

- J338- from intake manifold connection.
Installing
note the following:
♦ Always renew gaskets and seals.
Note



Specified torques:
If a new regulating flap control unit or throttle valve module has
been installed:
– Erase learnt values and adapt engine control unit - J623- to
regulating flap control unit and throttle valve module ⇒ Vehicle
diagnostic tester “Guided functions”.
1.9 Cleaning throttle valve module - J338-
Note
♦ If a new engine control unit - J623- is installed the throttle valve

module must be adapted. Adaptation must be performed only
with a new or cleaned throttle valve module, because soiling
or coking at the end stop of the throttle valve can lead to in‐
correct adaptation values.
♦ When cleaning the throttle valve housing it must not be
scratched.
– Remove throttle valve module (engine codes BLG, BMY,

BWK) ⇒ page 298 .
– Open throttle valve by hand and lock in open position using a
suitable object (e.g. wood or plastic wedge) -arrow-.
WARNING
Acetone is highly inflammable. Please comply with the acci‐

dent prevention regulations and the safety instructions when
handling highly inflammable fluids. Do not use compressed air
when cleaning the throttle valve. Wear protective goggles and
– Thoroughly clean throttle valve housing, especially around the

closed throttle valve -arrows- using commercially available
acetone according to DIN 53247 and a brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module ⇒ Vehicle diagnostic tester “Guided
functions”.
1.10 Assembly overview - high-pressure

pump
WARNING


6 bar).
prox. 6 bar. The appropriate procedure is described in the
chapter on releasing pressure in the high-pressure section ⇒
page 158 .
1 - Roller tappet
❑ Lightly coat with engine
oil when installing.
2 - O-ring
❑ Renew
❑ Lightly coat with engine
oil when installing.
3 - High-pressure pump with
fuel pressure regulating valve -
N276-
Caution
Only grasp high-pres‐
sure pump on housing
when removing and in‐
stalling!
When the high-pressure
piston spring package
loosens the high-pres‐
sure pump will leak and
must be replaced.
4 - 8 Nm
5 - Union
❑ High pressure
6 - Union nut, 18 Nm
❑ Observe safety precau‐
tions ⇒ page 158 .
❑ Counterhold when loos‐
ening connection to
high-pressure pump.
7 - Fuel hose
❑ Low pressure
❑ With spring-type clip.
8 - Union
❑ Low pressure
1.11 Checking fuel pressure in high-pressure

section

♦ Double hex socket 1/2”, 27mm - VAS 5301/7-

♦ Digital pressure gauge - VAS 6394/1-
♦ Test adapter - VAS 5570-
WARNING

6 bar).
page 158 .
Procedure
– Remove engine cover.
off.
rection of -arrow-.


rection of -arrow-.
– Remove fuel pressure sender - G247- -1-.
– Instead of fuel pressure sender - G247- , screw in adapter -

VAS 6394/2- and tighten to 22 Nm.
– Open cover -2- of digital pressure gauge - VAS 6394/1- and

tighten fuel pressure sender - G247- to digital pressure gauge
to 22 Nm.
– Screw pressure line -1- of digital pressure gauge - VAS
6394/1- hand-tight to adapter - VAS 6394/2- .

– Connect test adapter - VAS 5570- between fuel pressure

sender - G247- -1- and connector.
– Connect vehicle diagnostic tester -1- as follows:

– Push diagnostic cable connector -2- onto diagnostic connec‐
tion in driver footwell.
– Press following keys on display in succession:
Vehicle self-diagnosis
Vehicle self-diagnosis
01 - Engine electronics
011 - Measured values
– There, enter 248 and acknowledge with Q .

Display field 2 shows the nominal value; display field 3 shows the
actual value reported to the vehicle by the fuel pressure sender -
G247- .
– Switch on digital pressure gauge - VAS 6394/1- by pressing

key -A- briefly once.
Note
When button -A- is pressed for 2 seconds, the illumination will be

switched on for 20 seconds.
Digital pressure gauge - VAS 6394/1- should display 0 bar; if this

is not the case, press key -C- briefly once for zero point compen‐
sation.
– Start engine.
– Compare pressure displayed by digital pressure gauge - VAS
6394/1- with actual value of vehicle diagnostic tester .
The pressure values may deviate from each other by up to 5 bar.
If pressures do not correspond, fuel pressure sender - G247-
must be renewed.

WARNING
Digital pressure gauge - VAS 6394/1- is subject to high fuel

pressure! Whilst engine is running, pull off connector from fuel
pressure regulating valve - N276- . This reduces fuel pressure
to approx. 6 bar. Switch off ignition. Place a cleaning cloth
around fuel pressure sender - G247- , then reduce residual
pressure by carefully loosening fuel pressure sender - G247- .
Note
♦ When the engine is idling and the electrical connector is pulled

off the fuel pressure regulating valve - N276- , the pressure in
the high-pressure system will drop to approx. 6 bar.
♦ Once the high-pressure in the high-pressure area is reduced,
open the system immediately as the pressure will rise again
due to warming.
– Renew fuel pressure sender - G247- and again compare both

measured values.
If measured values again fail to correspond:
– Check wiring ⇒ Vehicle diagnostic tester.
If measured values correspond:
– Further testing is carried out with “Guided Fault Finding” in
⇒ Vehicle diagnostic tester.
1.12 Removing and installing high-pressure

pump

Condition
• Engine must be cold.
Removing
Comply with rules for cleanliness ⇒ page 180
WARNING

6 bar).
page 158 .
– Separate fuel supply line -arrow-.

– Pull connector and fuel supply line -arrows- off high-pressure

pump.
Note
Catch escaping fuel in a cloth.
– Remove wiring guide -2- and take clip -4- off high-pressure
line.
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.
– Loosen union nuts -3- and -1- of high-pressure line.
– Remove securing bolts -1-, -2- and -3- equally.

– Pull high-pressure pump -3- and roller tappet -1- out of

camshaft housing.
Installing
note the following:
Note
♦ Moisten high-pressure pump roller tappet with clean engine

oil.
♦ The high-pressure pump O-ring must always be renewed.
– Slide roller tappet -1- into camshaft housing.
– Insert new, lubricated O-ring -2- in groove of high-pressure

pump -3-.
– Place high-pressure pump -3- onto camshaft housing.
– Tighten securing bolts -1-, -2- and -3- equally.

– Tighten union nuts of high-pressure line -1- and -3- hand-tight.

– Install wiring guide -2- and fit clip -4- on high-pressure line.
Specified torque of wiring guide securing bolt: 8 Nm
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on lower part of intake manifold when tight‐
ening union nuts.
– Tighten union nut -1- of high-pressure line to 18 Nm.

– Tighten union nut -3- of high-pressure line to 18 Nm.
– Secure fuel supply line and connector -arrows- on high-pres‐

sure pump.
– Reconnect fuel supply line -arrow-.

1.13 Removing and installing injectors

Note safety precautions before beginning work ⇒ page 317 .
Note

Teflon seal on injector must be renewed each time after removing

injector ⇒ page 314 .

♦ Tool set - T10133-
Removing
Remove air filter ⇒ page 297 .
Remove regulating flap control unit - J808- and throttle valve
– Remove intake manifold and lower part of intake manifold ⇒
page 288 .
Note
Before removing, lock vacuum actuator using a 2.5 mm drill bit.
– Press the O-ring upwards by hand as shown, and remove it

from the injector.
– Screw slide hammer - T10133/3- to puller - T10133/15- .

– Then insert puller - T10133/15- into groove -arrow- on injector.
– Pull injector out by tapping carefully.

Installing
– Thoroughly clean injector holes in cylinder head using nylon

brush - T10133/4- .
– Check plastic support washer for damage, renew if necessary
⇒ page 314 .
– Renew spring element -arrow- and Teflon seal each time the
injectors are removed ⇒ page 314 .
– Renew O-rings between injector and lower part of intake man‐
ifold and moisten slightly with clean engine oil.
Note
The Teflon seal on the injector must not be oiled or greased.
– Push injector into cylinder head bore to stop by hand.
Note

The injector must insert easily. If necessary wait until the seal has
contracted sufficiently.
– Ensure correct position of injectors in cylinder head.

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 288 .
Note
♦ Before installation, lock vacuum actuator using a 2.5 mm drill

bit.
♦ After installation of lower part of intake manifold, remove
2.5 mm drill bit.
– Install intake manifold ⇒ page 288 .

– Install regulating flap control unit - J808- and throttle valve
Install air filter ⇒ page 297 .
1.14 Renewing Teflon seal and support

washer on injector
♦ Tool set - T10133-
Procedure
Renewing Teflon seal
Remove air filter ⇒ page 297 .
Remove regulating flap control unit - J808- and throttle valve
– Remove intake manifold and lower part of intake manifold ⇒
page 288 .
Note
Before removing, lock vacuum actuator using a 2.5 mm drill bit.
– Remove injectors ⇒ page 311 .

– Clean injector carefully.
– Carefully cut open seal with a knife as shown -arrow-. Avoid
contact between knife blade and valve body under all circum‐
stances.

– Remove old seal and clean seal groove in area of seal

-arrow-. Remove coking deposits using a brass wire brush.
– Fit new oil seal -1- onto assembly cone - T10133/5- . Using
assembly sleeve - T10133/6- (knurled end faces seal -1-),
gently slide seal onto assembly cone - T10133/5- as far as
possible.
– Turn assembly sleeve - T10133/6- around (knurl no longer

points to seal), and push seal -1- as far as stop onto assembly
cone - T10133/5- .
– Now place assembly cone - T10133/5- with seal onto injector
from front. Slide seal further onto injector using assembly
sleeve - T10133/6- .
The seal is not yet seated in its groove.

– Remove assembly sleeve - T10133/6- and assembly cone -
T10133/5- .
– Slide seal into annular groove by hand.
– Position spacer sleeve - T10133/11- onto valve body.
– Now push calibrating sleeve - T10133/7- over seal to stop onto
spacer sleeve - T10133/11- .

– Pull off calibrating sleeve - T10133/7- again.

– Now push calibrating sleeve - T10133/8- over seal to stop onto
spacer sleeve - T10133/11- .
– Pull off calibrating sleeve - T10133/8- again.
Now the Teflon seal has correct installation dimensions.

Renewing support washer
– Remove O-ring -3-.

– Cut support washer -2- open with a small pair of side cutters
and remove it.
– Pull spring element -1- off injector and replace with retaining
plate - T10133/12- .
– Place new support washer -1- onto assembly cone -

T10133/13- and position onto injector as shown.
– Slide support washer -1- into first groove -arrow- on injector
using calibration sleeve - T10133/17- (knurled side points to
injector).

– Now turn calibration sleeve - T10133/17- around (knurled side

no longer points to injector). Slide calibration sleeve over sup‐
port washer -1- in direction of -arrow- to stop on retaining plate
- T10133/12- .
– Pull calibrating sleeve - T10133/17- down again.
The support washer now has correct installation dimensions.
– Now position a new spring element -1- for retaining plate -

T10133/12- and position a new O-ring -3- in front of support
washer -2-.
Note
The Teflon seal -arrow- must not be oiled to install injector.
– Install injectors ⇒ page 311 .

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 288 .
Note
♦ Before installation, lock vacuum actuator using a 2.5 mm drill

bit.
♦ After installation of lower part of intake manifold, remove
2.5 mm drill bit.
– Install intake manifold ⇒ page 288 .

– Install regulating flap control unit - J808- and throttle valve
Install air filter ⇒ page 297 .
1.15 Safety precautions
WARNING
Fuel system is under pressure! Wear protective goggles and



off connection.
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
♦ For safety reasons, fuse No. 27 must be removed from fuse
holder on left under dash panel before opening fuel system.
Otherwise fuel pump will be activated by driver door contact
switch.
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Caution

sitions.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull all 4-pin connectors -arrows- off ignition coils.

– To do this, fit puller - T10094 A- on ignition coil with final output

stage -arrow- ⇒ page 341 .
– Slightly pull out ignition coil with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully release connector locking mechanism and pull off
connector.
– When installing ignition coil for final output stage, slide con‐
nector on until it audibly engages.
– Fit puller - T10094 A- as shown ⇒ page 341 .

– Press ignition coil with final output stage into cylinder head in
1.16 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.
1.17 Technical data

Engine code BLG, BMY, BWK
Idling check
Idling speed12) rpm 630 … 780
Engine control unit - J623-
System Motronic MED
Governed speed rpm From approx. 5600-6000
12) Not adjustable.

2 Engine control unit - J623-

Removing and installing engine control unit - J623- (Golf) ⇒ page
320
Removing and installing anti-theft engine control unit - J623-
(Golf) ⇒ page 321
Removing and installing engine control unit - J623- (Golf Plus,
Touran) ⇒ page 323
Removing and installing anti-theft engine control unit (Golf Plus,
Touran) - J623- ⇒ page 324 .
Removing and installing engine control unit - J623- (Tiguan) ⇒
page 326
Removing and installing anti-theft engine control unit - J623-
(Tiguan) ⇒ page 328
2.1 Removing and installing engine control

unit - J623- (Golf)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Remove securing bolts -1- and remove cover plate -2-.
– Release front connector -1- from engine control unit and pull
it off.
– Lever up catch -2- slightly.
– Then press engine control unit out of retainer
-in direction of arrow-.
– Then release rear connector on engine control unit and pull it
off.
Installing
– Fit rear connector to engine control unit and lock in position.
– Push engine control unit onto bracket.
– Fit front connector to engine control unit and lock it in position.
– Install cover plate for connectors.


– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit ⇒ Vehicle diagnostic tester
“Guided functions”.
– Install plenum chamber bulkhead ⇒ General body repairs;
– The readiness code must be generated if the fault memory has
been erased.
– Read control unit fault memory again.
2.2 Removing and installing anti-theft en‐

gine control unit - J623- (Golf)
♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

unit”.
Removing
– Remove wiper arms and plenum chamber cover: ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .
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 (scorching/
melting of plastics etc.).
2. Engine control unit J623 321

Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Insert a screwdriver between protective housing -A- and

bracket -arrow-.
– Lever up protective housing using screwdriver -A- and in side‐

wards motion pull off bracket -arrow-.
– Bend catch open slightly -1-.

– Then push engine control unit out of retainer -arrow-.
– Now release connector on engine control unit and pull off con‐
nector.
Installing
– Fit connector to engine control unit and lock connector in po‐
sition.
– Push engine control unit onto bracket.

– Press catch -1- against engine control unit.

– Select “Guided functions” on vehicle diagnostic tester .
– Perform vehicle identification and select engine code.
– Perform function “Renew control unit”.
– Push protective housing onto bracket.
– Tighten new shear-head bolts -1- evenly until heads shear off.
been erased.

unit - J623- (Golf Plus, Touran)
unit”.
Removing
– Loosen securing bolts -arrows- of control unit cover.
– Then remove securing nuts for control unit bracket -arrows-.

– Release connectors on engine control unit and pull off con‐

nector.
– 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.

been erased.

gine control unit - J623- (Golf Plus,
Touran)

♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

unit”.
Removing
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 (scorching/
melting of plastics etc.).
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Then remove securing nuts for control unit bracket -arrows-.

– Release connectors on engine control unit and pull off con‐

nector.
– 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.

– Install cover of protective housing.
– Tighten new shear-head bolts -arrows- evenly until heads

shear off.
been erased.

unit - J623- (Tiguan)

If you wish to renew the engine control unit, connect the vehicle
diagnostic tester and perform the guided function “Renewing con‐
trol unit”.
Removing
cover
– Pull connector -1- off heated windscreen control unit - J505- .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
– Remove retainer frame with engine control unit from plenum
chamber.
– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing
– Slide engine control unit -1- into retaining frame in

-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.


– Fit connectors to engine control unit and slide locking devices
-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

gine control unit - J623- (Tiguan)
If you wish to renew the engine control unit, connect the vehicle
diagnostic tester and perform the guided function “Renewing con‐
trol unit”.
♦ Grip pliers
Removing
cover
– Unscrew bolts -1-.
– Cover the plenum chamber with a clean cloth so that it is not
scratched.
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly.
– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.

– Slide connector locking devices -1- on engine control unit out‐

wards and pull off both connectors.
– Remove engine control unit.
Installing:
– Slide engine control unit -1- in direction of -arrow- in retaining

frame until it engages.
– Tighten the retaining frame.
– Fit connectors to engine control unit and slide locking devices

-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off.

26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamp and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
Assembly overview - catalytic converter and attachments (engine

codes BLG, BMY) ⇒ page 330
Assembly overview - catalytic converter and attachments (engine
code BWK) ⇒ page 332
Assembly overview - silencer with mountings (engine codes BLG,
BMY) ⇒ page 333
Assembly overview - silencer with mountings (engine code BWK)
⇒ page 334
Removing and installing front exhaust pipe (engine code BWK)
⇒ page 334 .
Separating centre and rear silencers (engine codes BLG, BMY)
⇒ page 335 .
Separating centre and rear silencers (engine codes BWK) ⇒ page
337 .
1.1 Assembly overview - catalytic converter and attachments (engine codes

BLG, BMY)
330 Rep. gr.26 - Exhaust system

1 - Heat shield
2 - 10 Nm
3 - Lambda probe after catalyt‐
ic converter - G130-
❑ Grease only the threads
with “G 052 112 A3”;
“G 052 112 A3” cannot
get into the slots on the
probe body.
❑ If seal is leaking, nip
open and renew.
4 - Seal
❑ Renew
5 - Exhaust pipe
6 - Double clamp, 25 Nm
❑ For separate replace‐
ment of centre and rear
silencers
❑ Tighten bolted connec‐
tions evenly.
7 - 25 Nm
❑ Renew
8 - Mounting
9 - 25 Nm
10 - Exhaust pipe
❑ With flexible connection
(de-coupling element).
❑ Do not bend flexible
connection more than
10° - otherwise it can be
damaged.
11 - 25 Nm
❑ Renew
12 - 23 Nm
❑ Renew
❑ Coat studs of turbocharger with high-temperature paste.
13 - Catalytic converter with exhaust pipe
14 - 25 Nm
15 - Bracket
16 - Lambda probe - G39- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-
17 - 10 Nm
18 - 25 Nm
❑ Renew studs and fastening nuts.
❑ Screw studs into cylinder head until they project by 25 mm
❑ Coat studs with high-temperature paste.
❑ Observe tightening sequence and specified torques: items -A- to -I- ⇒ page 237 .
1. Removing and installing parts of exhaust system 331

❑ The turbocharger and the exhaust manifold can only be renewed together.
1.2 Assembly overview - catalytic converter and attachments (engine code

BWK)
1 - Seal
❑ Renew
2 - 25 Nm
❑ Renew
3 - Exhaust pipe
4 - Double clamp, 25 Nm
❑ For separate replace‐
ment of centre and rear
silencers
❑ Tighten bolted connec‐
tions evenly.
5 - 10 Nm
6 - 25 Nm
7 - Washer
8 - Pin
9 - Bonded rubber bush
10 - 25 Nm
11 - Bracket
12 - Lambda probe after cat‐
alytic converter - G130-
❑ Grease only the threads
with “G 052 112 A3”;
“G 052 112 A3” cannot
get into the slots on the
probe body.
❑ If seal is leaking, nip
open and renew.
13 - 25 Nm
14 - Spring
15 - Bracket
16 - 25 Nm
17 - Mounting
18 - Exhaust pipe
❑ With flexible connection (de-coupling element).
❑ Do not bend flexible connection more than 10° - otherwise it can be damaged.
19 - 25 Nm
❑ Renew
20 - 23 Nm
❑ Renew
❑ Coat studs of turbocharger with high-temperature paste.

21 - Catalytic converter with exhaust pipe

22 - 25 Nm
23 - Bracket
24 - 10 Nm
25 - Lambda probe - G39- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-
26 - 25 Nm
❑ Renew studs and fastening nuts.
❑ Screw studs into cylinder head until they project by 25 mm
❑ Coat studs with high-temperature paste.
❑ Observe tightening sequence and specified torques: items -A- to -I- ⇒ page 237 .
❑ The turbocharger and the exhaust manifold can only be renewed together.
28 - Heat shield
1.3 Assembly overview - silencer with mountings (engine codes BLG, BMY)
1 - Mounting
2 - 25 Nm
3 - Bracket
sition
4 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
❑ Separating centre and
rear silencers ⇒ page
335
5 - 25 Nm
6 - Bracket
sition
7 - Mounting
8 - Rear silencer
9 - Mounting

1.4 Assembly overview - silencer with mountings (engine code BWK)
1 - Exhaust pipe with centre

and rear silencers
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
2 - 20 Nm
3 - Bracket
4 - 25 Nm
5 - Bracket
6 - Mounting
7 - 25 Nm
8 - Bracket
9 - 25 Nm
10 - Tunnel cross-piece
11 - 25 Nm
1.5 Removing and installing front exhaust

pipe (engine code BWK)
Removing
– Remove right drive shaft ⇒ Repairing drive shafts; Rep. gr.
40 ; Removing and installing drive shafts .




– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐
shaft and final drive; Rep. gr. 39 ; Removing and installing
propshaft .
– Push propshaft aside.
Installing
Installation is performed in the reverse order of removal.
Specified torques:
Pendulum support ⇒ page 27
Exhaust pipe ⇒ page 332
1.6 Separating centre and rear silencers

(engine codes BLG, BMY)

♦ The connecting pipe can be cut through at the cutting location

in order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.
♦ Chain-type pipe cutter - VAS 6254-
Or
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure
– Cut through exhaust pipe at cutting point -arrow 2- using

chain-type pipe cutter - VAS 6254- or pneumatic sabre saw -
V.A.G 1523A- .
– Position double clamp -4- centrally between side marks when
installing, arrows -1- and -3-.
– Install double clamp so that bolt ends do not protrude beyond

lower edge of double clamp -arrow-.
• Threaded connection faces to rear.
– Align rear silencer free of stress ⇒ page 337 .
Specified torques
Component Nm
Double clamp 25

Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.
1.7 Separating centre and rear silencers

(engine codes BWK)
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.
♦ Chain-type pipe cutter - VAS 6254-
Or
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure

– Cut through exhaust pipe at separating point -2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position double clamp centrally at side marks -1- and -3- when
installing.
– Install double clamp so that bolt ends do not protrude beyond

lower edge of double clamp -arrow-.
• Threaded connection faces to rear.
– Align rear silencer free of stress ⇒ page 338 .
Specified torques
Component Nm
Double clamp 25
Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.

28 – Ignition system
1 Repairing ignition system
General notes on ignition system
♦ The engine control unit - J623- is capable of self-diagnosis.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ In some tests, a fault may be detected and stored by the en‐
gine control unit - J623- . Therefore, after completing all
checks and repairs, read the fault memory and erase if nec‐
essary.
Assembly overview - ignition system ⇒ page 339 .
Problem solution for Hall sender - G40- (engine codes BLG, BMY)
⇒ page 340
Removing and installing ignition coils with output stage ⇒ page
341 .
Safety precautions ⇒ page 343 .
Spark plug test data ⇒ page 343 .
1.1 Assembly overview - ignition system
1. Repairing ignition system 339

1 - Connector
❑ Black, 4-pin.
❑ With assembly tool -
T10118- .
2 - Ignition coil 3 with output
stage - N291-
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N292-
⇒ page 341
3 - Connector
❑ Black, 2-pin.
❑ For knock sensor 1 -
G61- .
❑ Connector contacts are
gold-plated.
4 - Knock sensor 1 - G61-
❑ Connector contacts are
gold-plated.
❑ To remove, remove su‐
percharger ⇒ page 255 .
5 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
6 - Connector
❑ Black, 3-pin.
❑ For Hall sender - G40- .
❑ Problem solution if connector has slipped ⇒ page 340
7 - Hall sender - G40-
❑ Problem solution if connector has slipped ⇒ page 340
8 - O-ring
9 - 10 Nm
10 - Spark plug, 25 Nm
❑ Remove and install with spark plug socket and extension - 3122 B-
❑ Type and electrode gap ⇒ page 343 .
11 - Wiring guide
❑ Bolt to camshaft housing with 5 Nm torque.
12 - Earth wire
❑ Loosen or tighten only with ignition switched off.
13 - 10 Nm
❑ Loosen or tighten only with ignition switched off.
1.2 Problem solution for Hall sender - G40-
340 Rep. gr.28 - Ignition system

Engine numbers affected

Engine code BLG: engine number 002 900 ► - Engines ► model
year 2007
Engine code BMY: engine number 001 600 ► - Engines ► model
year 2007
Note
Engines as of model year 2007 ► are not affected.
Problem
Slipped connector on Hall sender - G40-
Procedure
– In case of complaint, place connector -1- back on Hall sender
- G40- so that it can be heard to engage.
– Secure connector -1- additionally with cable tie -2- 4-5 mm
wide.
– Guide pointed end from Hall sender - G40- through connector
-1- and the release clip.
– Bend end of cable tie -2- down and place round Hall sender -
G40- .
– Fix cable tie -2- on the edge next to the wires and pull tightly.
Wire may not be trapped by the cable tie -2-.
– Cut off remaining end of the cable tie -2-.
1.3 Removing and installing ignition coils

with output stage

Note
The ignition coil housings with output stages have been modified.
As a result, these ignition coils can only be removed and installed
with puller - T10094 A- . The previous puller - T10094- can con‐
tinue to be used if modified as described below.
– Remove marked area -2- using suitable workshop equipment

to attain the new nominal dimension -B- of 18 mm.
– Add the letter A to the end of tool designation -1-.
Removing
– Unscrew securing bolts -1- from crankcase breather union and

non-return valve.
– Pull off connector -2- from turbocharger air recirculation valve
- N249- and pull off hose connection -3-.
– Carefully pull hose -4- off intake manifold connection.
– Fit puller - T10094 A- on ignition coil with final output stage

-arrow-
– Slightly pull out ignition coil with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully release connector locking mechanism and pull off
connector.
Installing
– Fit puller - T10094 A- on ignition coil with final output stage.
– Push connector onto ignition coil with output stage until it en‐
gages audibly.

– Press ignition coil with final output stage into cylinder head in
1.4 Safety precautions

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull all 4-pin connectors -arrows- off ignition coils with final
output stage. ⇒ page 341
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er; fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
1.5 Test data, spark plugs

Firing order 1-3-4-2
Spark plugs
VW part number *) 13)
101 905 622
Electrode gap 0.8 to 0.9 mm
Specified torque 25 Nm
Change interval for Golf and Golf Plus ⇒ Maintenance ; Booklet 38 “Additional work
based on time and/or distance”
Change interval for Touran ⇒ Maintenance ; Booklet 18.1 “Additional work


Change interval for Tiguan ⇒ Maintenance ; Booklet 24.1 “Additional work
13) Current spark plugs ⇒ Electronic parts catalogue (ETKA)

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Copyright © 2017 Volkswagen AG, Wolfsburg K0058993820

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1.9 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

1.1 Engine number

Engine code and engine number can be found on the sticker

♦ Vehicles for certain export countries have no type plate. Fitting

1.2 Engine data

Engine code BLG BMY BWK

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

♦ Crankcases were installed with different size threaded holes.

Converting engine support - T40075-

1. Removing and installing engine (Golf, Golf Plus, Touran) 3

Special tools and workshop

♦ Engine support - T40075- with adapters /4, /5, /6 or engine

4 Rep. gr.10 - Removing and installing engine

♦ Pliers for spring-type clips - VAS 5024A-

The battery earth must be disconnected for the remaining proce‐

Engine cover panel ► November 2006

1. Removing and installing engine (Golf, Golf Plus, Touran) 5

– Release vacuum hose on vacuum reservoir -arrow- and pull it

– Pull vacuum hose off -arrow-.

– Unbolt heat shield over turbocharger -arrows-.

– Release hose guides -arrows- and remove coolant hose -1-

– Remove hose -2- from activated charcoal filter system

6 Rep. gr.10 - Removing and installing engine

– Remove securing bolts -arrows- of engine splash protection.

– Pull vacuum and breather hoses off engine.

1. Removing and installing engine (Golf, Golf Plus, Touran) 7

– Open all line guide fasteners -arrows-.

– Remove hoses for activated charcoal filter -arrows-.

– Pull activated charcoal filter -1- upwards out of bracket.

– Unbolt bracket -arrows-.

8 Rep. gr.10 - Removing and installing engine

– Pull connector off Lambda probe after catalytic converter -

– Unbolt exhaust pipe together with flexible joint -arrows-.

– Loosen securing bolts of double clamp -arrows- and pull ex‐

1. Removing and installing engine (Golf, Golf Plus, Touran) 9

– Disconnect pendulum support -arrows-.

– Detach slave cylinder -arrows- and place to one side. Do not

Do not depress clutch pedal.

– Remove poly V-belt ⇒ page 36 .

The air conditioning system lines must not be opened.

– Secure air conditioner compressor to lock carrier.

10 Rep. gr.10 - Removing and installing engine

– Screw adapter T40075/4 into crankcase to stop.

– Secure engine support - T40075- hand-tight to crankcase us‐

– Tighten all bolts on engine support - T40075- to 20 Nm.

1. Removing and installing engine (Golf, Golf Plus, Touran) 11