Service: Golf 2009, Golf Cabriolet 2012, Golf Plus 2009, Polo 2010, Touran 2003

Service
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Golf 2009 ➤ , Golf Cabriolet 2012 ➤ ,
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
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Copyright © 2018 Volkswagen AG, Wolfsburg D3E804CADC9
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Releasing high pressure in fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 7
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.2 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.3 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.4 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Removing and installing crankshaft sealing flange on gearbox side . . . . . . . . . . . . . . . . . . 58
2.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.1 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.2 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.3 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Removing and installing cylinder head cover and camshaft . . . . . . . . . . . . . . . . . . . . . . . . 82
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Contents i
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 ➤ , Polo 2010 ➤ , ...
4-cylinder direct injection engine (1.2 l engine, 2V, EA 111, turbocharger) - Edition 09.2018
2.3 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.4 Reworking valve seats . . . . . . . A. G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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4.1 Removing and installing d b top valve timing housing . . . . . u.ar.a. . . . . . . . . . . . . . . . . . . . . . . . . 112
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5 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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5.1 Assembly overview - timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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5.2 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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5.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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5.4 Removing and installing timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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5.5 Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . . 145
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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2.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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2.3 Removing and installing non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi 162

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3 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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3.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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4 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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4.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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4.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Assembly overview - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.3 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 205
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.2 Removing and installing charge air cooler (intake manifold) . . . . . . . . . . . . . . . . . . . . . . . . 212
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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

1 Injection systemn AG. ..V.ol.ks. w. a.g.e.n A................................................. 214
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2 Air filter
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and installing air filter housing . . . o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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3.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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3.4 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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4.1 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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4.2 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.3 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
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5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
satelettronica
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
nform
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6.1 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

m
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7 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
on
c
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7.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 245
o
his
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7.2 Removing and installing engine (motor) control unit J623 with protective housing . . . . . . 248
do
priv
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for
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

en
ng
t.
yi Co
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1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
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1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
p by
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by lksw
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
257
agen
Prote AG.
1.3 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.2 Removing and installing catalytic converter (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.3 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Contents iii
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iv Contents
00 – Technical data
1 Engine number/engine data
(VRL012264; Edition 09.2018)
satelettronica
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1. Engine number/engine data 1

Engine code and engine number can be found on the sticker

-arrow- on the pressure pipe.
The engine code is also on the vehicle data sticker and on the
crankcase above the gearbox.
The engine number consists of up to 9 characters (alphanumeric).
The first part makes up the “engine code”, and the second part (6
characters), the “serial number”. If more than 999,999 engines
were produced with the same code letters, the first of the six digits
is replaced by a letter.
Vehicles with four digit engine codes
Four-place engine codes are being introduced, starting with letter
“C”. The first 3 places show the mechanical design of engine and
are stamped on the engine as previously. The fourth digit denotes
the performance and torque rating of the engine and depends on
the engine control unit - J623- . The four-digit engine code can be
found on the type plate, the vehicle data label and on the engine
control unit.
Note
satelettronica
Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;
Vehicle data sticker .
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2 Rep. gr.00 - Technical data

Engine CBZB CBZA CBZC

code
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Dis‐ c 1197 1197 1197
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Tor‐ N 175/1550-410 160/1500-3500 160/1500-3500
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Com‐ 10 10 10
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1. Engine number/engine data 3

Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus
n AG. V2009
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4-cylinder direct injection engine (1.2
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Engine CBZB CBZAau
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Injection, Simos 10 Simos 10 Simos 10
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Type of Homogene‐ Homogeneous Homogeneous
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Charging Exhaust tur‐ Exhaust turbo‐ Exhaust turbo‐
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2 Safety precautions
⇒ “2.1 Safety regulations for working on fuel supply”, page 5
⇒ “2.2 Releasing high pressure in fuel system”, page 6 AG. Volkswagen
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Risk of injury due to highly pressurised fuel.
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♦ The fuel system is pressurised! The fuel pressure in the

high-pressure section of the injection system must be re‐
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duced to a residual pressure prior to opening the system;

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⇒ “2.2 Releasing high pressure in fuel system”,
on
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♦ To release the residual pressure of approx. 7 bar, the con‐
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♦ Wear protective goggles. Prote AG.
Risk of fire due to escaping fuel.

♦ The fuel pump will be activated by the driver door contact
switch when the driver door is opened. Therefore the pow‐
er supply to the fuel pump must be interrupted if the battery
power has NOT been disconnected yet.
♦ Pull off fuse for fuel pump control unit - J538- ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
Caution
Risk of damage to the electronic components when discon‐

necting the battery.
♦ Observe the necessary measures when disconnecting the
battery.
Always switch off the ignition before disconnecting the battery ⇒

Electrical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
2. Safety precautions 5
Even slight soiling can cause faults. For this reason, observe the
following rules for cleanliness when working on the fuel supply
system and injection system:
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♦ If system is open, do not work with compressed air. Do not
t to the co
move the vehicle.
♦ Protect disconnected electrical connectors from dirt and water,
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and reconnect them only when dry.
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2.2 Releasing high pressure in fuel system
satelettronica
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WARNING
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Risk of injury caused by high fuel pressure.
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♦ The injection system consists of a high-pressure section

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pressure of approx. 7 bar. The appropriate procedure is
described as follows.
Special tools and workshop equipment required

♦ Vehicle diagnostic tester
Releasing high pressure in fuel system:
– Connect vehicle diagnostic tester and then carry out the func‐
tion “Reducing high fuel pressure” in “Guided functions”.
• The fuel pressure will drop to the specified value.
– Switch off ignition.
The fuel rail is still filled with fuel, but the fuel is no longer under
high pressure.
WARNING
Risk of injury, avoid skin contact with fuel.

♦ Always wear eye protection and protective clothing when
opening the fuel system.
♦ Wrap a clean cloth around the connection before opening
the high-pressure section in order to catch escaping fuel.
– After the high pressure has been released, the high-pressure

system must be opened »immediately«. To do this, wrap a

clean cloth around the connection before opening it. Catch the
escaping fuel.
Note
♦ If the high-pressure system is not opened immediately, the

pressure will rise again due to reheating effects.
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– Clear event memory and generate the readiness code in en‐
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2.3 Safety precautions when using testers
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Please note the following if the use of test and measuring equip‐
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ment is required during a road test:
satelettronica
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WARNING
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Risk of accidents due to distraction and inadequate securing

of test and measuring equipment.
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Additional danger as a result of front passenger airbag deploy‐

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♦ Always strap test and measuring equipment in place on
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2.4 Safety precautions when working on the

cooling system
Please note the following if the use of test and measuring equip‐
ment is required during a road test:
WARNING
Risk of accidents due to distraction and inadequate securing

of test and measuring equipment.
Additional danger as a result of front passenger airbag deploy‐
ment in the event of an accident.
♦ Always strap test and measuring equipment in place on
rear seat and have a second person operate them.
♦ Operation of test and measuring equipment while driving
results in distraction.
♦ Greater injury hazard as a result of unsecured test and
measuring equipment must be eliminated.
2. Safety precautions 7
lkswage es n
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golfd bPlusy V 2009 ➤ , Polo 2010 ➤ , ... t gua
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2.5 Safety precautions when working on ig‐
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To prevent injuries to persons and/or damage to the injection
spec
and ignition system, the following must be observed:
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Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
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Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
l purpos
Fuel pump is activated by switching on ignition and via driver

door contact switch. If the battery power has not been discon‐
nf
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3 General repair instructions

⇒ “3.1 Rules for cleanliness”, page 9
⇒ “3.2 Foreign objects in engine”, page 9
⇒ “3.3 Contact corrosion”, page 9
⇒ “3.4 Routing and attachment of lines”, page 9
⇒ “3.5 Fitting radiator and condensers”, page 10
n AG. Volkswagen A
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3.1 Rules for cleanliness
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When working on the fuelausupply/injection system, carefully follow
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spec
cannot be carried out immediately.
es, in part or in w
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t to the co
♦ 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).
rrectness of i
♦ If system is open, do not work with compressed air. Do not
l purpos
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3.2 Foreign objects in engine
nform
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To prevent the ingress of foreign bodies during work on the en‐

a
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gine, seal open channels of the intake and exhaust sections with n in
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suitable plugs, for example from the engine bung set - VAS 6122- .
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3.3 Contact corrosion

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Contact corrosion can occur if non-approved fasteners are used
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For this reason, only connecting elements with a special surface co Vo
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coating have been fitted.
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Prote AG.
Furthermore, rubber and plastic components as well as adhe‐

sives are made of non-conductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic Parts Catalogue .
3.4 Routing and attachment of lines

♦ In order to ensure that lines are all installed in their original
position, the lines for the fuel, hydraulic and vacuum systems
and for the activated charcoal filter system as well as electrical
wires must be marked appropriately before they are removed.
Make sketches or take photographs if necessary.
♦ Because of the lack of space in the engine compartment, make
sure that there is sufficient clearance between lines and all
moving or hot components. This is to avoid damage to lines.
♦ Any clips, cable ties or other fastening devices that have been
cut through or damaged when loosening must be renewed.
♦ Insulation mats and other insulating devices must always be
re-fitted in their original positions.
3. General repair instructions 9

3.5 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does not
mean that these components have been damaged. It is not per‐
missible to renew radiators, condensers or charge air coolers only
because of such minor dents. gen AG
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10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 11
⇒ “1.2 Installing engine”, page 34
1.1 Removing engine

⇒ “1.1.1 Removing engine (Golf, Golf Plus, Golf Cabriolet)”, page
11
⇒ “1.1.2 Removing engine (Touran)”, page 19
⇒ “1.1.3 Removing engine (Polo)”, page 26 lkswage es n
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1.1.1 Removing engine (Golf, Golf Plus, Golf ho
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1. Removing and installing engine 11

equipment required
♦ Engine support - T10416- with adapters /1, /2, /3

♦ Torque wrench - 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-

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♦ Hose clamp pliers - VAS 6340-

♦ Torque wrench (40 … 200 Nm) - V.A.G. 1332-
♦ Guide pins - T10093-
♦ Commercially available stepladder (not illustrated)
12 Rep. gr.10 - Removing and installing engine

AG. Volkswagen AG d
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– Remove air filter
ility
ot p
⇒ “2.2 Removing and installing air filter housing”, page 217 .
wit
, is n
h re
– Open and close expansion tank cap to release pressure in
hole
spec
cooling system.
es, in part or in w
t to the co
– Drain coolant
⇒ “1.2 Draining and adding coolant”, page 171 .
– Observe rules for cleanliness
rrectness of i
⇒ “3.1 Rules for cleanliness”, page 9 .
l purpos
– Separate fuel supply line -1- and line to activated charcoal filter
-2-. To do this, press release buttons.
nf
ercia
orm
m
WARNING
atio
m
satelettronica
o
n in
or c
Fuel supply lines are under pressure! Wear eye protection and
thi
te
sd
protective gloves to avoid injury and skin contact. Wrap a cloth
iva
o
r
around the connection before loosening hose connections.

rp
cu
o
m
Then release pressure by carefully pulling hose off connection.
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove hose -1- from activated charcoal filter solenoid valve

1 - N80- to activated charcoal filter.
– Undo securing bolts -2- and pull activated charcoal filter up‐
wards.
– Open spring-type clips and pull coolant hoses -1- and -2- off.
– Press locking element -3- under the coolant hoses and pull the
hoses off upwards.
– Place coolant hoses towards rear.

– Release and detach coolant hoses from heat exchanger

-arrows-.
– Release coolant hoses -arrows- at gearbox end and detach.

– Remove Lambda probe - G39- -1- using Lambda probe open
ring spanner set - 3337- .
– Unscrew upper securing bolt of three-phase alternator -2- and
press alternator downwards a little.
satelettronica
– Unbolt oil supply pipe from turbocharger and from oil filter
housing ⇒ Item 7 (page 198) .
– Undo securing bolts -arrows- and remove heat shield from
turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
– Unscrew securing nuts on turbocharger -arrows-.

y li
erm
ab
ility
– Remove noise insulation ⇒ General body repairs, exterior;

ot p
Rep. gr. 50 ; Removing and installing noise insulation .

wit
, is n
h re
hole
– Remove front left and right wheel housing liners ⇒ General

spec
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing

es, in part or in w
and installing front wheel housing liner .

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

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Golf 2009 wag➤
en,AGolf
G
Cabriolet 2012
n AG d
oes ➤ , Golf Plus 2009 ➤ , Polo 2010 ➤ , ...
olks not
4-cylinder direct injection
d by V engine (1.2 l engine, 2V, EAgu 111, turbocharger) - Edition 09.2018
ar
e an
ris tee
ho
– Release coolant shose
au
t
-1- at charge air system cooler and re‐ or
ac
move coolant pipe
s -2-.
ce
le
un
pt
– Open spring-type clips and pull coolant hoses -1- off.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Detach connector -2- from coolant circulation pump - V50- .

– Detach connectors -3- for knock sensor 1 - G61- and -4- from
nform
ercia
engine speed sender - G28- .

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
satelettronica
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– If auxiliary heater is fitted, remove coolant pipes -2-.
– Move lock carrier into service position: ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Front body: Lock carrier - service
position .
– Unscrew exhaust pipe together with flexible joint -arrows-.

– Undo bolts of clamping sleeve -arrows- and pull exhaust pipe

towards the rear.
– Separate connectors -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
– Undo securing nuts -2- and press exhaust pipe out of rubber
itte
y li
rm
bushes towards rear with assembly lever.
ab
pe
ility
ot
– Pull exhaust pipe out forwards.
wit
, is n
h re
– Unscrew securing bolts -3- and remove catalytic converter
hole
spec
downwards.
es, in part or in w
t to the co
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
satelettronica
rrectness of i
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
l purpos
– All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
nform
ercia
when the engine is installed.

m
a
– Disconnect all electrical wiring from gearbox, alternator and
com
tion in
starter and lay to side.
r
te o
thi
– Pull off or disconnect all other electrical connections as nec‐
s
iva
do
r
essary from engine and lay to side.

rp
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en
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– Pull vacuum and breather hoses off engine.

n
t.
yi Co
Cop py
– Pull connectors off thermal switch and radiator fan.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Disconnect pendulum support -arrows-.

– 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 .
Vehicles with manual gearbox
– Disconnect selector mechanism from gearbox: ⇒ Rep. gr. 34 ;
Repairing selector mechanism
. Volkswagen AG
a gen AG d
– Remove slave cylinder ofVohydraulic
lksw clutch: ⇒ Rep. ogr.
es n 30 ;
ot g
Repairing clutch mechanism
ed
by ua
ran
ris tee
utho or
a ac
ss
Note
ce
le
un
pt
an
d
itte
Clutch pedal must not be depressed.
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ab
pe
ility
ot
Vehicles with dual clutch gearbox
wit
, is n
h re
– Remove selector lever cable: ⇒ Rep. gr. 34 ; Removing and
hole
spec
installing selector lever cable
es, in part or in w
t to the co
satelettronica
Continued for all vehicles
– Remove poly V-belt
rrectness of i
⇒ “1.2 Removing and installing poly-V belt”, page 47 .
l purpos
– Remove air conditioner compressor ⇒ Heating, air condition‐

ing; Rep. gr. 87
nform
ercia
Note
m
a
com
tion in
r
The air conditioning system lines must not be opened.

te o
thi
s
iva
do
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– Secure AC compressor to lock carrier.

um
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ng
t.
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– Ensure that lines are not kinked.
Co
Cop py
t. rig
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Engine support - T10416- with adapters -/1-, -/2- and -/3- is re‐
cop Vo
by lksw
quired to lower engine and gearbox.
cted agen
Prote AG.

– Screw adapter - T10416/1- to stop into crankcase.

– Position engine support - T10416- with adapters -/2- and -/3-
on crankcase.
– Secure engine support - T10416- hand-tight to crankcase us‐
ing a bolt -1-.
– Tighten all bolts on the engine support - T10416- to 20 Nm.
Note
Adjuster nut -2- sets correct angle between pin on engine support
- T10416- and engine and gearbox jack - V.A.G 1383 A- .
satelettronica
– Position engine and gearbox jack - V.A.G 1383 A- on engine
support - T10416- .
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
AG. Volkswagen AG d
agen oes
ksw
Note by
Vol not
gu
ara
ed
ris nte
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To remove securing bolts use a commercially availableasteplad‐
ut
h
ra
der . ss c
ce
e
nl
pt
du
an
itte
y li
– Unbolt engine side of assembly mounting from above
erm
ab
-arrows-.
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Lift cable guide above gearbox mounting.

m
atio
om
n in
– Unbolt gearbox side of assembly mounting from above

or c
-arrows-.
thi
te
sd
iva
– Carefully lower engine and gearbox.

r
rp
cu
o
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f
en
ng
Secure engine to engine and gearbox support - VAS 6095- to

t.
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op
carry out repairs. C py
t. rig
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– Unbolt gearbox. op Vo
by c lksw
cted agen
Prote
– Secure engine on engine and gearbox support - VAS 6095- .
AG.

AG. Volkswagen
1.1.2 Removing
Vol
kswengine (Touran) es not
agen AG do
y gu
db ara
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Note s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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equipment required
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
satelettronica
o
n in
or c
thi
te
sd
iva
o
r
rp
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Engine support - T10416- with adapters /1, /2, /3

♦ Engine and gearbox jack - V.A.G 1383 A-

4-cylinder direct injection engine
en AG. V (1.2 al gengine,
olksw en AG 2V, EA 111, turbocharger) - Edition 09.2018
ag does
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y Vol gu
se
db ara
nte
equipment required thori eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
satelettronica
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Commercially available stepladder (not illustrated).
Note
The battery earth must be disconnected for the remaining proce‐

dure. For this reason, check whether a coded radio is fitted. Then

cooling system.
– Drain coolant


– Separate fuel supply line -1- and line to activated charcoal filter
-2-. To do this, press release buttons.
WARNING
– Remove hose -1- between activated charcoal filter solenoid

valve 1 - N80- and activated charcoal filter.
– Undo securing bolts -2- and pull activated charcoal filter up‐
wards.
AG. Volkswagen AG d
agen oes
satelettronica
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
hoses off upwards.

– Place coolant hoses towards rear. t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Release and detach coolant hoses from heat exchanger

s
iva
do
-arrows-.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


– Unscrew upper securing bolt of three-phase alternator -2- and
turbocharger.
satelettronica
olkswagen AG
en AG. V
– Remove noise insulation o⇒lkswGeneral
ag body repairs,doexterior;
es n
ot
Rep. gr. 50 ; Removing
ed b and installing noise insulation . guar
y V
a is nte
or
– Remove front left au
th and right wheel housing liners ⇒ General eo
ra
body repairs; sRep. gr. 66 ; Wheel housing liner; Removing
s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Release coolant hose -1- at charge air system cooler and re‐
move coolant pipe -2-.
rrectness of i
– Open spring-type clips and detach coolant hoses -1-.

l purpos
– Removing radiator fan ⇒ page 194 .

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

– Detach connector -2- from coolant circulation pump - V50- .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
– Pull connector -1- off oil level and oil temperature sender -
rm
ab
G266- .
pe
ility
ot
wit
– If auxiliary heater is fitted, remove coolant pipes -2-.
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
ercia
– Unscrew exhaust pipe together with flexible joint -arrows-.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Undo securing bolts of clamping sleeve -arrows- and pull ex‐

haust pipe towards rear.

– Undo nuts -2- and press exhaust pipe out of rubber bushes
towards rear with an assembly lever.
– Pull exhaust pipe out forwards.
downwards.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
– Pull vacuum and breather hoses off engine.
– Disconnect pendulum support -arrows-.

– Remove right drive shaft, and unscrew left drive shaft from
gearbox and tie up: ⇒ Running gear, axles, steering; Rep. gr.
satelettronica
40 ; Repairing drive shafts; Removing and installing drive agen
AG. Volkswagen AG d
oes
shafts . olksw not
byV gu
ara
ed
nte
Vehicles with manual gearbox horis
eo
aut ra
– Disconnect selector mechanism from gearbox: ⇒ Rep. gr. 34 ; ss c
ce
e

nl
pt
du
an
itte
– Remove slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ;
y li
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
at
om
ion
c
in t
r

o
his
te
ing; Rep. gr. 87

a
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
ht. rig
rig ht
by
The air conditioning system lines must not be opened. copy Vo
by lksw
cted agen
Prote AG.
– Secure air conditioner compressor to lock carrier.

Engine support - T10416-enwith adapters

AG. Volkswagen-/1-,
AG do-/2- and -/3- is re‐
quired to lower engine
olkswand
ag gearbox. es n
o
yV t gu
db ara
ir se nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
on crankcase.
l purpos
– Secure engine support - T10416- finger-tight to crankcase us‐

ing bolt -1-.
nform
mercia
at
satelettronica
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.

support - T10416- .
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
Note
To remove securing bolts use a stepladder - VAS 5085- .

-arrows-.

– Lift cable guide above gearbox mounting.

– Unbolt gearbox side of assembly mounting from above
-arrows-.
Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
– Unbolt gearbox.
1.1.3 Removing engine (Polo)
Note
satelettronica
equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
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ng
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Cop py
ht. rig
rig ht
py by
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♦ Engine support - T10416- with adapters /1, /2, /3 by c lksw
cted agen
Prote AG.

swage es n
♦ Torque wrench b-yV.A.G
Volk
1331- ot g
ua
d ran
ir se
♦ Engine and th gearbox jack - V.A.G 1383 A-
o tee
or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
equipment required
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
satelettronica
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Guide pins - T10093-
♦ Commercially available stepladder (not illustrated)
Note

dure. For this reason, check whether a coded radio is fitted. Then

– Unscrew securing bolts -arrows- of intake air duct and inlet

connection on turbocharger.
– Pull vacuum hose -1- under intake hose.
– Unscrew securing bolt -2-.

– Withdraw air filter housing upwards.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery
satelettronica
cooling system.
– Drain coolant
– Disconnect fuel supply line -1- and line to activated charcoal

filter -2-. To do this, press release buttons.
WARNING
Fuel supply lines are under pressure! Wear . Voeye

lkswprotection
agen AG and
protective gloves to avoid injurylkand gen AG
swa skin contact. Wrapda oecloth
s no
around the connection before by
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o t gu
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Then release pressure oby ed
ris carefully pulling hose off connection. nte
e th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hoses off upwards.

hole
spec
es, in part or in w
– Place coolant hoses towards the rear.

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
28
by lksw
cted agen
Rep. gr.10 - Removing and installing engine Prote AG.
– Detach coolant hoses -arrows- from heat exchanger.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Undo and remove upper bolt of the three-phase alternator
-2- and press the alternator downwards a little.
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva

do
r
rp
cum
fo

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

– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing

– Open spring-type clip -1- at radiator for charge air system.

– Remove coolant pipe -2-.
– Open spring-type clips and detach coolant hoses -1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Pull connector -2- off coolant circulation pump - V50- .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nf
ercia
orm
m
atio
m
– Pull connectors -arrow- off oil level and oil temperature sender
o
n in
c
- G266- .
or
thi
te
sd
a
– Move lock carrier into service position: ⇒ General body re‐

iv
o
r
pairs, exterior; Rep. gr. 50 ; Front body: Lock carrier - service

rp
cu
o
position .
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Detach connector -1- for Lambda probe after catalytic con‐

verter - G130- -2-.

– Remove bolts -1-.

– Press support rings -2- off bolts.
– Loosen securing bolts for clamp -arrows- and push it rear‐

wards.
– Remove catalytic converter together with exhaust pipe down‐
wards.
satelettronica
olkswagen AG
– Pull off or disconnect all other electrical connections as nec‐agen
AG. V does
ksw
essary from engine and lay to side. by
Vol not
gu
d ara
se nte
– Pull vacuum and breather hoses off engine. thori eo
au ra
c
– Pull connectors off thermal switch and radiator
ss fan.
ce
e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
ot p
Bolt -1- must not be loosened.
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove pendulum support securing bolts -arrows-. n AG. Volkswagen AG do

lkswage es n
– Remove right drive shaft, and unscrew left drive shaft from byV
o ot g
ua
gearbox and tie up: ⇒ Running gear, axles, steering; Rep.
ir se
d
gr. ran
tee
40 ; Repairing drive shafts; Removing and installing
au drive
tho
or
ac
shafts . ss
ce
e
nl
pt
du
an
itte
y li
– Disconnect selector mechanism from gearbox: ⇒ Rep. gr. 34 ;
erm
ab
ility
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– Remove slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ;
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nf
ercia
o
rm
m
atio
satelettronica
m

o
n in
or c
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t.
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ing; Rep. gr. 87
Co
Cop py
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pyri by
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co lksw
by
Note cted agen
Prote AG.

Engine support - T10416- with adapters -/1-, -/2- and -/3- is re‐
quired to lower engine and gearbox.


on crankcase.
– Secure engine support - T10416- finger-tight to crankcase us‐
ing bolt -1-.
Note
satelettronica
support - T10416- .
– Lift engine and gearbox slightly using engine and gearbox
wage
n AGjack
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To remove securing bolts use a commercially available steplad‐
an
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erm
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– Unscrew earth wire -1-.
is n
h re
ole,
spec
Caution
t to the co
Nut -2- must not be loosened.
rrectne
– Unscrew securing bolts -arrows- for engine mounting.

ss o
cial p
– Remove entire engine mounting upwards.

inform
mer
atio
om
n
c
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te
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pr
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew securing bolts -arrows- from gearbox mounting.
Note
When lowering engine, guide it carefully to prevent damage.

Volkswagen AG
swa
gen AG
.
does
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Vol g
Secure engine to engine and by
ed gearbox support - VAS 6095- to uaran
carry out repairs. oris tee
th or
au ac
Procedure ss
ce
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nl
pt
du
– Unbolt gearbox.
an
itte
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ility
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1.2 Installing engine
h re
hole
spec
⇒ “1.2.1 Installing engine (Golf, Golf Plus, Golf Cabriolet)”,
es, in part or in w
t to the co
page 34
⇒ “1.2.2 Installing engine (Touran)”, page 37
satelettronica
rrectness of i
⇒ “1.2.3 Installing engine (Polo)”, page 39
l purpos
1.2.1 Installing engine (Golf, Golf Plus, Golf

Cabriolet)
nform
ercia
Installation is carried out in the reverse order. When installing,

m
at
om
note the following: ion

c
in t
or
his
ate
Caution
do
priv
cum
for
en
g
Observe the following points during all installation work, in par‐

n
t.
yi Co
ticular in the engine compartment, due to the space limitations: Cop py
t. rig
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yri
♦ Route all the various lines, e.g. for fuel, coolant, refriger‐
p by
co Vo
by lksw
ant, vacuum and electrical wiring, in their original posi‐ Prote
cted agen
tions.
AG.
♦ To avoid damaging lines, make sure there is sufficient

clearance to all moving or hot components.
– Check clutch release bearing for wear and renew if necessary

(vehicles with manual gearbox).
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100 (vehicles with
manual gearbox).
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
Align the engine mountings as follows:

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rm
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
satelettronica
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ 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-.
♦ Ensure that edges of support arm -2- and gearbox bracket
-1- are parallel at gearbox end.
– Install pendulum support.
Specified torques:
♦ Securing bolts for oil supply pipe
⇒ “1.1 Assembly overview - turbocharger”, page 197
♦ Specified torques for assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”,
AG. Volkswagen AG d
page 42 . lksw
agen oes
n o ot g
yV ua
♦ Securing bolts for engine bracket
ris
ed
b ran
tee
⇒ “5.1 Assembly overviewut - timing chain”, page 120
ho
or
sa ac
♦ Install drive shafts ⇒ Running
s
gear, axles, steering; Rep. gr.
ce
le

un
pt
an
d
shafts .
itte
y li
satelettronica
erm
ab
ility
ot p
wit
is n
♦ Install slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ; Re‐
h re
ole,
pairing clutch mechanism
spec
♦ Mount selector mechanism: ⇒ Rep. gr. 34 ; Repairing selector
t to the co
mechanism
rrectne
♦ Install selector lever cable: ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable ss o
cial p
f inform
♦ Install air conditioning system compressor ⇒ Heating, air con‐

mer
ditioning system; Rep. gr. 87 .

atio
om
n
c
♦ Install poly V-belt

i
or
n thi
e

t
sd
iva
o
pr
♦ Install noise insulation ⇒ General body repairs, exterior; Rep.

um
r
fo
gr. 50 ; Removing and installing noise insulation .

en
ng
t.
yi Co
op py
– Electrical connections and routing: ⇒ Electrical system; Rep. t. C rig
gh ht
gr. 97 . yri
p by
o Vo
by c lksw
cted
– Add coolant ⇒ “1.2 Draining and adding coolant”, page 171 .
agen
Prote AG.
♦ Install air filter

♦ Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Connect vehicle diagnostic tester - VAS 5051- .
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided Functions”.
– Carry out a vehicle system test ⇒ Vehicle diagnostic tester
“Guided fault finding”.
– Finish the vehicle system test so that any event entries stored
during assembly can be cleared automatically.
Note safety precautions applicable to a road test.

– Carry out road test.

– Then carry out vehicle system test again and rectify any faults
which may have occurred.
1.2.2 Installing engine (Touran)

note the following:
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
ant, vacuum and electrical wiring, in their original posi‐
tions.
satelettronica
manual gearbox).
are fitted in cylinder block and install if necessary. wage
e ks s no
Vol t gu
– Hook intermediate plate onto sealing flange and slide
ed
by onto ara
dowel sleeves -arrows-. thoris nte
eo
au ra
Align engine mountings as follows: ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ 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-.
♦ Ensure that edges of support arm -2- and gearbox bracket
-1- are parallel at gearbox end.
– Install pendulum support.
Specified torques:
♦ Specified torques for engine/gearbox assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 42
⇒ “5.1 Assembly overview - timing chain”, page 120
♦ Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
shafts .
satelettronica
pairing clutch mechanism n AG. Volkswagen AG do
lkswage es n
♦ Mount selector mechanism: ⇒ Rep. gr. 34 ; Repairing selectorbyV
o ot g
ua
mechanism ir se
d ran
tee
tho
u or
Vehicles with dual clutch gearbox ss
a ac
ce
le

un
pt
an
d

itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
⇒ “2.2 Removing and installing air filter housing”, page 217

nform
ercia

m
a
com
ti
– Electrical connections and routing: ⇒ Electrical system; Rep.

on in
gr. 97 .
r
te o
thi
s
iva
do

r
rp
cum
fo

en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
– Finish vehicle system test so that any event entries stored

– Then carry out vehicle system test again and rectify any faults
1.2.3 Installing engine (Polo)

note the following:
Caution
AG. Volkswagen AG d
agen oes
lksw not
Observe the following points during all installation dwork,
by
V in par‐
o gu
ara
ticular in the engine compartment, due to the spaceoris limitations:
e nte
h eo
ut
a ra
ss c
ce
le
tions. un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
satelettronica
t to the co
rrectne
manual gearbox).
s
are fitted in cylinder block and install if necessary.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
– Bolt on gearbox.
Specified torques for gearbox: ⇒ Rep. gr. 34 ; Removing and
installing gearbox
– Rock engine to align engine mountings stress-free.
Specified torques:
♦ Securing bolts for oil supply pipe ⇒ page 197
♦ Specified torques for engine/gearbox assembly mountings
♦ Install pendulum support
⇒ “2.1 Assembly overview - assembly mountings”,
page 42 .
♦ Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
shafts .
satelettronica
pairing clutch mechanism wage
es ks not
Vol gu
♦ Mount selector mechanism: ⇒ Rep.egr.d b 34 ; Repairing selector
y ara
nte
mechanism thoris eo
au ra
ss c ce
le
un
pt
an
d
itte

y li
erm
ab
ility

ot p
wit
is n

h re
ole,

spec

t to the co

rrectne

♦
ss o
cial p
– Electrical connections and routing: ⇒ Electrical system; Rep.

inform
gr. 97 .
mer
atio

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n
c
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or

thi
te

sd
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pr
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fo
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t.
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Cop py
.
t rig
gh ht
yri by
necting and reconnecting battery . cop Vo
by lksw
cted agen
Prote
AG.

– Finish vehicle system test so that any event entries stored


– Then carry out vehicle system test again, rectify any faults
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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satelettronica
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Assembly mountings
2.1 Assembly overview - assembly mount‐

ings
⇒ “2.1.1 Assembly overview - assembly mountings (Golf,
Golf Plus, Golf Cabriolet, Touran)”, page 42
⇒ “2.1.2 Assembly overview - assembly mountings (Polo)”, page
43
2.1.1 Assembly overview - assembly mount‐

ings (Golf, Golf Plus, Golf Cabriolet,
Touran)
Note
Securing bolts for engine/gearbox assembly mountings are
satelettronica
stretch bolts and must be renewed.
Engine mounting
A 1) = 20 Nm + 90° further
AG. Volkswagen AG d
agen oes
1) ksw
B = 40 Nm + 90° further by
Vol not
gu
ara
ed
is nte
C 1) = 60 Nm + 90° further or eo
h
aut ra
s c
1) Renew
s
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un
pt
an
d
itte
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erm
ab
ility
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h re
ole,
spec
Gearbox mounting
t to the co
A 1) = 40 Nm + 90° further
B 1) = 60 Nm + 90° further
rrectne
1) Renew
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Pendulum support
A 1) property class 8.8 = 40 Nm + 90° further.
A 1) property class 10.9 = 50 Nm + 90° further.
B 1) = 100 Nm + 90° further
1) Renew
AG. Volkswagen AG d
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2.1.2 Assembly overview - assembly mount‐
ce
e
nl
pt
du
an
ings (Polo)
itte
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erm
ab
ility
ot p
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Note
h re
hole
spec
Securing bolts for engine/gearbox assembly mountings are
es, in part or in w
t to the co
stretch bolts and must be renewed.
satelettronica
rrectness of i
Caution
l purpos
Nut -arrow- must not be loosened.

nform
ercia
Engine mounting
m
at
om
ion
A = 20 Nm + turn 90° further.

c
in t
or
his
te
B = 30 Nm + turn 90° further.

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Gearbox mounting
A = 40 Nm + turn 90° further.
C = 50 Nm + turn 90° further.
Caution
Bolt -arrow- must not be loosened.
2. Assembly mountings 43
4-cylinder direct injection engine (1.2 l engine, 2V, EAo111,
lksw
turbocharger) - Edition 09.2018
AG. V agen AG
agen does
lksw not
Pendulum support db
yV
o gu
ara
rise nte
A = 30 Nm + turn 90° further. tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
satelettronica
thi
te
sd
iva
o
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

13 – Crankshaft group
Volkswa AG. gen AG
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1 Cylinder block (pulley end)
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db ara
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s au ra
c
Caution
s
ce
e
nl
pt
du
an
The crankshaft must not be removed. Just loosening the main
itte
y li
erm
bearing caps will cause deformation of the cylinder block bear‐
ab
ility
ing seats. This deformation will cause a reduction of the bear‐
ot p
wit
ing clearance. Even if the bearing shells are not renewed,
, is n
h re
bearing damage could occur due to a different bearing clear‐
hole
spec
ance.
es, in part or in w
t to the co
If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
Measuring the main bearing clearance is not possible with nor‐
rrectness of i
mal workshop equipment.
l purpos
satelettronica
nf
ercia
or
Note
m
m
atio
om
n in
c
♦ If large quantities of swarf and abraded material are found, e.g.

or
thi
caused by seizure, then clean oil channels and renew oil filter
te
sd
a
in order to prevent this causing further damage.

iv
o
r
rp
cu
o
m
♦ All bearing and running surfaces must be oiled before assem‐
f
en
ng
t.
yi
bly.
Co
Cop py
ht. rig
♦ Secure engine to engine and gearbox support - VAS 6095- to
rig ht
py by
Vo
carry out repairs.
co lksw
by
cted agen
Prote AG.
⇒ “1.1 Assembly overview - poly V-belt drive”, page 45

⇒ “1.2 Removing and installing poly-V belt”, page 47
⇒ “1.3 Removing and installing crankshaft pulley”, page 48
⇒ “1.4 Renewing crankshaft oil seal - belt pulley end”,
page 52
1.1 Assembly overview - poly V-belt drive
1. Cylinder block (pulley end) 45

AG. Volkswagen AG d
1 - Bolt agen oes
olksw not
y V gu
❑ 20 Nm rise
d b ara
nte
tho eo
2 - Pulley s au ra
c
s
❑ For coolant pump
ce
e
nl
pt
du
an
❑ Use water pump wrench itte
y li
- V.A.G 1590- to loosen
erm
ab
and tighten.
ility
ot p
wit
, is n
3 - Dust cap
h re
hole
spec
4 - Bolt
es, in part or in w
❑ 40 Nm
t to the co
5 - Idler roller
rrectness of i
6 - Alternator
l purpos
7 - Bolt
❑ 25 Nm
nf
ercia
o
8 - Air conditioner compressor
rm
m
atio
m
9 - Bolt
o
n in
satelettronica
or c
❑ 25 Nm
thi
te
sd
iva
10 - Centring sleeve
o
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rp
cu
o
m
f
11 - Tensioning element
en
ng
t.
yi Co
op
❑ Only installed in vehi‐ C py
t. rig
cles with an air-condi‐
gh ht
pyri by
tioning compressor.
co Vo
by lksw
cted agen
Prote AG.
12 - Bolt
❑ Renew
❑ Removing and installing
with vehicle raised
❑ 40 Nm + turn 90° further
13 - Bolt
❑ Renew
❑ 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.
14 - Pulley
❑ For crankshaft
❑ With diamond-coated washer
❑ Contact surfaces must be free of oil and grease.
46 Rep. gr.13 - Crankshaft group

AGolf
G. Vol2009
kswage➤
n A,GGolf Cabriolet 2012 ➤ , Golf Plus 2009 ➤ , Polo 2010 ➤ , ...
agen does
4-cylinder
Volkswdirect injection engine (1.2 not l engine, 2V, EA 111, turbocharger) - Edition 09.2018
y gu
db ara
ise nte
1.2
r
au
tho Removing and installing poly-V belt eo
ra
ss c
⇒ “1.2.1 Removing and installing poly V-belt (vehicles with air-
ce
e
nl
pt
conditioning system)”, page 47
du
an
itte
y li
erm
⇒ “1.2.2 Removing and installing poly V-belt (vehicles without air-
ab
ility
conditioning system)”, page 48
ot p
wit
, is n
1.2.1 Removing and installing poly V-belt (ve‐
h re
hole
spec
hicles with air-conditioning system)
es, in part or in w
t to the co
♦ 16 mm spanner
rrectness of i
Removing
l purpos

nform
ercia
– Mark the direction of travel of the poly V-belt.

m
at
om
io
– Swing poly V-belt tensioning element with a 16 mm spanner
n
c
in t
r
in -direction of arrow- to slacken belt.

o
his
ate
do
riv
satelettronica
– Lock tensioning element in place with a 4 mm Allen key -1-.
p
cum
for
en
g
– Remove poly V-belt.

n
t.
yi Co
op py
Installing
t. C rig
gh ht
pyri by
Vo
– First, place poly V-belt over vibration dampers. Then slide belt
o
by c lksw
cted agen
onto tensioning roller. Prote AG.
Further assembly is basically a reverse of the dismantling se‐

quence.
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.
On completing work:
– Start engine, and check if belt runs properly.
Belt drive with air conditioner compressor

1 - Pulley - cooling system pump
2 - Idler roller
3 - Alternator pulley
4 - Tensioning pulley
5 - Air conditioner compressor pulley
6 - Crankshaft pulley

1.2.2 Removing and installing poly V-belt (ve‐

hicles without air-conditioning system)
Removing
. Volkswage n AG n AG d
wage oes
– Mark the directionyof
Voltravel of the poly V-belt.
ks not
gu
b ara
ed
– Swing poly V-belt
ho
ris tensioning element with a 16 mm spanner nte
eo
in -direction
s aut of arrow- to slacken belt. ra
c
s
– Remove poly V-belt.
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
es, in part or in w
t to the co
nator, air conditioner compressor) are secured tightly.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.
satelettronica
rrectness of i
l purpos
– First, fit poly V-belt -4- over crankshaft pulley -5-.

– Then, fit poly V-belt over pulleys of coolant pump -1- and al‐ nf
ercia
ternator -3-.
orm
m
atio
– After that, fit poly-V belt onto tensioning roller -2-.

om
n in
or c
– If necessary, use a screwdriver to release tension from ten‐

thi
e
sioning element.
t
sd
iva
o
r
rp
cu
On completing work:
o
m
f
en
ng
t.
yi Co
– Start engine, and check if belt runs properly. . Cop py
rig
ht ht
rig by
py
Belt drive without air conditioner compressor
co Vo
by lksw
cted agen
Prote AG.
1 - Pulley - cooling system pump
2 - Tensioning pulley
3 - Alternator pulley
4 - Poly V-belt
5 - Crankshaft pulley
1.3 Removing and installing crankshaft pulley


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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♦ Counter-hold tool - 3415-
l purpos
♦ Pin - 3415/2-
♦ Locating bolt - T10340-
nform
ercia
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-

m
a
com
tion in
Removing
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– Loosen securing bolt for pulley. Hold pulley with counterhold

- 3415- and -3415/2- .
Installing
AG. Volkswagen AG d
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– Undo and remove bolts -1- and remove coolant pipe bracket s
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-2-.
pt
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ility
Note
ot p
wit
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♦ All contact surfaces from securing bolt to crankshaft must be
hole
spec
free from oil and grease.
es, in part or in w
satelettronica
t to the co
♦ Always use a new bolt.
– Install pulley with new bolt and tighten bolt hand-tight.
rrectness of i
l purpos
– Remove screw plug -arrow- from crankcase.

nform
mercia
at
Note
om
ion
c
in t
or
♦ Use of locking pin is intended to prevent crankshaft from turn‐

his
ate
ing as well when tightening to specified torque.

do
priv
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or
♦ Otherwise, the torque setting might not be correct.

f
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ng
t.
yi Co
Cop py
t. rig
– Screw threaded locking pin - T10340- into crankcase as far as yri
gh by
ht
it will go.
op Vo
by c lksw
cted agen
Prote AG.
Caution
If locking pin - T10340- cannot be screwed in as far as stop,

this indicates that crankshaft is not in the correct position!
In this case, proceed as follows.
– Remove locking pin.

– Turn crankshaft 90° in direction of engine rotation.
– Screw threaded locking pin - T10340- into crankcase as far as
it will go.
– Tighten threaded locking pin - T10340- to 30 Nm.
– Turn crankshaft as far as stop in direction of engine rotation.

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

tation.
Caution
When tightening securing bolt, it is essential to use counterhold

- 3415- with -3415/2- to prevent damage to locking pin.
Specified torque: 150 Nm + turn 180° further.
Hold pulley with counterhold - 3415- and -3415/2- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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by
– Unscrew threadedrised locking pin - T10340- from crankcase.
ara
nte
ho eo
– Screw screwaut plug into the crankcase. ra
ss c
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un
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wit
, is n
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es, in part or in w
t to the co
rrectness of i
Specified torque for plug -arrow-: ⇒ page 52 .

l purpos
nform
mercia
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tion in
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Cop py
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by c lksw
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Prote AG.

– Install coolant pipe bracket -2-, and tighten bolts -1- to speci‐
fied torque ⇒ page 52 .
– Install poly V-belt
quence.
Specified torques
Component Specified torque
Item -1-: bolt M6 10 Nm
Item -1-: bolt M8 20 Nm
Crankcase plug 30 Nm
1.4 Renewing crankshaft oil seal - belt pulley end
Special tools and workshop agen

AG. Volkswagen AG d
oes
equipment required olksw not
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satelettronica
or eo
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aut ra
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nl
pt
du
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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n in
or c
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Prote AG.
♦ Seal puller - 2085-

♦ Assembly tool - T10417-
♦ Extension - 3161-

AG. Volkswagen AG d
agen oes
olksw not
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horis Golf 2009 ➤ , Golf Cabriolet 2012 ➤ ,e oGolf Plus 2009 ➤ , Polo 2010 ➤ , ...
ut
4-cylinder
ss a direct injection engine (1.2 l engine, 2V, EA 111,
ra
c turbocharger) - Edition 09.2018
ce
le
un
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d
itte
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Removing rm
ab
pe
ility
ot
– Remove front right wheel housing liner ⇒ General body re‐
wit
, is n
pairs; Rep. gr. 66 ; Removing and installing wheel housing
h re
hole
liner; Front wheel housing liner .
spec
es, in part or in w
t to the co
– Undo bolt for poly V-belt. Hold pulley with counterhold tool
rrectness of i
-3415- and -3415/2- .
l purpos
nform
mercia
a
com
tion in
r
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op
satelettronica
C py
t. rig
gh ht
yri
– Push attachment - 3161- into oil seal extractor - 2085- . p by
o Vo
by c lksw
cted agen
– Screw inner part of oil seal extractor - 2085- out as far as start
Prote AG.
of thread and lock with knurled screw.
– Oil threaded head of seal extractor. Fit oil seal extractor and,
applying firm pressure, screw it into oil seal as far as possible.
– Loosen knurled screw and turn inner part in
-direction of arrow- against crankshaft until the oil seal is pulled
out.
Installing
– Fit sleeve - T10417/1- onto crankshaft journal and slide oil seal
over sleeve.
– Remove sleeve - T10417/1- from crankshaft journal.

– Drive oil seal into valve timing housing as far as stop using
assembly tool - T10417- and striking evenly.
quence. AG. Volkswagen AG d
agen oes
Specified torques: olksw not
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♦ Install crankshaft belt pulley thoris
eo
⇒ “1.3 Removing and installing crankshaft pulley”,
s au page 48 . ra
c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
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ole,
spec
t to the co
rrectnes
satelettronica
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.

2 Cylinder block, gearbox end
Caution

ance.
Note
satelettronica
♦ If large quantities of swarf or metal particles (caused, for ex‐
ample, by partial seizure) are found when performing repairs,
clean oil passages thoroughly and renew oil filter in order to
prevent subsequent damage.
♦ All bearing and running surfaces must be oiled
en Abefore
G. Volksassem‐
wagen AG
bly. Vol
ksw
ag does
not
by gu
ara
♦ Secure engine to engine and gearbox
oris
ed support - VAS 6095- to nte
carry out repairs. aut
h eo
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ce
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⇒ “2.1 Assembly overview - cylinder block, gearbox end”,

un
pt
an
d
page 55
itte
y li
erm
ab
⇒ “2.2 Removing and installing flywheel”, page 57 ility
ot p
wit
is n
⇒ “2.3 Removing and installing crankshaft sealing flange on gear‐

h re
ole,
box side”, page 58

spec
⇒ “2.4 Removing and installing bracket for ancillaries”,

t to the co
page 65
2.1 Assembly overview - cylinder block,

rrectne
gearbox end
ss o
cial p
Note
inform
mer
atio
Repairing clutch ⇒ Repairing clutch; Rep. gr. 30 ; Removing and

om
installing clutch .
n
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or
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2. Cylinder block, gearbox end 55

1 - Bolt
AG. Volkswagen AG d
❑ Renew agen oes
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❑ Removing and installing rised b ara
nte
crankshaft pulley ut
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ra
⇒ “1.3 Removing and in‐ ss a c
stalling crankshaft pul‐
ce
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nl
pt
ley”, page 48
du
an
itte
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❑ Contact surface for se‐
erm
ab
curing bolt must be free
ility
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of oil and grease.
wit
, is n
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❑ Oil threads before in‐
hole
spec
serting.
es, in part or in w
❑ Secure pulley against
t to the co
turning with counterhold
- 3415- and adapter -
3415/2- .
rrectness of i
❑ The turning further an‐
l purpos
gle can be measured

with a commercial pro‐
tractor.
nform
ercia
❑ 150 Nm + turn 180° fur‐

m
satelettronica
at
ther
om
ion
c
in t
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2 - Pulley
o
his
ate
❑ Contact surfaces must
do
priv
c
be free of oil and grease.
um
for
en
ng
❑ Secure against turning

t.
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op
with counterhold tool -
C py
ht. rig
3415- and adapter - rig ht
py by
Vo
3415/2- when removing
co lksw
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cted agen
and installing. Prote AG.

poly V-belt
⇒ “1.2 Removing and in‐
stalling poly-V belt”,
page 47
3 - Washer
❑ Diamond coated washer is clipped onto belt pulley
4 - Seal
❑ Renew
5 - Engine
6 - Bolt
❑ Renew
7 - Flywheel/drive plate
❑ Removing and installing ⇒ “2.2 Removing and installing flywheel”, page 57
❑ When removing and installing flywheel, lock with counterhold - T10044- .
8 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
❑ ⇒ Fig. ““Install intermediate plate.”“ , page 57
9 - Bolt
❑ Renew after removal
❑ ⇒ Fig. ““Sealing flange on gearbox side - specified torque and tightening sequence”“ , page 57

10 - Sealing flange with sender wheel and oil seal

❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end
⇒ “2.3 Removing and installing crankshaft sealing flange on gearbox side”, page 58 .
11 - Engine speed sender - G28-
❑ Removing and installing ⇒ “1.2 Removing and installing engine speed sender G28 ”, page 269
12 - Bolt
❑ 5 Nm
Sealing flange on gearbox

agen
side
AG. Vo-lkspecified
swagen AGtorque and tightening
does
sequence Volksw not
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– Tightenhobolts
ris in 2 stages as follows. tee
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ac
Stage ss Tightening se‐ Specified torque
ce
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quence
nl
pt
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1. -1- to -6- Screw in by hand as far as stop
y li
erm
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2. -1- to -6- Tighten to 10 Nm
ility
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satelettronica
wit
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spec
es, in part or in w
Install intermediate plate. t to the co

rrectness of i
– Attach intermediate plate -1- to sealing flange -2- -arrow B-.
– Slide intermediate plate onto dowel sleeves -arrows A-.
l purpos
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ercia
orm
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2.2 Removing and installing flywheel
t. C rig
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Special tools and workshop equipment required Prote
cted AG.
agen
♦ Counter-hold tool - T10044-

Removing
– Tighten counterhold - T10044- on cylinder block with washer
-arrow-. Bring counterhold - T10044- to -position A- to loosen
flywheel.
– Mark position of flywheel in relation to engine.
– Unbolt flywheel.
AG. Volkswagen AG d
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olksw not
Installing: ed by
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Installation is carried outaut in the reverse order. When installing,
h eo
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note the following: ss c
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– Renew bolts.
an
d
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Bring counterhold - T10044- to -position B- to tighten flywheel.
erm
ab
satelettronica
ility
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Specified torque
wit
is n
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ole,
Component Nm
spec
Flywheel to crankshaft 60 + 90°1)
t to the co
1) 90° equals a quarter of a turn
rrectne
2.3 Removing and installing crankshaft s
sealing flange on gearbox side

s o
cial p
f inform

mer
atio
♦ Flared ring spanner tool insert AF 24 - V.A.G 1332/11-

om
n
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i
or
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by c lksw
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Prote AG.
♦ Depth gauge - VAS 6082-

♦ Assembly tool - T10134-

♦ Bolt M6x35 (3x)
♦ Hexagon key
Pressing sealing flange with sender wheel off crankshaft
satelettronica
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. n AG. Volkswagen AG do
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Procedure ir se
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or
– Remove flywheel
au or drive plate ac
⇒ “2.2 Removing and installing flywheel”, page 57 . ss
ce
e
nl
pt
du
– Set engine to TDC No. 1 cylinder

an
itte
y li
⇒ “5.2 Checking valve timing”, page 125 .

erm
ab
ility
ot p
– Remove sump
wit
, is n
⇒ “1.3 Removing and installing sump”, page 153 .

h re
hole
spec
– Remove engine speed sender - G28- -arrow-.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew securing bolts -arrows- of sealing flange -1-.
– To press off, screw 3 bolts M6 x 35 into sealing flange -1-

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

gen Ais
G.equipped
Volkswagenwith
AG doa sealing
lip support ring -2-. This support
Vol
ksw ring serves as a fitting
es sleeve
not
and must not be removed by prior to installation. gu
d ara
se n i
or tee
♦ Sealing flange and
au sender wheel -1- must not be separated or
th or
ac
turned after removal
ss from packaging.
ce
e
nl
pt
♦ The sender wheel -1- is held in its installation position on the

du
an
itte
assembly device - T10134- by a locating pin ⇒ page 61 .

y li
erm
ab
ility
♦ Sealing flange and oil seal form one unit and must only be
ot p
wit
renewed together with the sender wheel.

, is n
h re
hole
♦ The assembly device - T10134- is held in its position relative

spec
to the crankshaft by a guide pin ⇒ page 61 inserted into a

es, in part or in w
t to the co
hole in the crankshaft.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.

Set-up of assembly tool - T10134- :

A - Clamping surface
B - Hexagon nut
Volkswagen AG
C - Assembly housing swagen AG. does
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Vol gu
D- d by ara
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Locating pinthori eo
au ra
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E - Hexagon
ss socket head bolt
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nl
pt
du
F-
an
itte
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Guide pin for petrol engines (red knob)
erm
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ility
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G - Guide pin for diesel engines (black knob)
wit
, is n
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H - Knurled screws (qty. 3)
hole
spec
I - Inner part
es, in part or in w
t to the co
Mount seal with sender wheel on assembly tool - T10134-
– Screw on nut -B- until just before it touches the clamping sur‐
rrectness of i
face -A- of the threaded spindle.
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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op py
– Clamp assembly device - T10134- at clamping surface -A- of t. C rig
gh ht
threaded spindle in a vice -1-. yri
p by
co Vo
by lksw
cted
– Push assembly housing -C- downwards until it rests against
agen
Prote AG.
nut -B-.
• Inner part of assembly tool and assembly housing must be at
same height.
– If fitted, remove securing clip -arrow- from new sealing flange.
Note
Do not take the sender wheel out of the sealing flange or rotate it
out of position.

– Place sealing flange -1- with front side facing downwards on

a clean level surface.
– Push sealing lip support ring -2- downwards in
-direction of arrow- until it rests against flat surface.
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.
lkswage es n
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d ran
ir se tee
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a ac
ss
satelettronica
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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– Place sealing flange -1- with front side facing downwards onto
hole
spec
assembly tool - T10134- so that locating pin -D- is seated in
es, in part or in w
hole -3- in sender wheel hole -2-.

• The sealing flange must rest flat against the assembly tool. t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Screw knurled screws -H- into sealing flange -1-.

– Press sealing flange -1- and sealing lip support ring -2- against
surface of assembly tool - T10134- whilst tightening knurled
screws.
n AG. Volkswagen A
– This prevents the locating pin from slipping
ksw out of the sender
age G do
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wheel hole. y Vol ot g
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– When installing sealing flange, thensure
o that sender wheel re‐ or
au
mains fixed in assembly tool.
ss ac
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Mount assembly tool - T10134- with sealing flange on crankshaft nl
pt
du
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flange
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erm
ab
• Crankshaft flange must be free of oil and grease.
ility
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• Engine positioned at TDC No. 1 cylinder.
h re
hole
spec
– Screw on nut -B- until it reaches end of threaded spindle.
es, in part or in w
t to the co
– Press threaded spindle of assembly tool - T10134- in
-direction of arrow-, until nut -B- rests against assembly hous‐
ing -C-.
rrectness of i
– Align flat side of assembly housing to sealing surface of cyl‐
l purpos
inder block on sump side.
satelettronica
– Attach assembly tool - T10134- together with sealing flange
nform
ercia
-1- to crankshaft flange -2-.

m
at
om
i
– To do this, screw hexagon socket head bolts -E- into crank‐
on
c
shaft flange (approx. 5 full turns) using a hexagon key.
in t
or
his
ate
– Push guide pin for petrol engines (red knob) -F- into crankshaft
do
priv
c
flange.
um
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– To guide sealing flange -1-, screw two M6 × 35 mm bolts -2-

into cylinder block -3-.

Bolting assembly tool - T10134- onto crankshaft flange:

– Push assembly housing -C- by hand in -direction of arrow- until
sealing lip support ring -1- rests against crankshaft flange
-2-.
AG. Volkswagen
– Make sure that guide pin forlkspetrol
wage engines (red knob)
n AG do
es n-F- is
properly seated in holed bin
y Vcrankshaft. This ensures that the
o ot g
ua
sender wheel reaches
or
is its final installation position.
e ran
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th eo
s au ra
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s
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Note
un
pt
an
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The guide pin for diesel engines (black knob) must not be inserted
erm
ab
ility
in threaded hole of crankshaft.
ot p
wit
is n
h re
ole,
– Tighten the two hexagon socket head bolts of assembly tool
spec
hand-tight.
t to the co
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly housing -C-.
rrectne
Pressing sender wheel onto crankshaft flange using assembly
tool - T10134- :
satelettronica
ss o
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.
cial p
f inform
• After nut has been tightened to 35 Nm, a small air gap must
mer
still be present between cylinder block -2- and sealing flange
atio
m
-1-.
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c
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pr
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ng
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Cop py
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Vo
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by c lksw
Checking sender wheel installation position on crankshaft cted agen
Prote AG.
– Screw on nut -B- until it reaches end of threaded spindle.

– Unscrew the two bolts -2- from cylinder block.
– Pull guide pin for petrol engines (red knob) -F- out of crank‐
shaft flange.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange, un‐
screwing hexagon socket head bolts -E- from crankshaft
flange.
– Remove sealing lip support ring.
– Position depth gauge - VAS 6082- on crankshaft flange -2-.

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

– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: dimension -a- = 0.5 mm
– If specification is not achieved, press sender wheel further in
⇒ page 65 .
– If specification is achieved, proceed with remaining work
steps. en AG. V
olkswagen AG
ag does
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y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
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un
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Re-pressing sender wheel
an
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itte
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rm
ab
– Secure assembly tool - T10134- on crankshaft flange -2-.
pe
ility
ot
wit
– Make sure that locating pin of assembly tool - T10134- is prop‐
, is n
h re
erly seated in sender wheel hole.
hole
spec
– Tighten hexagon socket head bolts -E- by hand.
es, in part or in w
t to the co
– Push assembly tool - T10134- by hand against sealing flange
satelettronica
-1-.
rrectness of i
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly tool - T10134- .
l purpos
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
nform
ercia
– Screw knurled screws -H- into sealing flange -1-.

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– To guide sealing flange, screw two M6×35 mm bolts -2- into tion in
r
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cylinder block.
thi
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– Tighten nut -B- of assembly tool - T10134- to 40 Nm.

fo
en
ng
t.
yi Co
– Check sender wheel installation position on the crankshaft Cop py
again ⇒ page 64 .
t. rig
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pyri by
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– If the specification is not achieved, tighten nut of assembly tool
by lksw
cted agen
Prote
- T10134- to 45 Nm.
AG.
– Check sender wheel installation position on the crankshaft

again ⇒ page 64 .
2.4 Removing and installing bracket for an‐

cillaries
⇒ “2.4.1 Removing and installing ancillary bracket (top)”,
page 65
⇒ “2.4.2 Removing and installing ancillary bracket (bottom)”, page
68
2.4.1 Removing and installing ancillary brack‐

et (top)


AG. Volkswagen AG d
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♦ Open jaw socket tool AF13 - V.A.G 1331/14- (not shown)

es, in part or in w
t to the co
Removing
rrectness of i

l purpos

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
nf
ercia
ing and installing alternator .

rm
m
atio
m
– Drain coolant
o
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c

or
thi
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sd
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– Open spring-type clip -1- with the hose clip pliers - VAS 6340- .
iv
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Pull coolant hoses off engine oil cooler.

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– Unscrew and remove banjo bolt -2- and securing bolt -3-.
yi Co
Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

– Unscrew securing bolts -2- and -3- and remove oil and coolant
pipes.
– Place cloth under banjo bolt -4-.
– Remove oil supply line.
– Unscrew securing bolts -arrows- of heat shield and push heat
shield away to one side.
Note
Lambda probe -5- need not be removed.
– Unscrew securing bolts -1- and remove bracket.

Installing
satelettronica
– Place ancillary bracket in place on cylinder block.
– Tighten securing bolts -1- to specified torque using torque
wrench - V.A.G 1331- and open jaw socket tool AF13 - V.A.G
1331/14- ⇒ page 68 . AG. Volkswagen A n G do
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spec
es, in part or in w
t to the co
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at
om
ion
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or
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ate
do
priv
cum
for
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Cop py
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by
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AG. V2010a➤ olksw
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– Tighten securing bolts -arrows- of heat shield. aut or
ac
ss
– Position oil supply line and screw banjo bolt -4- back in again.
ce
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pt
an
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itte
– Start securing bolts -2- and -3- and bring coolant pipe into po‐
y li
rm
ab
sition.
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Tighten securing bolt for oil and coolant lines to specified torque
wit
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⇒ page 68 .
hole
spec
Tighten banjo bolt to specified torque ⇒ page 68 .
es, in part or in w
t to the co
– Secure coolant hose to engine oil cooler.
– Check coolant level and top up with coolant if necessary.
rrectness of i
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
l purpos
and installing alternator .

nform
ercia

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Tightening torque figure N21-10274
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Component Specified torque Note

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op py
Item -4- 20 Nm Renew seals
t. C rig
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banjo bolt pyri by
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by
Item -2 and 3- 8 Nm
cted agen
Prote AG.
securing bolts of lines
Tightening torques, figure N13-10408
Component Specified torque Note
Item -1-: bolt 25 Nm Ancillary
bracket to
cylinder
block (top)
2.4.2 Removing and installing ancillary brack‐

et (bottom)
Removing


ing; Rep. gr. 87
Note

– It is essential to ensure that lines are not kinked.
– Unscrew securing bolts -1- and remove bracket.
Installing
– Place ancillary bracket in place on cylinder block.
satelettronica
– Tighten securing bolts -1- to specified torque ⇒ page 69 .
quence.
Specified torques: AG. Volkswagen AG d
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♦ Specified torque for tensioning delement
by
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Component Specified
aut torque Note
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Item -1-: bolt 25 Nm Ancillary bracket to
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cylinder block (bot‐

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ate
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Cop py
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3 Crankshaft
Caution

ance.
AG. Volkswagen AG d
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⇒ “3.1 Renewing needle bearing in crankshaft”, page d by 70
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⇒ “3.3 Crankshaft dimensions”, page 73 utho eo
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3.1 Renewing needle bearing in crankshaft
s
satelettronica
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Only vehicles with a dual clutch gearbox
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♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
h re
ole,
spec
t to the co
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mer
atio
om
n
c
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♦ Internal puller - VAS 251 635-

sd
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pr
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fo
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t.
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Cop py
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pyri by
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Prote AG.

♦ Drift - VW 207 C-
AG. Volkswagen AG d
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Removing rise
d ara
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– Remove gearbox ⇒ sRep.
au gr. 34 ; Removing and installing ra
c
gearbox; Removing gearbox . s
ce
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un
pt
Installing
an
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Note
wit
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satelettronica
h re
ole,
spec
The needle bearing must always be renewed after the gearbox
has been separated from the engine.
t to the co
Condition:
rrectne
• The front edges of the inner puller must be free of chips.
Pulling out needle roller bearing
ss o
cial p
f
– Pull out needle bearing -1- with internal puller - VAS 251 635-
inform
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
mer
-B- from crankshaft -2-.

atio
om
– The internal puller must be positioned behind the needle-and-

c
i
or
n thi
cage assembly -arrow-.

te
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t.
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Cop py
t. rig
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by
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Prote AG.
3. Crankshaft 71
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- .
AG. Volkswagen AG d
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Installation depth: dimension -a- = 2.0 mm ut
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satelettronica
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s
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un
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Note
an
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If the needle bearing is inadvertently driven in too far, it must be
ility
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renewed because it will be damaged when it is pulled out again.
wit
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hole
spec
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
es, in part or in w
box; Installing gearbox .
t to the co
rrectness of i
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nform
mercia
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com
tion in
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3.2 Measuring axial clearance of crankshaft do

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Caution t. Cop py
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Risk of deformation of bearing pedestals.
op Vo
by c lksw
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Prote AG.
♦ The crankshaft must not be removed. Just loosening the
main bearing caps will cause deformation of the cylinder
block bearing pedestals. This deformation will cause a re‐
duction of the bearing clearance. Even if the bearing shells
are not renewed, bearing damage could occur due to a
different bearing clearance.
♦ If the bearing cap bolts are loosened, the cylinder block
must be replaced complete with the crankshaft.
♦ Measuring the main bearing clearance is not possible with
normal workshop equipment.

♦ Universal dial gauge holder - VW 387-
AG. Volkswagen AG d
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♦ Dial gaugess- VAS 6079-
a ra
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pt
du
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itte
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ility
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satelettronica
es, in part or in w
t to the co
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Procedure
nf
ercia
– Screw dial gauge - VAS 6079- with universal dial gauge brack‐
or
et - VW 387- to cylinder block as shown in the illustration.

m
m
atio
m
– Position dial gauge against crank web.

o
n in
or c
thi
e
– Press crankshaft against dial gauge by hand and set gauge to

t
sd
iva
“0”.
o
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cu
o
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en
– Push crankshaft away from dial gauge and read off measured
ng
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value. t. Cop py
rig
gh ht
• Axial clearance: 0.103 to 0.29 mm pyri by
Vo
o
by c lksw
cted agen
• Wear limit: 0.45 mm. Prote AG.
3.3 Crankshaft dimensions

Honing Crankshaft Conrod
dimension in mm main journal ∅ journal ∅
Basic dimension --- -0.022
42.00
-0.037
Stage I --- -0.022
41.75
-0.037
3. Crankshaft 73
AG. Volkswagen AG d
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injection engine (1.2 l oengine,
es n 2V, EA 111, turbocharger) - Edition 09.2018
olk o
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4 ss Pistons and conrods
au ra
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⇒ “4.1 Assembly overview - pistons and conrods”, page 74

un
pt
an
d
itte
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⇒ “4.2 Checking pistons and cylinder bores”, page 75
erm
ab
ility
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⇒ “4.3 Removing and installing oil spray jets”, page 76
wit
is n
h re
⇒ “4.4 Separating new conrod”, page 77
ole,
spec
4.1 Assembly overview - pistons and con‐
t to the co
rods
rrectne
Note
ss
All bearing and running surfaces must be oiled before assembly.
o
cial p
f inform
mer
atio
m
1 - Retaining ring
o
n
c
i
or
n thi
2 - Piston pin
te
sd
a
satelettronica
v
❑ If difficult to remove,
i
o
pr
cum
r
heat piston to 60°C.

fo
en
ng
t.
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❑ Remove and install us‐
Co
Cop py
ing drift - 10 - 14- .
t. rig
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pyri by
Vo
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3 - Piston
c by lksw
cted agen
Prote AG.
❑ Checking
⇒ “4.2 Checking pistons
and cylinder bores”,
page 75
❑ 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
⇒ “4.2 Checking pistons
and cylinder bores”,
page 75 .
❑ Checking ring-to-groove
clearance
⇒ “4.2 Checking pistons and cylinder bores”, page 75 .
5 - Oil scraper rings
❑ Carefully remove and install 3-part oil scraper rings by hand.
❑ Checking ring gap ⇒ “4.2 Checking pistons and cylinder bores”, page 75 .
❑ Ring-to-groove clearance not measurable.

6 - Conrod bolt
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
❑ M8 × 1: 30 Nm + turn 90° further
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod.
8 - Bearing shell
❑ Do not interchange used bearing shells. agen
AG. Volkswagen AG d
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❑ Insert bearing shells centrally. d byV gu
ara
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Checking radial clearance with Plastigage: ut
ho eo
ra
s a c
s
❑ New: 0.020 … 0.060 mm
ce
e
nl
pt
du
❑ Wear limit: 0.090 mm
an
itte
y li
❑ Do not rotate crankshaft when checking radial clearance.
erm
ab
ility
ot p
9 - Pressure relief valve
wit
, is n
h re
satelettronica
❑ Opening pressure of pressure relief valve: 1.8 … 2.2 bar
hole
spec
❑ 27 Nm
es, in part or in w
t to the co
10 - Oil spray jet
❑ For piston cooling.
rrectness of i
❑ Removing and installing ⇒ “4.3 Removing and installing oil spray jets”, page 76
l purpos
11 - Connecting rod
❑ Renew as set only.
nform
ercia
❑ Marking -A-: mark with cylinder number

m
❑ Marking -B-: mark paired conrods and conrod bearing caps
at
om
ion
c
in t
or
Caution
his
ate
do
riv
The conrod must be re‐

p
cum
or
installed in exactly the

f
en
ng
t.
yi
same position as it was
Co
op py
previously installed.
. C rig
ht ht
rig by
copy Vo
by lksw
cted
❑ Guided axially by piston.
agen
Prote AG.
❑ Separating new conrod ⇒ “4.4 Separating new conrod”, page 77 .
4.2 Checking pistons and cylinder bores

♦ External micrometer 75 - 100 mm - VAS 6071-
Checking piston
– Measure pistons approx 7 mm from the lower edge of skirt, at
90° to the piston pin axis. Deviations from nominal dimension:
max. 0.04 mm. Nominal dimension ⇒ page 76
4. Pistons and conrods 75

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 0.25 … 0.75 ---1)
1) 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 0.03 … 0.09 0.15
2nd compression ring 0.02 … 0.06 0.15
satelettronica
Oil scraper ring en AG. Volkswagen AG d
Cannot beswmeasured
ag oes
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Checking cylinder bores edb ara
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itte
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♦ Internal dial test indicator 50 - 100 mm - VAS 6078-
erm
ab
ility
ot p
Checking cylinder bores
wit
is n
h re
– Take measurements at 3 positions in both lateral direction
ole,
spec
-A- and longitudinal direction -B-. Deviations from nominal di‐
mension: max. 0.08 mm t to the co
– Nominal dimension ⇒ page 76

rrectne
Note
ss o
Do not measure cylinder bores when cylinder block is mounted

cial p
f in
on engine and gearbox support - VAS 6095- , as measurements

form
mer
may be incorrect.
atio
om
n
c
Piston and cylinder dimensions

or
n thi
te
sd
va
Honing dimen‐ Piston dia. Cylinder bore ∅

i
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pr
cum
r
sion
fo
2)
en
ng
t.
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Basic dimen‐ mm 70.955 . 71.00
Cop py
sion
ht rig
rig ht
py by
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Stage I mm 71.205 71.25
by c lksw
cted agen
Prote AG.
Stage II mm 71.455 71.50
2) Measure pistons approx. 12 mm from lower edge.
4.3 Removing and installing oil spray jets

♦ Bit - T10545-

Removing
– Remove noise insulation ⇒ General
AG. Volksbody
wagenrepairs,
AG do
exterior;
agen Assembly overview
Rep. gr. 66 ; Noise insulation; es n - noise in‐
olksw o
sulation . db
yV t gu
ar
e an
ris tee
– Remove sump tho or
au
⇒ “1.3 Removing
ss and installing sump”, page 153 . ac
ce
e
nl
– Turn crankshaft via vibration damper securing bolt in direction
pt
du
an
of engine rotation until the respective bolt is accessible.
itte
y li
erm
ab
– Unscrew pressure relief valve -1- using Torx bit T40 -
ility
ot p
T10545- .
wit
, is n
h re
– Remove oil spray jets -2-.
hole
spec
es, in part or in w
Installing
t to the co
Caution
rrectness of i
Risk of damage to oil spray jets.
l purpos
♦ Do not bend oil spray jets.
nform
ercia
satelettronica
♦ Check clearance of oil jets after reinstallation of pistons.
m
at
♦ Bent oil spray jets must be renewed.
om
ion
c
in t
or
his
ate
do
priv
cum
or
1- Pressure relief valve - 27 Nm

f
en
ng
t.
yi Co
op
2- Oil spray jet C py
t. rig
gh ht
yri
• Installation position: align leading edge of oil spray jet arrow
p by
o Vo
by c lksw
with machined surface of cylinder block. Prote
cted AG.
agen
– Install sump
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
4.4 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– Mark cylinder to which conrod belongs ⇒ Item 11 (page 75) .
– Lightly clamp conrod in a vice with protective aluminium jaws,
as shown in illustration.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.

♦ Conrod is clamped below the dashed line.
– Unscrew both bolts -arrows- about 5 turns.
4. Pistons and conrods 77

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

ing cap in -direction of arrow- until it is loose. . Volkswage
AG n AG d
agen oes
Specified torques o lksw not
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by ara
ed
♦ Specified torque for securing boltsho
risof conrod bearing cap nte
eo
⇒ “4.1 Assembly overview - pistons
aut and conrods”, page 74 . ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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.
♦ Do not remove the plastic packing pieces for protecting the
open valves until immediately before fitting cylinder head.
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
bly.
♦ Removing and installing intake manifold
satelettronica
⇒ “3.2 Removing and installing intake manifold”, page 223 .
G. Volkswagen AG d
⇒ “1.1 Assembly overview - cylinder head”, page 79
lksw
agen
A
oes
not
o
yV gu
⇒ “1.2 Removing and installing cylinder head edcover and
b
cam‐ ara
nte
ris
shaft”, page 82 ut
ho eo
ra
sa c
⇒ “1.3 Removing and installing cylinder
s head”, page 96
ce
e
nl
pt
du
⇒ “1.4 Checking compression”, page 102
an
itte
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erm
ab
1.1 Assembly overview - cylinder head
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 79
1 - Bolt
❑ 20 Nm
2 - High-pressure pump
Caution
Only grasp high-pres‐
sure pump on housing
when removing and in‐ agen
AG. Volkswagen AG d
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stalling! Volksw not
gu
d by ara
ise nte
When the high-pressure hor eo
ut
piston spring package ss a ra
c
loosens the high-pres‐
ce
le
un
sure pump will leak and
pt
an
d
must be replaced.
itte
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erm
ab
ility
ot p
❑ For fuel supply.
wit
is n
h re
❑ With fuel pressure regu‐
ole,
spec
lating valve - N276- .
t to the co
satelettronica
⇒ “5.1 Assembly over‐
view - high-pressure
pump”, page 236
rrectne
3 - Bolt
ss
❑ 10 Nm
o
cial p
f in
4 - Hall sender - G40-
form
mer
❑ With O-ring
atio
om
❑ Renew O-ring if dam‐
n
c
i
or
n
aged.
thi
te
sd
iva
o
5 - Bolt
pr
cum
r
fo
❑ 20 Nm
en
ng
t.
yi Co
op py
6 - Lifting eye t. C rig
gh ht
pyri by
7 - Bolt
o Vo
by c lksw
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❑ Tightening sequence ⇒ “1.2 Removing and installing cylinder head cover and camshaft”, page 82
8 - Cylinder head cover
Caution
Studs (M6 x 70) must be
screwed into cylinder
head before cylinder
head cover is installed.
The cylinder head cover
is guided by the studs, so
that the roller rocker fin‐
gers do not slip off the
supporting elements.
Cylinder head cover is
sealed using 2 different
sealants!
❑ Removing and installing ⇒ “1.2 Removing and installing cylinder head cover and camshaft”, page 82
❑ Remove sealant residue.
80 Rep. gr.15 - Cylinder head, valve gear

❑ Carefully clean sealing surfaces. They must be oil and grease free.
❑ Before fitting, apply sealant ⇒ Electronic Parts Catalogue “ETKA” .
❑ When installing, fit vertically from above onto studs and dowel pins.
Note
In vehicles with a production date of

06.2011 and later the gap between
the cylinder head cover and the cyl‐
inder head is sealed with a metal
gasket. The seal must be renewed if
a repair is carried out. The cylinder
head cover was adapted to the solid
gasket. Make sure to use liquid seal‐
ant for sealing cylinder head covers
which were previously sealed with
liquid sealant.
9 - Bolt
❑ 10 Nm
10 - Radiator outlet coolant - G62-
satelettronica
❑ Release pressure in cooling system before removing
11 - O-ring
❑ Renew
12 - Cylinder head gasket
❑ Renew
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❑ With hydraulic valve clearance compensation.

❑ Oil contact surface
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15 - Oil pressure switch - F1-

❑ Checking ⇒ “2.2 Checking oil pressure and oil pressure switch”, page 161
ss
❑ With encapsulated seal. Renew with oil pressure switch after unscrewing
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❑ 20 Nm
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18 - Roller tappet
❑ Lightly coat contact surface with engine oil.
1. Cylinder head 81
19 - 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 Removing and installing cylinder head

cover and camshaft
satelettronica
Note
Camshaft mounting is in cylinder head cover.
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♦ Camshaft clamp - T10414-

♦ Torque wrench - VAS 6583-
♦ Sealant ⇒ Electronic parts catalogue “ETKA”
♦ 2 studs M6x70 (e.g. bolts with sawn-off head)
Removing cylinder head cover
– Release pressure in high-pressure area
⇒ “2.1 Safety regulations for working on fuel supply”, page 5 .
1. Cylinder head 83
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Prior to opening the high-pressure area, the fuel pressure in
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the high-pressure area must be reduced to a residual pressure
of approx. 6 bar. The appropriate procedure is described in the
chapter on releasing pressure in the high-pressure section
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– Disconnect battery earth strap with ignition switched off.
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– Detach both hoses -1- from non-return valve.

– Undo bolt -2- and pull non-return valve out of cylinder head
cover.
– Undo and remove all bolts from the valve timing housing cover
-1-.
– Remove valve timing housing cover.

– Undo and remove bolts -1- and remove coolant pipe bracket
-2-.
– Undo screw plug -arrow- and remove from cylinder block.

– Screw locking pin - T10340- into cylinder block as far as it will
go.
– Turn crankshaft in direction of rotation of engine as far as the
stop.
Caution
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– Remove locking pin. utho
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1. Cylinder head 85
– Insert camshaft clamp - T10414- as far as stop in cylinder head

cover.
– Tighten securing bolt -1- finger-tight.
Caution
Sump must be removed only on vehicles ► 12.2009. AG. Volkswagen AG d

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– Loosen securing bolt -1- of camshaft sprocket.

– Hold camshaft pulley in place with counterhold - T10172- .
– Remove camshaft sprocket together with securing bolt.

– Place timing chain -1- on cast lug -arrow- in valve timing hous‐
ing.
Note
Cast lug on inside of valve timing housing prevents timing chain

from falling down.
– Unscrew bolts -1- and remove retaining clip.
– Pull connector -2- off charge air pressure sender - G31- .

– Unlock catches in -direction of arrow- and pull pressure pipe
-3- first off throttle valve module - J338- and then off turbo‐
charger.
– Open cover -4- and remove securing bolt.
– Pull all spark plug connectors off spark plugs using puller -
T10112A- , and move ignition cables to rear.
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– Pull connector -1- and fuel supply line -2- off high-pressure
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– Undo union nuts -3- and remove line.

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– Counterhold with an open-ended spanner on the threaded

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– Undo bolts of high-pressure pump and pull out of cylinder head

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– Unplug connectors from injectors.

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1. Cylinder head 87
– Unscrew bolts -arrows- and detach fuel rail from injectors.

– Remove turbocharger
⇒ “1.2 Removing and installing turbocharger”, page 199 .
– Detach connector of Hall sender - G40- .
– Pull out oil dipstick.
– Loosen cylinder head cover securing bolts from outside to in‐
side, alternately and diagonally and remove.
– Carefully remove cylinder head cover.
– Remove sealant residues on cylinder head and cylinder head
cover using a rotating brush, e.g. using a hand drill with a
plastic brush attachment (wear eye protection).
Note
In vehicles with a production date of 06.2011 and later the gap

between the cylinder head cover and the cylinder head is sealed
with a metal gasket. The seal must be renewed if a repair is car‐
ried out. The cylinder head cover was adapted to the solid gasket. swagen AG. Volkswagen AG does
satelettronica
Make sure to use liquid sealants ⇒ Electronic Parts Catalogue by
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“ETKA” for sealing cylinder head covers which were previously
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– Prevent dirt and sealant residues from entering cylinder head.
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– Remove camshaft clamp - T10414- .
spec
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– Place cylinder head cover on workbench as shown.
t to the co
– Unscrew securing bolts for retaining frame in specified se‐
rrectness of i
quence -A- to -J-.
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– Remove retaining frame.
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– Lift camshaft -1- out of cylinder head cover -2-.
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Note
Before installing, it is essential to lightly coat the camshaft and

camshaft bearings with engine oil.
– Place camshaft -1- into cylinder head cover -2-.

– Insert camshaft clamp - T10414- into camshaft grooves and

tighten bolt finger-tight.
– Place retaining frame onto
gen supporting
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Specified torques
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Compo‐ Sequence Specified torque
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Tightening sequence for retaining frame
Fitting the cylinder head cover
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Studs (M6 x 70) must be screwed into cylinder head before
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– Prevent dirt and sealant residues from entering cylinder head.

Condition
• The pistons cannot be positioned at TDC.
1. Cylinder head 89
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– Screw two studs (M6x70) -1- into cylinder head before fitting
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cylinder head cover.
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ant can enter oil channels and cause damage to engine.
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♦ In vehicles with a production date of 06.2011 and later the gap
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between the cylinder head cover and the cylinder head is

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repair is carried out. The cylinder head cover was adapted to
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cylinder head covers which were previously sealed with liquid
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– Clean sealing surfaces carefully. They must be free of oil and Prote
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grease.
– Apply liquid sealant ⇒ Electronic Parts Catalogue “ETKA” to
sealing surface -1-.
Bead of sealant must be 2 to 3 mm thick and must run along inside

edge in area of bolt holes.
– Evenly apply thin coat of liquid sealant ⇒ Electronic Parts
Catalogue “ETKA” to sealing surfaces marked with diagonal
lines -2-.
– Check that roller rocker fingers are correctly seated on sup‐
porting elements.
– Carefully fit cylinder head cover onto the cylinder head by slot‐
ting it onto the studs and dowel pins.
– Tighten new securing bolts in cylinder head cover in specified

sequence -A- to -J-.
Specified torque: 8 Nm + turn 90° further.
Caution
It is essential to remove sealant for cylinder head cover in area

of -arrows-.
In order to avoid leaks, do not mix together both sealants for
cylinder head cover and for valve timing housing.

– Remove excess sealant in the area of the -arrows-.

stop.
– Lift timing chain using assembly tool - T10118- .

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– Tighten new securing bolt finger-tight.
Timing chain must be guided over middle of guide rail.
1. Cylinder head 91
– Tighten chain tensioner to 60 Nm.
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– Secure camshaft sprocket with new bolt -1-, tightening
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– In process, hold camshaft pulley with counterhold - T10172- .
es, in part or in w
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– Remove camshaft clamp - T10414- from camshaft.
– Unscrew locking pin - T10340- from cylinder block.
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– Turn crankshaft 2 turns in direction of rotation of engine.
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– Turn securing bolt -1- 1/4 turn (90°) further.

– Remove camshaft clamp - T10414- and locking pin - T10340- .
♦ Install top valve timing housing
⇒ “4.1 Removing and installing top valve timing housing”, page
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♦ Install crankshaft pulley
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⇒ “1.3 Removing and installing crankshaft pulley”, page 48 .
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page 237 .
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♦ Attach fuel lines
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⇒ “5.1 Assembly overview - high-pressure pump”,
page 236 .
satelettronica
♦ Further assembly is basically a reverse of the dismantling se‐
rrectne
quence.
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Adapting engine control unit after timing chain has been removed
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♦ If the learnt values are not adapted, consequential damage
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♦ Not all engine control units support the procedure described
below. If the engine control unit does not support the function
below, the described procedure is not applicable.
Using VAS-PC
1. Cylinder head 93
– Connect vehicle diagnostic tester VAS-PC -1- as follows:

– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
– Press following buttons on display one after the other:
♦ Guided function
♦ Select vehicle
♦ GoTo agen
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Using offboard diagnostic information system service
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inder head
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Securing 50 Nm Turn 90° ⇒ 2nd stage must be
bolt for cam‐ further tightened only at the end
shaft pulley of the procedure after
the valve timing has
been checked
⇒ Renew
♦ Securing bolt for non-return valve
⇒ “2.1 Assembly overview - valve gear ”, page 104 .
♦ Securing bolts for upper valve timing housing cover
⇒ page 115 .
♦ Securing bolts for coolant pipe retainer ⇒ page 52
♦ Plug for cylinder block ⇒ page 52
♦ Securing bolts for intake pipe
⇒ “3.1 Assembly overview - intake manifold”, page 219 .
♦ Securing bolt for line guide
⇒ “1.1 Assembly overview - ignition system”, page 267 .
1. Cylinder head 95
♦ Union nut for high-pressure line

page 236 .
♦ Securing bolts for high-pressure pump
page 236 .
♦ Securing bolts for fuel rail
⇒ “3.1 Assembly overview - intake manifold”, page 219 .
1.3 Removing and installing cylinder head

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♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Bracket - T10358-
♦ Wing compensation plate - T10311- (only Golf Plus)
Removing
– Release pressure in high-pressure area
WARNING

bar).
satelettronica
Remove following components:

♦ Removing and installing bottom valve timing housing
⇒ “4.2 Removing and installing bottom valve timing housing”,
page 115 .
♦ Removing and installing top valve timing housing
⇒ “4.1 Removing and installing top valve timing housing”, page agen AG. Volkswagen AG do
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♦ Removing and installing turbocharger
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♦ Removing and installing intake manifold

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1. Cylinder head 97
– Fit support bracket - 10 - 222A- with adapter - 10 - 222A/8- as

shown.
Polo
– Position adapter - 10 - 222 A /8- on vehicle front end
-arrows- as shown.
– Attach hook to left lifting eye.
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– Attach hooks of support - 10 - 222 A- to bracket - T10358- as

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shown.
– Turn spindles until the hooks are lightly tensioned.
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cooling system.
ss
– Drain coolant
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– Detach fuel supply line -1- and line leading
ss to activated char‐
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coal filter -2- by pressing the release tabs.
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– Remove hose -1- from activated charcoal filter solenoid valve

1 - N80- to activated charcoal filter.
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– Remove securing bolts -2- and pull activated charcoal filter

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hoses off upwards.
– Place coolant hoses towards the rear.
– Remove thermostat housing from cylinder head.
Golf, Golf Plus, Touran, Golf Cabriolet

-arrows-.
– Remove assembly mounting and unscrew engine support.
Polo
– Unscrew earth wire -1-.
Caution
Nut -2- must not be loosened.
1. Cylinder head 99
– Unscrew securing bolts -arrows- for engine mounting.

– Remove entire engine mounting upwards.
All vehicles
– Unhook hook -1- from left lifting eye and push spindle onto left
side of support bracket - 10 - 222 A- .
– Remove cylinder head
⇒ “1.2 Removing and installing cylinder head cover and cam‐
shaft”, page 82 .
– Remove roller rocker fingers together with supporting ele‐
ments and place them on a clean surface.
satelettronica
– Ensure that roller rocker fingers and support elements are not
interchanged.
– Loosen cylinder head bolts in sequence given and then re‐gen AG. Volkswagen AG d
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Specified torque of non-return valve -arrow-: 7 Nm
Note
♦ The non-return valve -arrow- was discontinued on 16 Decem‐

ber 2010.
♦ Since 16 December 2010, the non-return valve
⇒ “2.3 Removing and installing non-return valve”, page 162
has been installed in the cylinder block from the sump side
(beginning with engine number CBZ 301939).
Condition
• The pistons cannot be positioned at TDC.
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♦ Do not remove
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♦ Handle new gasket very carefully. Damage will cause leakage.

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– Place clean cloths in cylinders so that no dirt or emery cloth
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particles can get in between cylinder wall and piston.
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cylinder block. Ensure that surfaces are not scored or scratch‐ spec
ed (if abrasive paper is used, grade must not be less than 100). t to the co
– Carefully remove metal particles, emery residue and cloths.

– Set No. 1 cylinder piston to top dead centre and then turn
rrectne
crankshaft approx. 45° in engine direction of rotation.

s
– Fit new cylinder head gasket. Inscription (Part No.) must be

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– Fit cylinder head. When doing this, observe centring pins in

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cylinder block.
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– Insert new cylinder head bolts and tighten hand-tight.

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– Tighten cylinder head bolts according to specifications

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⇒ page 101 .
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shaft”, page 82
– Adjust valve timing ⇒ “5.3 Adjusting valve timing”, page 127 .
quence.
Specified torques for cylinder head bolts:
Sta Bolts Specified tor‐ Comments
ge que
1. 1 … 10 40 Nm
2. 1 … 10 90° With rigid
spanner
3. 1 … 10 90° With rigid
spanner
1. Cylinder head 101

Tightening sequence:
♦ Securing bolts for engine mounting
⇒ “2.1 Assembly overview - assembly mountings”, page 42 .
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1.4 Checking compression
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♦ Spark plug socket - 3122 B-

♦ Compression tester - V.A.G 1763-
♦ Puller - T10112 A-

Prerequisites for check

• The engine oil temperature must be at least 30 °C.
• Voltage supply OK.
Procedure
– Pull connector off ignition transformer - N152- .
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– Pull spark plug connectors -arrows- out with the puller -
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– Unscrew spark plugs with spark plug socket - 3122 B- .
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– Remove fuse for fuel pump control unit from fuse holder. Fuse
ole,
assignment ⇒ Current flow diagrams, Electrical fault finding
spec
and Fitting locations
t to the co
Note
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Removing fuse interrupts voltage supply for fuel pump control
s
unit.
s o
cial p
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mer
– Check compression using compression tester - V.A.G 1763- ,

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- . atio
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Using compression tester: ⇒ Operating instructions .

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Compression pressures:
New bar pressure Wear limit bar pres‐ Difference between
sure cylinders bar pres‐
sure
10.0 … 15.0 7.0 max. 3.0
– Insert spark plugs using spark plug socket - 3122 B- and tight‐
en to 25 Nm.
quence.
– Read event memory, rectify any faults and then clear event
memory ⇒ Vehicle diagnostic tester “Guided Fault Finding”.
The readiness code must be generated if the event memory has
been cleared.
1. Cylinder head 103

2 Valve gear
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⇒ “2.2 Measuring axial play of camshaft”, page 106 orise nte
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⇒ “2.3 Removing and installing valve stem seals”, page
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❑ 50 Nm + turn 90° further urposes, in part or in wh
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2 - Camshaft sprocket
❑ Note position when in‐
stalling timing chain.
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3 - Bolt
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❑ 10 Nm
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❑ With O-ring
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head cover is installed.
The cylinder head cover
is guided by the studs, so
that the roller rocker fin‐
gers do not slip off the
supporting elements.
liquid sealants ⇒ Elec‐
tronic Parts Catalogue
“ETKA” !

stalling cylinder head cover and camshaft”, page 82
❑ Remove sealant residue.
❑ Before fitting, apply both liquid sealants ⇒ Electronic Parts Catalogue “ETKA” .
❑ When installing, fit vertically from above onto studs and dowel pins.

Note
In vehicles with a production date of

06.2011 and later the gap between
the cylinder head cover and the cyl‐
inder head is sealed with a metal
ants ⇒ Electronic Parts Catalogue
“ETKA” for sealing cylinder head
covers which were previously
sealed with liquid sealants.
6 - Non-return valve
❑ For crankcase ventilation. agen
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7 - Bolt
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O-rings are not available separately
as a replacement part.
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❑ If O-rings are damaged, renew non-return valve
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❑ Before installing, coat lightly with engine oil.
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9 - Camshaft
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❑ Checking axial clearance ⇒ “2.2 Measuring axial play of camshaft”, page 106 .
c
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❑ Coat with oil before inserting (also axial bearing shoulder).

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13 - Valve springs
❑ To remove and install with cylinder head removed, use valve assembly device - 2036- and valve lever -
VW 541/1 A-
❑ With cylinder head installed ⇒ “2.3 Removing and installing valve stem seals”, page 107 .
14 - Valve guide
❑ Checking ⇒ “3.1 Checking valve guides”, page 109
15 - Cylinder head
❑ Removing and installing ⇒ “1.3 Removing and installing cylinder head”, page 96
❑ Reworking valve seats ⇒ “3.4 Reworking valve seats”, page 111 .
❑ Reworking sealing surface ⇒ page 106 .
16 - Valves
❑ Do not rework; only lapping-in is permitted.
❑ Valve dimensions ⇒ “3.3 Valve dimensions”, page 111
2. Valve gear 105

17 - Plug
❑ 15 Nm
18 - Seal
❑ Renew
19 - Dowel pins
20 - Bolt
❑ Observe tightening sequence
❑ 8 Nm
21 - Bearing frame
❑ For camshaft.
Reworking cylinder head sealing surface

Cylinder head reworking dimension: a = at least 103.75 mm
satelettronica
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If sealing surface is reworked, valves olks
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doing this, ensure that the per‐ an
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missible minimum dimension
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t is maintained ⇒ page 111 . or
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2.2 Measuring axial play of camshaft

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♦ Dial gauge
Take measurement with cylinder head cover installed.
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Checking camshaft axial clearance

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Wear limit: max. 0.40 mm

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Golf 2009 ➤ , Golf Vol Cabriolet 2012 ➤ , Golf Plus
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2.3 Removing and installing valve stem seals ss
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♦ Spark plug socket - 3122B-

♦ Valve assembly device - 2036-
♦ Valve stem seal puller - 3364-
♦ Valve lever - VW 541/1 A- with press tool - VW 541/7-
♦ Pressure hose - VW 653/3-
♦ Valve stem seal fitting tool - 3365-
Removing
(With cylinder head installed)
– Remove cylinder head cover
shaft”, page 82 .
– Remove roller rocker fingers and place them on a clean sur‐
face. When doing this, ensure that roller rocker fingers are not
interchanged.
– Remove spark plugs with spark plug spanner -3122B- .
– Set piston of respective cylinder to “bottom dead centre”.
2. Valve gear 107

– Screw valve assembly device - 2036- onto cylinder head.

– Screw pressure hose -VW 653/3- into spark plug thread.
– Connect pressure hose to air pressure source of at least 6 bar.
– Remove valve spring using valve lever - VW 541/1 A- and
press tool - VW 541/7- .
– Pull off valve stem seals using valve stem seal puller - 3364-
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– Place plastic sleeve supplied on respective valve stem. This
h re
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will prevent damage to new valve stem seal.
spec
es, in part or in w
– Place new valve stem seal -1- in valve stem seal fitting tool -
t to the co
3365- .
satelettronica
– Oil valve stem seal sealing lip and press carefully over valve
rrectness of i
-2- onto valve guide.
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quence.
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– Install cylinder head cover

m
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shaft”, page 82 .
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– Adjust valve timing ⇒ “5.3 Adjusting valve timing”, page 127 .
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– Install top valve timing housing

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page 237
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Volkswag(1.2
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⇒ “3.1 Checking valve guides”, page 109
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⇒ “3.2 Checking valves”, page 109
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⇒ “3.3 Valve dimensions”, page 111
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⇒ “3.4 Reworking valve seats”, page 111
h re
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spec
3.1 Checking valve guides
es, in part or in w
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♦ Dial gauge
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Test sequence
AG.
– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine lateral play by moving valve in
-direction of arrow-.
Wear limit: 0.8 mm
If the amount of sideways play is exceeded:
– Renew cylinder head.
3.2 Checking valves

♦ Ruler - T40100-
♦ Depth gauge
♦ Valve seat refacing tool
3. Inlet and exhaust valves 109

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♦ When repairing engines with leaking valves, it is not sufficient
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mileage engines, it is necessary also to check valve guides for
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wear ⇒ “3.1 Checking valve guides”, page 109 .
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spec
♦ Valve seats are only to be reworked to the extent required to
es, in part or in w
yield a proper surface appearance. Before beginning to rework
t to the co
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
rrectness of i
guaranteed and the cylinder head must be renewed.
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The max. permissible reworking dimension is calculated as fol‐

lows:
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– Insert valve and press firmly against seat.

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– Measure distance between end of valve stem and top edge of p by
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ruler - T40100- .
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– Calculate maximum permissible reworking dimension from
measured distance and maximum dimension.
Maximum dimension: inlet valve 1.0 mm, exhaust valve 0.9 mm
Maximum dimension minus measured valve standout = max. per‐
missible reworking dimension.
Note
Material thickness of ruler - T40100- = 7.7 mm.
Example for inlet valve:

Material thickness -T40100- - measured standout = valve
standout
7.7 mm - 7.2 mm = 0.5 mm
Maximum dimension of inlet valve - valve standout = max.
permissible reworking dimension
1.0 mm - 0.5 mm = 0.5 mm 3)
Max. permissible reworking dimension of inlet valve: 0.5 mm.

3) The max. permissible reworking dimension is shown as dimension “b” in the
illustrations for reworking valve seats.

3.3 Valve dimensions

Valve dimensions
Note
Do not rework valves. Only lapping-in is permitted.

AG. Volkswagen AG d
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Dimension Inlet valve Outletbvalve
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α ∠° 44° 50' 44° 50'
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3.4 Reworking valve seats
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Reworking inlet valve seat
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a = 34.8 mm diameter
satelettronica
b = max. permissible reworking dimension1
c = 1.3 … 1.9 mm
rrectness of i
Z = cylinder head lower edge
α = 45° valve seat angle
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– Unclip line -1- from coolant reservoir-2-.
– Remove securing bolts -arrows-, and pull connector -1- off

coolant reservoir -2-.
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4. Cover for timing chain 113

– To improve guidance of valve timing housing cover, screw 2

studs M6x70 -1- into cylinder head cover.
Note
♦ The installation procedure must not be allowed to exceed 6

minutes from the moment when the sealant is applied to the
point when the securing bolts are tightened to 8 Nm.
♦ The sealant starts to harden after 5 minutes.
♦ Note that the securing bolts are tightened in 2 stages.

grease.
– Apply sealant ⇒ Electronic parts catalogue “ETKA” -1- to seal‐
ing surface using applicator gun - VAS 6966- .
Bead of sealant must be 2 to 3 mm thick and must run along inside

edge in area of bolt holes.
– Apply a little extra sealant in area of -arrows-.
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4.2 Removing and installing bottom valve

timing housing
Note
In this engine, the valve timing housing is split. This procedure

describes removal and installation of the bottom valve timing
housing.


equipment required
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♦ Double hexagon socket - VAS 262001- (not shown)
♦ Pin - 3415/2-

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– Undo all bolts from the valve timing housing cover -1-.
– Remove valve timing housing.
Installing
Note
♦ After the sealant is applied, the securing bolts must be tight‐

ened to 5 Nm + 30° further within 6 minutes.
♦ The sealant starts to harden after 6 minutes.
♦ Use new securing bolts.
♦ If the threaded holes and the sealing surfaces are not thor‐
oughly cleaned, the securing bolts may break off before the
final torque specification is reached.

grease.
– Clean threaded holes thoroughly.

– Apply sealant ⇒ Electronic parts catalogue “ETKA” -1- to seal‐

ing surface using applicator gun - VAS 6966- .
Bead of sealant must be 2 to 3 mm thick and must run around
holes in area of bolt holes.
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evenly until finger-tight.

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torque wrench - VAS 6583- and double hexagon socket - VAS
262001- .
Tighten securing bolts for valve timing housing to specified torque
⇒ page 119 .
Install crankshaft pulley
quence.
Specified torques and tightening sequence
Tightening Note Specified tor‐
sequence que
Securing The procedure must not be al‐ 5 Nm +30°
bolts A ... M lowed to exceed 6 minutes from
the moment when the sealant is
applied to the point when the se‐
curing bolts are tightened.
♦ Securing bolt for coolant pump pulley
⇒ “2.2 Removing and installing coolant pump”, page 179 .
satelettronica
♦ Securing bolt for idler pulley
⇒ “1.1 Assembly overview - poly V-belt drive”, page 45 .
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spec
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⇒ “5.5 Removing and installing timing chain and chain drive for
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Note
♦ If large quantities of swarf or metal particles (caused, for ex‐

ample, by partial seizure) are found when performing repairs,
clean oil passages thoroughly and renew oil filter in order to
prevent subsequent damage.
bly.
♦ Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
5.1 Assembly overview - timing chain

1 - Cylinder head with cylinder

head cover
cylinder head
stalling cylinder head”,
page 96 .
cylinder head cover
stalling cylinder head
cover and camshaft”,
page 82 .
❑ Do not rework sealing
surface.
❑ With integrated cam‐
shaft bearings.
❑ Remove sealant resi‐
due.
Caution
satelettronica
sealants!
❑ Before fitting, apply the

different sealants ⇒
Electronic Parts Cata‐
logue “ETKA” .
❑ When installing, insert
vertically from above so
that dowel pins fit into
holes in cylinder head
Note
AG. Volkswagen AG d
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ants ⇒ Electronic Parts Catalogue

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“ETKA” for sealing cylinder head

is n
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covers which were previously

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spec
sealed with liquid sealants.

t to the co
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The crankshaft must not
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be removed. Just loos‐
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ening the main bearing
t to the co
caps will cause deforma‐
tion of the cylinder block
bearing seats. This de‐
rrectness of i
formation will cause a re‐
duction of the bearing
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clearance. Even if the

bearing shells are not re‐
nform
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could occur due to a dif‐
m
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ance.
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Measuring the main cted agen
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bearing clearance is not
possible with normal
workshop equipment.
❑ Thoroughly clean sealing surfaces and threaded holes.

❑ Dismantling and assembling cylinder block
⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page 55 .
❑ Dismantling and assembling pistons and conrods ⇒ “4 Pistons and conrods”, page 74
3 - Bottom ancillary bracket
❑ For tensioning element and air conditioner compressor
❑ Removing and installing ⇒ “2.4 Removing and installing bracket for ancillaries”, page 65
❑ Removing and installing top ancillary bracket
⇒ “2.4 Removing and installing bracket for ancillaries”, page 65 .
4 - Bolt
❑ 25 Nm
5 - Sump
❑ Removing and installing ⇒ “1.3 Removing and installing sump”, page 153
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue “ETKA” .
6 - Bolt
❑ Renew
❑ 13 Nm
7 - Bolt
❑ Removing and installing crankshaft pulley ⇒ “1.3 Removing and installing crankshaft pulley”, page 48
❑ Renew

8 - Pulley
❑ With diamond coated washer (clipped onto belt pulley)
❑ Note tightening sequence ⇒ “1.3 Removing and installing crankshaft pulley”, page 48 .
❑ Removing and installing poly V-belt ⇒ “1.2 Removing and installing poly-V belt”, page 47
9 - Seal olkswagen AG
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❑ Renew olkswag does
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❑ Removing
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an oil seal - belt pulley end”, page 52
r tee
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10 - sBolt
au
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ac
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❑ 50 Nm
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11 - Engine support
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❑ For assembly mounting
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12 - Bolt
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❑ Renew
hole
spec
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13 - Sprocket
❑ For oil pump drive.
rrectness of i
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❑ Lock sprocket using counterhold tool -T10172- .

14 - Oil pump drive chain
nf
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❑ Before removing, mark direction of rotation (installation position).

rm
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15 - Cover
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or c
16 - Bolt
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❑ Renew.
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❑ Bolt: M6x40
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❑ Tighten with torque wrench - VAS 6583- . Cop py
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17 - Bolt
agen
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❑ Renew.
❑ Bolt: M6x20
❑ Tighten with torque wrench - VAS 6583- .
18 - Bottom valve timing housing
❑ Removing and installing ⇒ “4.2 Removing and installing bottom valve timing housing”, page 115
❑ Thoroughly clean sealing surfaces and threaded holes.
❑ Install with sealant ⇒ Electronic Parts Catalogue “ETKA” .
19 - Mounting pins
❑ Specified torque: 18 Nm
20 - Slide rail
❑ For timing chain
21 - Mounting pin
❑ 18 Nm
22 - Bolt
❑ Renew
5. Chain drive 123

23 - Tensioning rail
24 - Bolt
❑ 8 Nm
Caution
Observe tightening pro‐
cedure!
Removing and installing
top valve timing housing
stalling top valve timing n AG. Volkswagen AG do
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25 - Top valve timing housing ss
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Caution
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hole
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Removing and installing
t to the co
top valve timing housing
stalling top valve timing
rrectness of i
housing”, page 112
l purpos
26 - Timing chain
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Note
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♦ Only in vehicles manufactured

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♦ If timing chain has been removed

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learnt values and adapt engine
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⇒ “5.5 Removing and installing timing chain and chain drive for oil pump”, page 145
AG.
27 - Sprocket
❑ Lock sprocket using counterhold tool -T10172- .
28 - Chain tensioner
29 - Seal
❑ Renew, not available as a separate replacement part
❑ Only available in conjunction with ⇒ Item 28 (page 124)

5.2 Checking valve timing

equipment required
AG. Volkswagen AG d
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Test sequence
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-2-.
5. Chain drive 125

– Remove screw plug -arrow- from crankcase.

it will go.
Caution
AG. Volkswagen AG d
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If locking pin - T10340-d bcannot
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In this case, proceed
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– Turn crankshaft 1/4 revolution (90°) in direction of engine ro‐
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cover.

Grooves in camshaft -arrows- must be located in indicated posi‐

tion.
cover.

If camshaft clamp - T10414- cannot be inserted into camshaft
openings to stop, then timing is incorrect and must be readjusted
AG. Volkswagen AG d
⇒ “5.3 Adjusting valve timing”, page 127 . lksw
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Valve timing is OK if camshaft clamp - T10414-
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b ran
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cylinder head cover as far as stop and ifutbolt
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in hand-tight. ss
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– Remove camshaft clamp - T10414- and locking pin - T10340- .

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Specified torques:
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spec
♦ Securing bolt for non-return valve
es, in part or in w
⇒ “2.1 Assembly overview - valve gear ”, page 104 .
t to the co
♦ Plug for cylinder block ⇒ page 52
rrectness of i
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5.3 Adjusting valve timing
nform
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Note
m
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♦ Sump must be removed only on vehicles ► 12.2009.

r
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thi
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♦ In these vehicles, the timing chain can slip off crankshaft gear
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5. Chain drive 127


equipment required
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⇒ page 136 .

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♦ Pin - 3415/2-
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5. Chain drive 141


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⇒ page 145 .

– Install bottom valve timing housing
⇒ “4.2 Removing and installing bottom valve timing housing”,
page 115 .
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⇒ “1.1 Assembly overview - sump/oil pump”, page 149 .

17 – Lubrication
1 Sump, oil pump
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Prote AG.
1. Sump, oil pump 149

1 - Sealing cover
❑ Renew seal if damaged.
2 - Oil supply pipe
❑ For turbocharger
3 - Oil dipstick
❑ The oil level must not be
above the maximum
marking!
❑ Markings ⇒ page 152 .
4 - Top ancillary bracket
⇒ page 65
5 - Seal
❑ Renew if damaged
6 - Bush
7 - Oil filter
satelettronica
Note
Before removal of oil filter, cover al‐

ternator with a cleaning cloth.
❑ Loosen with oil filter tool
- 3417- .
❑ Observe fitting instruc‐
tions on oil filter
❑ With non-return valve
❑ 20 Nm AG. Volkswagen AG d
⇒ “2.1 Assembly over‐ agen oes
olksw not
view - oil filter”, byV gu
ara
ed
page 160 horis nte
eo
aut ra
8 - Bolt ss c
ce
e
nl
❑ 25 Nm
pt
du
an
itte
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9 - Seal
erm
ab
ility
ot p
wit
, is n
10 - Bolt
h re
hole
spec
❑ Renew
es, in part or in w

t to the co
11 - Engine oil cooler

❑ Removing and installing ⇒ “3.1 Removing and installing engine oil cooler”, page 164
rrectness of i
12 - Bolt
l purpos
❑ Note tightening sequence ⇒ “4.1 Removing and installing top valve timing housing”, page 112 .
nf
ercia
❑ 8 Nm
orm
m
13 - Top valve timing housing

atio
om
n in

or c
thi
e
❑ Removing and installing ⇒ “4.1 Removing and installing top valve timing housing”, page 112
t
sd
iva
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cu
14 - Bolt
o
m
f
en
ng
❑ 25 Nm
t.
yi Co
Cop py
. rig
15 - Bottom valve timing housing
ht ht
rig by
opy Vo
❑ Install with sealant ⇒ Electronic Parts Catalogue “ETKA” . by c lksw
cted agen
Prote AG.
❑ Removing and installing ⇒ “4.2 Removing and installing bottom valve timing housing”, page 115
150 Rep. gr.17 - Lubrication

16 - Bolt
❑ Renew
17 - Bolt
❑ Renew
18 - Drive chain
❑ For oil pump.
⇒ “5.5 Removing and installing timing chain and chain drive for oil pump”, page 145
❑ Before removing, mark direction of rotation (installation position).
19 - Bolt
❑ Renew
❑ Removing and installing crankshaft pulley ⇒ “1.3 Removing and installing crankshaft pulley”, page 48
satelettronica
❑ Secure pulley against turning with counterhold - 3415- and adapter - 3415/2- .
20 - Pulley
❑ Contact surfaces of pulley must be free .of Voloil
kswand
agengrease.
gen AG AG o
❑ Removing and installing poly VoV-belt
lkswa ⇒ “1.2 Removingdand es n installing poly-V belt”, page 47
ot g
y ua
❑ Secure pulley against rturning
ised b
with counterhold - 3415- and adapter
ran
t
- 3415/2- .
ee
tho or
21 - Washer au ac
ss
❑ Diamond coated washer is clipped onto belt pulley
ce
e
nl
pt
du
an
22 - Seal
itte
y li
erm
ab
ility
ot p
❑ Removing and installing ⇒ “1.4 Renewing crankshaft oil seal - belt pulley end”, page 52
wit
, is n
h re
hole
23 - Cover
spec
es, in part or in w
24 - Bolt
t to the co
❑ Renew
rrectness of i
25 - Sprocket
l purpos
❑ For oil pump drive.

❑ Lock with counterhold - T10172- .
nf
ercia
or
26 - Oil pump
m
m
atio
m
❑ Renew only as complete unit

o
n in
or c
❑ Removing and installing ⇒ “1.4 Removing and installing oil pump”, page 158
thi
te
sd
iva
o
r
rp
cu
o
m
f
❑ Removing and installing ⇒ “2.3 Removing and installing non-return valve”, page 162
en
ng
t.
yi Co
op
28 - Bolt
C py
ht. rig
rig ht
❑ Renew
py by
co Vo
by lksw
cted
❑ Loosen and tighten flywheel end bolts only with long-reach Allen key - T10058- .
agen
Prote AG.
❑ 13 Nm

29 - Nut
❑ 10 Nm
30 - Oil level and oil temperature sender - G266-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
31 - Seal
❑ Renew
32 - Oil drain plug
❑ With captive seal
❑ Renew
❑ 30 Nm
33 - Sump
❑ Removing and installing ⇒ “1.3 Removing and installing sump”, page 153
❑ Clean sealing surface before fitting.
❑ Install with sealant - D 176 600 A1- .
34 - Bolt
satelettronica
❑ Renew
35 - O-ring
❑ Renew
36 - Suction line
37 - Bolt
❑ 8 Nm
38 - Bolt
❑ 8 Nm
39 - Oil separator wage
es n
lks
❑ Removing and by Vinstalling ⇒ “4.2 Removing andt ginstalling
o o
ua oil separator”, page 166
ed ran
❑ Install with
thor sealant ⇒ Electronic Parts Catalogue “ETKA”
is tee
o
.
au ra
c
ss
ce
le
un
pt
Markings on oil dipstick

an
d
itte
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erm
ab
1 - Maximum marking
ility
ot p
wit
2 - Minimum marking
is n
h re
ole,
a - Area above hatched field up to maximum marking: Do not top

spec
up with engine oil!

t to the co
b - Oil level within hatched zone: engine oil can be added

c - Area from minimum marking up to hatched field: Must be top‐
rrectne
ped up, max. 0.5 l of engine oil!

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
cum
r
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen
n AG do
wage es n
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1.2 Engine oil:
V
by ua
ed ran
oris tee
th or
Engine oil specification and
au oil capacities ac
ss
ce
le
un
pt
an
d
Note
itte
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ab
ility
ot p
♦ Risk of damage to catalytic converter.
wit
is n
h re
♦ Oil level must not be above “max.” mark.
ole,
spec
Oil capacities ⇒ Maintenance ; Booklet “Capacities and specifi‐
t to the co
cations”
Engine oil specifications ⇒ Maintenance ; Booklet “Capacities
rrectne
and specifications”
Changing engine oil: ⇒ Maintenance ; Booklet “Engine oil: drain”.
ss o
cial p
f
1.3 Removing and installing sump
inform
mer
atio
om
n
c
♦ Bit - T10058-
i
or
satelettronica
thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Wedge - T10383/2-

♦ Cutting tool - T10561-
♦ Hand drill with plastic brush

♦ Scraper
♦ Safety glasses
Removing
satelettronica
Rep. gr. 50 ; Removing and installing noise insulationG.. Volkswagen
nA AG do
wage es n
– Drain engine oil ⇒ Maintenance ; Booklet y36.1
Vol .
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ua
b
ed ran
– Remove front right wheel housing liners
tho
ris ⇒ General body re‐ tee
or
pairs, exterior; Rep. gr. 66 ; Wheela housing liner; Assembly
u ac
ss .
overview - front wheel housing liner
ce
le
un
pt
an
d
itte
y li
erm
ab
– Unbolt exhaust pipe from catalytic converter (Golf, Golf Plus,
ility
ot p
Touran, Golf Cabriolet)
wit
is n
⇒ “2.1 Assembly overview - emission control”, page 261 .

h re
ole,
spec
– To prevent damage to flexible joint, remove exhaust system
bracket from assembly carrier -arrows-. t to the co
Polo
– Removing and installing catalytic converter (Polo)
rrectne
⇒ “2.2 Removing and installing catalytic converter (Polo)”,

page 265
ss o

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
– Unscrew bolts -3- for coolant pipe -4-.

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

swage es n
– Unscrew both securing byV
o bolts -3- and remove cover
lk otplate.
gu
ara
d
ir se nte
– Pull 3-pin connector
tho off oil level and oil temperature sender e o-
G266- -2-.ss au ra
c
ce
e
– Remove bolts from sump.
nl
pt
du
an
itte
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erm
ab
ility
Note
ot p
wit
, is n
h re
♦ The sump is sealed with liquid sealant ⇒ Electronic Parts
hole
spec
Catalogue .
es, in part or in w
t to the co
♦ When hardened, the sealant has a high adhesive strength.
♦ Two bolts must be loosened but not removed to secure the
sump from falling after seal has been cut.
rrectness of i
l purpos
– Cut through seal between oil sump -4- and engine -1-.
nf
ercia
– Use cutting tool - T10561- to do this.
orm
m
atio
• Centre the cut between bolts -3- only.
om
n in
c
– Position cutting tool - T10561- on seal -arrows- without it cant‐

or
satelettronica
thi
e
ing.
t
sd
iva
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Drive in cutting tool - T10561- -3- using a hammer as far as it

will go -arrow-.
– Do not cant cutting tool - T10561- when doing this.
– Do not cutting tool - T10561- sideways.
– Do not lever with cutting tool - T10561- .
– Perform procedure at other points as described until sump is
detached.
Note
When the seal has been broken, a sucking noise will be heard as
the sump detaches.
– Use wedge - T10383/2- to further loosen detached positions.

– Using a plastic hammer carefully drive in wedge.
– Drive in wedge - T10383/2- only to same depth as sealing
surface.
– Release sump carefully from adhesive.
– Remove bolts which are still holding sump.
– Remove sump.
– Remove sealant residues from cylinder block with a flat scra‐
per.

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

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

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted into the cylinder block flange at two
positions as guides.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
satelettronica
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Cut off nozzle on tube at front marking (∅ of nozzle approx.

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

sealing compound will enter the sump and may block the oil
suction pipe strainer.
♦ Use new sump bolts.
– Immediately position sump and tighten all sump bolts slightly.

– Tighten sump bolts to specified torque ⇒ page 157 .
– Tighten bolts securing cover plate on gearbox to specified tor‐
que ⇒ page 157 .
satelettronica
– Reconnect exhaust pipe to catalytic converter (Golf, Golf Plus,
Touran, Golf Cabriolet)
⇒ “2.1 Assembly overview - emission control”, page 261 .
Polo
AG. Volkswagen AG d
agen
– Removing and installing catalytic Volconverter (Polo)
ksw
oes
not
gu
⇒ “2.2 Removing and installing
ed by catalytic converter (Polo)”, ara
nte
is
page 265 thor eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
Let sealing compound dry for approx. 30 minutes after installing

, is n
h re
oil sump. Only then fill with engine oil.

hole
spec
es, in part or in w
– Replenishing engine oil 4)

.
t to the co
4) Observe capacities and specifications ⇒ “1.2 Engine oil:”, page 153 .

rrectness of i
Specified torques:
l purpos
Component Speci‐ Note

fied tor‐
que
nform
ercia
Bolts securing cover 40 Nm

m
at
om
plate on gearbox
ion
c
in t
r
Securing bolt for 13 Nm ⇒ Renew

o
his
te
sump
a
⇒ The sump must be installed

do
priv
within 5 minutes of applying

um
for
en
g
silicone sealing compound.

n
t.
yi Co
op
⇒ The sealing compound must
C py
t. rig
gh
dry for approx. 30 minutes af‐
ht
pyri by
Vo
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ter installing oil sump. Only by c lksw
cted agen
then fill with engine oil. Prote AG.

olkswagen AG
en AG. V
♦ Oil drain plug ksw
ag does
not
Vol
⇒ “1.1 Assembly overview - sump/oil pump”, page
ed
149
by gu
ara
ris nte
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ut ra
1.4 Removing and installing oil pump ss
a c
ce
e
nl
pt
du
an
itte
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erm
♦ Bit - T10058-
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m

o
n in
satelettronica
or c
thi
te
sd
iva
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rp
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Hand drill with plastic brush

♦ Scraper
♦ Safety glasses
♦ Sealant ⇒ Electronic parts catalogue (ETKA)
Removing
– Remove sump
– Pull cover -1- off oil pump.

– Unscrew securing bolts -arrows- of oil pump.

– Completely remove oil pump from drive chain.
wage es n
Installing yV
olks ot g
ua
b
ed ran
– Attach oil pump together with chain sprocket tohodrive
ris chain. tee
ut or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Tighten new bolts -arrows- to specified torque ⇒ page 159 .
es, in part or in w
t to the co
– If oil pump is to be renewed, transfer suction pipe from old
pump to new one.
rrectness of i
– Install sump
l purpos
Specified torques:
nform
ercia
satelettronica
m
at
om
Securing bolt for oil pump 14 Nm +90° further
ion
c
in t
or
♦ Specified torque for suction pipe
his
ate
⇒ “1.1 Assembly overview - sump/oil pump”, page 149 .
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

agen AG olksw
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 ➤ , Polo s2010 wage ➤ , ...
n AG. V does
olk no
4-cylinder direct injection engine (1.2 l engine, 2V, EA 111,
d by turbocharger) - Edition 09.2018t gua
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ris tee
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2 Oil filter, oil pressure switch ss
ce
e
nl
pt
du
an
⇒ “2.1 Assembly overview - oil filter”, page 160
itte
y li
erm
ab
⇒ “2.2 Checking oil pressure and oil pressure switch”,
ility
ot p
page 161
wit
, is n
h re
⇒ “2.3 Removing and installing non-return valve”, page 162
hole
spec
2.1 Assembly overview - oil filter
es, in part or in w
t to the co
1 - Seal
rrectness of i
l purpos
2 - Bush
3 - Top ancillary bracket
nf
ercia
orm
m
atio
m

o
n in
c
stalling bracket for ancil‐

or
thi
laries”, page 65
te
sd
iva
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cu
4 - Oil filter
satelettronica
o
m
f
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
yri by
Before removal of oil filter, cover al‐ cop Vo
by lksw
ternator with a cleaning cloth.
cted agen
Prote AG.
❑ Loosen with oil filter tool

- 3417- .
❑ Observe fitting instruc‐
tions on oil filter
❑ With non-return valve
❑ 20 Nm
5 - Bolt
❑ 25 Nm
6 - Bolt
❑ 25 Nm

4-cylinder direct injection engine (1.2 l engine, 2V, EA
agen
AG111,
. Volksturbocharger)
wagen AG
do - Edition 09.2018
w es n
olks ot g
byV ua
2.2 Checking oil pressure and oil pressure switch ho
ris
ed ran
tee
t or
au ac
ss
ce
le
un
pt
equipment required
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
satelettronica
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ 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
2. Oil filter, oil pressure switch 161

Test sequence
– Pull connector -1- off oil pressure switch.
– Remove oil pressure switch - F1- using hinged lever 24 mm -

T40175- and screw it 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 (+)
satelettronica
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 revolutions slowly. At 0.3…0.7 bar,
the LED must light up, otherwise the oil pressure switch must
be renewed.
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80°C; the oil pressure should be at least 2.0 bar.
AG. Volkswagen A
At higher engine speeds, the oil pressure
ksw
agenmust not exceed 7.0
G do
es n
bar. y Vol ot g
ua
db r e an
ris tee
Specified torque for oil pressure
ut
ho switch: 20 Nm or
a ac
ss
ce
e
2.3 Removing and installing non-return

nl
pt
du
an
itte
valve
y li
erm
ab
ility
ot p

wit
, is n
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♦ Kukko adapter -22/1-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Kukko puller -21/1-
lkswage es n
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byV ua
d ran
ir se
Noteth o tee
or
au ac
ss
♦ The non-return valve, which was installed at the top of the cyl‐
ce
le
un
pt
inder block and was accessible only by removing the cylinder
an
d
itte
head, was discontinued on 16 December 2010.
y li
rm
ab
pe
ility
♦ Since 16 December 2010, the non-return valve has been in‐
ot
satelettronica
wit
stalled in the cylinder block from the sump side (beginning with
, is n
h re
engine number CBZ 301939).
hole
spec
es, in part or in w
Removing
– Remove sump t to the co
rrectness of i
– Remove oil pump

l purpos
⇒ “1.4 Removing and installing oil pump”, page 158 .

– Clean sealing surface in area of non-return valve and mask
nform
ercia
with insulating tape -arrows- to protect against damage.

m
– Insert Kukko puller 21/1 -1- into non-return valve. Spread pull‐
com
tion in
er arms via “SW 14” hexagon nut.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Fit Kukko adapter 22/1 -2- onto sealing surface of cylinder

block. Then, screw adapter to Kukko puller 21/1 -1-.
– Pull non-return valve out of cylinder block by means of “22 mm”
hexagon nut.
Installing
– Remove insulating tape from cylinder block.
– Moisten O-rings of new non-return valve with clean engine oil.
– Slide valve into cylinder block until valve is flush with cylinder
block.
– Install oil pump
⇒ “1.4 Removing and installing oil pump”, page 158 .
– Install sump
2. Oil filter, oil pressure switch 163

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ar
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ oris,e Golf Plus 2009 ➤ , Polo 2010 ➤ , ... ante
eo
h
4-cylinder direct injection engines a(1.2
ut l engine, 2V, EA 111, turbocharger) - Edition r a 09.2018
c
s
ce
e
nl
pt
du
an
3 Engine oil cooler
itte
y li
erm
ab
ility
⇒ “3.1 Removing and installing engine oil cooler”, page 164
ot p
wit
, is n
3.1 Removing and installing engine oil cool‐
h re
hole
spec
er
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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o
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f
en
ng
t.
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op
satelettronica
C py
t. rig
gh ht
pyri by
Removing
co Vo
by lksw
cted agen
Prote AG.
– Drain coolant
– Open spring-type clip with the clip pliers - VAS 6340- and pull
coolant hose off.
– Unscrew 4 securing bolts from engine oil cooler and remove
engine oil cooler.
Installing
Renew seal if damaged.
– Position engine oil cooler -2- on bracket and tighten bolts al‐
ternately and diagonally to 8 Nm + +90° further.
– Fit coolant hose -1- onto oil cooler connection piece and se‐
cure it with spring-type clip.

4 Crankcase ventilation
⇒ “4.1 Assembly overview - crankcase breather system”,
page 165
⇒ “4.2 Removing and installing oil separator”, page 166
4.1 Assembly overview - crankcase breather system
1 - Bolt
❑ 9 Nm
2 - Bracket for coolant circula‐
tion pump
AG. Volkswagen AG d
3 - Bolt ksw
agen oes
not
Vol gu
❑ Micro-encapsulated ed b y ara
nte
ris
❑ Renew ut
ho eo
ra
a c
❑ 9 Nm ss
ce
le
un
pt
4 - Oil separator
an
d
itte
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satelettronica
rm
ab
pe
ility
ot
stalling oil separator”,
wit
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page 166
hole
spec
❑ Renew
es, in part or in w
t to the co
rrectness of i
l purpos
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Specified torque and tightening sequence

– Tighten bolts in the sequence -1 … 10- to 9 Nm.
4. Crankcase ventilation 165

4.2 Removing andwinstalling

agen
AG. Volkswoil
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♦ Applicator gun -auVAS
th 6966- eo
ra
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ce
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un
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erm
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wit
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ole,
spec
t to the co
rrectne
♦ Commercially available sealant remover for sealants contain‐
ss
ing silicone
o
cial p
f inform
♦ Sealant ⇒ Electronic Parts Catalogue
mer
atio
satelettronica
m
Removing
o
n
c
i
or
n
thi
te
sd
a
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐

iv
o
r
sulation .
p
cum
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fo
en
ng
t.
– Release wiring harness from retainers -arrows-.
yi Co
Cop py
t. rig
– Pull off connector -1-. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew bolt -2- and push coolant circulation pump - V50- to

the side.

– Loosen bolts -1 … 10- and unscrew them.
– Remove bracket for coolant circulation pump - V50- -1-.

– Carefully release oil separator from bonded joint.
Caution
In order to avoid scratches in the sealing surfaces of the cyl‐

inder block and thus to avoid leaks, do not clean the sealing
satelettronica
surfaces with mechanical means like a flat scraper.
Risk of soiling the lubrication system.
♦ Cover open parts of engine. wagen AG. Volkswagen AG doe
ks s no
Vol t gu
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Installing tho eo
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Install in reverse order of removal, observing the following:
ce
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• The oil separator must be renewed.

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rm
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• Used oil separators must not be reused.

pe
ility
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– Thoroughly clean sealing surface on cylinder block using com‐

h re
mercially available sealant remover.

hole
spec
– Remove any oil and grease from sealing surfaces.

es, in part or in w
t to the co
rrectness of i
Note
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Observe use-by-date of sealant.

nform
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Caution
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Risk of blocking lubrication system with excess sealant.

r
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♦ Do not apply sealant bead thicker than specified.

do
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rp
cum
fo
en
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t.
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op
– Cut off nozzle on tube at front marking (∅ of nozzle approx. C py
t. rig
1.5 mm).
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
4. Crankcase ventilation 167

– Apply bead of sealant along groove -arrows- onto clean seal‐

ing surface of oil separator as shown in illustration using
applicator gun - VAS 6966- .
• Width of sealant bead: 2 mm.
Caution
AG. Volkswagen AG d
agen oes
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• After the oil separator has been
by V fitted to the sealing sur‐
ol not
gu
face of the cylinder block,
risedensure that the oil separator is ara
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not moved anymore.uth o eo
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• This will prevent sealant from entering the oil circuit as well
s
ce
le
as leakage on the oil separator.

un
pt
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• The oil separator must be installed within 5 minutes of
erm
ab
sealant being applied.
ility
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ole,
spec
– Screw 2 studs a few turns into holes -arrows-.
t to the co
– Fit oil separator and bracket for coolant circulation pump -
V50- , screw in bolts and tighten them to specified torque
satelettronica
⇒ Fig. ““Specified torque and tightening sequence”“ ,
rrectne
page 165 .
Further installation is carried out in reverse order of removal. Ob‐
ss
serve the following:
o
cial p
f inform
– Install coolant circulation pump - V50-
mer
⇒ “2.3 Removing and installing coolant circulation pump V50
atio
m
”, page 180 .
o
n
c
i
or
n thi
te
sd
a
gr. 66 ; Noise insulation; Assembly overview – noise insula‐

iv
o
pr
tion .
um
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fo
en
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t.
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op py
Caution
. C rig
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rig by
copy Vo
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• After the oil separator has been fitted, wait at least 2 hours cted agen
Prote AG.
before operating the engine.
• It takes at least two hours for the sealant to cure suffi‐
ciently.
Specified torques:
♦ Securing bolts for oil separator
⇒ Fig. ““Specified torque and tightening sequence”“ ,
page 165 .
♦ Securing bolts for coolant circulation pump bracket
⇒ “2.3 Removing and installing coolant circulation pump V50
”, page 180 .

olkswagen AG
en AG. V
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ o,lkGolf
swa Plus 2009 ➤ , Polo
g doe2010
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4-cylinder direct injection engine (1.2 l engine, 2V,
ed bEA
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ara
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utho eo
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ss
19 – Cooling
ce
le
un
pt
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rm
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1 Cooling system/coolant
pe
ility
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wit
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Caution
spec
es, in part or in w
t to the co
♦ Observe the following points during all installation work, in
particular in the engine compartment, due to the space
limitations:
rrectness of i
l purpos
tions.
nform
ercia
m
a
com
tion in
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te o
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Note
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♦ Cooling system is pressurized when engine is warm. If nec‐
Co
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essary, release pressure before carrying out repairs.
t. C rig
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Vo
♦ Hose connections are secured with spring-type clips. In case
co lksw
by
cted agen
of repair, only use spring-type clips. Prote AG.
♦ 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).
⇒ “1.1 Coolant hose connection diagram”, page 169

⇒ “1.2 Draining and adding coolant”, page 171
⇒ “1.3 Checking cooling system for leaks”, page 175
1.1 Coolant hose connection diagram
1. Cooling system/coolant 169

1 - Expansion tank
2 - Coolant circulation pump -
V50-
❑ Removing and installing agen
AG. Volkswagen AG d
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⇒ “2.3 Removing and in‐ olksw not
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stalling coolant circula‐
ise
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tion pump V50 ”,uthor eo
page 180 ss a ra
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3 - Coolant pump
un
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4 - Intake manifold with charge
erm
ab
air cooler
ility
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❑ Remove and install
is n
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charge air cooler
ole,
spec
stalling charge air cooler
t to the co
(intake manifold)”,
page 212
5 - Heat exchanger for heater
rrectne
6 - Thermostat housing
ss
satelettronica
o
cial p
f in
❑ Available as separate
form
mer
replacement part ⇒
atio
m
Electronic Parts Cata‐

o
n
c
logue “ETKA” .
i
or
n thi
e
❑ Located in coolant hose.

t
sd
iva
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pr
❑ Use fingers to deter‐

um
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fo
mine exact location.

en
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op
❑ Renew together with C py
t. rig
coolant hose, if neces‐
gh ht
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sary.
co Vo
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Prote AG.
8 - Restrictor
9 - Radiator/cooler
10 - Exhaust turbocharger
11 - Low-temperature radiator for charge air system
❑ Radiator and low-temperature radiator for charge air system are comprised in one component
Polo
❑ Radiator and low-temperature cooler are separate components.
12 - Cylinder head/cylinder block
❑ If renewed, refill system with fresh coolant.
13 - Engine oil cooler
❑ Available as separate replacement part ⇒ Electronic Parts Catalogue “ETKA” .
❑ Located in coolant hose.
❑ Use fingers to determine exact location.
❑ Renew together with coolant hose, if necessary.
15 - Auxiliary heater
❑ Optional equipment
170 Rep. gr.19 - Cooling

1.2 Draining and adding coolant
Caution
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.

equipment requiredagen AG. Volkswagen AG do
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Vol ot g
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satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.
♦ Refractometer - T10007 A-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Safety glasses
♦ Safety gloves

Draining
WARNING
Hot steam may escape when expansion tank is opened. Wear

eye protection and protective clothing to avoid eye injuries and
scalds. Cover cap with a cloth and carefully open.
– Open filler cap -arrow- for coolant expansion tank.

– Place drip tray for workshop hoist - VAS 6208- underneath.
Drain coolant from engine cooling system.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
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satelettronica
ss
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nl
pt
du
– Pull connector -1- from radiator outlet coolant temperature
an
itte
sender - G83- .
y li
erm
ab
ility
– Pull retaining clip -arrow - out and pull connection piece off
ot p
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radiator.
, is n
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hole
Polo
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Open spring-type clip -arrow- and pull coolant hose off.

m
at
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ion
c
Note
in t
or
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ate
do
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Please observe disposal instructions!

p
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en
ng
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Drain coolant from charge air cooling system.
Co
Cop py
t. rig
gh ht
Golf, Golf Plus, Golf Cabriolet, Touran yri
p by
co Vo
by lksw
cted agen
Prote AG.
– Pull coolant hose (plug-in connector) -arrow- off lower con‐

nection of low-temperature radiator for charge air.
Polo

Golf 2009 ➤ , Golf Cabriolet 2012
gen AG. Vol➤
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does 2009 ➤ , Polo 2010 ➤ , ...
swa
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not
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b ara
ed nte
ris
– Open spring-type clip -arrow- andautpull
ho
coolant hose off. e or
ac
ss
ce
e
nl
pt
du
Note
an
itte
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erm
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ility
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Filling
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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satelettronica
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, 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 engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
wage
e
reliability under heavy loads, particularly in countries withVol trop‐
ks s no
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satelettronica
by
ical climates. ise
d ara
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♦ ONLY refractometer - T10007A- may be used
sa
ufor determining ra
c
current anti-freeze value. s
ce
e
nl
pt
du
♦ Frost protection must be guaranteed down to -25°C as a min‐
an
itte
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imum and, in countries with arctic conditions, down to approx.
erm
ab
-36°C. Increasing the frost protection is permissible only if cli‐
ility
ot p
matic conditions require stronger frost protection. It may, how‐
wit
, is n
ever, be increased only to a maximum of -48°C. Otherwise,
h re
the cooling effect will be impaired.
hole
spec
es, in part or in w
♦ Do not reduce the coolant concentration by adding water even
t to the co
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
rrectness of i
♦ Read off anti-freeze figures for respective replenished coolant
additives.
l purpos
♦ The temperature read off the refractometer - T10007A- corre‐

sponds the »ice flocculation point«. Flakes of ice may start
nf
ercia
forming in the coolant below this temperature. orm

m
atio
♦ Never reuse old coolant.

om
n in
or c
♦ Use only a water/coolant additive mixture as a slip agent for

thi
te
coolant hoses.
sd
iva
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rp
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f
en
ng
Recommended mixing ratios (use only distilled water for mixing):

t.
yi Co
Cop py
t. rig
Frost protection Amount of anti- Coolant ad‐ Distilled wa‐ yri
gh by
ht
down to freeze ditive 5) ter 5)
op Vo
by c lksw
cted agen
Prote
-25°C 40% 2.25 l 3.35 l
AG.
-35 °C 50% 2.8 l 2.8 l

5) The quantity of coolant can vary depending upon vehicle equipment.
• Coolant: ⇒ Electronic Parts Catalogue .


– Press connection against radiator and slide retaining clip

-arrow- into groove.
– Plug connector -1- into radiator outlet coolant temperature
sender - G83- .
Polo
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Push coolant hose onto connection and secure it with spring-
ce
e
nl
pt
type clip -arrow-.
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
– Fit coolant hose and tighten spring-type clip -arrow-.
nf
ercia
o
– Install noise insulation.
rm
m
atio
m
– Fill coolant circuit using cooling system charge unit -

o
n in
c
VAS 6096- : ⇒ Operating instructions for cooling system

or
thi
e
charge unit VAS 6096 .

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Fill with coolant up to maximum marking on expansion tank.
WARNING
Hot steam may escape when expansion tank is opened. Wear

eye protection and protective clothing to avoid eye injuries and
scalds. Cover cap with a cloth and carefully open.
– Check coolant level and top up as needed. Check coolant level

and top up if necessary. When the engine is at normal oper‐
ating temperature, the coolant level must be on the maximum
marking; when the engine is cold, between the minimum and
maximum markings.
1.3 Checking cooling system for leaks

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

satelettronica
AG. Volkswagen AG d
Prerequisites for check lksw
agen oes
not
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• Engine at operating temperature. rised ara
nte
ho eo
Test sequence aut ra
ss c ce
e
nl
pt
du
WARNING
an
itte
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erm
ab
ility
Hot steam may escape when expansion tank is opened. Place

ot p
cloth over cap and open with caution.

wit
, is n
h re
hole
spec
es, in part or in w
– Open filler cap on coolant expansion tank.

t to the co
– Screw adapter for cooling system tester - V.A.G 1274/8- into

coolant expansion tank.
rrectness of i
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling

l purpos
system tester - V.A.G 1274/8- .

– Join connection piece - V.A.G 1274 B/1- to cooling system
nform
ercia
tester - V.A.G 1274 B- using connecting hose supplied.

m
– Using hand pump of tester, build up a pressure of approx.

at
om
io
1.5 bar.
n
c
in t
or
his
e
• The pressure must not drop by more than 0.2 bar within 10 mi‐
at
do
riv
nutes.
p
cum
for
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– If the pressure drops more than 0.2 bar, locate and rectify
n
t.
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leaks. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Note
cted agen
Prote AG.
A pressure drop of 0.2 bar within 10 minutes is caused by the

coolant cooling down. The colder the engine, the lower the pres‐
sure loss. If necessary, repeat the check while the engine is cold.

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. Press pressure
relief valve on cooling system tester - V.A.G 1274 B- until pres‐
sure gauge displays value of »0«.
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 wagen AG. Volkswagen AG doe
system tester - V.A.G 1274/9- . yV
olks s no
t gu
b ara
ed
– Join connection piece - V.A.G 1274 B/1- to cooling tsystem
ho
ris nte
e or
tester - V.A.G 1274 B- using connecting hose supplied.
sa
u ac
s
ce
– Using hand pump on cooling system tester, build up a pres‐ e
nl
pt
du
sure of max. 1.6 bar.
an
itte
y li
erm
ab
The pressure relief valve must still remain closed.
satelettronica
ility
ot p
wit
If the pressure relief valve opens prematurely:
, is n
h re
hole
– Renew cap.
spec
es, in part or in w
– Increase pressure to over 1.6 bar.
t to the co
The pressure relief valve must open.
rrectness of i
If the pressure relief valve does not open:
l purpos
– Renew cap.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - thermostat”, page 178
⇒ “2.2 Removing and installing coolant pump”, page 179
⇒ “2.3 Removing and installing coolant circulation pump V50 ”,
page 180
2.1 Assembly overview - thermostat

Connection diagram for coolant hoses
⇒ “1.1 Coolant hose connection diagram”, page 169
Thermostat side
1 - Cylinder head
2 - O-ring
❑ Renew
3 - Coolant pipe
satelettronica
❑ Fitting location: below AG. Volkswagen AG d
agen
intake manifold. Volksw
oes
not
gu
by ara
❑ Note groove -arrow- for rise
d
nte
securing “retaining utho eo
ra
clip” (item 5). ss a c
ce
e
nl
4 - O-ring
pt
du
an
itte
y li
❑ Renew
erm
ab
ility
ot p
5 - Retaining clip
wit
, is n
❑ Check for firm seating
h re
hole
spec
6 - Bolt
es, in part or in w
❑ 11 Nm t to the co
7 - Thermostat housing
rrectness of i
8 - Seal
l purpos
❑ Renew
9 - Radiator outlet coolant -
nform
ercia
G62-
❑ Before removing, re‐
m
at
om
lease pressure in cool‐

ion
c
ing system if necessary.

in t
or
his
ate
10 - Bolt
do
priv
cum
or
❑ 10 Nm
f
en
ng
t.
yi Co
11 - O-ring t. Cop py
rig
gh
❑ Renew
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.2 Removing and installing coolant pump
Note
♦ Water pump wrench - V.A.G 1590- is only required if coolant

pump's poly-V belt pulley is removed.
♦ Specified torque for belt pulley: 20 Nm.

equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
n in
or c
thi
te
sd
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ng
t.
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♦ Torque wrench (5 … 50 Nm) - V.A.G 1331- Cop py
ht. rig
rig ht
♦ Water pump wrench - V.A.G 1590- py by
co Vo
by lksw
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system 179

Note
♦ Do not separate the integrated coolant pump seal from the

coolant pump.
♦ Damaged or leaking coolant pumps must be renewed com‐
plete with seal.
Removing
– Drain coolant
– Remove bracket -1-.
Note
As the bracket is only used during the vehicle production, it need

not be reinstalled.
satelettronica
– Pull vacuum hose from coolant pump (only vehicles with a
coolant pump that can be switched off).
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
– Undo bolts -arrows- of coolant pump horand pull pump out of cyl‐ eo
inder block. aut ra
ss c ce
e
Installing
nl
pt
du
an
itte
y li
erm
ab
note the following:

ility
ot p
wit
– Install coolant pump in cylinder block.

, is n
h re
hole
– Tighten securing bolts to specified torque ⇒ page 180 .

spec
es, in part or in w

t to the co

– Fill with coolant
rrectness of i

l purpos
Specified torques:
nf
ercia
orm
Securing bolt for coolant pump 9 Nm

m
atio
om
n in
or c
2.3 Removing and installing coolant circulation pump - V50-

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


equipment required
satelettronica
AG. Volkswagen AG d
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♦ Hose clamps to 25 mm - 3094-

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The fitting location of the coolant circulation pump - V50- is be‐

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181
AG.
2. Coolant pump, regulation of cooling system

– Clamp off coolant hoses -2- with hose clamps, up to Ø 25 mm
- 3094- .
– Pull off connectors -1- and coolant hoses -2-.
– Undo bolt -3- and remove pump from bracket.
Installing
note the following:
Specified torques:
Securing bolt for coolant circulation 10 Nm
pump
satelettronica
lkswage es n
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3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator/radiator fan”, page 183
⇒ “3.2 Removing and installing radiator”, page 187
⇒ “3.3 Removing and installing radiator fan V7 ”, page 194
3.1 Assembly overview - radiator/radiator

fan
⇒ “3.1.1 Assembly overview - radiator/radiator fan (Golf, Golf
Plus, Touran, Golf Cabriolet)”, page 183
⇒ “3.1.2 Assembly overview - radiator/radiator fan (Polo)”,
page 185
3.1.1 Assembly overview - radiator/radiator

fan (Golf, Golf Plus, Touran, Golf Cab‐
riolet)
satelettronica
Note
♦ This engine is equipped with a radiator combination compris‐

ing an engine and low-temperature radiator for the charge air
system
⇒ “2.1 Assembly overview - charge air system”, page 208 . swagen AG. Volkswagen AG does
k not
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♦ The engine and low-temperature radiator are designededas
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♦ Coolant hose schematic diagram ss c
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⇒ “1.1 Coolant hose connection diagram”, page 169 .

nl
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♦ Remove and install spring-type clips with hose clip pliers - VAS
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3. Radiator, radiator fan 183

1 - Radiator/cooler
stalling radiator”,
page 187
❑ After renewing, renew
entire coolant.
2 - Coolant hose
❑ To turbocharger
3 - Coolant hose
❑ On low-temperature
cooler at top.
4 - Coolant hose
❑ To turbocharger
AG. Volkswagen AG d
5 - Coolant hose wage
n oes
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❑ To charge air cooler ed in
by ara
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intake manifold.thoris eo
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6 - Radiator fan - V7-
ss c
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❑ With radiator fan control
pt
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unit - J293-
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stalling radiator fan V7 ”,

h re
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page 194
spec
7 - Coolant hose t to the co
❑ To coolant pipe under‐

neath intake manifold.
rrectne
8 - Coolant hose
❑ To engine oil cooler
ss o
9 - Expansion tank
cial p
f inform
❑ Check cooling system

mer
for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G
atio
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1274/8-
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10 - Connector
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11 - Sealing cover
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❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
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❑ Pressure relief valve must open at between 1.4 and 1.6 bar t. C rig
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12 - Bolt
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❑ 5 Nm
AG.
13 - Plastic inserts
❑ For securing bolts.
14 - Bracket
15 - Coolant hose
❑ To coolant circulation pump - V50- .
16 - Cowling
17 - Bolt
❑ 5 Nm
18 - Bolt
❑ 5 Nm

19 - Coolant hoses
❑ To thermostat housing.
20 - Coolant hose
❑ To heat exchanger for heater unit.
21 - Union
❑ To top of radiator.
22 - Union
❑ On bottom of radiator.
23 - Retaining clip
24 - Radiator outlet coolant temperature sender - G83-
25 - O-ring
❑ Renew if damaged AG. Volkswagen AG d
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26 - Radiator mounting olksw not
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27 - Radiator mounting horis
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28 - Bolt ss c
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❑ 5 Nm
pt
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3.1.2 Assembly overview - radiator/radiator
wit
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hole
spec
es, in part or in w
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Note
rrectness of i
♦ The radiator and low-temperature cooler are separate com‐
ponents.
l purpos
♦ The radiator is pushed onto the low-temperature cooler.
nf
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♦ The radiator and low-temperature cooler are removed and in‐
orm
stalled together
m
atio
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⇒ “3.2 Removing and installing radiator”, page 187 .

o
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♦ Coolant hose schematic diagram thi

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1 - Radiator/cooler
page 187
❑ After renewing, renew
entire coolant.
2 - Coolant hose
❑ To turbocharger
3 - Coolant hose
❑ Up upper charge air
cooler.
4 - Coolant hose
❑ To turbocharger
5 - Coolant hose
❑ To charge air cooler in
intake manifold.
6 - Fan ring
satelettronica
7 - Coolant hose
❑ To coolant pipe under‐
neath intake manifold. agen
AG. Volkswagen AG d
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8 - Coolant hose ed by gu
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❑ To engine oil cooler ut
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9 - Expansion tank s
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❑ Check cooling system
du
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for leaks using cooling

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system tester - V.A.G
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1274 B- and adapter for

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V.A.G 1274/8-
hole
spec
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10 - Connector
t to the co
11 - Sealing cover
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
rrectness of i
❑ Pressure relief valve must open at between 1.4 and 1.6 bar
l purpos
12 - Bolt
❑ 5 Nm
nform
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13 - Plastic inserts
m
at
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❑ For securing bolts.

on
c
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or
14 - Bracket
his
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15 - Coolant hose
um
for
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❑ To coolant circulation pump - V50- .

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16 - Radiator fan - V7-
t. rig
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❑ With radiator fan control unit - J293-
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17 - Cowling
18 - Bolt
❑ 2 Nm
19 - Heat shield
20 - Nut
❑ 8 Nm

AG. Volkswagen AG d
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Golf 2009ris➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009
ed
nte ➤ , Polo 2010 ➤ , ...
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h
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ss c
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21 - Radiator mounting
un
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22 - Low-temperature cooler
rm
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❑ Removing and installing ⇒ “3.2 Removing and installing radiator”, page 187
ot
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23 - Coolant hoses
h re
hole
spec
❑ To thermostat housing. es, in part or in w
t to the co
24 - Radiator fan thermal switch - F18-
25 - O-ring
rrectness of i
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26 - Radiator mounting
27 - Bolt
nform
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❑ 5 Nm
m
a
28 - Coolant hose
com
tion in
❑ To expansion tank
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3.2 Removing and installing radiator

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Cop py
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⇒ “3.2.1 Removing and installing radiator (Golf, Golf Plus, Touran, rig ht
py by
Golf Cabriolet)”, page 187 co Vo
by lksw
cted agen
Prote AG.
⇒ “3.2.2 Removing and installing radiator and low-temperature
cooler (Polo)”, page 191
3.2.1 Removing and installing radiator (Golf,

Golf Plus, Touran, Golf Cabriolet)
Note

ing an engine and low-temperature radiator for the charge air
system.
♦ The engine and low-temperature radiator are designed as a
single component.
Assembly overview - parts of cooling system, body side

⇒ “3.1 Assembly overview - radiator/radiator fan”, page 183 .


equipment required
AG. Volkswagen AG d
agen oes
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or eo
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Removing

Drain coolant from engine cooling system.

Touran, Golf Plus, Golf, Golf Cabriolet
– Pull connector -1- from radiator outlet coolant temperature
sender - G83- . gen AG
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– Pull retaining cliptho-arrow - out and pull connection piece off ee or
radiator. au ac
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Drain coolant from charge air cooling system.
t to the co
– Pull coolant hose (plug-in connector) -arrow- off lower con‐
nection of low-temperature radiator for charge air.
rrectne
Note
satelettronica
ss o
cial p
f
inform
mer
atio
– Detach upper coolant hoses from radiator.
om
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– Removing cowling with radiator fan - V7-

i
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pr
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⇒ “3.3 Removing and installing radiator fan V7 ”, page 194

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– Remove front bumper cover ⇒ General body repairs, exterior; . Cop py
Rep. gr. 63 ; Removing and installing front bumper cover .
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– Remove securing bolts -arrows-. Prote AG.
Note
To remove securing bolt for coolant lines on side of radiator, it is

necessary to drill a hole in plastic bracket.
Golf, Golf Plus, Golf Cabrio
– Draw dimensions -a- and -b- on plastic bracket and mark in‐
tersection -arrow- with a centre punch.
Dimensions
a = 45 mm
b = 20 mm
– Drill a hole into the plastic bracket with a 5-mm drill bit.
– Drill or mill hole out to 16 mm.

– Remove securing bolt -arrow-.

Touran
– Mark dimension -c- on plastic bracket and mark drilling point

-arrow- with a centre punch.
Dimensions
c = 25 mm
– Drill a hole into the plastic bracket with a 5-mm drill bit.
– Drill or mill hole out to 16 mm.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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– Remove securing bolt -arrow-.
hor eo
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All vehicles s
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– Lift radiator out of lower mounting and press it slightly towards

an
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– Remove side radiator support.

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– Undo and remove condenser bolts -arrows-.

– Secure condenser to lock carrier with cable ties.
– Remove radiator downwards.
Installing
note the following:
Fill with coolant ⇒ “1.2 Draining and adding coolant”, page 171 .
– Install air filter
⇒ “2.2 Removing and installing air filterVhousing”,
olkswa
page 217
AG. gen AG
agen do
– Electrical connections andVrouting
olks
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⇒ Current flow diagrams,
es n
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Electrical fault findingsand
ed b Fitting locations. ua
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Specified torques: aut or
ac
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Component Nm
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Radiator mounting to lock carrier 5
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Cowling to radiator 5
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Bracket for air conditioner compressor lines to 5
satelettronica
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radiator
ole,
spec
Radiator to condenser 5
t to the co
3.2.2 Removing and installing radiator and
rrectne
low-temperature cooler (Polo)
ss o
cial p
f
Note inform
mer
♦ The radiator and low-temperature cooler are separate com‐

atio
m
ponents.
o
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c
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or
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♦ The radiator is pushed onto the low-temperature cooler.

te
sd
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♦ The radiator and low-temperature cooler are removed and in‐

cum
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fo
stalled together.
en
ng
t.
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Cop py
t. rig
Assembly overview - parts of cooling system, body side
gh ht
pyri by
⇒ “3.2 Removing and installing radiator”, page 187 .
o Vo
by c lksw
cted agen
Prote AG.


equipment required
satelettronica
lkswage es n
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♦ Guide pins - 3411- rrectness of i
Removing
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– Separate connector -arrow-.
satelettronica
– Open hose guides at cowling -2- and push coolant hose -1-
aside.
AG. Volkswagen AG d
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– Raise cowling out of brackets. Volksw not
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– Remove cowling downwards. o rise nte
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– Detach upper coolant hoses from radiator sand
s a
from charge air c
cooler.
ce
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un
pt
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– Remove front bumper cover ⇒ General body repairs, exterior;

itte
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Rep. gr. 63 ; Removing and installing front bumper cover .
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
– Unscrew securing bolts -arrows-. t to the co

– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
rrectness of i
sition .
l purpos
– Lift radiator out of lower mountings and press it slightly towards

rear.
nform
ercia
– Remove side radiator support.

m
– Unscrew side securing bolt for air conditioner compressor

com
tio
lines.
n in
r
te o
thi
s
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Undo and remove condenser bolts -arrows-.

– Secure condenser to lock carrier with cable ties.
– Remove radiator and low-temperature cooler downwards.
– Pull radiator -1- in -direction of arrow- out of brackets on sides

of low-temperature cooler -2-.
Installing AG. Volkswagen AG d
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olksw not
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Installation is carried out in the reverse order. When installing,ised b ara
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note the following: hor eo
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Add coolant ⇒ “1.2 Draining and adding coolant”, pages 171 .
ce
e
nl
pt
satelettronica
du
– Electrical connections and routing ⇒ Current flow diagrams,
an
itte
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Electrical fault finding and Fitting locations.
erm
ab
ility
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Specified torques:
wit
, is n
h re
Component Nm
hole
spec
Radiator mounting to lock carrier 5
es, in part or in w
t to the co
Bracket for air conditioner compressor lines to 5
radiator
rrectness of i
Radiator to condenser 5
l purpos
3.3 Removing and installing radiator fan -

V7-
nf
ercia
orm
m
atio
⇒ “3.3.1 Removing and installing radiator fan V7 (Golf, Golf Plus,
om
Touran, Golf Cabriolet)”, page 194
n in
or c
thi
e
⇒ “3.3.2 Removing and installing radiator fan V7 (Polo)”,

t
sd
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page 195 o
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cu
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3.3.1 Removing and installing radiator fan -

t.
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op py
V7- (Golf, Golf Plus, Touran, Golf Cab‐
t. C rig
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op Vo
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Removing
– Disconnect connector -1-.

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gen AG d
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wa oes
no➤
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n
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– Unscrew bolts of cowling -arrows-. ss a ac
ce
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un
– Remove cowling downwards.
pt
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ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Unscrew bolts -arrows- and remove radiator fan - V7- .

Installing
nform
ercia

m
a
com
ti
note the following:
on in
r
te o
thi
Specified torques:
s
iva
do
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rp
c
Component Nm
um
fo
satelettronica
en
ng
t.
yi
Radiator fan to cowling 5
Co
Cop py
t. rig
Cowling to radiator opyri
gh
5 by
Vo
ht
by c lksw
cted agen
Prote AG.
3.3.2 Removing and installing radiator fan -

V7- (Polo)
Removing
– Separate connector -arrow-.
– Open hose guides at cowling -2- and remove coolant hose

-1-.
– Raise cowling out of brackets.
– Remove cowling downwards.

Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 AG.➤
Vol,ksPolo
wagen2010
AG do ➤ , ...
agen
Volksw2V, EA 111, turbocharger)es n - Edition 09.2018
ot
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db ara
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– Unscrew securing bolts -arrows- from heattho shield.
r eo
s au ra
c
– Unclip fan guard and remove to rear.s
ce
le
un
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, is n
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t to the co
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– Remove electric cable -1- from cable guide.
l purpos
– Unscrew nuts -arrows- and remove radiator fan - V7- .
nform
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Installing
m
a
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tion in
note the following:
r
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thi
Specified torques:
s
iva
do
satelettronica
r
rp
cum
fo
Component Nm
en
ng
t.
yi Co
Radiator fan to cowling 8 Cop py
t. rig
gh ht
Heat shield to cowling yri
2
p by
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by c lksw
cted agen
Prote AG.

21 – Turbocharging/supercharging
1 Exhaust turbocharger
⇒ “1.2 Removing and installing turbocharger”, page 199
⇒ “1.3 Removing and installing charge pressure positioner V465
”, page 205
G. Volkswage
1.1 Assembly
olks
overview
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- turbocharger
n AG d
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1- Connectorauth ra
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2 - Spacer
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❑ Refer to TPI.
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❑ 1 mm
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❑ 2 mm
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3 - Nut
hole
spec
❑ Renew
es, in part or in w
t to the co
❑ 8 Nm
4 - Charge air pressure con‐
rrectness of i
troller - V465-
l purpos
⇒ page 205
5 - Retaining clip
nform
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❑ Renew
m
at
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io
6 - Bolt
n
c
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or
❑ 10 Nm
his
ate
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7 - Heat shield
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8 - Nut
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Cop py
❑ Renew
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❑ Coat thread of nut with cop Vo
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high-temperature paste
agen
Prote AG.
❑ Stage 1: 18 Nm, stage 2:

12 Nm, stage 3: 12 Nm
Caution
The securing nuts have
to be tightened in 3
stages and in the specific
order
stalling turbocharger”,
page 199 .
This ensures that the
gasket seats correctly.
If this 3-stage tightening
sequence is not adhered
to, leaks will develop be‐
tween the cylinder head
and exhaust manifold.
1. Exhaust turbocharger 197

❑ Renew studs
AG. Volkswagen AG d
Insert coated end of stud into cylinder head. agen oes
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Because of the coating, do not use high-temperature pastehor oris oil to screw in stud. nte
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aut ra
s c
Screw studs into cylinder head until they project only 25 mm +/- 1.0 mm. s
ce
le
un
pt
an
d
9 - Turbocharger with exhaust manifold
itte
y li
rm
ab
❑ If renewed, erase learnt values and adapt engine control unit ⇒ Vehicle diagnostic tester “Guided func‐
pe
ility
tions”
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
The turbocharger can only be re‐
newed together with the exhaust
manifold.
rrectness of i
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 199
l purpos
10 - Heat shield
11 - Seal
nform
ercia
❑ Renew
m
satelettronica
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
1 - Bolt
um
fo
en
g
❑ 8 Nm
n
t.
yi Co
Cop py
.
2 - Pressure pipe
ht rig
rig ht
py by
co Vo
3 - Turbocharger with exhaust
by lksw
cted agen
Prote
manifold
AG.
❑ With charge pressure

positioner - V465- .
❑ If renewed, erase learnt
values and adapt en‐
gine control unit ⇒ Vehi‐
cle diagnostic tester
“Guided functions”
Note
The turbocharger can only be re‐

newed together with the exhaust
manifold.
page 199
4 - Heat shield
5 - Bolt
❑ 10 Nm
6 - O-ring
❑ Renew
7 - Oil return pipe
8 - Seal
❑ Renew
9 - Bolt
❑ 8 Nm
198 Rep. gr.21 - Turbocharging/supercharging

10 - Wire
11 - Bracket
12 - Bracket
13 - Lambda probe - G39-
14 - Bracket
15 - Bolt
❑ 8 Nm
16 - Banjo bolt
❑ 20 Nm
17 - O-ring
❑ Qty. 2
❑ Renew
❑ One O-ring between banjo bolt and return line
❑ One O-ring between return line and ancillary bracket
18 - Oil supply pipe
satelettronica
19 - Coolant pipes
20 - Bolt
❑ 8 Nm
21 - Bolt
❑ 8 Nm
22 - Seal lkswage es n
o ot g
byV ua
❑ Renew ir se
d ran
tee
tho
or
23 - Bolt ss
au ac
❑ 20 Nm
ce
e
nl
pt
du
an
itte
24 - Bracket
y li
erm
ab
25 - Seal
ility
ot p
wit
, is n
❑ Renew
h re
hole
26 - Bolt
spec
es, in part or in w
❑ 8 Nm
t to the co
rrectness of i
1.2 Removing and installing turbocharger

l purpos
Note
nform
mercia
♦ The turbocharger can only be renewed together with the ex‐

at
om
io
haust manifold.
n
c
in t
or
his
♦ Secure all hose connections with hose clips comparable to

ate
do
riv
production standard.
p
cum
for
♦ Hose connections and hoses for charge air system must be

en
ng
t.
yi
free of oil and grease before assembly.
Co
Cop py
t. rig
gh ht
♦ Charge air system must be free of leaks. yri
p by
co Vo
by lksw
cted
♦ Renew self-locking nuts.
agen
Prote AG.
♦ It is recommended that spring-type clips should be installed

using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- .

Caution
Note the following points after repair work on turbocharger:

♦ Fill turbocharger with engine oil at oil supply line connec‐
tion.
♦ After installing turbocharger run engine for approx. 1 mi‐
nute at idling speed.
♦ Do not rev engine, otherwise oil supply to turbocharger will
not be guaranteed.
Note

satelettronica
lkswage es n
o ot g
byV ua
d ran
♦ Torque wrench - V.A.G 1331- o
ir se tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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 avoid any subsequent damage, the following
work must be carried out:
♦ Check air filter container, air filter element and intake ho‐
ses for dirt. . Volkswage
n AG d AG
oes agen
♦ Check the whole charge air path and Vocharge
lksw air cooler for not
gu
foreign objects. d by ara
ise nte
or eo
h
If foreign objects are found in the
a charge air system, the charg‐
ut ra
c
ed air routing must be cleaned and the charge air cooler must
ss
ce
le
be renewed, if necessary.
un
pt
an
d
itte
y li
rm
ab
pe
ility
Removing
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
satelettronica
dure. Please check whether a coded radio is fitted. Then obtain
anti-theft coding first if necessary.
rrectness of i
l purpos

nform
ercia

m
a
com
tion in
– Drain coolant
r
te o
thi
s
iva
do
r
– Detach hoses -1- and connector -2- from turbocharger.

rp
cum
fo
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull connector -2- off charge air pressure sender - G31- with
intake air temperature sender 2 - G299- .
charger.
– Open cover -4- and remove securing bolt.
– Pull all spark plug connectors off spark plugs using puller -
T10112 A- . Then, move ignition cables towards rear.
– Pull coolant hoses from coolant pipes -1-.
– Undo and remove banjo bolt -4- of oil pipe.

– Unscrew securing bolts -2- and -3- and remove oil and coolant
pipes.
– Remove lambda probe - G39- -1- using lambda probe open
– Undo and remove upper bolt of three-phase alternator and
– Undo bolts -arrows- and remove heat shield from turbocharg‐
er.
– Remove bracket -1-.

Golf, Golf Plus, Touran
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Unscrew securing nuts -2-. s
ce
le
un
pt
an
d
itte
y li
downwards.
rm
ab
pe
ility
Polo
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia
– Remove lambda probe after catalytic converter - G130- -1-.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove bolts -1-.

– Push support rings -2- off the bolts.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Loosen securing bolts for clamp -arrows- and push it rear‐ erm
ab
wards.
ility
ot p
wit
, is n
h re
wards.
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
ercia
– Undo and remove bolt -1- of oil return pipe -2- and pull oil re‐
m
at
om
turn pipe out of turbocharger.
ion
c
in t
or
– Undo and remove bolt securing the heat shield -3- and pull the
his
ate
shield off the exhaust manifold.
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew all nuts -arrows- securing exhaust manifold.

– Remove exhaust manifold together with turbocharger from the
cylinder head. . Volkswage AG n AG d
agen oes
– Remove seal from studs. olksw not
yV gu
db ara
Installing rise nte
tho eo
au ra
– Place turbocharger together
ss with exhaust manifold and a new c
gasket in position on the cylinder head.
ce
le
un
pt
an
d
itte
y li
rm
ab
Caution
pe
ility
ot
wit
, is n
The securing nuts have to be tightened in 3 stages and in the
h re
specific order.
hole
spec
es, in part or in w
This ensures that the gasket seats correctly.
t to the co
If this 3-stage tightening sequence is not adhered to, leaks will
develop between the cylinder head and exhaust manifold.
rrectness of i
l purpos
– Tighten bolts in specified sequence -A- to -H- in 3 stages.
satelettronica
Stage 1: 18 Nm
nform
ercia
Stage 2: 12 Nm
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
Stage 3: 12 Nm agen oes
olksw not
y V gu
d b ara
Perform further installation in reverse order, paying
orise attention to nte
the following: auth eo
ra
ss c
♦ Renew seals, gaskets and self-locking nuts.
ce
le
un
pt
an
d
♦ Fill turbocharger with engine oil at oil supply line connection.
itte
y li
erm
ab
♦ After installing turbocharger, run engine at idling speed for
ility
ot p
about 1 minute to ensure that oil is supplied to the turbocharg‐
wit
is n
er.
h re
ole,
spec
production standard.
t to the co
Specified torques:
rrectne
♦ Assembly overview - turbocharger
s
Golf, Golf Plus, Touran
s o
cial p
f in
♦ Assembly overview - catalytic converter and add-on parts
form
mer
⇒ “2.1 Assembly overview - emission control”, page 261
atio
m
Polo
o
satelettronica
c
i
or
n thi
e
♦ Assembly overview - catalytic converter and add-on parts

t
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
♦ Secure alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
gh ht
pyri by
and installing alternator .
co Vo
by lksw
cted agen
Prote AG.
♦ Fill with coolant
⇒ “1.2 Draining and adding coolant”, page 171
♦ Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
Note
If a new turbocharger has been installed:
– Erase learnt values and adapt charge pressure positioner -

V465- to engine control unit ⇒ Vehicle diagnostic tester “Gui‐
ded Functions”.
1.3 Removing and installing charge pres‐

sure positioner - V465-
Removing
• Check if a spacer is installed before removing or renewing the
charge pressure positioner - V465- .
• Refer to the current TPI to determine whether a spacer needs
to be installed, and if so which one.

– Disconnect connector -arrow- from charge pressure positioner

- V465- -1-.
– Disconnect connector on lambda probe - G39- -arrow- and

unclip from bracket -1-.
AG. Volkswagen AG d
agen oes
olksw not
V
satelettronica
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Unclip electrical wiring on lambda probe - G39- -1- from brack‐
ility
ot p
et -3-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Remove securing bolts -arrows-.
om
ion
c
in t
r
– Push heat shield -1- from turbocharger to one side so that the
o
his
te
control rod is accessible.

a
do
priv
cum
or
– Wire/line retainer -2- remains in installation position.

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

AG. Volkswagen AG d
agen o
– Remove securing clipVo-3-
lkswfrom connection between
es n
ocontrol
t gu rod
y
and turbo charger
sed -2-.
b ara
n ri tee
ho
– Remove nuts ut -arrows- and detach charge pressure positioner
or
ac
sa
- V465- -1-.
s
ce
e
nl
pt
du
– If installed, remove spacer -4-.
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
One or two spacers may be installed.
spec
es, in part or in w
t to the co
Installing
rrectness of i
note the following:
l purpos
– Secure charge pressure positioner - V465- with new nuts.

Use new securing clip -3-.
nform
ercia
– Adapt engine control unit - J623- to charge pressure positioner

m
at
- V465- using ⇒ Vehicle diagnostic tester; “Guided functions” .
om
ion
c
satelettronica
in t
or
– If necessary, insert spacer -2-.
his
ate
do
priv
c
Install new securing nuts -arrows- only after adaption using ⇒ Ve‐
um
for
hicle diagnostic tester; “Guided functions” . en

ng
t.
yi Co
op
Specified torques
C py
ht. rig
rig ht
py by
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 197
co Vo
by lksw
cted agen
Prote AG.

2 Charge air system agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
Note utho eo
ra
s a c
s
ce
e
nl
pt
du
6340- .
an
itte
y li
erm
ab
ility
ot p
production standard
wit
, is n
h re
♦ Hose connections and hoses for charge air system must be
hole
free of oil and grease before assembly.
spec
es, in part or in w
t to the co
♦ Charge air system must be free of leaks.
⇒ “2.1 Assembly overview - charge air system”, page 208
rrectness of i
⇒ “2.2 Removing and installing charge air cooler (intake mani‐
l purpos
fold)”, page 212
2.1 Assembly overview - charge air system
nform
ercia
satelettronica
⇒ “2.1.1 Assembly overview - charge air system (Golf, Golf Plus,
m
at
om
i
on
c
in t
or
⇒ “2.1.2 Assembly overview - charge air system (Polo)”,
his
ate
page 210
do
priv
cum
for
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
ing an engine and low-temperature radiator for the charge air Prote AG.
system.
♦ The engine and low-temperature radiator are designed as a
single component.
♦ Coolant hose schematic diagram
6340- .
2.1.1 Assembly overview - charge air system (Golf, Golf Plus, Touran, Golf Cab‐
riolet)

1 - Radiator with low-tempera‐

ture radiator for charge air sys‐
tem
radiator
page 187
Note
♦ This engine is equipped with a

radiator combination comprising
an engine and low-temperature
radiator for the charge air sys‐
tem.
♦ The engine and low-temperature AG. Volkswagen AG d
radiator are designed as a single
ksw
agen oes
not
component. y Vol gu
db e
ara
ris nte
tho eo
2 - Intake manifold au ra
c
ss
satelettronica
ce
e
nl
pt
du
an
itte
stalling intake manifold”,
y li
erm
ab
page 223
ility
ot p
3 - Sealing strip
wit
, is n
h re
❑ Make sure it is properly
hole
spec
seated when installing
es, in part or in w
the charge air cooler.
t to the co
4 - Seal
❑ Renew
rrectness of i
l purpos

nform
ercia
5 - Intake manifold charge air

cooler
m
at
om
io
❑ Removing and installing ⇒ “2.2 Removing and installing charge air cooler (intake manifold)”, page 212
n
c
in t
or
his
e
6 - Coolant hose
at
do
riv
❑ To turbocharger
p
cum
for
en
ng
7 - Bolt
t.
yi Co
Cop py
❑ When installing, first tighten evenly until finger-tight, then diagonally across from inside to outside to
t. rig
gh ht
yri
specified torque. p by
co Vo
by lksw
cted
❑ 7 Nm
agen
Prote AG.
8 - Coolant hose
9 - Hose clamp
❑ Secured to valve timing housing (top).
10 - Coolant hose
❑ To turbocharger
11 - Coolant circulation pump - V50-
❑ Fitting location: below intake manifold.
❑ Removing and installing ⇒ “2.3 Removing and installing coolant circulation pump V50 ”, page 180
12 - Bolt
❑ 8 Nm
2. Charge air system 209

13 - Bracket
14 - Connector
15 - Bolt
❑ 10 Nm
wage es n
16 - Coolant hose yV
olks ot g
ua
d b
❑ To engine oil cooler oris
e ran
tee
th or
u
17 - Coolant pipe ss a ac
ce
le
❑ Secured to sump
un
pt
an
d
itte
18 - Bolt
y li
rm
ab
pe
❑ 8 Nm
ility
ot
wit
, is n
19 - Coolant hose
h re
hole
spec
20 - Union
es, in part or in w
t to the co
21 - O-ring
rrectness of i
satelettronica
l purpos
2.1.2 Assembly overview - charge air system

(Polo)
nform
mercia
a
com
tio
Note n in
r
te o
thi
s
iva
♦ Radiator and charge air cooler are separate components.

do
r
rp
cum
fo
♦ Radiator is mounted onto charge air cooler.

en
ng
t.
yi Co
op
♦ Radiator and charge air cooler are removed and installed to‐ C py
ht. rig
gether. rig ht
py by
co Vo
by lksw
♦ Coolant hose schematic diagram cted agen
Prote AG.
6340- .

1 - Radiator/cooler
radiator
page 187
2 - Intake manifold
page 223 AG. Volkswagen AG d
agen oes
lksw not
3 - Sealing strip byV
o gu
ara
ed
❑ Make sure it is properlyhoris nte
eo
s aut ra
c
s
ce
e
nl
pt
du
4 - Seal
an
itte
y li
❑ Renew
erm
ab
ility
ot p
wit
, is n
h re
hole
satelettronica
spec
es, in part or in w
5 - Intake manifold charge air
t to the co
cooler
rrectness of i
l purpos
(intake manifold)”,
page 212
nf
ercia
6 - Coolant hose
orm
❑ To turbocharger
m
atio
om
n in
7 - Bolt
or c
thi
e
❑ Observe tightening se‐

t
sd
iva
quence
o
r
rp
cu

o
m
f
en
ng

t.
yi Co
op
(intake manifold)”, page 212 C py
ht. rig
rig ht
❑ 7 Nm py by
co Vo
by lksw
cted agen
8 - Coolant hose Prote AG.
9 - Hose clamp
❑ Secured to valve timing housing (top).
10 - Coolant hose
❑ To turbocharger
11 - Coolant circulation pump - V50-
❑ Fitting location: below intake manifold.
❑ Removing and installing ⇒ “2.3 Removing and installing coolant circulation pump V50 ”, page 180
12 - Bolt
❑ 8 Nm
13 - Bracket
14 - Connector
15 - Bolt
❑ 10 Nm

16 - Coolant hose
❑ To engine oil cooler
17 - Coolant pipe
❑ Secured to sump
18 - Bolt AG. Volkswagen AG d
agen oes
❑ 8 Nm olksw not
y V gu
d b ara
19 - Coolant hose rise nte
tho eo
au ra
20 - Charge air cooler ss c
ce
le
un
❑ Removing and installing ⇒ “3.2 Removing and installing radiator”, page 187
pt
an
d
itte
y li
erm
ab
ility
ot p
2.2 Removing and installing charge air cool‐
wit
is n
h re
er (intake manifold)
ole,
spec
t to the co
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
♦ Support bridge - 3250- gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove intake manifold

– Unscrew bolts securing charge air cooler in specified se‐

quence -A- to -F-.
– Pull charge air cooler out of the intake manifold.
Installing
Note
Charge air cooler is installed into intake manifold using a work‐

shop press.
– Push sealing strip -1- in -direction of arrow- onto edge of

charge air cooler.
– Check that the new gasket is correctly seated on the intake
manifold.
– Push charge air cooler into exhaust manifold as far as it will
go.
Do not tilt charge air cooler when installing it.
satelettronica
– Position support - 3250- centrally on charge air cooler.
– Carefully lower ram of workshop press until housing of charge
air cooler -1- lies on intake manifold -2-. en AG. V
olkswagen AG
ag does
lksw not
– Screw in bolts uniformly until bolt heads are touching
yV
o surface gu
db ara
of intake manifold. or
ise nte
h eo
ut ra
Further installation is performed in the reverse
ss
a order of removal. c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Specified torques:
es, in part or in w
t to the co
♦ Tighten bolts to 7 Nm in sequence as specified -A- to -F-.

♦ Installing intake manifold
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

24 – Mixture preparation - injection

1 Injection system olkswage
es n
ot g
byV ua
d
General notes on injection o
ir se
ran
tee
th or
u
♦ The engine control unit - J623- is capable of self-diagnosis.
ss
a ac
Before carrying out repairs and fault finding, read event mem‐
ce
e
nl
pt
ory. Also the vacuum hoses and connections must be checked
du
an
itte
(unmetered air).
y li
erm
ab
ility
♦ Fuel hoses in engine compartment must be secured only with
ot p
wit
spring-type clips. The use of crimp-type or screw-type clips is
, is n
h re
not permissible.
hole
spec
♦ For trouble-free operation of electrical components, a voltage
es, in part or in w
t to the co
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‐
rrectness of i
age the Lambda probe.
l purpos
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
satelettronica
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
nform
ercia
characteristics of the engine. When door is opened, the fuel

m
at
pump is activated for 2 seconds to build up pressure in the fuel
om
io
system.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
214 Rep. gr.24 - Mixture preparation - injection

2 Air filter
⇒ “2.1 Assembly overview - air filter”, page 215 agen
AG. Volkswagen AG d
oes
olksw not
V gu
⇒ “2.2 Removing and installing air filter housing”,
d by page 217 ara
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2.1 Assembly overview - air filter
th
au ra
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le
⇒ “2.1.1 Assembly overview - air filter (Golf, Golf Plus, Touran,
un
pt
an
d
Golf Cabriolet)”, page 215
itte
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ab
⇒ “2.1.2 Assembly overview - air filter (Polo)”, page 216 pe
ility
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2.1.1 Assembly overview - air filter (Golf, Golf Plus, Touran, Golf Cabriolet)
h re
hole
spec
es, in part or in w
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1 - Air filter upper part
2 - Bolt
rrectness of i
❑ Tighten with torque
screwdriver - VAS 6494-
l purpos
❑ 1.6 Nm
satelettronica
3 - Bolt
nform
ercia

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❑ 1.6 Nm
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4 - Bracket
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6 - Bonded rubber bush
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❑ 8 Nm
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7 - Sealing strips
8 - Air filter lower part
stalling air filter hous‐
ing”, page 217
9 - Rubber mounting
10 - Intake connecting pipe
❑ With cover.
11 - Bolt
❑ 3 Nm
12 - Intake air guide
13 - Bolt
❑ 1.6 Nm
14 - Spring-type clip
❑ Remove and install with hose clip pliers - VAS 6340- .
15 - Intake hose
16 - Vacuum hose
2. Air filter 215

❑ To cylinder head cover.
olkswagen AG
en AG. V
2.1.2 Assembly
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❑ Remove and install with
is n
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hose clip pliers - VAS
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spec
6340- .
t to the co
4 - Intake hose
5 - Vacuum hose
rrectne
❑ To cylinder head cover.
ss o
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satelettronica
inform
7 - Air filter upper part
mer
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8 - Bolt
o
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or

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❑ 1.6 Nm
um
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9 - Filter element
Co
Cop py
t. rig
10 - Rubber mounting
gh ht
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Vo
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11 - Air filter lower part cted agen
Prote AG.
stalling air filter hous‐
ing”, page 217
12 - Bolt
❑ 8 Nm
13 - Rubber mounting
14 - Water drain hose
15 - Intake air guide
16 - Bolt
❑ 3 Nm
17 - Bolt
❑ 10 Nm

2.2 Removing and installing air filter hous‐

ing
⇒ “2.2.1 Removing and installing air filter housing (Golf, Golf Plus,
⇒ “2.2.2 Removing and installing air filter housing (Polo)”,
page 218
2.2.1 Removing and installing air filter hous‐

ing (Golf, Golf Plus, Touran, Golf Cab‐
riolet)
Removing
– Press catches -arrows- and take cover -1- off intake connect‐
ing pipe.
– Pull intake connecting pipe out of intake air duct.
– Pull spring-type clip -2- together with intake hose off turbo‐
charger.
satelettronica
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– Pull vacuum hose -1- off air filter housing.
wit
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– Undo bolt -2- and pull air filter housing upwards off locating
hole
spec
pins -3-.
es, in part or in w
t to the co
Installing
Install in reverse order of removal. During this procedure, observe
the following:
rrectness of i
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nf
ercia
orm
m
atio
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c
– Press air filter housing onto locating pins -3- from above.
or
thi
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– Tighten securing bolt -2- to 8 Nm.

iv
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rp
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– Pull vacuum hose -1- off air filter housing connecting pipe.
m
f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
2. Air filter 217

2.2.2 Removing and installing air filter hous‐

ing (Polo)
Removing
– Unscrew securing bolts -arrows- of intake air duct and inlet
connection on turbocharger.
AG. Volkswagen AG d
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spec
– Pull vacuum hose -1- under intake hose.
t to the co
– Unscrew securing bolt -2-.
satelettronica
– Withdraw air filter housing upwards.
rrectne
Installing
ss o
cial p
f inform
mer
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n
c
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sd
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– Press air filter housing onto locating pins from above.

p
cum
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– Tighten securing bolt -2- to 8 Nm.

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Cop py
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– Attach intake hose -1-. opyri
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c by lksw
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– Tighten securing bolts -arrows-.

Specified torques
♦ Inlet connection to turbocharger: 10 Nm
♦ Intake air duct: 3 Nm

3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 219
⇒ “3.2 Removing and installing intake manifold”, page 223
⇒ “3.3 Removing and installing throttle valve module J338 ”, page
224
⇒ “3.4 Cleaning throttle valve module J338 ”, page 226
3.1 Assembly overview - intake manifold
Note
♦ If hoses were pulled off during repair work, check that all hoses
are firmly connected after reinstallation.
♦ Tug on hoses having catches to make sure they are securely
seated. AG. Volkswagen AG d
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mer
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3. Intake manifold 219

Note
olkswagen AG
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♦ If hoses were pulled off during repairowork,
lksw check that all hoses es no
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♦ Tug on hoses having catches
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ra
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1 - Connection hose
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❑ To air filter
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spec
2 - Connector
t to the co
❑ For intake manifold
sender - G71- .
rrectne
Note
ss
♦ Suction pipe pressure transduc‐
o
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satelettronica
er - G71- is clipped to suction
inform
pipe.
mer
atio
♦ If a clip is damaged, use securing
om
n
bolts ⇒ ETKA (Electronic Parts
c
i
or
n thi
Catalogue) .
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♦ Specified torque: 5 Nm
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t.
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3 - Connector ht. Cop py
rig
rig ht
4 - Bolt py by
co Vo
by lksw
❑ 10 Nm
cted agen
Prote AG.
❑ For crankcase ventila‐
tion.
6 - Connection hose
❑ To turbocharger
7 - O-ring
❑ Renew
8 - Intake manifold
page 223
9 - Connection hose
Note
Installed in engines with switchable

coolant pump only.
❑ To coolant pump.
10 - Coolant circuit solenoid valve - N492-
Note
Installed in engines with switchable

coolant pump only.

11 - Union
❑ For fuel supply.
❑ Remove and install with hose clip pliers - VAS 6340-
13 - Fuel hose
❑ Low pressure
❑ To high-pressure pump
14 - Activated charcoal filter solenoid valve 1 - N80-
15 - Connection hose
❑ To activated charcoal filter
16 - Connecting hoses
AG. Volkswagen AG d
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❑ For throttle valve module - J338- ed b ara
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18 - Connection hose aut ra
c
ss
19 - Connector
ce
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un
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❑ For charge air pressure sender - G31- with intake air temperature sender 2 - G299- .
satelettronica
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Part II
h re
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spec
t to the co
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mer
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Cop py
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rig ht
py by
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1 - Pressure pipe
2 - Bolt
❑ 7 Nm
3 - Retaining clip
4 - Fuel pressure sender -
G247-
❑ Checking fuel pressure
sender - G247-
⇒ “6.1 Checking fuel
pressure sender G247 ”,
page 241 .
❑ 22 Nm
5 - Fuel distributor
6 - Bolt
❑ 20 Nm
7 - Adapter
❑ 30 Nm
satelettronica
8 - Union nut
❑ 25 Nm
9 - Union nut
❑ 25 Nm
10 - O-ring
❑ Renew
11 - Spring element
❑ Observe proper seating
of injector.
12 - Injector, cylinder 1 - N30-
AG. Volkswagen AG d
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❑ Injector, cylinder 3 - N32- tho r eo
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❑ Injector, cylinder 4 - N33-s s c
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❑ With Teflon seal and support washer.

nl
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❑ After removing injector, Teflon seal and support washer must be renewed
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⇒ “4.2 Renewing seals on injectors”, page 230 .

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❑ Removing and installing injectors ⇒ “4.1 Removing and installing injectors”, page 228 .
wit
, is n
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13 - Cylinder head
hole
spec
❑ Removing and installing ⇒ “1.3 Removing and installing cylinder head”, page 96
es, in part or in w
t to the co
14 - Bolt
❑ 8 Nm
rrectness of i
15 - Intake manifold
l purpos
❑ With intake manifold pressure sender - G71- (clipped onto intake manifold).
❑ Removing and installing ⇒ “3.2 Removing and installing intake manifold”, page 223
nform
ercia
16 - Seal
m
at
om
❑ Renew
ion
c
in t
or
17 - Throttle valve module - J338-

his
ate
do
riv
❑ Removing and installing ⇒ “3.3 Removing and installing throttle valve module J338 ”, page 224
p
cum
or
❑ Cleaning ⇒ “3.4 Cleaning throttle valve module J338 ”, page 226

f
en
ng
t.
yi Co
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided t. Cop py
functions”.
rig
gh ht
pyri by
Vo
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222
AG.
Rep. gr.24 - Mixture preparation - injection
18 - Adapter
19 - O-ring
❑ Renew
20 - Bolt
❑ 7 Nm
21 - O-ring
❑ Renew
22 - Charge air pressure sender - G31- with intake air temperature sender 2 - G299-
23 - Bolt
❑ 5 Nm
3.2 Removing and installing intake manifold

satelettronica
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♦ Torque wrench
ss (5 … 50 Nm) - V.A.G 1331-
ce
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es, in part or in w
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Removing
nform
ercia
– Drain coolant
m
at
om
ion
– Remove throttle valve module

c
in t
or
⇒ “3.3 Removing and installing throttle valve module J338 ”,

his
ate
page 224 .
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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– Remove coolant hoses -3- and pull off connector -1-.

– Unscrew securing bolts from ignition transformer - N152- -2-
and place ignition transformer to one side.
– Undo and remove intake manifold bolts -arrows- below fuel

rail.
Installing
Note
♦ If hoses were pulled off during repair work, check that all hoses
satelettronica
♦ Tug on hoses having catches to make sure they are securely
seated.
Installation is performed in the reverse order of removal.

Specified torques:
♦ Intake manifold securing bolts: 8 Nm
wage es n
3.3 Removing and installing throttle valve
olks ot g
byV ua
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module - J338-
utho
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or
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nl
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es, in part or in w
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nform
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c
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or
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ate
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priv
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Cop py
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AG. Volkswagen AG d
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V gu
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Removing
nl
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ab
ility
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hole
spec
es, in part or in w
t to the co
satelettronica
charger.
rrectness of i
l purpos
nform
mercia
at
om
ion
– Unplug connector -1- from throttle valve module - J338- .
c
in t
or
his
e
– Unscrew bolts -2- and remove throttle valve module -3- from
at
do
riv
intake manifold.
p
cum
for
en
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Installing
n
t.
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Cop py
– Insert new seal into groove of intake manifold.
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Fit throttle valve module -3- together with adapter -2- and se‐
curing bolts -1- onto intake manifold -4-.
– Tighten securing bolts -2- to 7 Nm.
satelettronica
– Plug connector -1- onto throttle valve module -3-. AG. Volkswagen AG d
agen oes
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Before installing, lightly coat O-rings on turbocharger and in pres‐
s
ce
le
sure pipe with engine oil.

un
pt
an
d
itte
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ab
– Attach pressure pipe -3- to turbocharger.
pe
ility
ot
wit
, is n
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hole
spec
– Press pressure pipe -3- onto throttle valve module.
es, in part or in w
t to the co
Retaining clips must engage audibly.
– Tighten screws -1- of retaining clips to 7 Nm.
rrectness of i
– Plug connector -2- onto charge pressure sender - G31- with
l purpos

If a new throttle valve module was installed:
nform
ercia
– Erase learnt values and adapt engine control unit - J623- to

m
a
com
t
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
ion in
tions”.
r
te o
thi
s
iva
do
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rp
cum
fo
3.4 Cleaning throttle valve module - J338-

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
♦ If a new engine control unit - J623- is installed the throttle valve
module must be adjusted. Adaptation is only allowed to be
made with a new or cleaned throttle valve module.
♦ Contamination and coking in end stop can result in incorrect
adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.

– Remove throttle valve module

⇒ “3.3 Removing and installing throttle valve module J338 ”,
page 224 .
– 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. It is essential to observe acci‐

dent prevention regulations and safety instructions when han‐
dling highly flammable fluids. Do not use compressed air when
cleaning throttle valve. Wear eye protection and protective
clothing to avoid injury and skin contact.
AG. Volkswagen AG d
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– Thoroughly clean throttle valve housing, especially around
by Vo
the gu
ara
d
closed throttle valve -arrows- using commercially orise available nte
acetone according to DIN 53247 and a brush. auth eo
ra
ss c
– Wipe the inside of the throttle valve housing with a lint-free
ce
le
un
pt
cloth.
satelettronica
an
d
itte
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– Allow acetone to flash off completely and reinstall cleaned
erm
ab
ility
throttle valve module.
ot p
wit
is n
– Erase learnt values and adapt engine control unit - J623- to
h re
ole,
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
spec
tions”.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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en
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t.
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Cop py
t. rig
gh ht
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Vo
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by
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olkswagen AG
wag en AG. V
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2009 ➤ , Polo olks2010 ➤ , ...
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4-cylinder direct injection engine (1.2 l engine, 2V, EA 111,
sed turbocharger) - Edition 09.2018 uara
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4 Injectors
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⇒ “4.1 Removing and installing injectors”, page 228
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ab
ility
⇒ “4.2 Renewing seals on injectors”, page 230
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⇒ “4.3 Cleaning injectors”, page 234
h re
hole
spec
4.1 Removing and installing injectors
es, in part or in w
t to the co
Note safety precautions before starting repair work
rrectness of i
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Note
Teflon seal on injector must be renewed each time after removing
nform
ercia
injector ⇒ “4.2 Renewing seals on injectors”, page 230 . m
at
om
ion
c
in t
or
his
te

a
do
priv
cum
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satelettronica
f
en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Tool set - T10133-
Removing
– Remove coolant hose out of guide on pressure pipe.

charger.
– Remove high-pressure pump
page 237 .
– Unscrew bolts -arrows- and detach fuel rail from injectors.
satelettronica
– Manually press O-ring upwards as shown and remove it from
injector.
– Bolt hammer - T10133/3- and puller - T10133/15- to each oth‐
er.
AG. Volkswagen AG d
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– Then insert puller - T10133/15- into groove -arrow- on injector.

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es, in part or in w
t to the co
rrectness of i
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mercia
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tion in
r
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thi
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229
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4. Injectors
AG.
– Tap injector carefully to remove it.

Installing
AG. Volkswagen AG d
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– Clean injector bores in cylinder head thoroughly with a nylon
un
pt
brush - T10133/4- .
an
d
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– Check plastic support washer for damage and, if necessary,
ility
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renew ⇒ “4.2 Renewing seals on injectors”, page 230 .
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spec
t to the co
satelettronica
rrectness o
cial p
f
– Renew spring element -arrow- and Teflon seal each time the
inform
injectors are removed
mer
atio
om
n
– Install new O-rings for injectors and coat lightly with clean en‐
c
i
or
n
gine oil.
thi
te
sd
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pr
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en
ng
Note
t.
yi Co
Cop py
ht. rig
Do not oil or grease the Teflon seal on the injector. rig ht
py by
co Vo
by lksw
cted agen
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– Push injector into cylinder head bore as far as it will go by
AG.
hand.
Note
The injector must insert easily. If necessary wait until the seal has
contracted sufficiently.
– Ensure injectors are correctly seated and positioned in cylin‐

der head.
4.2 Renewing seals on injectors


♦ Tool set - T10133-
AG. Volkswagen AG d
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Procedure
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Renewing Teflon seal
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– Remove injectors
hole
spec
⇒ “4.1 Removing and installing injectors”, page 228 .
es, in part or in w
t to the co
– Clean injector carefully.
– Carefully cut oil seal open with a knife -arrow- as shown. Avoid
satelettronica
rrectness of i
contact between knife blade and valve body under all circum‐
stances.
l purpos
– Remove old seal and clean seal groove in area of seal

-arrow-. Remove any deposits (coking) with a brass wire
nf
ercia
brush.
orm
m
atio
om
n in
or c
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sd
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Put new seal -1- on assembly cone - T10133/5- . Using as‐

sembly sleeve - T10133/6- (knurled end faces seal -1-), gently
slide the seal onto the assembly cone - T10133/5- as far as
possible.
– Turn assembly sleeve - T10133/6- around.
The knurled end no longer faces the seal.
4. Injectors 231
AG. Volkswagen AG d
– Push oil seal -1- to end of assembly cone - T10133/5- . lkswagen oes
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– Then place assembly cone - T10133/5- with sealrionto se
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from front. Slide the seal with assembly sleeve th- T10133/6-
o eo
further onto the injector. au ra
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The seal is not yet seated in its groove.
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– Remove assembly sleeve - T10133/6- and assembly cone -
T10133/5- .
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– Push seal into annular groove by hand.
nf
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– Fit spacer sleeve - T10133/11- onto valve body.
orm
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– Now push the calibration sleeve - T10133/7- over the seal as
om
satelettronica
n in
far as it will go until it is touching the spacer sleeve -
or c
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– Then push calibration sleeve - T10133/8- over seal as far as Prote
cted AG.
agen
it will go until it is touching spacer sleeve - T10133/11- .
– Pull the calibration sleeve - T10133/8- off.
Now the Teflon seal has correct installation dimensions.

Renewing support washer
– Remove O-ring -3-.

– Cut open support washer -2- with small side cutters and re‐
move.
– Withdraw spring element from injector -1- and then slide re‐
taining plate - T10133/12- on.
lkswage es n
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– Slide new support washer -1- onto assembly cone -
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T10133/13- and push assembly cone onto injector as shown.
an
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– Slide support washer -1- into first groove -arrow- on injector
pe
ility
using calibration sleeve - T10133/14- (knurled side faces to‐
ot
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wards injector).
h re
hole
– Turn calibration sleeve - T10133/14- round (knurled side no
spec
longer faces towards injector).
es, in part or in w
t to the co
satelettronica
rrectness of i
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– Push calibration sleeve in -direction of arrow- as far as it will
nform
ercia
go -1-until it touches retaining plate - T10133/12- .

m
a
– Pull calibration sleeve - T10133/14- off again.
com
tion in
r
The support washer now has correct installation dimensions.

te o
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Prote AG.
– Now fit new spring element -1- for retaining plate - T10133/12-
and position a new O-ring -3- in front of support washer -2-.
4. Injectors 233
Note
The Teflon seal -arrow- must not be oiled to installswinjector.

agen
AG. Volkswagen AG d
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– Installing injectors ris
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⇒ “4.1 Removing and installing utho
injectors”, page 228
eo
ra
a c
ss
Further installation is carried out in reverse order of removal.
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4.3 Cleaning injectors
hole
spec
es, in part or in w
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♦ Ultrasonic cleaning device - VAS 6418-
rrectness of i
♦ Mounting plate for injection modules - VAS 6418/1-
l purpos
♦ Cleaning fluid - VAS 6418/2-
satelettronica
Cleaning
nform
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– Remove injectors
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tion in
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Note
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Observe ultrasonic unit safety regulations and operating instruc‐

n
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tions. Cop py
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– The ultrasonic unit must be filled with cleaning fluid - VAS
c by lksw
cted agen
6418/2- .
Prote AG.
Note
The ultrasonic unit must be filled with cleaning agent to upper

edge of holes (see detail).
– Insert injectors-1- into mounting plate for injection modules -

VAS 6418/1- to stop -2-.

– Dip injectors together with mounting plate for injection mod‐

ules - VAS 6418/1- into cleaning fluid.
– Set temperature to 50 degrees with rotary knob -4-.
– Set a cleaning time of 30 minutes with the rotating knob -5-.
– Switch on ultrasonic unit with button -3-.
Note
As soon as the cleaning temperature is 50 degrees, the set time

will begin to elapse.
– The combustion chamber seals (Teflon seals) of every injector

must always be renewed after the cleaning
– Then reinstall injectors
satelettronica
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Cop py
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Prote AG.
4. Injectors 235
5 High-pressure pump
⇒ “5.1 Assembly overview - high-pressure pump”, page 236
⇒ “5.2 Removing and installing high-pressure pump”, page 237
5.1 Assembly overview - high-pressure

pump
WARNING

bar).
satelettronica
1 - Bolt
❑ 20 Nm
2 - Fuel hose
❑ Low pressure
❑ With spring-type clip.
❑ Remove and install with wagen AG. Volkswagen AG doe
hose clip pliers - VAS Vol
ks s no
t gu
by
6340- . ir se
d ara
nt ee
tho or
4 - Union nut au ac
ss
❑ Observe safety precau‐
ce
le
un
pt
tions
an
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itte
⇒ “2 Safety precau‐
y li
erm
ab
tions”, page 5 .
ility
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❑ Counterhold when loos‐

wit
is n
ening connection to
h re
ole,
high-pressure pump.
spec
❑ 25 Nm
t to the co
5 - Union nut
❑ Observe safety precau‐
rrectne
tions
⇒ “2 Safety precau‐
s
tions”, page 5 .
s o
cial p
❑ Counterhold when loos‐

inform
ening connection to
mer
high-pressure pump.
atio
om
❑ 25 Nm
n
c
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or
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Prote AG.

6 - 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.
❑ Removing and installing ⇒ “5.2 Removing and installing high-pressure pump”, page 237
7 - O-ring
❑ Renew
❑ Lightly coat with engine oil when installing.
8 - Roller tappet
satelettronica
❑ Lightly coat with engine oil when installing.
9 - Connector
n AG. Volkswagen A
5.2 RemovingVoand lksw installing high-pressure
age G do
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Special tools and
ss workshop equipment required
a ra
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nform
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Removing
Observe safety precautions ⇒ “2 Safety precautions”, page 5 .
5. High-pressure pump 237

WARNING

bar).
– Detach fuel supply line -arrow-.
Note
Collect escaping fuel with a cleaning cloth.
Caution
satelettronica
and installing!
– Detach connector -1- and fuel supply line -2- from high-pres‐
agen
AG. Volkswagen AG d
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sure pump. olksw not
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– Undo union nuts -3- and remove high-pressure line.
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on fuel rail when loosening and tightening
union nuts.
– Undo bolts -4- of high-pressure pump and pull out of cylinder

head cover together with tappet. agen
AG. Volkswagen AG d
oes
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Installing Vol gu
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ris
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Caution ss c
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un
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and installing!
rm
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spec
satelettronica
es, in part or in w
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Note
rrectness of i
♦ Moisten roller tappet of high-pressure pump with clean engine
oil.
l purpos
♦ The high-pressure pump O-ring must be renewed.
nform
ercia
– Push roller tappet -1- into cylinder head cover.

m
a
com
tion in
– Insert new, lubricated O-ring -2- in groove of high-pressure
r
te o
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pump -3-. s
iva
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– Position high-pressure pipe -3- on cylinder head cover.

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– Screw in securing bolts -4- by hand until bolt heads are seated
Co
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on flange.
t. rig
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Prote AG.
5. High-pressure pump 239

– Tighten bolts uniformly until flange is seated on camshaft

housing.
Tighten securing bolts to specified torque ⇒ page 240 .
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on fuel rail when tightening union nuts.
– Tighten union nuts -3- of high-pressure line to specified torque

⇒ page 240 .
– Attach fuel supply line -2- and connector -1- to high-pressure
pump.
– Connect different parts of fuel supply line -arrow- together.

AG. Volkswagen
agen AG do
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Specified torques: by Vol ot g
ua
ed ran
ris tee
Component tho Specified torque or
au ac
Securing bolts for ss
high-pressure 20 Nm
satelettronica
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pump
nl
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Union nuts for high-pressure lines 25 Nm
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6 Senders and sensors

⇒ “6.1 Checking fuel pressure sender G247 ”, page 241
6.1 Checking fuel pressure sender - G247-

♦ Pressure sensor tester - VAS 6394-
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satelettronica
♦ 27 mm flared open ring spanner with 3/8" drive
rrectness of i
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♦ Test instrument adapter - VAS 5570- (not illustrated) C py
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Procedure cop Vo
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WARNING

bar).
6. Senders and sensors 241

– Pull off connector -1- and remove fuel pressure sender - G247-
-2- with an open-ended spanner.
– Moisten tapered seal of adapter - VAS 6394/3- with clean en‐

gine oil and screw into fuel rail. Specified torque: 22 Nm AG. Volkswagen AG d
agen oes
olksw not
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rm
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spec
es, in part or in w
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– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester - VAS 6394/1- . Specified torque: 22 Nm
rrectness of i
– Connect pressure line of tester - VAS 6394/1- to adapter - VAS
6394/3- .
l purpos
nform
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com
tion in
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– Connect fuel pressure sender -1- and electrical connector of Cop py
fuel pressure sender using test instrument adapter - VAS
t. rig
gh ht
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5570- .
p by
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Prote AG.

– Connect vehicle diagnosis, testing and information system -

VAS 5051B- -1- as follows:
Engine control units KWP (Keyword Protocol)
– Press following buttons on display in succession:
Vehicle self-diagnosis
Vehicle self-diagnosis
01 - Engine electronics
011 - Measured values
– Select measured value block 1 4 0 and acknowledge with

Q.
Display field 3 shows the actual value reported to the vehicle by

the fuel pressure sender - G247- .
Engine control units UDS (Unified Diagnostic Service)
satelettronica
Note
olkswagen AG
en AG. V
A new generation of engine control units Vol
kshas
wag been introduced does n
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(UDS => Unified Diagnostic Service). ed b These new-generation en‐
y ua
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gine control units require a different
horis procedure for requesting the tee
required values. s aut or
ac
s ce
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nl
pt
– Press the following buttons on display one after the other.
du
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Guided function
ility
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– Confirm the test version and the brand.

wit
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– Select the vehicle type.

hole
spec
es, in part or in w
– Select the model year.

t to the co
– Specify the engine version.

– Specify that the “Engine” vehicle system is used.
rrectness of i
l purpos
Read measured values
– Follow the programmed steps of the tester until step »Select

displayable measured values«.
nform
ercia
– Search for “IDE00589 fuel pressure” in plain text.

m
at
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ion
c
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Done
o
his
ate
do
riv
Read
p
cum
or
All engine control unit versions

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6. Senders and sensors 243

wage es n
– Switch on tester - VAS 6394/1- by briefly pressing button -A- y Volks ot g
ua
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♦ When button -A- is pressed for 2 seconds, the illumination is
erm
ab
switched on for 20 seconds.
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♦ If the tester - VAS 6394/1- reading is not 0 bar, carry out a zero
h re
reset ⇒ Operating instructions .
hole
spec
es, in part or in w
t to the co
– Connect vehicle diagnostic tester to diagnostic connection.
rrectness of i
– Compare pressure displayed on tester - VAS 6394/1- with ac‐
tual value displayed on vehicle diagnostic tester .
l purpos
• A maximum pressure deviation of 5 bar is permissible.
nform
ercia
– If deviation is greater than 5 bar, renew fuel pressure sender

- G247- .
m
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in t
or
WARNING
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bar). Cop py
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Prior to opening the high-pressure area, the fuel pressure in p by
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AG.

– Repeat test with new fuel pressure sender - G247- and com‐
pare both measured values.
If measured values again fail to correspond:
– Perform line test ⇒ Vehicle diagnostic tester.

7 Engine control unit - J623-

⇒ “7.1 Removing and installing engine (motor) control unit J623
”, page 245 AG. Volkswagen n AG do
ks wage es n
⇒ “7.2 Removing and installing engine (motor) Vol control unit J623 ot g
by ua
with protective housing”, page 248 ris
ed ran
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7.1 Removing and installing
ss
a engine (motor) ac
control unit - J623-
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⇒ “7.1.1 Removing and installing engine control unit J623 (Golf,
erm
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ility
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⇒ “7.1.2 Removing and installing engine control unit J623 (Golf
h re
Plus, Touran)”, page 246
hole
spec
es, in part or in w
⇒ “7.1.3 Removing and installing engine control unit J623 (Polo)”,
t to the co
page 247
7.1.1 Removing and installing engine control
rrectness of i
unit - J623- (Golf, Golf Cabriolet)
l purpos
satelettronica
If the engine control unit is to be renewed, connect the ⇒ Vehicle
diagnostic tester and carry out guided function “Renew control
nform
ercia
unit”.
m
at
Removing
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ion
c
in t
r

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ate
do
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– Remove windscreen wiper arms: ⇒ Electrical system; Rep.

p
cum
gr. 92 ; Windscreen wiper system; Removing and installing
for
en
g
wiper arms .
n
t.
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Cop py
– Remove plenum chamber bulkhead ⇒ General body repairs;
t. rig
gh ht
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Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
p by
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by c lksw
cted agen
– Push retaining frame downwards in -direction of arrow- and
Prote AG.
remove engine control unit.
– Push locking devices of connectors in -direction of arrow- and

pull off connectors.
Installing
7. Engine control unit J623 245

– Fit connectors to engine control unit and slide locking devices

onto stop in -direction of arrow-.
– Place engine control unit in retaining frame and push upwards

in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install windscreen wiper arms: ⇒ Electrical system; Rep. gr.
92 ; Windscreen wiper system; Removing and installing wiper
arms
satelettronica
unit - J623- (Golf Plus, Touran) n AG. Volkswagen AG do
lkswage es n
Vo ot g
If the engine control unit is to be renewed, connect the ⇒edVehicle
by ua
ran
diagnostic tester and carry out guided function “Renew hor control
is tee
unit”. aut or
ac
ss
Removing
ce
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nl
pt
du
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erm
ab
ility
ot p

wit
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hole
– Loosen securing bolts -arrows- of control unit cover. spec

es, in part or in w
– Loosen securing nuts -arrows- of control unit bracket.

t to the co
rrectness of i
l purpos
nf
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orm
m
atio
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or c
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Cop py
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cted agen
Prote AG.

– Release connectors from engine control unit and pull off.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
AG. Volkswagen AG d
Installing agen oes
olksw not
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– Push engine control unit onto control unit bracket untilrisit en‐
e d
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gages in catches. ut
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– Attach connectors to engine control unit and lock.
ce
le
un
pt
satelettronica
an
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itte
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rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
– Tighten bolts -arrows- to 10 Nm.
t to the co
rrectness of i
l purpos
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tion in
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– Tighten securing bolts -arrows- to 5 Nm. en

ng
t.
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op
– If engine control unit - J623- is renewed, erase learnt values C py
ht. rig
and adapt engine control unit ⇒ Vehicle diagnostic tester “Gui‐ rig ht
py by
ded functions”.
co Vo
by lksw
cted agen
Prote AG.
– The readiness code must be generated if the event memory
has been cleared.
– Again read control unit event memory.

unit - J623- (Polo)
unit”.

Removing
– Press clips -arrows A- outwards and pull engine control unit

out to side -B-.
Installing
– Insert new engine control unit and press it to left.
– Connect connectors and lock.
– If engine control unit - J623- is renewed, erase learnt values
satelettronica
and adapt engine control unit ⇒ Vehicle diagnostic tester “Gui‐
ded functions”.
has been cleared.
– Install air filter AG. Volkswagen AG d
⇒ “2.2 Removing and installing air filter housing”, page o217 agen
lksw .
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– Carry out road test. rise nte
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– Again read control unit event memory. s au ra
c
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nl
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7.2 Removing and installing engine (motor)

an
itte
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erm
ab
control unit - J623- with protective hous‐
ility
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, is n
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hole
⇒ “7.2.1 Removing and installing engine control unit J623 with

spec
protective housing (Golf, Golf Cabriolet)”, page 248

es, in part or in w
t to the co

protective housing (Golf Plus, Touran)”, page 251
rrectness of i

protective housing (Polo)”, page 253
l purpos

nform
ercia
unit - J623- with protective housing

m
(Golf, Golf Cabriolet)

at
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ion
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or

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ate

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unit”.
cum
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Removing
yi Co
Cop py
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– Switch off ignition. gh ht
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by
– Remove windscreen wiper arms: ⇒ Electrical system; Rep. Prote
cted AG.
agen
gr. 92 ; Windscreen wiper system; Removing and installing
wiper arms .

– Push retaining frame downwards in -direction of arrow- and

remove engine control unit.
lkswage es n
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un
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– Unscrew shear-head bolts -arrows- using a pair of pliers.
erm
ab
ility
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is n
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spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
– Insert screwdriver between both locking plates -arrow-.

atio
om
n
c
– Carefully press screwdriver in direction of -arrow- while simul‐

i
or
n thi
e
taneously bending locking bar -1- upwards.

t
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cted agen
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– Bend locking bar -1- in direction of -arrow- until it can be pulled

off connectors.

– Push locking devices of connectors in -direction of arrow- and

pull off connectors.
Installing
– Fit connectors to engine control unit and slide locking devices

onto stop in -direction of arrow-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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– Fit locking bar -1- onto connectors
s aut and press it in direction of ra
c
-arrow-. s
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pt
– Insert pin -2- as far as stop into hole on engine control unit.
an
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Use new shear-head bolts to secure locking clamp to engine

control unit -arrows-.
nform
ercia
– Evenly tighten shear-head bolts until bolt heads shear off

-arrows-.
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cted agen
Prote AG.

– Place engine control unit in retaining frame and push upwards

in direction of -arrow-.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .

unit - J623- with protective housing (Golf
. Volkswagen AG
gen AG
Plus, Touran) yV
olkswa does
not
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Special tools and workshop equipment hrequired
or
is tee
t or
au ac
♦ Hot air blower from wiring harness
ss repair set - VAS 1978-
ce
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un
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pt
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es, in part or in w
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rrectness of i
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♦ Nozzle attachment from wiring harness repair set - VAS 1978-
nform
ercia

m
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unit”.
ion in
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te o
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Removing
s
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en
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t.
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op
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Note Prote AG.
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, cables, connections and control units in the vicinity

of the engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

AG. Volkswagen AG d
agen oes
ksw
Golf 2009 ➤ , Golf Cabrioletby
Vol 2012 ➤ , Golf Plus 2009 n➤ ot g, Polo 2010 ➤ , ...
ua
d
oris
e engine (1.2 l engine, 2V, EA 111, rturbocharger)
an
tee - Edition 09.2018
th or
au ac
– Turn potentiometer for
ss temperature adjustment -2- to maxi‐
ce
e
mum heater output (600 °C).
nl
pt
du
an
itte
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– Set two-stage switch for air flow rate -3- to position 3. erm
ab
ility
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wit
WARNING
, is n
h re
hole
spec
When shear-head bolts are heated up, parts of the protective
es, in part or in w
housing will be subjected to a large amount of heat. Wear pro‐
t to the co
tective gloves to avoid injury.
rrectness of i
– Move nozzle of hot air blower towards shear-head bolt.
l purpos
– Switch hot air blower on and heat bolt for approx. 20 to 25

seconds.
nform
ercia
– Unscrew shear-head bolt using grip pliers on bolt head.

m
at
om
i
The procedure for the 2nd shear bolt is identical.
on
c
in t
or
– Then loosen securing nuts -arrows- of control unit bracket.
his
ate
do
priv
cum
or

f
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– 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 catch.
– Attach connectors to engine control unit and lock.
– Tighten securing bolts -arrows- to 10 Nm.

– Fit cover of protective housing.

– Evenly tighten new shear-head bolts -arrows- until bolt heads

shear off.
ded functions”.
– Read event memory, rectify any faults and then clear
AG. Volksevent
wagen AG
memory ⇒ Vehicle diagnostic tester “Guidedagen does
olksw Fault Finding”. not
V y gu
db ara
– Install plenum chamber bulkhead ris ⇒ General body repairs;
e nte
tho
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . eo
au ra
c
ss
ce
e
nl
pt
has been cleared.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
unit - J623- with protective housing (Po‐
satelettronica
lo)
rrectness of i
l purpos
unit”.
Removing
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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– Open line guide -1- and raise catch -2-.

rp
cu
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f
en
ng
– Remove engine control unit from its bracket.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew shear-head bolt -1- using a pair of pliers.

– Turn engine control unit -2- around and also unscrew second
shear-head bolt using a pair of pliers.

– Pull bracket -1- and protective housing -2- off engine control
unit -3- in -direction of arrow-.
– Release connector from engine control unit and pull off.
Installing
– Attach and lock connectors. AG. Volkswagen AG d
agen oes
olksw not
– Push protective housing over enginedcontrolby
V unit. gu
ara
ise nte
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– Install protective housing bracketut with new shear bolts.
ho eo
ra
s a c
s
– Tighten shear-head bolts evenly until bolt head breaks off.
ce
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un
pt
an
d
itte
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erm
ab
– Insert engine control unit into mounting bracket on plenum
ility
ot p
chamber bulkhead until it audibly engages in catch -1-.
wit
is n
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ole,
– Press line into line guide -1- and close.
spec
t to the co
ded functions”.
rrectne
satelettronica
ss
o
cial p
f
has been cleared.
inform
mer
– Install air filter
atio
⇒ “2.2 Removing and installing air filter housing”, page 217
om
n
c
i
or
n
thi
te
sd
va

i
o
pr
cum
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

26 – Exhaust system
1 Exhaust pipes and silencers
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 clamping sleeve 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. lkswage es n
o ot g
byV ua
d ran
ir se tee
⇒ “1.1 Assembly overview
utho - silencers”, page 255 or
a ac
ss
⇒ “1.2 Separating exhaust pipes from silencers”, page 257
ce
le
un
pt
an
⇒ “1.3 Installation position of clamp”, page 259
d
itte
y li
satelettronica
erm
ab
1.1 Assembly overview - silencers
ility
ot p
wit
is n
⇒ “1.1.1 Assembly overview - silencers (Golf, Golf Plus, Touran,
h re
ole,
spec
⇒ “1.1.2 Assembly overview - silencer (Polo)”, page 257
t to the co
1.1.1 Assembly overview - silencers (Golf, Golf Plus, Touran, Golf Cabriolet)
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Exhaust pipes and silencers 255

1 - Bolt
❑ 25 Nm
2 - Bracket
❑ Observe installation po‐
sition
3 - Mounting
4 - Bracket
sition
5 - Bolt
❑ 25 Nm
6 - Rear silencer
❑ Separating centre and AG. Volkswagen AG d
agen
rear silencers Volksw
oes
not
gu
⇒ “1.2 Separating ex‐ ed b y ara
nte
haust pipes from silenc‐
thoris
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ers”, page 257 sa
u ra
c s
ce
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7 - Mounting
nl
satelettronica
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8 - Mounting
y li
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ab
ility
9 - Centre silencer
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wit
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❑ Combined in one unit
h re
with rear silencer as
hole
spec
original equipment. Can
es, in part or in w
be renewed individually
t to the co
for repair purposes.
❑ Aligning exhaust sys‐ rrectness of i
tem free of stress
❑ Separating centre and
l purpos
rear silencers
⇒ “1.2 Separating ex‐
nf
ercia
haust pipes from silenc‐

or
ers”, page 257

m
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atio
om
n in
or c
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te
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t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.
256 Rep. gr.26 - Exhaust system

1.1.2 Assembly overview - silencer (Polo)
1 - Bracket with mounting

2 - Bracket with mounting
3 - Mounting
4 - Bracket
sition
5 - Bolt
❑ 25 Nm
6 - Rear silencer
❑ Combined in one unit AG. Volkswagen AG d
with rear silencer agen
ksw as
oes
ol not
V
original equipment.
ed by Can gu
ara
be renewed
horis individually nte
eo
forsrepair
au
t
purposes. ra
c
s
❑ Aligning exhaust sys‐
ce
le
un
pt
satelettronica
tem free of stress
an
d
itte
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rm
ab
rear silencers
pe
ility
ot
⇒ “1.2 Separating ex‐

wit
, is n
haust pipes from silenc‐ h re

hole
ers”, page 257 spec

es, in part or in w
7 - Bolt
t to the co
❑ 25 Nm
8 - Centre silencer
rrectness of i
❑ Combined in one unit

l purpos
with rear silencer as

original equipment. Can
be renewed individually
nform
ercia
for repair purposes.

m
❑ Aligning exhaust sys‐

com
tion in
tem free of stress

r
te o
thi

s
iva
do
rear silencers
r
rp
cum
⇒ “1.2 Separating exhaust pipes from silencers”, page 257

fo
en
ng
t.
yi Co
9 - Bolt t. Cop py
rig
gh
❑ 25 Nm
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.2 Separating exhaust pipes from silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.

♦ Chain-type pipe cutter - VAS 6254-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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ss c
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un
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spec
t to the co
Or
♦ Pneumatic sabre saw - V.A.G 1523A-
rrectne
Procedure
ss o
cial p
f inform
mer
satelettronica
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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t.
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Cop py
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– Cut through exhaust pipe at cutting point -arrow 2- using chain- cop Vo
by lksw
type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
cted agen
Prote AG.
1523A- .
– Position clamp -4- centrally at side marks when installing, ar‐
rows -1- and -3-.
– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
• Threaded connection faces to rear.
– Aligning rear silencer free of stress ⇒ page 259 .

Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.
Installation position of clamp and specified torque
⇒ “1.3 Installation position of clamp”, page 259 .
1.3 Installation position of clamp
Note
Gradual introduction of clamp with continuous clip.
Specified torque and mounting dimensions of clamping sleeve.
satelettronica
Clamp -A- with 2 individual clips.
Specified torque: 25 Nm.
olksw
Installation dimensions -a- 5 mm (only
swa
gfor
en Afront
G. V clamp)
agen AG
does
k not
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Clamp -B- with continuous clip.sed by ara
nte
ri
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Specified torque: 35 Nmaut ra
c
ss
Installation dimensions -a- 8.5 mm (only for front clamp)
ce
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un
pt
an
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itte
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erm
ab
ility
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ole,
Installation dimension -a- for vehicles with marking -A- on front

spec
exhaust pipe
t to the co
1 - Clamping sleeve
2 - Front exhaust pipe
rrectne
3 - Securing nut
ss
4 - Securing nut
o
cial p
f in
a - Installation dimension
form
mer
atio
A - Marking
om
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c
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Installation position of front clamp

pr
cum
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fo
en
ng
– Install clamp so that end of bolt -arrow- does not extend be‐
t.
yi Co
op
yond lower edge of clamp. C py
t. rig
gh ht
yri
• Threaded connection faces right
p by
o Vo
by c lksw
cted agen
Prote AG.

Installation position of rear clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces to rear.
AG. Volkswagen AG d
agen oes
olksw not
satelettronica
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
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un
pt
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d
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ab
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Exhaust gas cleaning

⇒ “2.2 Removing and installing catalytic converter (Polo)”,
page 265
2.1 Assembly overview - emission control

⇒ “2.1.1 Assembly overview - emission control (Golf, Golf Plus,
⇒ “2.1.2 Assembly overview - emission control (Polo)”,
page 263
2.1.1 Assembly overview - emission control (Golf, Golf Plus, Touran, Golf Cab‐
riolet)

❑ Only grease threads
with “G 052 112 A3”.
satelettronica
❑ “G 052 112 A3” must not
get into the slots on the agen
AG. Volkswagen AG d
oes
probe body. olksw not
byV gu
ara
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❑ Remove and install us‐ orise nte
ing ring spanner for aut
h eo
ra
Lambda probe - 3337- ss c
ce
e
nl
❑ 50 Nm
pt
du
an
itte
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2 - Nut
erm
ab
ility
❑ Renew
ot p
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❑ Coat studs of turbo‐
h re
charger with high-tem‐
hole
spec
perature paste.
es, in part or in w
t to the co
❑ 23 Nm
3 - Catalytic converter with ex‐
haust pipe
rrectness of i
4 - Seal
l purpos
❑ Renew
nf
ercia
5 - Seal
orm
m
❑ Renew
atio
om
n in
c
6 - Exhaust pipe
or
thi
te
sd
a
7 - Clamping sleeve
iv
o
r
rp
cu
❑ Tighten bolted connec‐

o
m
f
en
ng
tions evenly.
t.
yi Co
op py
❑ Installation position and
. C rig
ht ht
rig
specified torque py by
o Vo
⇒ “1.3 Installation posi‐
by c lksw
cted agen
tion of clamp”,
Prote AG.
page 259
8 - Nut
❑ Renew
❑ 25 Nm
9 - Exhaust pipe
❑ With decoupling element.
❑ Do not bend flexible joint more than 10°. Otherwise, it can be damaged.
2. Exhaust gas cleaning 261

wage e
Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus y2009 Volks ➤ , Polo 2010 ➤ , ... s not g
b ua
4-cylinder direct injection engine (1.2 l engine, ris 2V, EA 111, turbocharger) - Edition 09.2018
ed ran
tee
tho
u or
a ac
10 - Mounting ss
ce
le
un
pt
11 - Bolt
an
d
itte
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❑ 25 Nm
erm
ab
ility
ot p
12 - Nut
wit
is n
❑ Renew
h re
ole,
spec
❑ 25 Nm
t to the co
13 - Seal
❑ Renew
rrectne
14 - Nut
❑ Renew
ss
❑ Stage 1: 18 Nm, stage 2: 12 Nm, stage 3: 12 Nm
o
cial p
f inform
mer
Caution
atio
m

o
n
c
i
or
n
thi
te
sd
iva
o
r
order
p
cum
r
fo
satelettronica
en
ng
t.
yi
Co
op py
page 199 . t. C rig
gh ht
pyri by
Vo
o
This ensures that the
c by lksw
cted agen
gasket seats correctly.
Prote AG.
If this 3-stage tightening

sequence is not adhered
❑ Specified torque for stud in cylinder head: 18 Nm (oil before inserting).

15 - Bolt
❑ 20 Nm
16 - Bracket
❑ With charge pressure positioner - V465- .
Note
Turbocharger can only be renewed

complete with exhaust manifold and
charge air controller - V465- .
18 - Heat shield
19 - Bolt
❑ First tighten all securing bolts by hand when installing.
❑ 10 Nm
20 - Heat shield
21 - Bolt
❑ 10 Nm

22 - Bolt
❑ 10 Nm
AG. Volkswagen
23 - Lambda probe after catalytic converter - G130- lkswagen AG do
es n
Vo ot g
❑ Grease only the threads with “G 052 112 A3”; ed by “G 052 112 A3” cannot get into the uaslots on the probe body.
ran
ris tee
❑ If seal is leaking, nip open and renew. ut
ho
or
a ac
❑ Specified torque: 50 Nm ss
ce
e
nl
pt
du
24 - Bolt
an
itte
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erm
ab
ility
ot p
❑ 10 Nm
wit
, is n
h re
25 - Bolt
hole
spec
❑ 25 Nm
es, in part or in w
t to the co
2.1.2 Assembly overview - emission control (Polo)
rrectness of i
l purpos
satelettronica
❑ Grease only the threads
nf
ercia
o
with “G 052 112 A3”;
rm
m
“G 052 112 A3” cannot
atio
m
get into the slots on the

o
n in
c
probe body.
or
thi
te
sd
a
❑ Remove and install us‐

iv
o
r
rp
cu
ing ring spanner for
o
m
f
Lambda probe - 3337-
en
ng
t.
yi Co
op
❑ 50 Nm C py
t. rig
gh ht
yri
2 - Nut
p by
co Vo
by lksw
cted
❑ Renew
agen
Prote AG.
❑ Coat studs of turbo‐

charger with high-tem‐
perature paste.
❑ 23 Nm
3 - Catalytic converter with ex‐
haust pipe
❑ With decoupling ele‐
ment.
❑ Do not bend flexible joint
more than 10°. Other‐
wise, it can be dam‐
aged.
stalling catalytic con‐
verter (Polo)”,
page 265
4 - Seal
❑ Renew
5 - Mounting
6 - Clamping sleeve
❑ Installation position and specified torque ⇒ “1.3 Installation position of clamp”, page 259
❑ Tighten bolted connections evenly.

7 - Mounting
8 - Seal
❑ Renew
9 - Nut
❑ Renew
❑ Stage 1: 18 Nm, stage 2: 12 Nm, stage 3: 12 Nm
Caution
order
page 199 .
This ensures that the agen
AG. Volkswagen AG d
oes
gasket seats correctly. yV
olksw not
gu
d b ara
ise nte
If this 3-stage tightening thor eo
satelettronica
sequence is not adheredss au ra
c
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
❑ Specified torque for stud in cylinder head: 18 Nm (oil before inserting).
wit
is n
h re
ole,
10 - Bolt
spec
❑ 20 Nm
t to the co
11 - Bracket
rrectne
❑ With charge pressure positioner - V465- .

ss o
cial p
f in
Note
form
mer
atio
m
Turbocharger can only be renewed

o
n
c
complete with exhaust manifold and

i
or
n thi
charge air controller - V465- .

te
sd
iva
o
pr
cum
r
13 - Heat shield
fo
en
ng
t.
yi Co
14 - Bolt Cop py
ht. rig
rig ht
py by
co Vo
by lksw
❑ 10 Nm Prote
cted AG.
agen
15 - Heat shield
16 - Bolt
❑ 10 Nm
17 - Bolt
❑ 10 Nm
18 - Lambda probe after catalytic 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.

19 - Bolt
❑ 10 Nm
20 - Bolt
❑ 25 Nm
2.2 Removing and installing catalytic con‐

verter (Polo)
AG. Volkswagen
lksw
agen equipment required
AG do
es n
o ot g
yV u
♦ Lambda
ris
ed probe open ring spanner set - 3337- ran
b a
t ee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
nf
ercia
orm
m
atio
om
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or c
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sd
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en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote
Removing
AG.

– Unscrew upper securing bolt from alternator -2-.
– Then, press alternator down slightly.
– Undo bolts -arrows- and remove heat shield from turbocharg‐
er.

. Volkswagen AG
gen AG doe
swa
Golf 2009 ➤ , Golf yCabriolet
Volk 2012 ➤ , Golf Plus s2009
not ➤ , Polo 2010 ➤ , ...
gu
b ara
4-cylinder direct ris injection engine (1.2 l engine, 2V, EA 111,
e d
nte turbocharger) - Edition 09.2018
ho eo
aut ra
– Unscrew securing
s nuts on turbocharger -arrows-.
s c
ce
e
nl
pt
– Remove noise insulation ⇒ General body repairs, exterior; du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove lambda probe after catalytic converter - G130- -1-.

m
at
om
ion
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– Unscrew securing bolts -1-.

– Press support rings -2- off bolts.
– Loosen securing bolts for clamp -arrows- and push it rear‐

wards.
wards.
Installing
Installation is performed in the reverse order of removal.
Specified torques:
♦ Assembly overview - emission control (Polo)
⇒ “2.1.2 Assembly overview - emission control (Polo)”,
page 263 .
♦ Specified torque for clamp
⇒ “1.3 Installation position of clamp”, page 259 .

28 – Ignition system
1 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 the
checks and repairs, read the event memory and clear it if nec‐
essary .
WARNING
To prevent injuries to persons and/or damage to the injection

and ignition system, the following mustwbe
agenobserved:
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♦ Do not touch or disconnectedignition
by cables when the en‐
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♦ Switch off ignition before
ss connecting or disconnecting in‐ c
jection and ignition system wiring as well as test instru‐
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Note the following if testers and measuring instruments have
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♦ Test instruments and measuring equipment must always
ole,
be secured to the rear seat and operated by a second
spec
person from this location.
t to the co
If the engine is to be turned at starter speed without starting:
rrectne
♦ Remove fuse for fuel pump control unit - J538- from fuse hold‐
er. Fuse assignment ⇒ Current flow diagrams, Electrical fault
ss
finding and Fitting locations

o
cial p
f inform
♦ Remove all spark plug connectors -arrows- from spark plugs

mer
using puller - T10112 A- .

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⇒ “1.1 Assembly overview - ignition system”, page 267

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⇒ “1.2 Removing and installing engine speed sender G28 ”, page

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⇒ “1.3 Test data, spark plugs”, page 269

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1.1 Assembly overview - ignition system
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1. Ignition system 267

1 - Wiring guide
2 - Bolt
❑ 8 Nm
3 - Cover
4 - Connector
❑ Renew O-ring
❑ Location: cylinder head
cover.
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Note markings on ignition ca‐
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♦ D Ignition transformer = ig‐
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nition cable cylinder 1
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♦ B Ignition transformer = ig‐
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♦ C Ignition transformer = ig‐
♦ A Ignition transformer = ig‐
rrectne
8 - Spark plug
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❑ Remove and install with

f in
puller - T10112 A- and
form
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spark plug socket - 3122

atio
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B- .
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❑ Type and electrode gap

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⇒ “1.3 Test data, spark

t
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❑ 25 Nm
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10 - Connector
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11 - Bolt
❑ The specified torque influences the function of the knock sensor.
❑ 20 Nm
12 - Ignition transformer - N152-
Note markings on ignition cables.
♦ D Ignition transformer = ignition cable cylinder 1
♦ B Ignition transformer = ignition cable cylinder 2
♦ C Ignition transformer = ignition cable cylinder 3
♦ A Ignition transformer = ignition cable cylinder 4
13 - Engine speed sender - G28-
❑ Fitting location: on gearbox side below intake manifold.
❑ Removing and installing ⇒ “1.2 Removing and installing engine speed sender G28 ”, page 269
14 - Bolt
❑ 5 Nm
268 Rep. gr.28 - Ignition system

15 - Bolt
❑ 7 Nm
1.2 Removing and installing engine speed

sender - G28-
♦ Bit - T10370-
satelettronica
Removing
Engine speed sender is located under intake manifold on sealing
flange on flywheel end of crankcase.
– Pull off connector -1- of engine speed sender - G28- .
– Remove gasket -2- from cylinder block and remove engine
speed sender - G28- using hexagon bit - T10370- .
Installing
– Install engine speed sender - G28- and tighten securing bolt
to 5 Nm.
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Engine code CBZB, CBZA

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Firing order 1-3-4-2

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Spark plugs
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spec
VW part number 6) 03F 905 600

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Electrode gap 0.7 to 0.8 mm

Specified torque 25 Nm
rrectne
Change interval ⇒ Maintenance ; Booklet ; Time or distance de‐

pendent additional work
ss o
cial p
f inform
6) For current spark plugs please see ⇒ Electronic Parts Catalogue (ETKA)
mer
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Prote AG.

Service: Golf 2009, Golf Cabriolet 2012, Golf Plus 2009, Polo 2010, Touran 2003

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Service

4-cylinder direct injection engine (1.2 l engine, 2V, EA

CBZ CBZ CBZ

Service Department. Technical Information

matter of course, be observed.

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

2.3 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

2.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

2.3 Removing and installing non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi 162

3 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

3.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

6.1 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

1. Engine number/engine data 1

Engine code and engine number can be found on the sticker

2 Rep. gr.00 - Technical data

Engine CBZB CBZA CBZC

Pow‐ k 77/5000 63/4800 66/4800

1. Engine number/engine data 3

bocharger charger charger

4 Rep. gr.00 - Technical data

2.1 Safety regulations for working on fuel

Please note the following when working on fuel supply system:

♦ The fuel system is pressurised! The fuel pressure in the

duced to a residual pressure prior to opening the system;

♦ To release the residual pressure of approx. 7 bar, the con‐

the high pressure. To do this, wrap a clean cloth around

Risk of fire due to escaping fuel.

Risk of damage to the electronic components when discon‐

Always switch off the ignition before disconnecting the battery ⇒

aging until immediately before installing. Do not use parts that

♦ If system is open, do not work with compressed air. Do not

2.2 Releasing high pressure in fuel system

Risk of injury caused by high fuel pressure.

♦ The injection system consists of a high-pressure section

Special tools and workshop equipment required

Risk of injury, avoid skin contact with fuel.

– After the high pressure has been released, the high-pressure

6 Rep. gr.00 - Technical data

♦ If the high-pressure system is not opened immediately, the

and measuring instruments during a

Risk of accidents due to distraction and inadequate securing

Additional danger as a result of front passenger airbag deploy‐

2.4 Safety precautions when working on the

Risk of accidents due to distraction and inadequate securing

Fuel pump is activated by switching on ignition and via driver

nected or the fuel pump fuse must be removed for safety

reasons before opening the fuel system.

8 Rep. gr.00 - Technical data

3 General repair instructions

♦ Carefully cover opened components or seal them if repairs

move the vehicle.