Engine Axx Bpy Bwa Repair Manual Eng

Service
Workshop Manual
Eos 2006 ➤
Golf 2004 ➤
Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger)
Engine ID AXX BPY BWA
Edition 03.2017
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg K0058992820

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) - Edition 03.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Sealing flange and flywheel or drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Assembly overview - sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Renewing crankshaft oil seal (belt pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Removing and installing sealing flange (belt pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Removing and installing crankshaft sealing flange (flywheel end) . . . . . . . . . . . . . . . . . . . . 31
2.5 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Identification of crankshaft upper bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.4 Removing and installing toothed belt, vehicles without split toothed belt guard . . . . . . . . . . 55
1.5 Removing and installing toothed belt, vehicles with split toothed belt guard . . . . . . . . . . . . 66
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.5 Renewing exhaust camshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.6 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.7 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.8 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contents i
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1.1 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.2 Assembly overview - parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.3 Drain oiling filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.5 Removing and installing oil pump with balance shaft gear assembly . . . . . . . . . . . . . . . . 107
1.6 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.7 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.8 Checking oil pressure and oil pressure switch (single pin oil pressure switch) . . . . . . . . . . 113
1.9 Checking oil pressure and oil pressure switch (2-pin oil pressure switch) . . . . . . . . . . . . . . 115
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.1 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 118
1.2 Assembly overview - coolant circulation pump V50 (vehicles with bypass thermostat) . . . . 120
1.3 Assembly overview - coolant circulation pump V50 (vehicles with no bypass thermostat)
........................................................................ 121
1.4 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.5 Coolant hose schematic diagram (vehicles to 06.2005) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.6 Coolant hose schematic diagram (vehicles from 06.2005) . . . . . . . . . . . . . . . . . . . . . . . . 124
1.7 Bypass thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.8 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.10 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.11 Removing and installing coolant thermostat housing with thermostat . . . . . . . . . . . . . . . . 133
1.12 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 134
1.13 Removing and installing radiator, Golf and Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.14 Removing and installing radiator, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.15 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.2 Releasing fuel pressure in high-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3 Fuel tank, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Assembly overview - fuel tank (engine code BPY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Assembly overview - fuel tank (engine codes AXX, BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.4 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4 Fuel tank, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.1 Assembly overview - fuel tank (engine code BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5 Fuel tank, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.2 Assembly overview - fuel tank (engine codes AXX, BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6 Repairing fuel supply system, Golf, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.3 Checking fuel pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7 Repairing fuel supply system, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
ii Contents
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
7.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

7.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7.3 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
8 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.2 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9 Activated charcoal filter system (Golf, Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.1 Assembly overview - activated charcoal filter system (engine codes AXX, BWA) . . . . . . . . 214
9.2 Checking fuel tank breather (engine codes AXX, BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . 215
9.3 Schematic diagram of activated charcoal filter system (engine code BPY) . . . . . . . . . . . . 217
9.4 Assembly overview - activated charcoal filter system (Golf with engine code BPY) . . . . . . 219
9.5 Assembly overview - activated charcoal filter system (Eos with engine code BPY) . . . . . . 220
9.6 Removing and installing activated charcoal filter (engine code BPY) . . . . . . . . . . . . . . . . 221
9.7 Removing and installing fuel system diagnostic pump V144 (Golf with engine code BPY)
........................................................................ 222
9.8 Removing and installing fuel system diagnostic pump V144 (Eos with engine code BPY)
........................................................................ 223
9.9 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
10 Activated charcoal filter system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.1 Assembly overview - activated charcoal filter system (engine codes AXX, BWA) . . . . . . . . 231
10.2 Checking fuel tank breather (engine codes AXX, BWA) . . . . . . . . . . . . . . . . . . . . . . . . . . 232
10.3 Schematic diagram of activated charcoal filter system (engine code BPY) . . . . . . . . . . . . 233
10.4 Assembly overview - activated charcoal filter system (engine code BPY) . . . . . . . . . . . . . . 235
10.5 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.1 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.3 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.5 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.6 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.7 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.1 Assembly overview - charge air cooling, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.2 Assembly overview - sound amplifier, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
2.3 Assembly overview - charge air cooling, Eos, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.4 Removing and installing charge air cooler (Golf, Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.5 Removing and installing charge air cooler, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2.6 Schematic diagram of turbocharging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.3 Assembly overview - engine cover panel/air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.4 Removing and installing engine cover panel/air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1.5 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.6 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1.7 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.8 Removing and installing intake manifold flap motor V157 and intake manifold flap
potentiometer G336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
1.9 Assembly overview - fuel rail (vehicles up to 05.2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Contents iii
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.10 Assembly overview - fuel rail (vehicles from 05.2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

1.11 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
1.12 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.13 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.14 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.15 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
1.16 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.17 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
1.18 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
1.19 Renewing Teflon seal on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3 Engine control unit J623 , Golf, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 300
3.2 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 300
4 Engine control unit J623 (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 304
4.2 Removing and installing anti-theft engine control unit J623 (with locking plate) . . . . . . . . 305
4.3 Removing and installing anti-theft engine control unit J623 (with locking clip) . . . . . . . . . . 309
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.1 Assembly overview - exhaust system; Golf, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.2 Assembly overview - exhaust system, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.3 Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
1.4 Separating centre and rear silencers, Golf, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
1.5 Separating centre and rear silencers, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
1.6 Removing and installing front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . 318
1.7 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1.3 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1.4 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 323
1.5 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
iv Contents
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
00 – Technical data
1 Engine number
(VRL010190; Edition 03.2017)
The engine number (“code letters” and “serial number”) can be
found on the left on the joint between the engine and the gearbox.
The engine code is also stamped on the right side of the cylinder
head and on the cylinder block.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.
1. Engine number 1
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2 Engine data
Code AXX BPY BWA
Manufactured 10.04 ► 03.05 ► 06.05 ►
Exhaust emissions fulfil EU 4 standard, EU ULEV 2 EU 4 standard, EU
2 ddk 2 ddk
Displacement cm3 1984 1984 1984
Power KW at rpm 147/5700 147/5700 147/5700
Torque Nm at rpm 280/2000 280/2000 280/2000
Bore ∅ mm 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8
Compression ratio 10.5 10.5 10.3
Valves per cylinder 4 4 4
RON 98 unleaded1 95 unleaded2) 98 unleaded1
Injection, ignition Motronic MED 9.1 Motronic MED 9.1 Motronic MED 9.1
Type of mixture formation Homogeneous Homogeneous Homogeneous
Knock control 2 sensors 2 sensors 2 sensors
Lambda control 2 probes 2 probes 2 probes
Three-way catalytic converter yes yes yes
Camshaft timing adjustment yes yes yes
Electronic power control yes yes yes
1) Also 95 RON with reduced power
2) Also 91 RON with reduced power
2 Rep. gr.00 - Technical data

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
10 – Removing and installing engine

1 Removing and installing engine
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G 1331-

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Pliers for spring-type clips - VAS 5024A-
♦ Stepladder - VAS 5085-
♦ Engine support - T10012-
♦ Cable tie
Removing engine ⇒ page 4 .
Securing engine to assembly stand ⇒ page 9 .
Installing engine ⇒ page 11 .
Assembly mountings ⇒ page 13
1. Removing and installing engine 3

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.1 Removing engine

Securing engine to assembly stand ⇒ page 9 .
Note
♦ The battery earth must be disconnected for the remaining pro‐

cedure. Therefore, first check whether a coded radio is fitted.
Then obtain anti-theft coding first if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
– Disconnect earth strap at battery with ignition switched off ⇒

Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery.
– Remove engine cover panel/air filter ⇒ page 273 .
– Remove battery and battery tray.
Golf, Eos:
– Remove wiper arms, plenum chamber cover and plenum
chamber bulkhead ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system .
– Pull engine wiring harness connector off engine control unit.
4 Rep. gr.10 - Removing and installing engine

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Release feed-through for engine wiring harness -arrow- and

pull off upwards.
Passat:
– Remove wiper arms and plenum chamber cover ⇒ Rep. gr.
92 .
– Pull engine wiring harness connector off engine control unit.
– Release feed-through for engine wiring harness -arrow- and

pull off upwards.
All vehicles:
– Unscrew cable from alternator at fuse holder -arrow-.
– Unscrew earth cable from longitudinal member -arrow-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Open wiring guide catches on longitudinal member -arrows-.

– Separate all connectors between engine wiring harness and
body and lay engine wiring harness on engine.
Engine code BPY:
WARNING
The fuel system is pressurised!

♦ Wear protective goggles and protective clothing to avoid
injury and contact with the skin.
♦ Before loosening line connections, wrap a cloth around
the connection. Then release pressure by carefully pulling
off line.
– Disconnect lines -1, 2 and 3-. Do this by operating release

buttons.
Engine codes AXX, BWA:
WARNING

off line.
– Disconnect breather line -1- and fuel supply line -2-.

Golf, Eos:
– Disconnect breather line -2-. Pull activated charcoal filter with

hoses upwards out of bracket.
Continued for all vehicles:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Noise insulation .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove left and right wheel housing liner front part.
– Remove charge air hoses -arrows-.
– Unbolt heat shield for right-hand drive shaft -arrows-.

– Remove left and right drive shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Removing and installing drive shafts .
– Remove front exhaust pipe with catalytic converter
⇒ page 318 .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier .
– Drain coolant ⇒ page 126 .
– Empty air conditioning ⇒ Rep. gr. 87 .
– Disconnect refrigerant line -arrow- from air conditioner com‐

pressor.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove refrigerant line from condenser -arrow-.
– Unscrew bolts -1…3- and remove pendulum support.

– Pull off or disconnect all other electrical connections from the
engine and gearbox as necessary and lay open.
– Separate all connecting, coolant, vacuum and intake hoses
from engine.
Vehicles with manual gearbox:
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 .
– Clamp-off hose for pipe/hose line -A- to slave cylinder using

hose clips - 3094- .
– Pull out clip -arrow- for pipe/hose line to stop.
– Pull pipe/hose line out of slave cylinder breather.
Caution
Do not operate clutch pedal any more.
Vehicles with automatic gearbox:

– Disconnect selector lever cable from gearbox ⇒ Automatic
gearbox 09G; Rep. gr. 37 ; Repairing selector mechanism .
Vehicles with DSG®:
– Remove selector lever cable from gearbox: ⇒ Power trans‐
mission; Rep. gr. 34 ; Selector mechanism .
– Unscrew coolant circulation pump - V50- -arrows-.

– Insert engine bracket - T10012- in engine and gearbox jack -
V.A.G 1383 A- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Place engine bracket - T10012- on engine as shown and tight‐

en bolt -1- and nut -2- to approx. 20 Nm.
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
– Unscrew assembly mounting on engine side from engine

bracket -arrows-.
– Unscrew assembly mounting on gearbox side from gearbox

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

♦ Engine and gearbox must be guided carefully when lowering
to prevent damage to the bodywork.
– Carefully lower engine with gearbox.
1.2 Securing engine to assembly stand

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Lifting tackle - 2024 A-

♦ Workshop hoist - VAS 6100-
♦ Engine and gearbox support - VAS 6095-
Secure engine on engine and gearbox support - VAS 6095- to
carry out repairs.
– Disconnect gearbox.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Attach lifting tackle - 2024 A- as follows and lift from engine

and gearbox jack - VAS 6100- using workshop crane - V.A.G
1383 A- .
Pulley end: 2nd hole in hook rail at position 1.
Flywheel end: 1st hole in hook rail at position 7.
Caution
Use securing pins on the hooks and locking pins to avoid dam‐
aging the engine and vehicle.
♦ The positions marked 1…4 on the bar must face towards the
V-belt pulley end.
♦ The holes in the hook rails are counted up from the hook.
– Secure engine to engine and gearbox support - VAS 6095- .
1.3 Installing engine

Assembly mountings ⇒ page 13 .
Installation is carried out in the reverse order. When installing,
note the following:
Caution

sitions.
– Insert new dowel sleeves in the cylinder block for centring the
engine and gearbox.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
– Lightly grease input shaft splines with grease - G 000 100- .
– Check clutch and clutch actuation mechanism and install ⇒
Manual gearbox; Rep. gr. 30 ; Repairing clutch actuation
mechanism .
– When installing engine and gearbox assembly, ensure suffi‐
cient clearance to subframe and radiator.
– Align engine mountings as follows:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ 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-.
– Install pendulum support.
Note
♦ Specified torques for assembly mountings ⇒ page 13 .

♦ Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 .
– Install front exhaust pipe.

– Install right and left drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Removing and installing drive shaft .
– Install selector mechanism and adjust if necessary ⇒ Rep. gr.
34 .
– Reconnect pipe/hose line to slave cylinder breather ⇒ Manual
gearbox; Rep. gr. 30 ; Repairing clutch control .
Vehicles with automatic gearbox:
– Install selector lever cable and adjust if necessary ⇒ Auto‐
matic gearbox 09G; Rep. gr. 37 ; Repairing selector mecha‐
nism .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Assembly overview - Body - front .
– Install plenum chamber bulkhead (Golf and Eos only), plenum
chamber cover and wiper arms ⇒ Electrical system; Rep. gr.
92 ; Window wiper system; Removing and installing window
wiper system .
– Connect battery and observe required procedures after con‐
necting battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Fill coolant system with coolant ⇒ page 126 .
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
– Read all fault memories and clear all fault entries that have
been created during assembly.
– Perform road test.
– Then carry out the vehicle system test again and correct any
faults that have been created.
Note
If the fault memory was cleared, the readiness code must be gen‐
erated ⇒ Vehicle diagnostic tester.“Guided functions”.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Specified torques:
Bolted connection Specified torque
Nuts and bolts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
1.4 Assembly mountings

Engine mounting
A = 20 Nm + 90° (1/4 turn) further 1)
B = 40 Nm + 90° (1/4 turn) further 1)
C = 60 Nm + 90° (1/4 turn) further 1)
1) Renew
Gearbox mounting
1 = 40 Nm + 90° (1/4 turn) further 1)
2 = 60 Nm + 90° (1/4 turn) further 1)
1) Renew
Pendulum support
Note
First bolt pendulum support to gearbox and then to subframe.
A Property class 8.8 = 40 Nm + 90° (1/4 turn) further 1)

A Property class 10.9 = 50 Nm + 90° (1/4 turn) further 1) 2)
B = 100 Nm + 90° (1/4 turn) further 1)
1) Renew

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2)On manual gearboxes, class 10.9 bolts may only be used if

threaded inserts (e.g. HeliCoil) are installed. Identification: shoul‐
der along beginning of thread -arrow-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
Caution
The cylinder bore may not be worked on (reboring, honing,

grinding) may not be carried out using workshop tools! This will
damage the surface of the cylinder bore.
Note
♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renew oil spray jets.
♦ Renew engine oil cooler.
♦ Renew oil filter element.
Assembly overview ⇒ page 15 .

Removing and installing poly V-belt ⇒ page 22
1.1 Assembly overview
1. Dismantling and assembling engine 15

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Part I ⇒ page 17
Part II ⇒ page 18
Part III ⇒ page 20
Part IV ⇒ page 22
16 Rep. gr.13 - Crankshaft group

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.1.1 Part I
1 - Ancillary bracket
❑ Note tightening se‐
quence ⇒ page 18
2 - 23 Nm
3 - 23 Nm
4 - Alternator
❑ Removing and installing
⇒ Electrical system;
Rep. gr. 27 ; Removing
and installing alternator
❑ To facilitate attachment
of alternator, knock
back threaded bushes
for alternator securing
bolts slightly.
5 - 40 Nm
❑ Note tightening se‐
quence ⇒ page 18
6 - Bush
❑ Qty. 2
7 - 25 Nm
8 - Air conditioner compressor
⇒ Air conditioning sys‐
tem; Rep. gr. 87 .
9 - Poly V-belt
❑ Mark direction of rota‐
tion with chalk or felt pen
before removing.
❑ Check for wear
❑ Do not kink
⇒ page 22
10 - Pulley
❑ For poly V-belt.
11 - 20 Nm + 90° (1/4 turn) further
❑ Renew
12 - 23 Nm
13 - Tensioning device for poly V-belt
❑ Swing with open-end spanner to slacken poly V-belt.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Bolt-tightening sequence for ancillary bracket
1.1.2 Part II, vehicles without split toothed belt

guard
Note
Vehicles as of 01/2006 have a new toothed belt guard. Identifi‐

cation: the upper part of the toothed belt guard has no cover
⇒ Item 25 (page 20) and the toothed belt guard is split in the
area of the engine bracket. Assembly overview - vehicles with split
toothed belt guard ⇒ page 20 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - 10 Nm
2 - Upper toothed belt guard
3 - 50 Nm + 180° (1/2 turn) fur‐
ther
❑ Renew
❑ Use counterhold - 3036-
to loosen and tighten.
4 - Camshaft sprocket
❑ Locked in installation
position by Woodruff
key.
5 - 10 Nm
❑ Install with locking fluid
6 - Rear toothed belt guard
7 - Woodruff key
❑ Check for firm seating
8 - 25 Nm
❑ Specified torque for stud
in cylinder head
⇒ Item 27 (page 48)
9 - Semi-automatic belt ten‐
sioner
10 - Coolant pump
⇒ page 129
11 - O-ring
❑ Renew
12 - 25 Nm
13 - Damper wheel
14 - 15 Nm
15 - 35 Nm
16 - Damper wheel
17 - Sealing flange
18 - Diamond-coated washer
❑ Renew
19 - Crankshaft pulley
❑ Contact surface between toothed belt pulley, diamond-coated washer and crankshaft must be free of oil
❑ Can only be fitted in one position
20 - 90 Nm + 90° (1/4 turn) further
❑ Renew
❑ Do not oil
❑ Use counterhold - 3415- to loosen and tighten.
21 - Toothed belt
❑ Mark direction of rotation with chalk or felt pen before removing.
❑ Check for wear

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
22 - Lower toothed belt guard

23 - Engine support
24 - 45 Nm
25 - Cap for toothed belt guard
1.1.3 Part III, vehicles with split toothed belt

guard
Note

⇒ Item 25 (page 20) and the toothed belt guard is split in the area
of the engine bracket. Assembly overview - vehicles without split
toothed belt guard ⇒ page 18 .
1 - 10 Nm
2 - Upper toothed belt guard
3 - 50 Nm + 180° (1/2 turn) fur‐
ther
❑ Renew
❑ Locked in installation
position by Woodruff
key.
5 - 10 Nm
❑ Install with locking fluid
6 - Rear toothed belt guard
7 - Woodruff key
8 - 25 Nm
❑ Specified torque for stud
in cylinder head
⇒ Item 27 (page 48)
9 - Semi-automatic belt ten‐
sioner
10 - Coolant pump
⇒ page 129
11 - O-ring
❑ Renew

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
12 - 25 Nm
13 - Damper wheel
14 - 15 Nm
15 - 35 Nm
16 - Damper wheel
17 - Sealing flange
❑ Renew
❑ Contact surface between toothed belt pulley, diamond-coated washer and crankshaft must be free of oil
❑ Can only be fitted in one position
20 - 90 Nm + 90° (1/4 turn) further
❑ Renew
❑ Do not oil
❑ Use counterhold - 3415- to loosen and tighten.
21 - Toothed belt
❑ Mark direction of rotation with chalk or felt pen before removing.
❑ Check for wear
22 - Lower toothed belt guard
23 - Securing bolts
❑ For lower toothed belt guard
❑ Qty. 7
❑ 8 Nm
24 - Engine support
25 - 45 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.1.4 Part IV
1 - Knock sensor 1 - G61-

❑ To remove, the coolant
thermostat housing
must be removed
⇒ page 133
❑ Gold-plated contacts
2 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
❑ To remove, the oil filter
bracket must be re‐
moved ⇒ page 111
4 - Cable bracket
5 - Bolt
6 - Cable bracket
7 - Bolt
8 - Seal
❑ Renew
9 - Oil filter bracket with attach‐
ments
❑ Dismantling and assem‐
bling ⇒ page 102
10 - 15 Nm + 1/4 turn further
(90°)
❑ Renew
11 - Intake manifold support
12 - Bolt
13 - 10 Nm
14 - Engine speed sender - G28-
15 - Sealing ring
❑ Renew
16 - 15 Nm
17 - Coolant thermostat housing with thermostat
❑ Removing and installing ⇒ page 133
18 - O-ring
❑ Renew
19 - 40 Nm
20 - Ancillary bracket
❑ Tightening sequence ⇒ page 18
1.2 Removing and installing poly-V belt

Special tools and workshop equipment required

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Locking pin - T10060A-
Removing poly V-belt:

– Mark poly V-belt direction of rotation.
Vehicles with activated charcoal filter in engine compartment:
– Unhook activated charcoal filter and swing to side.
All vehicles:
– Turn tensioning device in direction of arrow to relieve tension
on poly V-belt.
– Lock tensioning element using locking pin - T10060A- .

– Remove poly V-belt.
Installing poly V-belt:
– Installation is carried out in the reverse order. When installing,
note the following:
Note
♦ When fitting poly V-belt, check the direction of belt rotation and
make sure the belt is seated properly in the belt pulleys.
♦ Fit poly V-belt for air conditioner compressor last
After completing repairs always:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Start engine and check belt running

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2 Sealing flange and flywheel or drive

plate
Note
Repairing clutch ⇒ Manual gearbox ; Rep. gr. 30 ; Repairing

clutch .
⇒ “2.1 Assembly overview - sealing flange”, page 25

⇒ “2.2 Renewing crankshaft oil seal (belt pulley end)”,
page 26
⇒ “2.3 Removing and installing sealing flange (belt pulley end)”,
page 28
⇒ “2.4 Removing and installing crankshaft sealing flange (fly‐
wheel end)”, page 31
⇒ “2.5 Removing and installing flywheel”, page 32
⇒ “2.6 Removing and installing drive plate”, page 33
2.1 Assembly overview - sealing flange

(90°)
3 - 15 Nm
4 - Sealing ring
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Replacing ⇒ page 26
5 - Sealing flange (belt pulley
end)
❑ Must seat on dowel
pins.
⇒ page 28
❑ Remove sump in order
to remove and install.
6 - Cylinder block
oil pump with balance
shaft gear assembly
⇒ page 107 .
crankshaft
⇒ page 35 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 40
(90°)
❑ Renew
2. Sealing flange and flywheel or drive plate 25

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
8 - Flywheel/drive plate
❑ Removing and installing flywheel ⇒ page 32
❑ Removing and installing drive plate ⇒ page 33
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
10 - Sealing flange with oil seal
❑ Renew only as complete unit
❑ Renew
2.2 Renewing crankshaft oil seal (belt pulley end)

equipment required
♦ Seal puller - 3203-

♦ Counterhold - 3415-
♦ Assembly tool - T10053-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

Remove seal:
– Remove poly V-belt ⇒ page 22 .
– Remove toothed belt:
Vehicles with split toothed belt guard ⇒ page 66 .
Vehicles without split toothed belt guard ⇒ page 55 .
– Remove crankshaft pulley. by locking the toothed-belt pulley
using counterhold - 3415- .
– To guide seal extractor, screw centre bolt into crankshaft up

to the stop by hand.
– Unscrew inner part of oil seal extractor - 3203- nine turns (ap‐
prox. 20 mm) out of outer part and lock with knurled screw.
– Lubricate threaded head of oil seal extractor - 3203- , place it

in position and, exerting firm pressure, screw it into the oil seal
as far as possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
Install seal:
– Remove oil residue from crankshaft journal using clean cloth.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Fit guide sleeve - T10053/1- onto crankshaft journal.

– Slide dry oil seal over guide sleeve onto crankshaft journal.
– Press in oil seal using assembly tool - T10053- and bolt -

T10053/2- (M16 x 1.5 x 60) onto stop.
Note
♦ Contact surface between pulley, diamond-coated washer and

crankshaft must be free of oil.
♦ The centre bolt must be renewed.
♦ Thread and shoulder must be free of oil and grease.
– Fit toothed belt pulley -2- with diamond-coated washer -3- and
tighten bolt -1- hand-tight.
– Lock toothed belt pulley using counterhold - 3415- .

– Tighten new centre bolt to 90 Nm and turn 90° (1/4 turn) further
(turning further can be done in several stages).
Further assembly is basically the reverse of the removal proce‐
dure.
Installing toothed belt and adjusting valve timing.
2.3 Removing and installing sealing flange (belt pulley end)

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Hand drill with plastic brush
♦ Silicone sealant - D 176 404 A2-
♦ Scraper
Removing sealing flange:
– Turn crankshaft back slightly.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove crankshaft pulley. by locking the toothed-belt pulley

using counterhold - 3415- .
– Drain engine oil.
– Remove sump ⇒ page 104 .
– Unscrew sealing flange (belt pulley end).
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
– Remove sealant residue from cylinder block with a flat scraper.
– Cover seal with a clean cloth.
Note
If seal is to be renewed, drive out seal.
– Remove residual sealant on sealing flange using a rotating

plastic brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing sealing flange:
– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

nozzle).
– Apply sealant bead of about 2…3 mm as shown -arrows- to
clean sealing surface of sealing flange.
Note
♦ Before applying sealant bead, cover sealing ring with a clean

cloth.
♦ The sealing compound bead must not be thicker that 2…3 mm.
Otherwise excessive sealing compound will enter the sump
and may block the oil suction pipe strainer.
♦ Check the expiry date of the sealant.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ When fitting sealing flange with oil seal installed use guide
sleeve - T10053/1- .
♦ Leave the sealant to dry for approx. 30 minutes after assem‐
bly. Only then fill with engine oil.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Fit sealing flange immediately and lightly tighten all bolts

-arrows-.
– Tighten sealing flange securing bolts diagonally and alternate‐
ly. Specified torque: 15 Nm
– Remove excess sealant.
– Install sump ⇒ page 104 .
– If necessary, install seal ⇒ page 26 .
Note
♦ Contact surface between pulley, diamond-coated washer and

crankshaft must be free of oil.
♦ The centre bolt must be renewed.
♦ Thread and shoulder must be free of oil and grease.
– Fit toothed belt pulley -2- with diamond-coated washer -3- and
tighten bolt -1- hand-tight.
– Lock toothed belt pulley using counterhold - 3415- .

– Tighten new centre bolt to 90 Nm and turn 90° (1/4 turn) further
(turning further can be done in several stages).
dure.
Installing toothed belt and adjusting valve timing.
2.4 Removing and installing crankshaft

sealing flange (flywheel end)
Removing sealing flange:
– Remove gearbox.
– Remove flywheel.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unbolt sealing flange -arrows-.

Installing sealing flange:
Note
Do not additionally oil or grease the oil seal sealing lip.
– Clean sealing surfaces. They must be free of oil and grease.

– Remove oil residue from crankshaft journal using clean cloth.
– Use protective sleeve supplied when installing. Remove pro‐
tective sleeve first after sealing flange has been slid onto
crankshaft journal. The sealing flange locates on dowel pins.
– Tighten securing bolts to 15 Nm -arrows-.

dure.
2.5 Removing and installing flywheel

♦ Counterhold 3067
Removing:
Note
To avoid damaging the dual-mass flywheel during removal, the

bolts -B- must not be removed using a pneumatic or impact driver.
It is only permissible to remove the bolts -B- by hand.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Turn flywheel -A- so that bolts -B- are centred over holes
-arrows-.
– When removing bolts -B-, make sure that screw heads do not
jam on flywheel.
– Insert counterhold - 3067- in hole on cylinder block.

– Mark position of flywheel in relation to engine.
– Unbolt flywheel.
Installing:
note the following:
– Renew bolts.
Specified torque
Component Nm
Dual-mass flywheel to crankshaft 60 + 90°1)
1) 90° equals a quarter of a turn
2.6 Removing and installing drive plate

♦ Counterhold - VW 558-
♦ Depth gauge
♦ Hexagon bolt M8×45 and two M10 hexagon nuts
Loosening and tightening drive plate:
– Secure counterhold - VW 558- to drive plate with hexagon bolt
M8x45. Insert two M10 hexagon nuts between counterhold
and drive plate.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Installation position of counter hold: -A- to loosen, -B- to tighten.

Installing drive plate:
– Fit drive plate using ring with recesses -1-.

– Fit new bolts -3- and tighten to 30 Nm.
– Check dimension -a- at three points and calculate average.
Specification: 19.5…21.1 mm
Note
Measure through hole in drive plate to milled surface of cylinder

block.
If specification is not attained:
– Remove drive plate again and fit shim -2-. Tighten bolts -3-
again to 30 Nm.
– Tighten bolts to 60 Nm and turn 90° (1/4 turn) further (turning
further can be done in several stages).

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
3 Crankshaft
Note
♦ Before removing crankshaft, make provision for a suitable sur‐

face for storing crankshaft to ensure that sender wheel
⇒ Item 4 (page 36) is not damaged or lies against any other
item.
♦ Secure the engine to engine and gearbox support - VAS 6095-
in order to carry out the repairs.
⇒ “3.1 Assembly overview - crankshaft”, page 35

⇒ “3.1.1 Removing and installing sender wheel”, page 37
⇒ “3.2 Pulling needle bearing out of and driving into crankshaft”,
page 37
⇒ “3.3 Crankshaft dimensions”, page 39
⇒ “3.4 Identification of crankshaft upper bearing”, page 39
3.1 Assembly overview - crankshaft
Note
For vehicles with DSG® a needle bearing must be installed in rear end of crankshaft.
3. Crankshaft 35
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - 65 Nm + 90° (1/4 turn) fur‐

ther
❑ Renew
❑ Threaded along com‐
plete length.
❑ Only tighten to 65 Nm
when measuring crank‐
shaft radial clearance.
Do not turn further.
2 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
3 - 10 Nm + 90° (1/4 turn) fur‐
ther
❑ Renew
4 - Sender wheel
❑ For engine speed send‐
er - G28-
❑ Always renew sender
wheel if securing bolts
have been unscrewed
❑ Can only be installed in
one position (holes are
offset).
⇒ page 37
5 - Crankshaft
❑ Axial clearance, new:
0.07…0.23 mm; wear
limit: 0.30 mm
❑ Check radial clearance with Plastigage, new: 0.017…0.037 mm, wear limit: 0.07 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions ⇒ page 39 .
❑ Removing and installing needle bearing ⇒ page 37
6 - Thrust washers
❑ For bearing 3
7 - Bearing shell for cylinder block
❑ With oil groove.
❑ Classification for ordering spare parts ⇒ page 39 .
❑ Do not interchange used bearing shells (mark).
8 - Sprocket
❑ For oil pump drive.
9 - Bearing shell for bearing cap
❑ Without oil groove.
❑ Do not interchange used bearing shells (mark).

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
3.1.1 Removing and installing sender wheel

– Renew sender wheel -2- each time bolts -1- are loosened.
Note
♦ The second time the countersunk head bolts are tightened, the
contact points in the sender wheel for the countersunk heads
are deformed so far that the bolt head -arrows- seats on the
crankshaft -3-, and the sender wheel is loose under the bolt.
♦ The sender wheel can only be installed in one position, the
holes are offset.
3.2 Pulling needle bearing out of and driving

into crankshaft
Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-
♦ Drift - VW 207 C-
3. Crankshaft 37
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Condition:
• The front edges of the inner puller must not be chipped.
• Gearbox has been removed.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

renewed because it will be damaged when it is pulled out again.
3.3 Crankshaft dimensions

(Dimensions in mm)
Honing dimen‐ Crankshaft Conrod
sion main journal ∅ journal ∅
Basic dimension 54.00 -0.017 47.80 -0.022
-0.037 -0.042
Stage I 53.75 -0.017 47.55 -0.022
-0.037 -0.042
Stage II 53.50 -0.017 47.30 -0.022
-0.037 -0.042
Stage III 53.25 -0.017 47.05 -0.022
-0.037 -0.042
3.4 Identification of crankshaft upper bear‐

ing
Upper bearing shells of the proper thickness are allocated to the
cylinder block in the factory. Coloured dots are used to identify
the thickness of the bearing shells.
Letters on the lower sealing surface of the cylinder block indicate
which bearing thickness is to be used at each position.
S = black
R = red
G = yellow
B = blue
W = white
Note
♦ Arrow points in direction of travel.

♦ If the coloured marks are no longer readable, use blue bearing
shells.
♦ Lower bearing shells with colour mark “yellow” are always
supplied as spare parts.
3. Crankshaft 39
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 40
⇒ “4.1.1 Bearing shells - installation position”, page 41
⇒ “4.2 Separating new conrod”, page 41
⇒ “4.3 Removing and installing pistons”, page 42
⇒ “4.4 Checking pistons and cylinder bores”, page 43
4.1 Assembly overview - pistons and conrods
1 - Conrod bolt
❑ 45 Nm + 90° (1/4 turn)
further
❑ Renew
❑ Oil threads and contact
surface
❑ To measure radial clear‐
ance, tighten to 30 Nm
but not further.
2 - Securing bolt with pressure
relief valve
❑ 27 Nm
❑ Opening pressure: 1.3
to 1.6 bar
3 - Oil spray jet
❑ For piston cooling
4 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod.
❑ Mark cylinder number
-B-
❑ Installation position:
markings -A- face to‐
wards belt pulley end.
5 - Bearing shell
❑ Note installation position ⇒ page 41
❑ Do not interchange used bearing shells.
❑ Axial clearance, new: 0.10 to 0.35 mm, wear limit: 0.4 mm
❑ Check radial clearance with Plastigage: new: 0.02…0.06 mm, wear limit: 0.09 mm. Do not rotate crank‐
shaft when checking radial clearance.
6 - Connecting rod
❑ With industrially cracked conrod cap.
❑ Renew as set only.
❑ Mark cylinder number -B-
❑ Installation position: markings -A- face towards belt pulley end.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
❑ Separating new conrod ⇒ page 41 .
7 - Locking ring
8 - Piston pin
❑ If difficult to remove, heat piston to 60°C.
❑ Remove and install using drift - VW 222 A- .
9 - Piston
❑ Checking ⇒ page 44
❑ Mark installation position and cylinder number.
❑ Arrow on piston crown points to belt pulley end.
❑ Install using piston ring clamp.
❑ Checking cylinder bores ⇒ page 44 .
❑ Piston and cylinder dimensions ⇒ page 43 .
10 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install.
❑ Marking faces to piston crown
❑ Checking ring gap ⇒ page 43 .
❑ Checking ring-to-groove clearance ⇒ page 43 .
4.1.1 Bearing shells - installation position

Bearing shell -1- with oil hole -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Distance -a- must be identical on both sides.
4.2 Separating new conrod

On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:
– Mark which cylinder the conrod belongs to ⇒ page 40 .
– Lightly clamp the conrod in a vice using aluminium vice
clamps, as shown in the illustration.
Note
♦ Only clamp conrod lightly so as not to damage it.

♦ Conrod is clamped below the dashed line.
– Unscrew both bolts -arrows- about 5 turns.
4. Pistons and conrods 41

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Using a plastic hammer, carefully knock against conrod bear‐

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

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

Removing
– Remove cylinder head ⇒ page 50 .
– Remove oil pump with balance shaft gear assembly
⇒ page 107 .
– Mark piston installation position and corresponding cylinder
number.
– Mark conrod installation position and corresponding cylinder
number ⇒ Item 6 (page 40) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
Note
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installing
note the following:
• Specified torque ⇒ page 40 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
♦ If a further tightening angle is specified for certain bolts, these

must be renewed.
♦ Arrow on piston crown points to belt pulley end.
♦ Offset piston ring gaps by 120°.
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position ⇒ Item 9 (page 41) .
– Install conrod bearing cap, noting installation position
⇒ Item 6 (page 40) .
– Install cylinder head ⇒ page 50 .
– Install oil pump with balance shaft gear assembly
⇒ page 109 .
4.4 Checking pistons and cylinder bores

Checking piston ring gap

♦ Feeler gauge
– Push ring squarely from above down into cylinder bore to ap‐
prox. 15 mm from bottom end of cylinder.
Piston ring Ring gap
New Wear limit
Compression rings mm 0.20 to 0.40 0.8
Oil scraper ring mm 0.25 to 0.50 0.8
Checking ring-to-groove clearance

♦ Feeler gauge
– Clean annular groove before check.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Piston ring Clearance

New Wear limit
Compression rings mm 0.06 to 0.09 0.20
Oil scraper ring mm 0.03 to 0.06 0.15
Checking piston

♦ Micrometre 75 - 100 mm - VAS 6071-
– Measure pistons approx 10 mm from the lower edge of skirt,
at 90° to the piston pin axis.
Deviation from nominal dimension: max. 0.04 mm
Checking cylinder bores

♦ Cylinder gauge - VAS 6078-
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
– Deviation from nominal dimension: max. 0.08 mm
Note
Cylinder bores must not be measured when cylinder block is

mounted on a repair stand with engine and gearbox support - VAS
6095- , as measurements may then be incorrect.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Piston and cylinder dimensions
Caution
The cylinder bore may not be worked on (reboring, honing,

grinding) may not be carried out using workshop tools! This will
damage the surface of the cylinder bore.
Piston ∅ Cylinder bore ∅

Basic dimension mm 82.465 1) 82.51
1)Dimensions without graphite coating (thickness 0.02 mm). The
graphite coating wears away.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ If an exchange cylinder head is installed, all the contact sur‐

faces between the supporting elements, roller rocker fingers
and the running surfaces of the camshaft must be oiled before
the cylinder head cover is fitted.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ Renew cylinder head bolts.
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
Assembly overview - cylinder head ⇒ page 46 .

Removing and installing cylinder head ⇒ page 50 .
Removing and installing toothed belt ⇒ page 55
Checking compression ⇒ page 76 .
1.1 Assembly overview - cylinder head
46 Rep. gr.15 - Cylinder head, valve gear

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - 10 Nm
2 - Cylinder head cover
⇒ page 48
3 - Seal
❑ Renew if damaged or
leaking
4 - Crankcase breather valve
5 - Sealing cover
6 - Seal
leaking
7 - 4 Nm
8 - Gasket for cylinder head
cover
leaking
9 - Vacuum pump
10 - 4 Nm
11 - Inlet camshaft control
valve 1 - N205-
⇒ page 92
12 - Sealing ring
❑ Renew
13 - 10 Nm
14 - Cable bracket
15 - Sealing ring
leaking
16 - 10 Nm
17 - Housing
18 - Seal
❑ Renew
19 - Transportation shackle
20 - 25 Nm
21 - 10 Nm
❑ Threaded stud for intake manifold
22 - Partition
23 - Cylinder head gasket
❑ Renew
❑ Observe installation position: Part number to cylinder head
1. Cylinder head 47
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
24 - 10 Nm
25 - Hall sender - G40-
26 - Sealing ring
27 - 10 Nm
❑ Stud for tensioning roller.
28 - 20 Nm
❑ Stud for exhaust manifold.
29 - Cylinder head bolt
❑ Renew
❑ Observe sequence for loosing and tightening ⇒ page 50
❑ Specified torque: 40 Nm + 1/2 turn (180°) further.
Checking cylinder head for distortion:

– Use straightedge 500 mm - VAS 6075- and feeler gauge to
check for distortion at several points.
♦ Max. permissible distortion: 0.1 mm.
– Renew cylinder head if max. distortion is exceeded.
1.2 Removing and installing cylinder head

cover
♦ Spring-type clip pliers - VAS 6499-
♦ Puller - T40039-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing:
– Unscrew bolts -arrows-.
– Remove ignition coils with output stages ⇒ page 323 .

– Separate wires -2, 3 and 4- from cylinder head cover.
Engine code BPY:

– Remove activated charcoal filter line from cylinder head cover
-1-.
– Remove crankcase breather valve from cylinder head cover
-arrows-.
– Unbolt crankcase breather line with heat shield from turbo‐

charger -1-.
– Remove activated charcoal filter line to turbocharger from cyl‐
inder head cover -2-.
– Loosen cylinder head cover working from outside inwards.
– Remove cylinder head cover.
Installing:
note the following:
Note
Renew cylinder head cover gaskets if damaged.
1. Cylinder head 49
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Tighten cylinder head cover in several stages in tightening se‐

quence as shown.
– Ensure the upper toothed belt guard is correctly fitted.
Specified torques ⇒ page 46
Component Nm
Cylinder head cover to cylinder head 10
Toothed belt guard to cylinder block 101)
1) Install with locking fluid
1.3 Removing and installing cylinder head

equipment required
♦ Drip tray - V.A.G 1306-

♦ Puller - T40039-
♦ Pliers for spring-type clips - VAS 5024A-
♦ Bit - T10070-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Caution

sitions.
Removing cylinder head ⇒ page 51

Installing cylinder head ⇒ page 54
1.3.1 Removing cylinder head

• The engine must be no more than warm to touch.
Note
♦ All cable ties which were opened or cut during removal must
be renewed at the same points.
♦ If engine oil is dirty, change oil ⇒ Maintenance ; Booklet 18.1 .
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing battery .
Golf, Eos:
– Remove plenum chamber bulkhead ⇒ Rep. gr. 50 .
All:
– Remove intake manifold ⇒ page 277 .
– Remove right wheel housing liner front part.
– Remove catalytic converter together with front exhaust pipe
⇒ page 318 .
1. Cylinder head 51
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull charge air hose -arrow- off charge air cooler.
– Unscrew bolts -arrows- and remove charge air pipe.

– Pull off or disconnect all other electrical connections from tur‐
bocharger and lay to side.
– Unbolt oil supply line and coolant supply line from turbocharg‐
er -arrows-.
– Remove oil return line -arrows- at turbocharger.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove bolts -1- and -2- and remove support for turbocharg‐
er.
– Remove battery and battery tray.
– Pull off coolant hoses -1- and -2-.

– Pull off or disconnect all the other electrical connections as
necessary from the cylinder head and lay open.
– Unscrew cable retainer and place wiring harness to side.
1. Cylinder head 53
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unscrew coolant flange -arrows-.

– Remove locking pin - T10060A- from tensioner for poly V-belt.
– Remove toothed belt.
– Remove cylinder head cover ⇒ page 48 .
– Observe correct sequence when loosening cylinder head

bolts.
Note
Check that all hoses and other connections to engine, gearbox

and body have been detached.
– Remove cylinder head.
1.3.2 Installing cylinder head
Note
♦ There must be no oil or coolant in the cylinder head bolt pock‐

ets in the cylinder head.
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
♦ Renew cylinder head bolts.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. When doing this, ensure that surfaces are not
scored or scratched (if sand paper is used, grade must not be
less than 100).
– Carefully remove metal particles, emery residue and cloths.
– If crankshaft has since been turned, position cylinder number
1 piston to TDC and then turn crankshaft back slightly.
– Fit new cylinder head gasket. Inscription (Part No.) must be
readable.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Observe centring pins in cylinder block -arrows-.

– Fit cylinder head.
– Insert cylinder head bolts and tighten hand-tight.
– Then tighten cylinder head bolts in indicated sequence as fol‐

lows:
Stage Tighten
1 – Tighten to 40 Nm using torque wrench.
2 – Turn 90° further (1/4 turn) using a rigid wrench.
3 – Turn 90° further (1/4 turn) using a rigid wrench.
– Install cylinder head cover ⇒ page 48 .

– Install toothed belt.
dure.
Filling with new coolant ⇒ page 126 .
1.4 Removing and installing toothed belt,

vehicles without split toothed belt guard
Note

of the engine bracket. Removing and installing toothed belt, ve‐
hicles with split toothed belt guard ⇒ page 66 .
1. Cylinder head 55
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Bracket - T10339-
♦ Wing compensation plate - T40045- only Golf
♦ Adapter - 10 - 222 A /18- only Golf and Eos
♦ Rack - 10 - 222 A /1-
♦ Support - 10 - 222 A-
Note
To remove engine bracket, lift engine a considerable amount with

support bracket - 10-222A- . Disconnect drive shafts from gearbox
to prevent damage through extreme bending angles.
Removing toothed belt ⇒ page 67

Installing toothed belt ⇒ page 63
1.4.1 Removing toothed belt


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
WARNING

off line.
♦ For safety reasons, the fuse for the fuel pump must be
removed before opening the fuel system ⇒ page 140 .
Otherwise, the fuel pump could be activated by the driver
door contact switch.
Engine code BPY:

buttons.

Golf, Eos:
– Disconnect breather line -2-. Pull activated charcoal filter -A-
with hoses upwards out of bracket.
WARNING
Hot steam may escape when expansion tank is opened. Wear

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

again.
1. Cylinder head 57
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Release clamp -arrow- and detach coolant hose. Collect es‐

caping coolant with a cloth.
– Pull off connector -1-. Loosen expansion tank and lay it to side.
– Remove poly V-belt tensioner -A- and secure bracket -

T10339- to both upper threaded holes.
Golf:
– Fit support bracket - 10-222A- with rack - 10-222A/1- and
adapter - 10 - 222 A /18- on wing edges.
– Place the wing compensation plate - T40045- below the right
and left wing edge as shown. Take up weight of engine in its
installation position.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Eos:
adapter - 10 - 222 A /18- on wing edges. Take up weight of
engine in its installation position.
Passat:
– Remove stop buffers for bonnet -arrows-.
– Fit support bracket - 10-222A- with rack - 10-222A/1- on wing

edges as shown. Take up weight of engine in its installation
position.
Caution
Ensure that the edges of the wings are not damaged.

1. Cylinder head 59
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Set camshaft pulley to “TDC” marking by turning crankshaft.

The mark on the camshaft toothed-belt pulley must align with
the arrow on the toothed-belt guard.
– Remove belt pulley with vibration damper.
– Unscrew bolts from toothed belt guard lower part -arrows-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove lower bolt -3-.

Golf, Eos with engine codes BPY and Passat:
– Loosen bolts of right wheel housing liner and push to side.
– Remove bolt -1- through hole in wheel housing.

Note
Following work steps are necessary to raise the engine high

enough.
– Loosen front exhaust pipe with catalytic converter from turbo‐

charger -arrows-.
– Pull catalytic converter from turbocharger.
– Unscrew bolts -2- and -3- at pendulum support.

– Disconnect drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts.
1. Cylinder head 61
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Loosen pipes of air conditioning system from body -arrows-.
Note
Do not open air conditioning system!
– If fitted, unscrew auxiliary heater coolant pipes from engine.
– Remove securing bolts from assembly mounting/engine

bracket -arrows- and remove complete assembly mounting.
Caution
When raising engine using support bracket - 10-222A- , ensure

that no components or hoses are damaged, strained or torn
off.
– Raise engine with support bracket - 10-222A- until the upper

bolts -1- (only engine code AXX, BWA) and -2- of engine
bracket can be loosened and removed.
– Lift engine further, until the engine bracket can be removed
upwards.
– Unscrew remaining bolts from toothed belt guard -arrows- and

remove toothed belt guard from engine.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.4.2 Installing toothed belt
Note
♦ When camshaft is turned, crankshaft must not be at TDC.

Danger of damage to valves and piston crowns.
♦ The engine must be no more than warm to touch.
♦ Specified torques ⇒ page 18 .
– Fit toothed belt on crankshaft pulley (note direction of rotation).

– Secure toothed belt guard lower part with the two lower bolts.
– Install belt pulley/vibration damper using new bolts. Specified
torque: 20 Nm + turn 90° further.
– Turn crankshaft and camshaft to TDC No. 1 cylinder
-arrows-.
– Fit toothed belt in the sequence: tensioning roller, camshaft

pulley, coolant pump and last onto idler roller -arrow-.
1. Cylinder head 63
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
Check that tensioning roller is seated correctly in the cylinder

head.
– Tension toothed belt. To do so, turn hexagon key at the ec‐

centric adjuster clockwise (direction of arrow) until the notch
is above the indicator (toothed belt over-tensioned).
– Then release tension on toothed belt.
– Now tension toothed belt until the notch and the indicator are
aligned.
– Tighten securing nut to 25 Nm.
– Turn crankshaft two turns in engine direction of rotation until
engine is again at TDC. It is important that the last 45° rotation
(1/8 turn) is performed without interruption.
– Check toothed belt tension again. Specification: indicator and
notch must align.
– Check valve timing again.

If the markings do not align:
– Repeat valve timing adjustment.
If the markings align:
– Install toothed belt guard -arrows-.

– Install engine support on cylinder block from above and tighten
bolts hand-tight.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
♦ Note the different bolt lengths. Bolt -3- is about 25 mm shorter

than bolts -1 and 2-.
♦ Golf, Eos with engine code BPY and Passat: The bolt -1- can
be installed through the hole in wheel housing and tightened.
– Lower engine with support bracket - 10-222A- until lower bolt

-3- can be tightened.
– Tighten all bolts to 45 Nm.
– Install engine assembly mounting. Specified torques
⇒ page 13 .
– Tighten bolts for engine assembly mounting and engine brack‐

et hand-tight -arrows-; to do so, bring surfaces into contact
using support bracket - 10 - 222 A- .

et. Specified torque: ⇒ page 13 .
– Remove support bracket - 10 - 222 A- .
– Remove bracket - T10339- and install poly V-belt tensioner.
– Install poly V-belt ⇒ page 22 .
– Reconnect fuel and breather lines. Ensure that plug-in con‐
nectors are properly secured.
– Install coolant expansion tank and check coolant level.
gr. 50 ; Body - front; Noise insulation .
– Reconnect current supply.
– Install engine cover panel/air filter.
1. Cylinder head 65
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.5 Removing and installing toothed belt,

vehicles with split toothed belt guard
Note

of the engine bracket. Removing and installing toothed belt, ve‐
hicles without split toothed belt guard ⇒ page 55 .

equipment required
♦ Bracket - T10339-
♦ Wing compensation plate - T40045- (only Golf)
♦ Adapter - 10 - 222 A /18- (only Golf and Eos)
♦ Rack - 10 - 222 A /1-
♦ Support - 10 - 222 A-
Removing toothed belt ⇒ page 67

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Installing toothed belt ⇒ page 63
1.5.1 Removing toothed belt

WARNING

off line.
Engine code BPY:

buttons.

1. Cylinder head 67
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Golf, Eos:
– Separate breather line -2- and pull activated charcoal filter
-A- with hoses upwards out of bracket.
WARNING

– Open coolant expansion tank to release pressure and close

again.
– Release clamp -arrow- and detach coolant hose. Collect es‐

caping coolant with a cloth.
– Pull off connector -1-. Loosen expansion tank and lay it to side.
– Remove poly V-belt tensioner -A- and secure bracket -

T10339- to both upper threaded holes.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Golf:
– Fit support bracket - 10 - 222 A- with rack - 10 - 222 A /1- and
adapter - 10 - 222 A /18- on wing edges.
– Place the wing compensation plate - T40045- below the right
and left wing edge as shown. Take up weight of engine in its
installation position.
Eos:
adapter - 10 - 222 A /18- on wing edges. Take up weight of
engine in its installation position.
Passat:
– Remove stop buffers for bonnet -arrows-.
1. Cylinder head 69
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Fit support bracket - 10-222A- with rack - 10-222A/1- on wing

edges as shown. Take up weight of engine in its installation
position.
Caution
Ensure that the edges of the wings are not damaged.
– Remove bolts -arrows- and remove toothed belt guard up‐

wards.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Set camshaft pulley to TDC marking by turning crankshaft.

The mark on the camshaft toothed-belt pulley must align with
the arrow on the toothed-belt guard.
– Remove belt pulley with vibration damper.
Note
♦ The TDC markings must align before removing the vibration

damper.
♦ The crankshaft must not be turned until the TDC position is
additionally marked.
– Remove lower bolts from toothed belt guard lower part

-arrows-.
– Mark TDC position -arrow-.
1. Cylinder head 71
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove lower bolt -3-.

Golf, Eos with engine codes BPY and Passat:
– Loosen bolts of right wheel housing liner and push to side.
– Remove bolt -1- through hole in wheel housing.

Note
The following work step is necessary to raise the engine high

enough.
– Unscrew bolts -2- and -3- at pendulum support.
– Remove securing bolts from assembly mounting/engine

bracket -arrows- and remove complete assembly mounting.
Caution
When raising engine using support bracket - 10-222A- , ensure

that no components or hoses are damaged, strained or torn
off.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Raise engine with support bracket - 10-222A- until the upper

bolts -1- (only Golf, Eos with engine codes AXX, BWA) and
-2- of engine bracket can be loosened and removed.
– Unscrew the two upper bolts from toothed belt guard

-arrows- and remove toothed belt guard from engine down‐
wards.
– Now remove engine bracket from engine upwards.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
1.5.2 Installing toothed belt
Note
♦ When camshaft is turned, crankshaft must not be at TDC.

Danger of damage to valves and piston crowns.
♦ The engine must be no more than warm to touch.
♦ Specified torques ⇒ page 20 .
– Set camshaft and crankshaft to TDC markings.

– Fit toothed belt on crankshaft pulley (note direction of rotation).
1. Cylinder head 73
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Fit toothed belt in the sequence: tensioning roller, camshaft

pulley, coolant pump and last onto idler roller -arrow-.
Note
Check that tensioning roller is seated correctly in the cylinder

head.
– Tension toothed belt. To do so, turn hexagon key at the ec‐

centric adjuster clockwise (direction of arrow) until the notch
is above the indicator (toothed belt over-tensioned).
– Then release tension on toothed belt.
– Now tension toothed belt until the notch and the indicator are
aligned.
– Tighten securing nut to 25 Nm.
– Turn crankshaft two turns in engine direction of rotation until
engine is again at TDC. It is important that the last 45° rotation
(1/8 turn) is performed without interruption.
– Check toothed belt tension. Specification: indicator and notch
must align.
– Check valve timing. The markings must align -arrows-.

If the markings do not align:
– Repeat valve timing adjustment.
If the markings align:
– Bring engine bracket to installation position.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Install toothed belt guard from below -arrows-.

– Install belt pulley/vibration damper using new bolts. Specified
torque: 20 Nm + turn 90° further.
– Check valve timing again: The markings must align -arrows-.
– Tighten the two upper bolts of toothed belt guard -arrows-.

– Fit engine bracket on cylinder block and tighten bolts hand-
tight.
Note
♦ Note the different bolt lengths. Bolt -3- is about 25 mm shorter

than bolts -1 and 2-.
♦ Engine code BPY: The bolt -1- can be installed through the
hole in wheel housing and tightened.
– Lower engine with support bracket - 10-222A- until lower bolt

-3- can be tightened.
– Tighten all bolts to 45 Nm.
– Install engine assembly mounting. Specified torques
⇒ page 13 .
1. Cylinder head 75
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

et hand-tight -arrows-; to do so, bring surfaces into contact
using support bracket - 10 - 222 A- .

et. Specified torque: ⇒ page 13 .
– Remove support bracket - 10 - 222 A- .
– Remove bracket - T10339- and install poly V-belt tensioner.
– Reconnect fuel and breather lines. Ensure that plug-in con‐
nectors are properly secured.
– Install coolant expansion tank.
– Install engine cover panel/air filter.
1.6 Checking compression

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Spark plug socket - 3122 B-

♦ Puller - T40039-
♦ Compression tester - V.A.G 1763-
♦ Adapter - V.A.G 1381/5A-
Test specification:
• The engine oil temperature must be at least 30 °C.
• Voltage supply OK.
– Remove ignition coils with output stages ⇒ page 323 .
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
1. Cylinder head 77
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Check compression using compression tester - V.A.G 1763- ,

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .
Note
Using compression tester ⇒ operating instructions .
– Have a second mechanic operate the starter.

– Operate starter until tester shows no further pressure in‐
crease.
Compression pressures:
Engine code New Wear limit Difference be‐
bar pressure bar pressure tween cylin‐
ders
bar pressure
AXX, BWA, 11.0…14.0 7.0 max. 3.0
BPY
– After completing work, read fault memory of engine control
unit, clear all fault entries that have been stored during checks
and repairs.
Note

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2 Valve gear
Note
♦ Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be
used further without reducing service life, provided the cracks
do not exceed a maximum of 0.3 mm in width, or when no more
than the first 4 turns of the spark plug thread are cracked.
♦ Cylinder head and retaining frame must only be renewed to‐
gether.
♦ After installing camshafts wait for approx. 30 minutes before
starting engine. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
♦ Always renew gaskets and seals.
Assembly overview - valve gear ⇒ page 79

Valve dimensions ⇒ page 81
Checking valve guides ⇒ page 81
Renewing valve stem seals ⇒ page 82
Renewing exhaust camshaft seal ⇒ page 86
Removing and installing camshaft adjuster ⇒ page 89
Removing and installing inlet camshaft control valve 1 - N205-
⇒ page 92
Removing and installing camshafts ⇒ page 94
2.1 Assembly overview - valve gear
2. Valve gear 79
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - 50 Nm + 180° (1/2 turn) fur‐

ther
❑ Renew
3 - Sealing ring
❑ Renewing ⇒ page 86
4 - Cylinder head
5 - Valve guide
6 - Valve stem seal
❑ Renewing ⇒ page 82
7 - Valve springs
8 - Upper valve spring plate
9 - Valve cotter
10 - Hydraulic compensation
element
❑ Do not interchange
❑ Oil contact surface
11 - Woodruff key
12 - Exhaust camshaft
❑ Check radial clearance
with Plastigage (roller
rocker fingers not instal‐
led). Wear limit: 0.1 mm.
❑ Runout: max. 0.035 mm
13 - Ladder frame
❑ With integrated camshaft bearings.
❑ Clean sealing surface; reworking not permitted.
❑ Remove sealant residue.
14 - 8 Nm + 1/4 turn further (90°)
❑ Renew
15 - Camshaft adjuster
16 - 20 Nm and 1/8 turn (45°) further
❑ Use camshaft clamp - T10252- to loosen and tighten.
❑ Renew
17 - Inlet camshaft
❑ Check radial clearance with Plastigage; wear limit: 0.1 mm
❑ Runout: max. 0.035 mm
18 - Chain tensioner
❑ Secure with locking pin - T10115- before removing.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
19 - Drive chain
❑ Check for wear
20 - 10 Nm
21 - 10 Nm
23 - Outlet valve
❑ Do not rework. Only lapping in is permitted.
❑ Valve dimensions ⇒ page 81
❑ Checking valve guides ⇒ page 81
24 - Inlet valve
❑ Do not rework. Only lapping in is permitted.
❑ Valve dimensions ⇒ page 81
❑ Checking valve guides ⇒ page 81
25 - Sealing cover
❑ Renew
❑ Removing: pierce centre of cap using screwdriver and lever out.
❑ Installing: Do not use sealant, press in 1…2 mm using thrust piece - 3334- .
2.2 Valve dimensions

Inlet and exhaust valves must not be reworked. Only lapping-in
is permitted.
Dimension Inlet valve Outlet valve
∅a mm 33.75…33.95 27.90…28.10
∅b mm 5.98 5.95
c mm 103.97 101.87
α ∠° 45 45
2.3 Checking valve guides

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
2. Valve gear 81
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Insert new valve in guide. End of valve stem must be at same

height as guide. On account of differing stem diameters, only
use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine rock. Wear limit: 0.8 mm
If the amount of sideways play is exceeded:
– Renew cylinder head.
2.4 Renewing valve stem seals

(With cylinder head installed)

equipment required
♦ Spark plug socket - 3122 B-

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Adapter - T40012-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

♦ Dismantling and assembling device for valve cotters - VAS
5161 A-
♦ Guide plate - VAS 5161/19-
Removing valve stem oil seals ⇒ page 83 .
Installing valve stem oil seals ⇒ page 85 .
2.4.1 Removing valve stem oil seals

– Remove camshafts ⇒ page 94 .
– Remove roller rocker fingers and place onto a clean surface.
When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Remove spark plug with spark plug socket and extension -
3122 B- .
– Secure guide plate - VAS 5161/19- with knurled screws - VAS
5161/12- to cylinder head as shown.
– Set piston of the respective cylinder to “bottom dead centre”.
– Screw adapter - T40012- into spark plug hole and connect to
compressed air supply of at least 6 bar.
– Knock loose sticking valve cotters using punch - VAS 5161/3-

and a plastic-headed hammer.
– Screw snap-in device - VAS 5161/6- with engaging fork - VAS

5161/5- into guide plate - VAS 5161/19- .
– Insert assembly cartridge - VAS 5161/8- into guide plate - VAS
5161/19- .
– Attach pressure fork - VAS 5161/2- to snap-in device - VAS
5161/6- .
2. Valve gear 83
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
On the exhaust side, the pressure fork - VAS 5161/2- must be

hooked in as shown.
– Press down assembly cartridge - VAS 5161/8- . At the same

time, turn knurled screw of assembly cartridge - VAS 5161/8-
clockwise until ends engage in valve cotters.
– Move knurled screw back and forth lightly to press apart valve
cotters and capture them in the assembly piece.
– Release pressure fork - VAS 5161/2- .
– Remove assembly cartridge - VAS 5161/8- .
– Pull off valve stem oil seals with puller 3364.
– If puller 3364 cannot be used due to cramped conditions, drive

out roll pin -arrow- using drift and remove slide hammer.
– Place lower part of puller device 3364 on valve stem seal.

– Insert a punch -1- through hole in lower section of puller.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2.4.2 Installing valve stem seals

– To prevent damage to new valve stem seals -B-, attach plastic
sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem oil seal fitting tool - 3365- and push carefully onto
valve guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Set up disassembly and assembly tool - VAS 5161- as shown.
Inlet side
Exhaust side
2. Valve gear 85
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
♦ If the valve cotters have been removed from the installation

cartridge, they must first be inserted into the insertion device
- VAS 5161/18- .
♦ Press assembly cartridge - VAS 5161/8- onto inserting device
from above and capture valve cotters.
– Press assembly cartridge - VAS 5161/8- down using pressure

fork - VAS 5161/2- and turn knurled screw of assembly car‐
tridge back and forth while pulling upwards.
– Release the pressure fork - VAS 5161/2- with knurled screw
still in pulled-out position.
– Remove removal and installing device for valve cotters - VAS
5161 A- .
dure.
– Installing camshafts ⇒ page 94 .
2.5 Renewing exhaust camshaft seal

equipment required

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Seal puller - 2085-

♦ Adapter - 2085/2-
♦ Two-arm puller - T40001- with claw - T40001/6- and claw -
T40001/7-
♦ Thrust piece - T10353-

Remove seal:
– Loosen securing bolt for camshaft pulley and unscrew approx.
10 mm (use counterhold - 3036- ).
2. Valve gear 87
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull off camshaft toothed belt pulley using puller - T40001- ,

hook - T40001/6- and hook - T40001/7- . The puller - T40001-
is supported by the securing bolt -arrow-.
– Remove securing bolt and camshaft pulley.
– To guide seal extractor, screw adapter - 2085/2- into camshaft

to stop by hand.
– Screw inner part of oil seal extractor - 2085- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
– Lubricate threaded head of oil seal extractor - 2085- , place it

in position and, exerting firm pressure, screw it into the oil seal
as far as possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Install seal:
– Remove oil residue from camshaft journal using a clean cloth.
– Tape over groove in taper of camshaft (e.g. with Sellotape).
– Carefully push dry seal onto camshaft journal.
– Press in oil seal to stop using fitting sleeve - T10071- , thrust

piece - T10353- and a washer -arrow-. To do this, use screw
- T10071/4- .
Note
The thrust piece - T10353- is required for the length compensa‐

tion of the bolt - T10071/4- . Washers can also be used for this
purpose.
– Insert parallel key into camshaft.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Install camshaft sprocket. To tighten bolt, hold camshaft tooth‐

ed belt pulley in position using counterhold - 3036- . Specified
torque: ⇒ page 79 .
Note
♦ When turning the camshaft, the pistons must not be at TDC.

This could otherwise result in damage to valves and pistons.
♦ Ensure the parallel key is correctly seated.

dure.
Filling with new coolant ⇒ page 126 .
2.6 Removing and installing camshaft adjuster

equipment required
2. Valve gear 89
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Bit - T40080-
♦ Camshaft clamp - T10252-
♦ Locking pin - T10115-
♦ Pin wrench - T10020-
Removing camshaft adjuster
– Remove high-pressure pump ⇒ page 289 .
– Remove cylinder head cover ⇒ page 48 .
– Pull off coolant hoses -1 and 2-, unscrew bolt -3- and loosen
coolant pipe from heat shield.
– Unscrew cable retainer -arrow-.
– Remove cover from camshaft adjuster -arrows-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Align mark on camshaft toothed belt pulley with mark on tooth‐

ed belt guard. The indentations -arrows- now point vertically
to each other.
– Fit camshaft clamp - T10252- as shown and secure -arrows-.

– Loosen securing bolt for camshaft adjuster using special
wrench, long reach - T40080- .
Note
Do not cant special wrench, long reach - T40080- ! It could oth‐

erwise »twist«.
– Press chain tensioner together -arrow A- and secure it with

locking pin - T10115- -arrow B-.
– Remove securing bolt from camshaft adjuster and remove
camshaft adjuster together with chain.
Installing camshaft adjuster
• The camshafts are located with the camshaft clamp -

T10252- .
– Fit chain onto camshaft adjuster.
2. Valve gear 91
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Hold camshaft adjuster in front of exhaust camshaft so that

notch -A- and pin -B- align.
– Lay chain over inlet camshaft chain sprocket starting at top

-arrow- without changing its position.
– Slowly turn inlet camshaft using 2-hole pin wrench - T10020-

in direction of arrow -A- until the camshaft adjuster fits on the
camshaft.
Note
If pin does not fit into notch, remove chain and fit it again.
– Tighten camshaft adjuster securing bolt to 20 Nm + 1/8 turn

(45°) further. Use special wrench, long reach - T40080- for this
purpose.
Note
Do not cant special wrench, long reach - T40080- ! It could oth‐

erwise »twist«.
– Remove locking pin - T10115- -arrow B-.

dure.
– Installing high-pressure pump ⇒ page 289 .
2.7 Removing and installing camshaft control valve 1 - N205-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required

♦ TORX bit set - V.A.G 1766-
♦ Ratchet insert 1/4" - VAS 6234-
♦ Pliers for spring-type clips - VAS 5024 A-
Removing
– Pull off connector -1-.
– Loosen wiring harness -2- from retainer.
– Unscrew bolt -3-.
Note
Do not pull inlet camshaft control valve 1 - N205- out of connector.
2. Valve gear 93
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unscrew bolts -arrows- and pull inlet camshaft control valve 1

- N205- out of housing.
Installing
Note
♦ The inlet camshaft control valve 1 - N205- and housing must

be free of dirt and soiling.
♦ Unpack the new inlet camshaft control valve 1 - N205- imme‐
diately prior to installation.
Caution
♦ Ensure the inlet camshaft control valve 1 - N205- is pro‐

tected from knocks and impacts.
– Moisten O-ring with engine oil.

– Carefully insert inlet camshaft control valve 1 - N205- into
housing and press vertically to valve axis to stop by hand.
– Tighten bolts to 4 Nm.
dure.
2.8 Removing and installing camshafts

♦ Two-arm puller - T40001-
♦ Sealant - D 154 103 A1-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing camshafts
Note
♦ The sealing surfaces on the bottom of the retaining frame and

top of the cylinder head must not be reworked.
♦ The camshaft bearings are integrated into the cylinder head
and the retaining frame. The toothed belt must be relieved of
tension before the retaining frame is removed.
♦ Renew camshaft oil seal and sealing cap if retaining frame has
been unfastened.
– Remove camshaft adjuster ⇒ page 89 .

– Loosen securing bolt for camshaft pulley and unscrew approx.
10 mm (use counterhold - 3036- ).
– Pull off camshaft toothed belt pulley using puller - T40001- ,

hook - T40001/6- and hook - T40001/7- . The puller - T40001-
is supported by the securing bolt -arrow-.
– Remove securing bolt and camshaft pulley.
– Remove rear toothed belt guard from cylinder head.
– Loosen retaining frame bolts evenly working from outside in‐
wards and remove retaining frame.
– Carefully lift out the camshafts and place them down on a
clean surface.
2. Valve gear 95
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove old sealant from groove in retaining frame as well as

from sealing surfaces.
– Prevent dirt and residual sealant from entering cylinder head.
Installing camshafts
Note
♦ Sealing surfaces must be free of oil and grease.

♦ The pistons cannot be positioned at TDC.
♦ Ensure that all roller rocker fingers are properly seated on
valve stem ends.
– Oil running surfaces of camshafts.
– Insert camshafts carefully in the camshaft bearings of cylinder

head. Cams -A- of cylinder 4 must face each other.
– Apply even, slightly projecting sealant bead (D 154 103 A1)

into clean groove of retaining frame.
Note
♦ Sealant must not be applied too thickly. If necessary wipe

away excess sealant with a lint-free cloth.
♦ The retaining frame must be positioned and bolted on without
interruption because the sealant begins to harden immediately
when the sealing surfaces come into contact with each other.
– Place retaining frame on cylinder head.

– Tighten bolts lightly in several stages, working from inside out‐
wards.
– Then tighten bolts in the sequence shown to 8 Nm 1/4 (90°)

turn further.
– Drive in sealing cap ⇒ Item 25 (page 81) about 1…2 mm using
thrust piece - 3334- .
– Install camshaft oil seal ⇒ page 86 .
– Install rear toothed belt guard.
– Insert parallel key into camshaft.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Install camshaft sprocket. To tighten bolt, hold camshaft tooth‐

ed belt pulley in position using counterhold - 3036- . Specified
torque: ⇒ page 79 .
Note
♦ When turning the camshaft, the pistons must not be at TDC.

This could otherwise result in damage to valves and pistons.
♦ Ensure the parallel key is correctly seated.

– Install camshaft adjuster ⇒ page 89 .
– Install cylinder head cover ⇒ page 48 .
dure.
2. Valve gear 97
Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
17 – Lubrication
1 Parts of lubrication system
Note
♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renew oil spray jets.
♦ Renew engine oil cooler.
♦ Renewing oil filter.
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter!
Engine oil ⇒ page 98 .

Assembly overview - parts of lubrication system ⇒ page 98
Draining oil filter housing ⇒ page 103 .
Removing and installing sump ⇒ page 104 .
Removing and installing oil pump with balance shaft gear assem‐
bly ⇒ page 107 .
Removing and installing oil pressure switch - F1- ⇒ page 112 .
Checking oil pressure and oil pressure switch (single pin oil pres‐
sure switch) ⇒ page 113 .
Checking oil pressure and oil pressure switch (2-pin oil pressure
switch) ⇒ page 115 .
1.1 Engine oil:

Oil capacities:
With oil filter 4.6 l
without oil filter 4.1 l.
Engine oil specifications ⇒ Maintenance ; Booklet ; Service ta‐
bles .
Change engine oil ⇒ Maintenance ; Booklet ; Engine oil: Drain or
extract; renew oil filter and replenish engine oil .
Markings on oil dipstick:
1 - Max. mark
2 - Min. mark
a - Oil level in max. mark area: do not replenish engine oil.
b - Oil level in middle range: can be topped up with engine oil.
c - Oil level in min. mark area: Replenish with approx. 0.5 l engine
oil!
1.2 Assembly overview - parts of lubrication system
98 Rep. gr.17 - Lubrication

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Part I ⇒ page 100

Part II ⇒ page 101
Part III ⇒ page 102
1. Parts of lubrication system 99

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.2.1 Part 1
1 - 15 Nm
2 - Oil dipstick
❑ Markings ⇒ page 98 .
❑ The oil level must not be
above the max. mark!
3 - Dipstick guide
4 - Guide tube
5 - Adapter
6 - Oil pump with balance shaft
gear assembly
❑ With 12 bar pressure re‐
lief valve
⇒ page 107
(90°)
❑ Renew
❑ Note different bolt
lengths ⇒ page 110 .
8 - 15 Nm
9 - 8 Nm
❑ To secure charge air
pipe.
10 - Oil pan
❑ Clean sealing surface
before fitting.
⇒ page 104
11 - 15 Nm
12 - Oil drain plug
❑ 30 Nm
❑ With captive seal
❑ Renew
13 - Sprocket
14 - 10 Nm
❑ Not for engine code BPY
15 - Protective cap
16 - Oil level and oil temperature sender - G266-
17 - Sealing ring
❑ Renew
❑ Lubricate before installing.
18 - 20 Nm + 1/4 turn further (90°)
❑ Renew

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
19 - Chain guard
20 - Chain
21 - Sealing flange
❑ Must seat on dowel sleeves.
❑ Remove sump in order to remove and install ⇒ page 104 .
❑ Renewing crankshaft oil seal - belt pulley end ⇒ page 26 .
1.2.2 Part 2
1 - Chain guard
2 - Chain
❑ Before removing, mark
running direction (instal‐
lation position) with
paint.
3 - Dowel sleeves
4 - Adapter
5 - Oil pump with balance shaft
gear assembly
❑ Before installing, ensure
that both dowel sleeves
for centring are instal‐
led.
6 - 9 Nm
7 - Cover
❑ Prevents engine oil from
foaming
8 - 40 Nm
9 - 8 Nm
10 - Oil intake tube
❑ Clean strainer if soiled
11 - O-ring
❑ Renew
(90°)
❑ Renew
❑ Note different bolt
lengths ⇒ page 110 .
13 - Outer rotor
❑ Check running surfaces for scoring.
❑ Marking must be visible.
14 - Inner rotor
❑ Check running surfaces for scoring.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
15 - Oil pump cover

16 - Sprocket
17 - 20 Nm + 1/4 turn further (90°)
❑ Renew
18 - Chain tensioner with tensioning rail
❑ Preload when installing ⇒ page 111 .
19 - 15 Nm
1.2.3 Part 3 Oil filter bracket
1 - Tube
❑ For crankcase ventila‐
tion.
2 - Oil pressure switch - F1-
❑ 1.4 bar, black.
⇒ page 112
❑ Specified torque: 20 Nm
❑ With earth wire for oil
pressure switch (only
with single pin oil pres‐
sure switch).
3 - 15 Nm + turn 90° further
❑ Renew
❑ With earth wire for oil
pressure switch (only
with single pin oil pres‐
sure switch).
4 - Bracket
5 - 25 Nm
6 - Engine oil cooler
❑ Observe notes
⇒ page 98
❑ Ensure clearance to ad‐
jacent components
7 - Seal
❑ Renew
8 - 15 Nm + turn 90° further
❑ Renew
9 - Sealing ring
❑ Renew
❑ Coat with oil before inserting
❑ Service tag at top
10 - Dust cap
11 - Oil filter housing
❑ 25 Nm
❑ Remove and install with oil filter tool - 3417-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
❑ Emptying ⇒ page 103
12 - Oil filter element
❑ Empty oil filter housing before removing ⇒ page 103 .
❑ Renew ⇒ Maintenance ; Booklet ; Engine oil: draining or extracting; renewing oil filter and replenishing
engine oil
13 - Baffle plate
14 - Seal
❑ Renew
15 - Oil filter bracket
❑ With pressure relief valve, approx. 4 bar.
16 - Spring-type clip
1.3 Drain oiling filter housing
Note
A valve is opened in the oil filter housing when oil drain adapter -
T40057- is screwed in. When oil drain adapter - T40057- is
removed, the valve closes again.

♦ Oil drain adapter - T40057-
– Unscrew dust cap from oil filter housing -arrow-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Hold hose of oil drain adapter - T40057- in a catch pan and

screw oil drain adapter - T40057- into oil filter housing.
– Allow engine oil to drain off.
1.4 Removing and installing sump

equipment required
♦ U/J extension and socket, 10 mm - 3185-

♦ Bit - T10058-
♦ Scraper

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing sump:
– Drain engine oil.
Note
Please observe disposal instructions!
– Unscrew bolts -arrows-.
– Unscrew securing bolts -1- and -2-.
– Unbolt oil return line -arrows-.

– Pull off connector -1- on vehicles with oil level and oil temper‐
ature sender - G266- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove securing bolts for sump to gearbox -arrows-.

– Loosen sump bolts on flywheel end using T-bar and socket,
10 mm - 3185- and remove with special wrench, long reach -
T10058- .
– Unscrew remaining bolts and remove sump. Loosen sump
with light blows of a rubber headed hammer if necessary.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove remaining sealant from sump e.g. with rotating plastic

brush or similar.
Installing sump:
Note

♦ The sump must be installed immediately and tightened after
applying silicone sealing compound.
– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

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

sealant enters the sump and may block the oil suction pipe
strainer.
♦ If gearbox is removed, sump must align smoothly with cylinder
block.
♦ If gearbox is installed, sump must rest against gearbox.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Put sump in position immediately and tighten bolts as follows:

1 - Tighten all sump/cylinder block bolts only very lightly and di‐
agonally.
2 - Tighten sump/gearbox bolts lightly.
3 - Further tighten all sump/cylinder block bolts lightly using di‐
agonal sequence.
4 - Tighten sump/gearbox bolts to 40 Nm.
5 - Tighten all sump/cylinder block bolts diagonally to 15 Nm.
dure.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.5 Removing and installing oil pump with

balance shaft gear assembly
♦ Locking pin - T10027-

Removing oil pump with balance shaft gear assembly
⇒ page 107
Installing and adjusting oil pump with balance shaft gear assem‐
bly ⇒ page 109
Preloading chain tensioner ⇒ page 111
1.5.1 Removing oil pump with balance shaft

gear assembly
– Pull off chain guard. Release retaining tabs if necessary
through openings -arrows- using a small screwdriver.
– Turn crankshaft to TDC No. 1 cylinder.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
Check that there is a marking on balance shaft sprocket which

aligns with locking hole -arrow-. If there is no mark, mark position
using a waterproof pen. The mark is required for reinstalling.
– Loosen bolt on oil pump sprocket. Counterhold on centre bolt

of vibration damper.
Caution
The balance shaft drive sprocket must not be loosened!
– Relieve tension on chain guide using a screwdriver -arrow-

and lock using a 3 mm hexagon socket head key -1-.
– Remove oil pump sprocket and disengage chain at balance

shaft drive.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Loosen balance shaft gear assembly bolts from inside out‐

wards and remove it. Assembly overview - oil pump with
balance shaft gear assembly ⇒ page 101 .
1.5.2 Removing and installing oil pump with

balance shaft gear assembly
• Chain tensioner preloaded ⇒ page 111
– Place intermediate plate over dowel sleeves of balance shaft
gear assembly as shown -arrows-.
– Install oil pump with balance shaft gear assembly and inter‐
mediate plate. Tighten securing bolts from inside outwards to
15 Nm + 1/4 turn (90°) further.
Note
Note different bolt lengths ⇒ page 110 .
– Turn crankshaft to TDC No. 1 cylinder.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Align marking on balance shaft chain sprocket -arrow- with

locking hole.
– Lock sprocket in this position using locking pin - T10027- . Lay

chain over balance shaft sprocket.
– Install oil pump sprocket and hand-tighten the bolt.
Note
The oil pump sprocket can only be installed correctly in one po‐
sition. For installation, only the oil pump may be turned.
– Remove locking pin - T10027- and hexagon socket head key

-1-. Secure oil pump sprocket. Specified torque 20 Nm + 1/4
turn (90°) further. Counterhold on centre bolt of vibration
damper.
dure.
Bolt allocation for balance shaft gear assembly

A - Hexagon head collar bolt M7x40
B - Hexagon collared bolt M7x70
C - Hexagon head collar bolt M7x90
D - Hexagon head collar bolt M7x55
E - Plug with O-ring

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.5.3 Preloading chain tensioner

– Pre-tension piston by hand -arrow-.
– Press chain guide in direction of arrow and lock in place using

3 mm hexagon socket head key -1-.
1.6 Removing and installing oil filter bracket

Removing:
– Remove coolant pipes ⇒ page 131 .
– Remove engine oil cooler by unscrewing bolts -A- and -B-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull connector -A- off oil pressure switch and unscrew bolt
-B- for earth wire.
– Unscrew securing bolts -arrows- and remove oil filter bracket.
Installing:
– Renew gaskets ⇒ Item 7 (page 102) and
⇒ Item 14 (page 103) .
– Install baffle plate ⇒ Item 13 (page 103) .
– Install oil filter bracket and tighten bolts evenly to 15 Nm + 90°.
– Install engine oil cooler with bracket for coolant pipes.
dure.
1.7 Removing and installing oil pressure

switch - F1-
♦ Jointed wrench 24 mm - T40175-
Removing:
Rep. gr. 50 ; Noise insulation .
– Remove left charge air pipe -item 1 and 2-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove electrical connector -1- from retainer and pull con‐

nector -arrow- off oil pressure switch.
Vehicles with a 1-pin oil pressure switch:
– Unscrew bolt -B- for earth line (ignore arrows).

All vehicles:
– Unscrew oil pressure switch with 24 mm articulated wrench -

T40175-
Installing:
– Insert oil pressure switch by hand and tighten to 20 Nm.
Note
For single pin oil pressure switch, check earth wire is connected.

dure.
1.8 Checking oil pressure and oil pressure

switch (single pin oil pressure switch)
Note
Single pin and 2-pin oil pressure switches have been installed.
Check which type of oil pressure switch has been installed.
Checking oil pressure and oil pressure switch (2-pin oil pressure
switch) ⇒ page 115 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

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

♦ Voltage tester - V.A.G 1527 B-
♦ Adapter set - V.A.G 1594C-
• Engine oil level OK.
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Note
Functional check and repair of the optical and acoustic oil pres‐
sure display: Current flow diagrams ⇒ Vehicle diagnostic tester
“Functions and component selection”.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove oil pressure switch - F1- ⇒ page 112 and screw it into
tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cable from auxiliary measuring
set - V.A.G 1594C- . LED must not light up.
– If the LED lights up, renew 1.4 bar oil pressure switch - F1- .
If LED does not light up:
– Start engine and increase engine revolutions. At 1.2…1.6 bar,
the LED must light up. Otherwise renew oil pressure switch.
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80 °C, the oil pressure should be between 2.7…
4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
– Check strainer in oil suction pipe for contamination/soiling
⇒ Item 10 (page 101) .
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
If no fault is found:
– Renew oil pump and balance shaft gear assembly
⇒ page 107 .
If the specification is exceeded:
– Check oil channels.
– If necessary, replace oil filter bracket with pressure relief valve.
1.9 Checking oil pressure and oil pressure

switch (2-pin oil pressure switch)
Note
Single pin and 2-pin oil pressure switches have been installed.
Check which type of oil pressure switch has been installed.
Checking oil pressure and oil pressure switch (single pin oil pres‐
sure switch) ⇒ page 113 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Oil pressure tester - V.A.G 1342-
♦ Test instrument adapter/DSO (2-pin) - VAS 5256-
♦ Hand multimeter - V.A.G 1526D-
• Engine oil level OK.

• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Note
Functional check and repair of the optical and acoustic oil pres‐
sure display: Current flow diagrams ⇒ Vehicle diagnostic tester
“Functions and component selection”.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove oil pressure switch - F1- ⇒ page 112 and screw it into
tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect test instrument/DSO adapter (2-pin) - VAS 5256- to
oil pressure switch
– Connect Multimeter - V.A.G 1526D- to test instrument/DSO
adapter (2-pin) - VAS 5256- and check for continuity.
• Oil pressure switch must be open below 1.2 bar.
– Start engine and increase engine speed. At 1.2…1.6.bar, the
oil pressure switch must close, otherwise renew oil pressure
switch.
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80 °C, the oil pressure should be between 2.7…
4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
– Check strainer in oil suction pipe for contamination/soiling
⇒ Item 10 (page 101) .
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
– Renew oil pump and balance shaft gear assembly
⇒ page 107 .
– Check oil channels.
– If necessary, replace oil filter bracket with pressure relief valve.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
19 – Cooling
1 Parts of cooling system
WARNING

Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Secure all hose connections with hose clips which conform to
production standard.
♦ Hose clip pliers - VAS 6362- and -VAS 6499- are recommen‐
ded for installing spring-type clips.
♦ Renew gaskets and seals.
♦ The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
Assembly overview - parts of cooling system, engine side

⇒ page 118 .
Assembly overview - parts of cooling system, body side
⇒ page 122 .
Connection diagram for coolant hoses ⇒ page 123
Draining and filling with coolant ⇒ page 126 .
Removing and installing coolant pump ⇒ page 129 .
Removing and installing coolant pipes ⇒ page 131
Removing and installing thermostat housing with thermostat
⇒ page 133
Removing and installing radiator fan - V7- and radiator fan 2 -
V177- ⇒ page 134
Removing and installing radiator ⇒ page 134
Checking cooling system for leaks ⇒ page 137 .
1.1 Assembly overview - parts of cooling system, engine side
118 Rep. gr.19 - Cooling

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Securing bolt
❑ 40 Nm
2 - Securing bolt
❑ 30 Nm
3 - Coolant pipe
4 - Connection hose
5 - O-ring
❑ Renew
6 - Union
7 - 10 Nm
8 - Retaining clip
9 - O-ring
❑ Renew
10 - Radiator outlet coolant -
G62-
11 - Connection hose
12 - Connector
16 - Coolant pipe
17 - 5 Nm
19 - Coolant pipe
20 - 5 Nm
21 - Thermostat housing
❑ With thermostat
❑ Checking thermostat ⇒ Vehicle diagnostic tester “Function and component selection”.
❑ Starts to open at 87 °C
22 - 15 Nm
23 - Coolant pump
24 - 15 Nm
1. Parts of cooling system 119

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.2 Assembly overview - coolant circulation pump - V50- (vehicles with bypass
thermostat)
1 - 3 Nm
2 - Coolant pipe
4 - Coolant line
❑ To turbocharger
6 - Coolant hose
❑ With bypass thermostat
❑ Checking bypass ther‐
mostat ⇒ page 125
7 - 5 Nm
8 - Radiator outlet coolant tem‐
perature sender - G83-
9 - Retaining clip
10 - O-ring
❑ Renew
11 - Lower coolant hose
12 - T-piece
13 - Coolant hose
14 - Bracket
15 - Coolant circulation pump -
V50-
❑ The function can be
checked using final con‐
trol diagnosis ⇒ Vehicle
diagnostic tester.
16 - Coolant hose
17 - 8 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.3 Assembly overview - coolant circulation pump - V50- (vehicles with no by‐
pass thermostat)
1 - 3 Nm
2 - Coolant pipe
4 - Coolant line
❑ To turbocharger
5 - Coolant hose
6 - Bracket
7 - Coolant hose
❑ To cooler opening
V50-
❑ The function can be
checked using final con‐
trol diagnosis ⇒ Vehicle
diagnostic tester.
9 - 8 Nm
10 - 5 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.4 Assembly overview - parts of cooling system, body side
1 - Sealing cover
❑ Checking pressure re‐
lief valve in filler cap
⇒ page 139 .
2 - Connector
3 - 5 Nm
4 - Expansion tank
❑ Checking cooling sys‐
tem for leaks
⇒ page 137 .
5 - Sealing strip
❑ Passat only
6 - O-ring
❑ Renew if damaged
7 - Lower coolant hose
❑ To connection for ther‐
mostat.
8 - 5 Nm
9 - 5 Nm
10 - Radiator fan 2 - V177-
⇒ page 134
11 - Radiator fan - V7-
⇒ page 134
❑ With radiator fan control
unit - J293- .
12 - Connector
13 - Cowling
14 - Radiator/cooler
❑ After renewing, renew entire coolant.
15 - Upper coolant hose
❑ To connection on cylinder head.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.5 Coolant hose schematic diagram (vehicles to 06.2005)
1 - Radiator/cooler
⇒ page 134
❑ If renewed, refill system
with fresh coolant.
V50-
❑ The function of the
pump can be checked
using final control diag‐
nosis ⇒ Vehicle diag‐
nostic tester.
❑ The flow of the coolant
in the run-on phase is
opposite to the flow
shown.
3 - Bypass thermostat
❑ With thermostat
❑ Checking thermostat
⇒ Vehicle diagnostic
tester “Function and
component selection”.
5 - Coolant pump
6 - Cylinder head/cylinder
block
with fresh coolant.
7 - Turbocharger
⇒ page 248
8 - Expansion tank
❑ With cap
❑ Checking pressure relief valve in filler cap ⇒ page 139 .
9 - Heat exchanger for heater
❑ If renewed, refill system with fresh coolant.
10 - Hose
❑ Only for automatic gearbox.
11 - Gear oil cooler
13 - Coolant connection
15 - Intake manifold

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
16 - Hose
❑ Only for auxiliary radiator
17 - Auxiliary radiator
❑ Optional equipment
18 - Hose
❑ Only for auxiliary radiator
1.6 Coolant hose schematic diagram (vehicles from 06.2005)
1 - Expansion tank
❑ With cap
❑ Checking pressure re‐
lief valve in filler cap
⇒ page 139 .
2 - Turbocharger
⇒ page 248
3 - Cylinder head/cylinder
block
with fresh coolant.
5 - Heat exchanger for heater
with fresh coolant.
❑ Only for automatic gear‐
box.
7 - Gear oil cooler
❑ Only for automatic gear‐
box.
9 - Intake manifold
⇒ page 277
10 - Radiator/cooler
⇒ page 134
❑ If renewed, refill system with fresh coolant.
11 - Coolant circulation pump - V50-
❑ The flow of the coolant in the run-on phase is opposite to the flow shown.
❑ The function can be checked using final control diagnosis ⇒ Vehicle diagnostic tester.
❑ With thermostat
❑ Checking thermostat ⇒ Vehicle diagnostic tester “Function and component selection”.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.7 Bypass thermostat

Assembly overview - bypass thermostat
1 - Retaining clip
2 - Bottom part of housing
3 - Working element
4 - Spring
5 - O-ring
6 - Housing, upper part
Checking bypass thermostat

– Remove working element ⇒ Item 3 (page 125) .
– Heat working element in coolant bath.
Opening begins at approx. 75 °C
Fully open at approx. 85 °C
Opening lift approx. 5 mm
Installation position of bypass thermostat
Bypass thermostat for gearbox oil coolant circuit:
The arrow on lower part of housing points towards heat ex‐
changer for heater.
Bypass thermostat for turbocharger coolant circuit:
Arrow on lower part of housing points towards coolant circu‐
lation pump - V50- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.8 Draining and adding coolant

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

♦ Drip tray for workshop hoist - VAS 6208-
♦ Coolant system charge unit - VAS 6096-
♦ Refractometer - T10007 A-
Drain coolant ⇒ page 126 .
Fill with coolant ⇒ page 127
1.8.1 Draining coolant
Note
Observe disposal regulations!

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
WARNING

– Open cap for coolant expansion tank.

– Release plug-in connector -arrow- and remove coolant hose
from radiator.
– Also remove hose from engine oil cooler -arrow-.
1.8.2 Filling with coolant
Caution
Only clean water may be used for mixing. Soiled water does
not have the required quality to ensure the coolant's function.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
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 motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Use ONLY refractometer - T10007A- for determining current
anti-freeze value.
♦ The normal frost protection must be to -25 °C, in countries with
arctic conditions to -36°C. Only when the climatic conditions
demand it, may the frost protection be increased, but never to
more than -48 °C It may, however, be increased only to a
maximum of -48°C. Otherwise, the cooling effect will be im‐
paired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant at this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixture ratios:

Frost Anti-freeze Coolant ad‐ Water1
protection to proportion ditive
-25°C 40 % 3.2 l 4.8 l
-36°C 50 % 4.0 l 4.0 l
1)The quantity of coolant can vary depending upon the vehicle
equipment.
– Reconnect hose and plug-in connector
With cooling system charge unit - VAS 6096- :
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Fill coolant circuit using cooling system charge unit -

VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096.
Without cooling system charge unit - VAS 6096- :
– Slowly fill coolant to upper marking of shaded field on expan‐

sion tank.
– Fit expansion tank cap.
Vehicles with no auxiliary heater
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Run engine until radiator fan - V7- cuts-in.
From heater coolant shut-off valve - N279-
Caution
The auxiliary heater must only be switched on when the coolant

circuit is filled, described as follows:
– Connect vehicle diagnostic, testing and information system -

VAS 5051 A- as follows:
– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary heater” and “Final control diagnosis” one after the
other.
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- .
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed at approx. 2,000
rpm for about 1 minute.
– Run engine until radiator fan - V7- cuts-in.
Continued for all vehicles
WARNING

– Check coolant level and top up as needed. When engine is at

normal operating temperature, the coolant level must be at the
upper mark; when engine is cold, in the middle of the shaded
field.
1.9 Removing and installing coolant pump


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing coolant pump:
WARNING


– Remove toothed belt.
– Unscrew coolant pump securing bolts -1- and remove coolant
pump -2-.
– Remove O-ring -3-.
Installing coolant pump:
note the following:
– Renew O-ring.
– Clean or smooth sealing surface for O-ring.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Moisten new O-ring -3- with coolant.

– Fit coolant pump -2-.
• Installation position: plug in the housing faces downwards.
– Tighten bolts -1- for coolant pump.
– Fill with coolant ⇒ page 126 .
Specified torques:
Component Nm
Coolant pump to cylinder block 15
Toothed belt guard to cylinder block 101)
1) Install with locking fluid
1.10 Removing and installing coolant pipes

Removing:
Golf:
– Remove pipe -A- and hose -B- -arrows-.
All vehicles:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull connector -3- off charge air pressure sender - G31- .

– Unscrew bolts -2- and -4-.
– Loosen clamp -1-, disconnect plug-in connector on charge air
cooler and remove charge air pipe and hose downwards.
– Disconnect electrical connectors -arrows-.
– Detach coolant hoses from coolant pipes -arrows-.
– Pull off hose -A- and unscrew bolt -B-. Remove front coolant
pipe.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Loosen connector -A- from retainer, pull off hose -B- and un‐
screw bolts -C-. Remove rear coolant pipe.
Installing:
Install in reverse order of removal.
1.11 Removing and installing coolant ther‐

mostat housing with thermostat
Note
Checking thermostat ⇒ Vehicle diagnostic tester “Function and

component selection”.
Removing:
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator
– Remove coolant pipes ⇒ page 131 .
– Pull coolant hose -2- off coolant distribution housing, to do this,
pull out retaining clip -1-.
– Unscrew bolts -arrows- and remove thermostat housing with

thermostat from engine.
Installing:
– Clean sealing surface for O-ring.
– Renew O-ring and moisten it with coolant.
– Fit thermostat housing on cylinder block and tighten bolts
evenly to 15 Nm.
– Further assembly is basically the reverse of the removal pro‐
cedure.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.12 Removing and installing radiator fan -

V7- and radiator fan 2 - V177-
Removing radiator fan
– Remove upper securing bolts of cowling -arrows-. Loosen
coolant pipes if necessary, and push to side.
– Separate connector -1- and unscrew lower cowling securing

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

– Unscrew nuts -arrows- and remove fan.
Installing radiator fan:
note the following:
Specified torques ⇒ page 122 .
1.13 Removing and installing radiator, Golf and Eos

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required

Removing radiator
– Remove charge air hoses -arrows-.
– Bring lock carrier into service position ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Lock carrier service position .
– Pull coolant hoses off radiator.
– Remove cowling together with radiator fan ⇒ page 134 .
Note
To prevent damage to condenser or to refrigerant lines and ho‐

ses, ensure that lines and hoses are not stretched, kinked or bent.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove bolts -arrows- from radiator.

– Remove radiator downwards.
Installing radiator
note the following:
– Never reuse old coolant.
1.14 Removing and installing radiator, Passat

equipment required


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing radiator
– Pull coolant hoses off radiator.
– Remove cowling together with radiator fan ⇒ page 134 .
– Remove bolts -arrows- from radiator.
– Lightly fold back radiator and unclip sealing strip -1-.

– Remove radiator upwards.
Installing radiator
note the following:
– Never reuse old coolant.
1.15 Checking cooling system for leaks

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Cooling system tester - V.A.G 1274-

Checking pressure relief valve in filler cap ⇒ page 139 .
• Engine at operating temperature.
Test sequence
WARNING

– Open cap for coolant expansion tank.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Set cooling system tester - V.A.G 1274- with adapter -

V.A.G 1274/8- on expansion tank.
– Use hand pump on tester to create a pressure of about 1.0 bar.
If the pressure drops:
– Find leaks and rectify.
1.15.1 Check pressure relief valve in cap.

– Attach cooling system tester - V.A.G 1274- with adapter -
V.A.G 1274/9- to cap.
– Operate hand pump.
• The pressure relief valve must open at a pressure of 1.4…1.6
bar

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
20 – Fuel supply system

1 Safety precautions
Safety precautions when working on fuel supply system
⇒ page 140 .
Releasing fuel pressure in high-pressure section ⇒ page 141 .
1.1 Safety regulations for working on fuel

supply
WARNING
♦ The fuel pressure in the high-pressure pipe can reach

120 bar! Observe the safety precautions when releasing
pressure in the high-pressure section ⇒ page 141 .
♦ The fuel system is pressurised! Wear protective goggles
and protective clothing to avoid injury and contact with the
skin.
off line.
For reasons of safety, the power supply to the fuel pump must
be interrupted before the fuel system is opened. The fuel pump
would otherwise be activated when the driver's door is opened.
Use the following options to interrupt the power supply:
♦ Disconnect battery
Or
♦ Removing fuse for fuel pump control unit - J538-
Or
♦ Pull off connector from fuel delivery unit flange or fuel
pump control unit - J538-
Caution

sitions.
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
♦ Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
♦ Always switch off the ignition before connecting or discon‐
necting injection or ignition system lines or tester cables.
140 Rep. gr.20 - Fuel supply system

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work starts, the extraction hose of a fume extrac‐
tion system which is switched on must be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
♦ If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
1.2 Releasing fuel pressure in high-pres‐

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

imum approx. 120 bar) and a low-pressure section (approx. 6
bar).
Prior to opening the high-pressure area, e.g. when removing
the high-pressure pump, fuel rail, injectors, a fuel line, or the
fuel pressure sender - G247- , the fuel pressure in the high-
pressure area must be reduced to a residual pressure of
approx. 6 bar. The appropriate procedure is described as fol‐
lows.
1. Safety precautions 141

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull electrical connector off fuel pressure regulating valve -

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

off the fuel pressure regulating valve - N276- , the pressure in
the high-pressure system will drop to approx. 6 bar.
♦ When the high-pressure is reduced, the high-pressure system
must be opened, because the fuel pressure can rise by warm‐
ing up.
– Switch off ignition.
WARNING

off line.
– Wrap a clean cloth around the connection and carefully open

to release residual pressure of approx. 6 bar. Catch the es‐
caping fuel.
– After completing work, read fault memory of engine control
unit, erase all fault entries that have been created by pulling
off connector.
Note

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following “5 rules”:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.
2. Rules for cleanliness 143

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
3 Fuel tank, Golf

⇒ page 140 .
Rules for cleanliness ⇒ page 143 .
Assembly overview - fuel tank (engine code BPY) ⇒ page 144
Assembly overview - fuel tank (engine codes AXX, BWA)
⇒ page 146
Emptying fuel tank ⇒ page 147 .
Removing and installing fuel tank ⇒ page 152 .
3.1 Assembly overview - fuel tank (engine code BPY)
1 - Securing bolt
2 - Earth connection
❑ Ensure firm seating
3 - Vacuum line
❑ To fuel system diagnos‐
tic pump - V144-
4 - 10 Nm
5 - Rivet
6 - Protective plate
❑ Riveted as standard to
bottom clamp
❑ When replacing fuel
tank, hold protective
plate against filler pipe
and rivet to clamp
7 - Cable bracket
❑ Clipped onto protective
plate
8 - 25 Nm
❑ Renew
❑ To secure the securing
straps for the fuel tank,
only bolts with loose
washers must be used.
If different bolts are
used, the securing
straps might twist during
tightening. Bolts ⇒ ET‐
KA (Electronic parts
catalogue) .
9 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G 1383 A- .
10 - Clamping washer
11 - Exhaust system retainer
12 - Securing strap
❑ Observe installation position

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
13 - Heat shield
14 - Supply line
❑ To fuel rail
15 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
16 - Vacuum line
❑ From fuel system diagnostic pump - V144- to intake manifold.
❑ Clipped onto fuel tank.
17 - Breather line
❑ From activated charcoal filter to activated charcoal filter solenoid valve 1 - N80-
❑ Clipped onto side of fuel tank.
18 - Sealing ring
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
19 - Fuel delivery unit
❑ If fuel delivery unit was renewed, adapt engine control unit to fuel pump ⇒ Vehicle diagnostic tester
“Guided Functions”.
❑ Checking fuel pump ⇒ page 183 .
❑ Note installation position on fuel tank ⇒ page 146
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 182
20 - Locking ring 110 Nm
❑ Remove and install using wrench - T10202- .
21 - Return line
❑ blue
22 - Sealing cover
23 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
24 - To activated charcoal filter
25 - Supply line
❑ black
3. Fuel tank, Golf 145

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Installation position of fuel delivery unit

Marking -3- on sender points opposite to direction of travel.
Return line (blue or with blue mark) -1-
Black supply line -2-
3.2 Assembly overview - fuel tank (engine codes AXX, BWA)
1 - Securing bolt
2 - Sealing cover
4 - 10 Nm
5 - Cable bracket
6 - 25 Nm
❑ Renew
used, the securing
tightening. Bolts ⇒ ET‐
KA (Electronic parts
catalogue) .
7 - Fuel tank
gearbox jack - V.A.G
1383 A- .
⇒ page 152
8 - Clamping washer
10 - Securing strap
sition
11 - Heat shield
12 - Supply line
❑ To fuel rail
13 - Fuel filter
❑ Installation position: arrow indicates direction of flow.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
14 - Breather line
15 - Sealing ring
❑ Renew
❑ If fuel delivery unit was renewed, adapt engine control unit to fuel pump ⇒ Vehicle diagnostic tester
“Guided Functions”.
18 - Supply line
❑ black
19 - Return line
❑ blue
20 - Tank flap unit

3.3 Emptying fuel tank


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Fuel extraction unit - VAS 5190-
♦ Special wrench - T10202-
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-

– Note safety precautions before beginning work ⇒ page 140 .
Emptying fuel tank when fuel pump is intact ⇒ page 148 .
Emptying fuel tank if it is more than 3/4 full ⇒ page 150 .
Emptying fuel tank if it is less than 3/4 full ⇒ page 151
3.3.1 Emptying fuel tank when fuel pump is

intact
♦ Adapter for fuel extraction - VAS 5190 /3-
♦ Remote control - V.A.G 1348/3A-
WARNING

off line.
♦ Connect fuel extractor - VAS 5190- earth wire to vehicle
earth.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.
Note
Press in securing ring to release the fuel lines.
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
– Pull 5-pin connector off fuel delivery unit flange.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
Note
This step serves only to have the fuel pump running when the
engine is stopped.
– Remove filler cap from fuel tank filler neck.

– Operate remote control - V.A.G 1348/3A- and shut-off tap on
fuel extractor - VAS 5190- until fuel tank is empty.
Caution
Fuel pump must not run »dry«.
3.3.2 Emptying fuel tank if it is more than 3/4

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

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

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank as much as possible through fuel filler neck.

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

enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel.
♦ Emptying the fuel tank completely ⇒ page 151 .
3.3.3 Emptying fuel tank if it is less than 3/4 full

fuel delivery unit.
WARNING

off line.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Open locking ring using key - T10202- .

– Lift sender flange.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange
⇒ page 179 .
3.4 Removing and installing fuel tank

Removing fuel tank ⇒ page 152

Installing fuel tank ⇒ page 154
3.4.1 Removing
– If necessary, empty fuel tank using fuel extractor - VAS 5190-
⇒ page 147 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
fuel delivery unit.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
– Pull 5-pin connector -arrow- off flange.

– Remove rear right wheel.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner; Rear wheel housing liner .
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
– Separate hoses -1- and -2- (only engine code BPY).

– Unbolt fuel filler neck from body -arrows-.
– Unclip electrical wiring from filler neck.
– Remove centre and rear silencers.
– Remove heat shield for centre and rear silencers.
WARNING

off line.
– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note
♦ Press in securing ring to release the fuel lines.

♦ Vehicles with auxiliary heater, the fuel line of the metering
pump - V54- must also be separated.
♦ On vehicles with engine code BPY the vacuum line (green) for
the fuel system diagnostic pump - V144- must be separated
additionally.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unscrew securing strap and securing bolts. When doing this,

support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Carefully lower fuel tank.
3.4.2 Installing
Install in reverse order of removal. During this step, observe the
following:
♦ To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. If different bolts are used, the
securing straps might twist during tightening.
♦ Install breather lines and fuel lines free of kinks.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Ensure wiring/line connections are secured properly by pulling
back.
♦ Check earth connection on fuel tank and body to filler neck.
♦ If fuel delivery unit was renewed, adapt engine control unit to
fuel pump ⇒ Vehicle diagnostic tester “Guided Functions”.
Specified torques:
Component Nm
Fuel tank to body - M6 bolts 10
Fuel tank to body - M8 bolts 251)
1) Renew

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4 Fuel tank, Eos

⇒ page 140 .
Assembly overview - fuel tank (engine code BWA) ⇒ page 155
Assembly overview - fuel tank (engine code BPY) ⇒ page 157
Emptying fuel tank ⇒ page 159 .
Removing and installing fuel tank ⇒ page 163 .
4.1 Assembly overview - fuel tank (engine code BWA)
1 - Securing bolt
2 - Sealing cover
4 - 11 Nm
5 - Cable bracket
6 - 25 Nm
❑ Renew
used, the securing
tightening.
7 - Fuel tank
1383 A- .
⇒ page 163
8 - Clamping washer
10 - Securing strap
sition
11 - Heat shield
12 - Supply line
❑ To fuel rail
13 - Fuel filter
❑ Fitting position ⇒ page 156
❑ Arrow points in direction of flow.
14 - Breather line
4. Fuel tank, Eos 155

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
15 - Sealing ring
❑ Renew
❑ Only when installing, moisten inside of flange with fuel
18 - Supply line
❑ black
19 - Return line
❑ blue
20 - Tank flap unit

Blue return line -1-
Installation position of fuel filter

Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Securing bolt
3 - 11 Nm
4 - Rivet
❑ Riveted as standard to
bottom clamp
❑ When replacing fuel
tank, hold protective
plate against filler pipe
and rivet to clamp
6 - Cable bracket
❑ Clipped onto protective
plate
7 - 25 Nm
❑ Renew
used, the securing
tightening.
8 - Fuel tank
1383 A- .
⇒ page 163
9 - Clamping washer
11 - Securing strap
❑ Observe installation position
12 - Heat shield
13 - Supply line
❑ To fuel rail
14 - Fuel filter
❑ Arrow points in direction of flow.
15 - Vacuum line
❑ green
❑ From fuel system diagnostic pump - V144- to intake manifold.
16 - Breather line
❑ white

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
❑ From activated charcoal filter to activated charcoal filter solenoid valve 1 - N80-
17 - Sealing ring
❑ Renew
❑ Only when installing, moisten inside of flange with fuel
20 - Return line
❑ blue
21 - Sealing cover
22 - Tank flap unit
23 - Supply line
❑ black


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Location of fuel filter

Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.



intact

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
WARNING

off line.
earth.
fuel with a cloth.
Note
fuel delivery unit.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull 5-pin connector off fuel delivery unit flange.

Note
engine is stopped.

Caution

full
Caution

part of the body.
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At a distance of -a- = 820mm from the end of the hose, mark
extraction hose with insulating tape -arrow-.
– Push extraction hose into fuel tank until marking -arrow- on
hose coincides with filler neck.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Empty fuel tank as far as possible.

Note

♦ If the fuel tank has to be drained fully, proceed as follows:
⇒ page 162 .

fuel delivery unit.
WARNING

off line.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

⇒ page 179 .


4.4.1 Removing
– If necessary, empty fuel tank using fuel extractor - VAS 5190-
⇒ page 159 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
fuel delivery unit.
Note
– Pull 5-pin connector -arrow- off flange.

– Remove stiffener braces -A and B- ⇒ Running gear; Rep. gr.

42 ; Removing and installing stiffener braces .
– Remove heat shield for centre silencer.
– Unclip wire from filler neck -1-.

– Separate breather line -3- (only engine code BPY).
– Unbolt filler neck from body -2-.
Only engine code BPY

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Disconnect breather line -1- (white) and vacuum line -2-

(green) for the fuel system diagnostic pump - V144- behind
fuel tank, press securing ring inwards for this.
Continued for all vehicles
WARNING
The fuel system is pressurised! Wear protective goggles and

protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note

♦ On vehicles with engine code BPY the vacuum line (green) for
the fuel system diagnostic pump - V144- must be separated
additionally.
– Remove securing strap and securing bolts -arrows-. When

doing this, support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
– Carefully lower fuel tank.
4.4.2 Installing fuel tank

Install in reverse order of removal. During this step, observe the
following:
♦ To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. If different bolts are used, the
securing straps might twist during tightening.
♦ Do not interchange supply line and return line (return line blue,
supply line black).
♦ Ensure that line connections are tight.
– Install stiffener braces ⇒ Running gear; Rep. gr. 42 ; Remov‐
ing and installing stiffener braces .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Specified torques:
Component Nm
Fuel tank to body - M6 bolts 10
Fuel tank to body - M8 bolts 251)
1) Renew

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
5 Fuel tank, Passat

⇒ “1 Safety precautions”, page 140
⇒ “2 Rules for cleanliness”, page 143
⇒ “5.1 Assembly overview - fuel tank (engine code BPY)”,
page 167
⇒ “5.2 Assembly overview - fuel tank (engine codes AXX, BWA)”,
page 169
⇒ “5.3 Emptying fuel tank”, page 170
⇒ “5.4 Removing and installing fuel tank”, page 174
1 - Fuel line
2 - Sealing cover
3 - Securing bolt
4 - Tank flap unit
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
5 - Breather line
6 - Vacuum line
❑ To protective plate for
filler neck.
❑ Ensure good contact to
body
9 - Clamps
10 - Fuel tank
port using engine and gearbox jack - V.A.G 1383 A- .
5. Fuel tank, Passat 167

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
11 - Securing straps
12 - Heat shield
14 - 25 Nm
❑ To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If different
bolts are used, the securing straps might twist during tightening. Bolts ⇒ ETKA (Electronic parts cata‐
logue) .
❑ Renew
15 - Sealing ring
❑ Renew
If fuel delivery unit was renewed, adapt engine control unit to fuel pump ⇒ Vehicle diagnostic tester “Guided
Functions”.
❑ Removing and installing fuel gauge sender ⇒ page 199 .
17 - 8 Nm
❑ For filler neck.
19 - Suction-jet pump
20 - Flange with fuel filter
❑ With 6.2 bar pressure relief valve

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
5.2 Assembly overview - fuel tank (engine codes AXX, BWA)
1 - Fuel line
2 - Sealing cover
3 - Securing bolt
4 - Tank flap unit
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
5 - Breather line
7 - Fuel tank
1383 A- .
⇒ page 174
8 - Securing straps
9 - Heat shield
11 - 25 Nm
straps for the fuel tank, only bolts with loose washers must be used. If different bolts are used, the securing
straps might twist during tightening. Bolts ⇒ ETKA (Electronic parts catalogue) .
❑ Renew
12 - Sealing ring
If fuel delivery unit was renewed, adapt engine control unit to fuel pump ⇒ Vehicle diagnostic tester “Guided
Functions”.
❑ Removing and installing fuel gauge sender ⇒ page 199 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
14 - Suction-jet pump
15 - Flange with fuel filter
❑ With 6.2 bar pressure relief valve



intact

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
WARNING

off line.
earth.
fuel with a cloth.
Note
fuel delivery unit.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull connector -A- off fuel delivery unit flange.

– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive (+).
Note
engine is stopped.

Caution

full
Caution

part of the body.
– Use insulating tape to mark the extraction hose -arrow- at a

distance of -a- = 990 mm from the end of the hose.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Push extraction hose into fuel tank until marking -arrow- on

hose coincides with filler neck.
Note
♦ The shaft piece -1- is not used.

♦ There is a flap on the bottom end of the fuel filler neck in the
fuel tank, this must not be damaged by the extraction hose.
Therefore, only push the hose in as far as the marking.
– Drain fuel tank as much as possible through fuel filler neck.

Note

The tank may be removed while containing remaining fuel.
♦ Emptying the fuel tank completely ⇒ page 173 .

fuel delivery unit.
WARNING

off line.
– Pull connector -A- and fuel line -B- off flange.
Note
♦ Press in securing ring to release fuel line.

♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Caution
Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.

⇒ page 196 .


5.4.1 Removing fuel tank
Note
The rear axle must be lowered to remove the fuel tank.

If necessary, empty fuel tank using fuel extractor - VAS 5190-
⇒ page 170 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
fuel delivery unit.
– Pull 5-pin connector off flange.
Note

Engine code BPY:
– Pull breather lines and vacuum line -arrows- off activated

charcoal filter.
– Pull breather line and pressure retention valve -arrows- off ac‐
tivated charcoal filter.
Note
Grasp securing ring (grey) on pressure retention valve and pull

valve off upwards.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unclip electrical wire on filler neck.

– Unbolt filler neck from body -arrows-.
WARNING

off line.
Note

♦ The vacuum line is only installed for engine code BPY.
– Separate breather line (white), vacuum line (green) and fuel

line (black) at union.
– Support rear axle using engine and gearbox jack - V.A.G 1383
A- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove securing bolts -arrows- and lower rear axle.
– Unscrew securing bolts for securing straps. First support fuel

tank with engine and gearbox jack - V.A.G 1383 A- .
– Slowly lower fuel tank.
Note
The filler neck must be “guided out” between body and rear axle.
To do this, take the fuel tank off engine and gearbox jack - V.A.G
1383 A- with the assistance of a second mechanic.
5.4.2 Installing fuel tank

– With the aid of a second mechanic, guide the filler neck in be‐
tween rear axle and body. Then place fuel tank on engine and
gearbox jack - V.A.G 1383 A- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Raise fuel tank slowly up to installation position and secure it

in place.
Note
To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. If different bolts are used, the se‐
curing straps might twist during tightening. Bolts ⇒ ETKA (Elec‐
tronic parts catalogue) .
– Secure rear axle to body again ⇒ Body; Rep. gr. 42 .

The remaining installation steps are carried out in the reverse se‐
quence of removal. During this step, observe the following:
back.
Specified torques:
Component Nm
Fuel tank to body 25 Nm 1)
Filler neck to body 8 Nm + 90° (1/
4 turn) further
1) Renew

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
6 Repairing fuel supply system, Golf,

Eos
Note
♦ Fuel hoses on the engine must only be secured with spring-

type clips which conform to the production standard.
♦ Hose clip pliers - VAS 6362- and -VAS 6499- are recommen‐
ded for installing spring-type clips.

⇒ page 140 .
Comply with rules for cleanliness ⇒ page 143 .
Removing and installing fuel delivery unit ⇒ page 179 .
Removing and installing fuel gauge sender - G- ⇒ page 182 .
Check fuel pump ⇒ page 183 .
6.1 Removing and installing fuel delivery

unit
6. Repairing fuel supply system, Golf, Eos 179

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing:
Caution
Condition:
• Fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
Note
♦ When replacing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
♦ If necessary, empty fuel tank using fuel extractor - VAS 5190-
⇒ page 147 .
♦ Note safety precautions before beginning work ⇒ page 140 .
♦ Observe rules for cleanliness ⇒ page 143 .

– Remove cover -1- with fuel pump control unit -2- from fuel de‐
livery unit.
WARNING

off line.
– Pull off connector -arrow-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull fuel lines -1- and -2- off the flange.
Note

– Open locking ring using key - T10202- and raise flange slightly.
– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
♦ If delivery unit is to be renewed, drain old delivery unit before

disposal.
♦ Observe disposal regulations!
Installing:
– Fit gasket.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Coat inner side of seal with fuel.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Press sealing flange down against spring pressure, and move

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

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

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Reconnect connector -arrow-.

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

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

sender - G-
Note
Gradual introduction of fuel delivery units with modified fuel gauge

senders - G- .
Removing (old version):

– Remove fuel delivery unit ⇒ page 179 .
– Note colour co-ordination of cables for reinstallation.
– Release connectors -arrows- and pull off connectors
-1, 2 and 3-. Then bend back locking lugs of connectors.
– Lift retaining tabs -4- and -5- using a screwdriver, and pull off
fuel gauge sender - G- downwards -arrow-.
Installing:
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press upwards until it engages.
– Connect connectors -1…3-. Observe colour co-ordination.
– Check connectors are secured properly by pulling.
– Install fuel delivery unit ⇒ page 179 .
Removing (new version):

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull fuel gauge sender - G- slightly to side and upwards at the

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

-arrows- must also be pushed to the side slightly.
– Release electrical connectors -1 to 3- and pull them off. Then

bend back locking lugs of connectors.
Installing:

– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
6.3 Checking fuel pump - G6-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Pressure gauge - VAS 6550-

♦ Multimeter - V.A.G 1715-
♦ Measuring container, capacity 2 litres
Check function and voltage supply ⇒ page 184 .
Check fuel pressure ⇒ page 187 .
Checking holding pressure ⇒ page 189 .
Checking fuel delivery rate ⇒ page 190 .
Checking current draw ⇒ page 194 .
6.3.1 Checking function and voltage supply

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

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
• Fuel pump control unit - J538- OK.

Test sequence
Note
Function of fuel pump is checked using final control diagnosis.
– Connect vehicle diagnostic tester as follows:

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

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

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

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
fuel delivery unit.
– First check that the connector -arrow- is fitted securely by pull‐

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

off line.
– Pull fuel lines -1- and -2- off the flange.
Note


– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump defective, renew fuel delivery unit ⇒ page 179 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
6.3.2 Checking fuel pressure
Note
The fuel pump is activated via the final control diagnosis.
WARNING
Fuel supply line is pressurised. Wear protective goggles and

Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
fuel with a cloth.
Note
Press in securing ring to release fuel line.
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 189 .
– Check return line between fuel filter and fuel pump for kinks
and blockages.
– Pressure limit valve in fuel filter is defective. Renew fuel filter.
If specification is not obtained
– Check fuel pressure upstream of fuel filter; proceed as follows:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull fuel supply line -arrow- off fuel filter.
– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
– Switch ignition on and activate the fuel pump with the final
control diagnosis function.
– While the fuel pump is operating, close the shut-off tap -A-.
Pressure must rise to at least 7.0 bar. When 7.0 bar is reached,
open shut-off tap again immediately.
If pressure has risen:
– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐
tive. Renew fuel filter.
If pressure does not rise:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
6.3.3 Checking holding pressure

• Fuel pressure OK and pressure tester - VAS 6550- connected.
Test sequence
pressure.
– Watch pressure drop on pressure gauge. Pressure must re‐
main above 3.0 bar for 10 minutes.
If the pressure drops further:
pressure.
– After pressure has built up, close cut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
flow.
If the pressure does not drop now:
Note
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.
– Check fuel pipe to high-pressure pump for leaks.

– Renew high-pressure pump ⇒ page 289 .
If the pressure drops again:
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel supply line to fuel filter for leaks.
If no fault is found on the fuel line:
– Check pressure retention valve in fuel delivery unit. Proceed
as follows:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
pressure.
– After pressure has built up, close cut-off tap -A-.

If the pressure drops:
– Pressure retention valve in fuel pump defective; renew fuel
delivery unit ⇒ page 179 .
If the pressure does not drop:
– Pressure retention valve in fuel filter is OK, pressure limiting
valve in fuel filter is defective. Renew fuel filter.
6.3.4 Checking fuel delivery rate

fuel delivery unit.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

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

– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal clamp in the engine
compartment.
Note
engine is stopped.
WARNING

off line.
fuel with a cloth.
Note

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

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

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

shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of
shut-off tap.
– Drain measuring container.
– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect multimeter - V.A.G 1715-
to outputs -1 and 5- of test instrument/DSO adapter 5-pin -
VAS 5565- .
– Operate remote control for 30 seconds while measuring volt‐
age at fuel pump.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm3/30 s
**) Voltage at fuel pump with engine not running and pump run‐
ning.
Reading example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 580cm3/30 s.
– Check fuel lines for possible restrictions (kinks) or blockages.
– Remove cap from fuel filler neck and repeat check. If fuel de‐
livery rate is now reached, check fuel tank breather.
If reading again does not match specification:
– Check fuel filter (proceed as follows):
WARNING

off line.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

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

fuel delivery unit.

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

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

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


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
7 Repairing fuel supply system, Passat
Note
♦ Fuel hoses on the engine must only be secured with spring-

type clips which conform to the production standard.
♦ Spring-type clip pliers - VAS 6499- or space saving hose clip
pliers - VAS 6362- are recommended for installation/removal
of spring-type clips.

⇒ page 140 .
Removing and installing fuel delivery unit ⇒ page 196 .
Checking fuel pump ⇒ page 200 .
Assembly overview - high-pressure pump ⇒ page 287 .
Removing and installing high-pressure pump ⇒ page 289
7.1 Removing and installing fuel delivery

unit

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing:
Caution
Condition:
• Fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
Note
♦ The fuel filter and the pressure relief valve are fitted in the
flange of the fuel delivery unit.
♦ When replacing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
♦ If necessary, empty fuel tank using fuel extractor - VAS 5190-
⇒ page 170 .

fuel delivery unit.
WARNING

off line.
– Pull 5-pin connector -A- and fuel line -B- off flange.
Note

7. Repairing fuel supply system, Passat 197

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Caution
– Lift flange.
– Separate coupling -A- and remove suction-jet pump -B-. Do

this by pressing lugs -arrows- together.
Note
Press in safety ring of coupling -A- to release fuel line.
– Pull seal and fuel delivery unit out of opening of fuel tank.
Note
♦ If delivery unit is to be renewed, drain old delivery unit before

disposal.
♦ Observe disposal regulations!
Install fuel delivery unit:
Caution
Do not bend float arm of fuel gauge sender - G- when installing.
– Insert fuel delivery unit (without suction-jet pump) into fuel

tank.
– Install suction-jet pump -B- and reconnect coupling -A-. Check

coupling is secured properly by pulling.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Push flange onto fuel delivery unit.
Note
Ensure hoses are secured correctly.
– Now pull seal -A- over the flange and seat it in the opening of
the fuel tank.
– Moisten seal lightly with fuel and push flange into fuel tank.
– Observe installation position: Marking -A- points towards rear

of vehicle.
– Tighten locking ring using wrench - T10202- . Specified torque
⇒ Item 21 (page 168) .
The remaining installation steps are carried out in the reverse se‐
quence of removal. During this step, observe the following:
♦ The -arrow- on the cover points forwards.

♦ Fuel lines are to be installed free of kinks.
back.
7.2 Removing and installing fuel gauge

sender - G-
Removing:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull fuel gauge sender - G- slightly to side and upwards at the

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

-arrows- must also be pushed to the side slightly.
– Release electrical connectors -1 to 3- and pull them off. Then

bend back locking lugs of connectors.
Installing:

– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
7.3 Checking fuel pump
Note
When replacing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Pressure gauge - VAS 6550-

♦ Multimeter - V.A.G 1715-
♦ Measuring container, capacity 2 litres
7.3.1 Checking function and voltage supply

• Battery voltage at least 11.5 V.
• Fuse for fuel pump on fuse holder OK ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
• Fuel pump control unit - J538- OK.
• Fuel pressure sender for low-pressure - G410- OK.
Note
Function of fuel pump is checked using final control diagnosis.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Connect vehicle diagnostic tester as follows:

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

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

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

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
fuel delivery unit.
– First check that connector -A- is securely seated by pulling the

connector without pressing the catch. If connector was not in‐
serted correctly, repeat functional check of fuel pump.
unit for damage.
WARNING

off line.
– Pull off fuel line -B- from the flange.
Note

Caution
– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
7.3.2 Checking fuel pressure

Test conditions:
• Function of fuel pump has been checked ⇒ page 201 .
Test sequence
Note safety precautions before beginning work ⇒ page 140 .
– Observe rules for cleanliness ⇒ page 143 .
WARNING

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

adapter - VAS 6550/1- and -VAS 6550/2- .
pressure.
If fuel pressure is OK, check holding pressure ⇒ page 205 .
– Pressure limiting valve in flange defective, renew flange with
fuel filter ⇒ page 196 .
– Check fuel lines for possible restrictions (kinks) or blockages.
– Renew flange with fuel filter and pressure limiting valve
⇒ page 196 .
– Repeat check.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
7.3.3 Checking holding pressure

Prerequisites for check
• Fuel pressure OK and pressure tester - VAS 6550- connected.
Test sequence
pressure.
If the pressure drops further:
pressure.
– After pressure has built up, close cut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
flow.
If the pressure does not drop now:
Note
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.
– Check fuel pipe to high-pressure pump for leaks.

– Renew high-pressure pump ⇒ page 289 .
If the pressure drops again:
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel line to flange for leaks.
If no fault is found on the fuel line:
Pressure limiting valve in flange defective or pressure retention
valve in fuel pump leaking.
– First replace flange with fuel filter and repeat pressure reten‐
tion check. If leak is still present, renew fuel delivery unit.
7.3.4 Checking fuel delivery rate

– Remove seat bench ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
fuel delivery unit.

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

Note
engine is stopped.
WARNING

off line.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
fuel with a cloth.
Note

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

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

shut-off tap.
– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, connect multimeter - V.A.G 1715- to
wires -1- and -5- of adapter - VAS 5565- in addition.
– Operate remote control for 30 seconds while measuring volt‐
age at fuel pump.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm3/30 s
**) Voltage at fuel pump with engine not running and pump run‐
ning.
Reading example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 580 cm3/30 s.
– Check fuel line for possible restrictions (kinks) or blockages.
– Remove cap from fuel filler neck and repeat check. If fuel de‐
livery rate is now reached, check fuel tank breather.
– Remove fuel delivery unit and check filter strainer for soiling.
– If no fault is found here either, renew flange with fuel filter.
– Repeat check.
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Measure current draw of fuel pump ⇒ page 208 .
7.3.5 Checking current consumption

fuel delivery unit.

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

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Measure current draw of fuel pump.
• Specification: max. 10 amps
Note
♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.
If the current draw is exceeded:


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
8 Electronic power control (EPC)

Function of EPC system ⇒ page 210 .
Assembly overview - accelerator module ⇒ page 210
Removing and installing accelerator pedal module ⇒ page 211
8.1 Function of EPC system

With the EPC system, the throttle valve is not operated by a cable
from the accelerator There is no mechanical connection between
the accelerator and the throttle valve.
The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in one housing) connected to the accelerator.
The position of the accelerator (driver's requirement) is a main
input value for the engine control unit.
The throttle valve is actuated by an electric motor (throttle valve
positioner) in the throttle valve control module over the full engine
speed and load range.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit.
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator position sender. That is, when the
accelerator is depressed halfway, the throttle valve positioner
opens the throttle valve by the same amount. The throttle is then
approximately half open.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator position sender.
This means that the throttle valve can already be completely open
even though the accelerator is only depressed half way. This has
the advantage of preventing throttling losses at the throttle valve.
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP…),
the engine control unit calculates the optimal throttle valve open‐
ing angle for the respective situation.
This also results in significantly improved consumption and ex‐
haust emission values under certain load conditions.
“EPC” is a system comprising all components which contribute to
determining, controlling or monitoring the position of the throttle
valve, e.g. accelerator position sender, the throttle valve control
module, the electronic power control warning lamp and the engine
control unit.
8.2 Assembly overview - accelerator module

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
- G79- with accelerator posi‐
tion sender 2 - G185-
❑ Not adjustable.
❑ The accelerator position
sender passes the posi‐
tion of the accelerator
on to the engine control
unit.
❑ -A- openings for release
tool .
⇒ page 211
3 - 10 Nm
4 - Cover
8.3 Removing and installing accelerator

pedal module
♦ For left-hand drive vehicles: release tool - T10238-
Or
8. Electronic power control (EPC) 211

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ For right-hand drive vehicles: release tool - T10240-

Removing
– Remove steering column cover -arrows-.
– Prise out cap -3- using a screwdriver.

– Remove bolts -2-.
– Release connector -1- -arrow- and pull off accelerator module.
– Push release tool - T10238- into holes as shown to stop and

remove accelerator module.
Installing

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Reconnect connector -1- to accelerator module -4-. Lock con‐

nector -arrow-.
– Press accelerator module onto securing pins -5-.
– Insert centring pin -6- into hole in vehicle floor.
– Secure accelerator module with bolt -2- and install cap -3-.
– Install steering column trim.

Specified torque:
Component Nm
Accelerator module to body 10
8. Electronic power control (EPC) 213

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
9 Activated charcoal filter system (Golf,

Eos)
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Spring-type clip pliers - VAS 6340- or hose clip pliers - VAS
6362- are recommended for installation of spring-type clips.
Definition of colours or colour markings on the plug-in connectors

and wiring for fuel, vacuum and breather.
Application Colour
Fuel supply black
Fuel return blue
Breather white, beige
Vacuum green
Assembly overview - activated charcoal filter system (engine co‐
des AXX, BWA) ⇒ page 214
Checking fuel tank breather (engine codes AXX, BWA)
⇒ page 215 .
Schematic diagram of activated charcoal filter system (engine
code BPY) ⇒ page 217
Assembly overview - activated charcoal filter system (Golf with
engine code BPY) ⇒ page 219
Assembly overview - activated charcoal filter system (Eos with
engine code BPY) ⇒ page 220
Removing and installing activated charcoal filter (engine code
BPY) ⇒ page 221
Removing and installing fuel system diagnostic pump - V144-
(Golf with engine code BPY) ⇒ page 222
Removing and installing fuel system diagnostic pump - V144-
(Eos with engine code BPY) ⇒ page 223
Checking fuel system for leaks (engine code BPY) ⇒ page 223
9.1 Assembly overview - activated charcoal filter system (engine codes AXX,
BWA)

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Activated charcoal filter

❑ Location: on right in en‐
gine compartment.
2 - Pressure retention valve
with connecting hose
3 - Connection hose
❑ From fuel tank
4 - 10 Nm
5 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit
6 - Connection hose
❑ To intake manifold
7 - Bracket
❑ For activated charcoal
filter.
8 - Vent hole
9.2 Checking fuel tank breather (engine co‐

des AXX, BWA)
♦ Hand operated vacuum pump - VAS 6213-
9. Activated charcoal filter system (Golf, Eos) 215

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Adapter set - V.A.G 1318/17A-
♦ Adapter - V.A.G 1318/20–1-
Test specification:
• Ignition must be switched off.
Test sequence
– Pull off breather line -1-. To do this, press release button.
– Then connect hand vacuum pump - VAS 6213- -1- to breather

line -2- to activated charcoal filter as shown.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for “vacuum”.
– Operate hand vacuum pump - VAS 6213- several times. There
must be no development of vacuum.
If vacuum builds up:
– Check breather hole on activated charcoal filter
⇒ Item 8 (page 215) for soiling and clean if necessary.
If vacuum does not build up:
– Seal breather hole -arrow- and operate vacuum pump again

several times. Vacuum must build up.
If vacuum does not build up:
– Renew activated charcoal filter.
9.3 Schematic diagram of activated charcoal filter system (engine code BPY)

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Separation point
❑ Front right in engine
compartment under
coolant expansion tank
2 - Breather line
❑ white or white marking
❑ From activated charcoal
filter to activated char‐
coal filter solenoid valve
1 - N80-
❑ Installation position: On
right under vehicle
❑ Secured to fuel tank.
3 - Breather line
❑ green or green marking
❑ From engine to fuel sys‐
tem diagnostic pump -
V144-
❑ Installation position: On
right under vehicle
❑ Secured to fuel tank.
❑ Front right on fuel tank in
vicinity of fuel filter
5 - Filler neck
6 - Breather line
❑ From filler neck to acti‐
vated charcoal filter
7 - Air filter
❑ For fuel system diagno‐
sis pump - V144- .
8 - Fuel system diagnostic
pump - V144-
❑ Fitting location: In rear right wheel housing beneath liner
❑ Checking fuel system for leaks ⇒ page 223
9 - Connecting cable
❑ From fuel system diagnostic pump - V144- to activated charcoal filter.
❑ Clip onto bracket
❑ Location: down in spare wheel well
❑ Rear right on fuel tank
12 - Exhaust turbocharger
13 - Brake servo
14 - Vacuum pump
15 - Non-return valve
❑ Location: Arrow points in direction of flow

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
16 - Activated charcoal filter solenoid valve 1 - N80-

❑ Checking ⇒ Vehicle diagnostic tester
17 - Dual non-return valve
18 - Throttle valve module - J338-
Removing and installing ⇒ page 286
9.4 Assembly overview - activated charcoal filter system (Golf with engine code
BPY)
1 - Fuel tank
2 - Breather line
❑ Behind wheel housing
liner
3 - Breather line
❑ On underbody.
4 - Breather line
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
❑ Press release button to
pull off
5 - 8 Nm
❑ Location: down in spare
wheel well
⇒ page 221
❑ On underbody.
liner
9 - 3 Nm
10 - Air filter
sis pump - V144- .
12 - Bracket
sis pump - V144- .
13 - 2 Nm
14 - 6 Nm
15 - Fuel system diagnostic pump - V144-
❑ Fitting location: In rear right wheel housing beneath liner

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
❑ Checking fuel system for leaks ⇒ page 223
16 - Connector
17 - Vacuum line
❑ From intake manifold
9.5 Assembly overview - activated charcoal filter system (Eos with engine code
BPY)
1 - Hose retainer
2 - Breather line
❑ To remove and install,
remove bumper
3 - Air filter
sis pump - V144- .
4 - 6 Nm
5 - Bracket
sis pump - V144- .
6 - 3 Nm
7 - Retaining plate
8 - Rubber mounting
9 - 8 Nm
pump - V144-
❑ Location: Behind rear
right wheel housing
⇒ page 222
❑ Checking fuel system
for leaks ⇒ page 223
11 - Hose clamp
13 - Breather line
liner
14 - Fuel tank
15 - Breather line
❑ To activated charcoal filter solenoid valve 1 - N80-
❑ Press release button to pull off
16 - Breather line
❑ On underbody.
❑ Location: down in spare wheel well
❑ Activated charcoal filter / fuel system diagnostic pump - V144-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
19 - Vacuum line
20 - 2 Nm
9.6 Removing and installing activated char‐

coal filter (engine code BPY)
Removing:
– Remove heat shield -arrows-.
– Position engine and gearbox jack - V.A.G 1383 A- below rear
axle to support.
– Loosen securing bolts of rear axle -arrows- and unscrew them

approx. 20 mm.
– Lower rear axle slowly using engine and gearbox jack -
V.A.G 1383 A- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull off breather lines -A- by pressing release tab.

– Remove bolts -B-.
Note
A reinforcement plate is installed in the Eos. To loosen and tighten

securing bolts -B-, use T-bar and 10 mm socket - 3185- .
– Release retaining tabs -A- using a screwdriver. Turn activated

charcoal filter approx. 90° to right -B- and remove activated
charcoal filter.
Installing:
note the following:
– Fit breather lines so that they engage audibly.
– Install rear axle ⇒ Running gear; Rep. gr. 42 .
Specified torque
Component Nm
Activated charcoal filter to body 8
9.7 Removing and installing fuel system di‐

agnostic pump - V144- (Golf with engine
code BPY)
Removing:
pairs, exterior; Rep. gr. 66 .
– Detach vacuum line -1-.
– Separate electrical connector -2-.
– Pull off breather line -3- by pressing release tab.
– Unscrew nuts -arrows-.
– Detach diagnostic pump with bracket.
Installing:
note the following:
• The breather line -3- must engage audibly.
– Install rear right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 .
Specified torques: ⇒ page 219

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
9.8 Removing and installing fuel system di‐

agnostic pump - V144- (Eos with engine
code BPY)
Removing:
– Pull off vacuum line -1-, breather line (air outlet) -2- and breath‐
er line (air inlet) -3-.
– Unscrew nuts -arrows-.
– Remove diagnostic pump with bracket and disconnect elec‐
trical connector.
Installing:
note the following:
♦ Reconnect electrical connector before securing diagnostic
pump with bracket.
♦ Breather line -2- must audibly engage.
Specified torques: ⇒ page 220
9.9 Checking fuel system for leaks

♦ Fuel system tester (so-called smoke tester) - KLI 9210-
♦ Adapter hose - KLI 9210/55-1-
♦ Vehicle diagnostic tester - VAS 5051B- , -VAS 5052- or -VAS
5053-
♦ Hose clamps to 25 mm - 3094-
The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in con‐
nector or the release button is coloured.
Plug-in connector Colour code on plug-in connec‐
tor
Fuel supply black
Fuel return blue
Vacuum green
Test specification:
• A leak has been detected by the fuel system diagnostic pump
- V144- .
• Guided fault finding has been performed with the vehicle di‐
agnostic tester .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Preparation of fuel system tester - KLI 9210- :
Note
The fuel system tester - KLI 9210- may differ in appearance de‐
pending on the version.
– Check on fuel system tester - KLI 9210- if there is enough fluid

in smoke generator.
– Set valve -D- to “Hold”.
– Open nitrogen bottle -H-.
– Connect test hose -G- to self-test connection -B-.
– Set valve -D- to “Test”.
– Regulate pressure to 10 in. H2O (25 mbar) with pressure re‐
ducer -J-.
– Now pressure must be maintained for at least 2 minutes.
Check tester if pressure is not maintained.
Checking fuel system for leaks:
– Connect adapter hose - KLI 9210/55-1- to breather line -A- as

shown. (colour marking: white)
– Connect measuring hose -G- from fuel system tester - KLI

9210- to adapter hose - KLI 9210/55-1- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Connect vehicle diagnostic tester to vehicle.

– On vehicle diagnostic tester, select operating mode Guided
functions .
– Select guided function “Checking tank ventilation system for

leaks”.
– Initiate test.
– Observe pressure gauge - KLI 9210- while test is running.
• Fuel system diagnostic pump - V144- must pump up pressure
in fuel system to at least 7 in. H2O (18 mbar).
The minimum pressure was not reached, but the available pres‐
sure does not drop.
– Switch off ignition and perform a pressure retention test
⇒ page 225 . If no pressure drop can be detected: Check
vacuum supply of fuel system diagnostic pump - V144-
⇒ page 229 .
The minimum pressure was not reached and the available pres‐
sure drops immediately:
– Clamp off hose to activated charcoal filter solenoid valve 1 -

N80- using a hose clip -arrow-.
– Repeat check. If the minimum pressure is reached now, renew
activated charcoal filter solenoid valve 1 - N80- .
If the minimum pressure was again not reached and the available
pressure drops immediately:
– Leek in fuel system, perform test “leak detection in fuel sys‐
tem” ⇒ page 227 .
Switch off ignition if the minimum pressure is reached.
The valve in the fuel system diagnostic pump - V144- closes and
the pressure is retained.
– Observe pressure gauge:
If the pressure does not drop at first, perform a pressure retention
test to localise any potential small leaks ⇒ page 225 .
If the pressure drops, clamp off hose to activated charcoal filter

solenoid valve 1 - N80- using a hose clip -arrow-.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 - N80- .
If the pressure still drops, perform “leak detection in fuel system”
⇒ page 227 .
Pressure retention test

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Set valve -D- to “Test”. Set the available pressure to 10 in. H2O
(25 mbar).
– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
10 in. H2O (25 mbar), the fuel system is filled.
Note
Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.
– Once pressure has stabilised, set valve -D- to “Hold”.

• After 5 minutes the pressure must not drop below 8 in. H2O
(20 mbar).
If the pressure is not held for at least 5 minutes, localise leak as
follows:
– First check activated charcoal filter solenoid valve 1 - N80- for

leaks. To do this, clamp off hose to activated charcoal filter
– Repeat pressure test by setting valve -D- again to “Test”.

– Observe pressure gauge and flow meter. When the through‐
put quantity decreases and the pressure increases to 10 in.
H2O (25 mbar), the fuel system is filled.
⇒ page 227 .
After completing work, perform guided function “Checking fuel
tank breather system for leaks” using ⇒ Vehicle diagnostic tester.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
9.9.1 Leak detection in fuel system

Test specification:
• Procedure for “checking fuel system for leaks” has been com‐
pleted ⇒ page 223 .
• Fuel system tester - KLI 9210- is connected to vehicle via
adapter hose - KLI 9210/55-1- .
– Connect fuel system tester - KLI 9210- to vehicle battery.
– Remove rear right wheel housing liner.
– Clamp off hose between fuel system diagnostic pump - V144-
and air filter -arrow-.
Eos
Golf

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

(20 mbar).
– If the pressure no longer drops, renew fuel system diagnostic
pump - V144- .
If the pressure is not held for at least 5 minutes or does not build
up, localise leak as follows:
– Fill fuel system with smoke, set valve -D- again to “Test” for
this.
– While fuel system is being filled, press button -I- for smoke
generator for approx. one minute.
The fuel system is now pressurised and filled with smoke.
– Check whether smoke escapes from any fuel system line or
hose. Also check fuel tank cap.
Note
♦ Light up the components and hoses with a strong floodlight. In

the floodlight, smoke is more visible.
♦ For leak detection in accessible areas, also use ultrasonic de‐
tector or commercially available leak detecting spray.
♦ Depending on how long the fault finding takes, it may be nec‐
essary to press the smoke generator button from time to time.
This ensures that sufficient smoke is present in the fuel sys‐
tem.
♦ To inspect flanges for fuel pump and fuel filter, open assembly
opening in vehicle interior.
– Renew leaking hoses or components.

9.9.2 Schematic overview of activated charcoal filter system

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

2 - Location of adapter hose -
KLI 9210/55-1-
❑ For leak detection in fuel
system
4 - Breather line
❑ Throttle valve module -
J338-
5 - Solenoid valve
sis pump - V144- .
6 - Vacuum line
7 - Air filter
sis pump - V144- .
pump - V144-
9 - Fuel tank
10 - Sealing cover
9.9.3 Checking vacuum supply of fuel system

diagnostic pump - V144-
♦ Turbocharger tester - V.A.G 1397A-
♦ T-piece - 251 201 346-

♦ Hose ∅ 6mm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
♦ Fitting location of fuel system diagnostic pump - V144- .

♦ Golf: In rear right wheel housing below wheel housing liner.
♦ Eos: Behind rear right wheel.
Golf:
– Remove rear right wheel and wheel housing liner.
– Pull off vacuum line -1- from fuel system diagnostic pump -
V144- .
– Connect turbocharger tester - V.A.G 1397A- with T-piece and
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐
nostic pump - V144- -2-.
Eos:
V144- .
All vehicles:
– Switch on measuring range I (absolute pressure measure‐
ment).
– Connect vehicle diagnostic tester and start engine.
functions .

leaks”.
– Initiate test.
– Observe display on turbocharger tester - V.A.G 1397A- while
test is running.
• Pressure must pulsate and must not exceed 0.7 bar (absolute
pressure) during test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
10 Activated charcoal filter system (Pas‐

sat)
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Spring-type clip pliers - VAS 6340- or space saving hose clip
pliers - VAS 6362- are recommended for installing and remov‐
ing spring-type clips.
The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in con‐
nector or the release button is coloured.
Plug-in connector Colour code on plug-in connec‐
tor
Fuel supply black
Fuel return blue
Vacuum green
Assembly overview - activated charcoal filter system (engine co‐
des AXX, BWA) ⇒ page 231
Checking fuel tank breather (engine codes AXX, BWA)
⇒ page 232 .
Schematic diagram of activated charcoal filter system (engine
Assembly overview - activated charcoal filter system (engine
Checking fuel system for leaks (engine code BPY) ⇒ page 223
10.1 Assembly overview - activated charcoal filter system (engine codes AXX,
BWA)
10. Activated charcoal filter system (Passat) 231

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

❑ Location: in rear right
wheel housing.
❑ To remove, unscrew se‐
curing bolts and pull ac‐
tivated charcoal filter
downwards out of re‐
tainer.
2 - Pressure retention valve
with connecting hose
❑ To remove, pull off at se‐
curing ring.
3 - From fuel tank
4 - Breather line
N80-
5 - Breather line
filter
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit
7 - Connection hose
8 - 10 Nm
10.2 Checking fuel tank breather (engine co‐

des AXX, BWA)

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Test sequence
– Pull off breather line -2-. To do this, press release button.
– Then connect hand vacuum pump - VAS 6213- as shown to

breather line.
sition -A- for “vacuum”.
– Operate hand vacuum pump - VAS 6213- several times. There
must be no development of vacuum.
– Seal breather hole on activated charcoal filter -arrow- and op‐

erate vacuum pump several times again. Vacuum must build
up.
10.3 Schematic diagram of activated charcoal filter system (engine code BPY)

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Vacuum line
❑ green or green marking
2 - Breather line
❑ white or white marking
filter to activated char‐
coal filter solenoid valve
1 - N80-
right wheel housing
pump - V144-
6 - Brake servo
10 - Throttle valve module -
J338-
❑ In engine compartment
on right.
❑ On fuel tank at front right
14 - Filler neck
15 - Breather line
❑ From fuel tank to activated charcoal filter

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
10.4 Assembly overview - activated charcoal filter system (engine code BPY)
1 - Securing bolts
pump - V144-
right wheel housing
3 - Vacuum line
4 - Clip
5 - Connection hose
❑ Activated charcoal fil‐
ter / fuel system diag‐
nostic pump - V144-
6 - Vacuum hose
7 - Connection hose
❑ Fuel system diagnostic
pump - V144- / air filter.
8 - Air filter
9 - 10 Nm
❑ Location: in rear right
wheel housing.
❑ To remove, unscrew se‐
curing bolts and pull ac‐
tivated charcoal filter
downwards out of re‐
tainer.
11 - Breather line
N80-
12 - Breather line
❑ From fuel tank
10.5 Checking fuel system for leaks

♦ Fuel system tester (so-called smoke tester) - KLI 9210-
♦ Adapter hose - KLI 9210/55-1-
♦ Vehicle diagnostic tester - VAS 5051B- , -VAS 5052- or -VAS
5053-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Hose clamps to 25 mm - 3094-
Test specification:
• A leak has been detected by the fuel system diagnostic pump
- V144- .
• Guided fault finding has been performed with the vehicle di‐
agnostic tester .
Preparation of fuel system tester - KLI 9210- :
Note
The fuel system tester - KLI 9210- may differ in appearance de‐
pending on the version.
– Check on fuel system tester - KLI 9210- if there is enough fluid

in smoke generator.
– Open nitrogen bottle -H-.
– Connect test hose -G- to self-test connection -B-.
– Regulate pressure to 10 in. H2O (25 mbar) with pressure re‐
ducer -J-.
– Now pressure must be maintained for at least 2 minutes.
Check tester if pressure is not maintained.
Checking fuel system for leaks:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Connect adapter hose - KLI 9210/55-1- to breather line -A- as

shown. (colour marking: white)
– Connect measuring hose -G- from fuel system tester - KLI

9210- to adapter hose - KLI 9210/55-1- .
– Connect vehicle diagnostic tester to vehicle.

functions .

leaks”.
– Initiate test.
– Observe pressure gauge - KLI 9210- while test is running.
• Fuel system diagnostic pump - V144- must pump up pressure
in fuel system to at least 7 in. H2O (18 mbar).
The minimum pressure was not reached, but the available pres‐
sure does not drop.
– Switch off ignition and perform a pressure retention test
⇒ page 238 . If no pressure drop can be detected: Check
vacuum supply of fuel system diagnostic pump - V144-
⇒ page 241 .
The minimum pressure was not reached and the available pres‐
sure drops immediately:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Clamp off hose to activated charcoal filter solenoid valve 1 -

N80- using a hose clip -arrow-.
– Repeat check. If the minimum pressure is reached now, renew
activated charcoal filter solenoid valve 1 - N80- .
If the minimum pressure was again not reached and the available
pressure drops immediately:
– Leek in fuel system, perform test “leak detection in fuel sys‐
tem” ⇒ page 239 .
Switch off ignition if the minimum pressure is reached.
The valve in the fuel system diagnostic pump - V144- closes and
the pressure is retained.
– Observe pressure gauge:
If the pressure does not drop at first, perform a pressure retention
test to localise any potential small leaks ⇒ page 238 .
If the pressure drops, clamp off hose to activated charcoal filter

⇒ page 239 .
Pressure retention test
– Set valve -D- to “Test”. Set the available pressure to 10 in. H2O
(25 mbar).
Note
Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.

(20 mbar).
If the pressure is not held for at least 5 minutes, localise leak as
follows:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– First check activated charcoal filter solenoid valve 1 - N80- for

leaks. To do this, clamp off hose to activated charcoal filter
– Repeat pressure test by setting valve -D- again to “Test”.

– Observe pressure gauge and flow meter. When the through‐
put quantity decreases and the pressure increases to 10 in.
H2O (25 mbar), the fuel system is filled.
⇒ page 239 .
10.5.1 Leak detection in fuel system

Test specification:
• Procedure for “checking fuel system for leaks” has been com‐
pleted ⇒ page 235 .
• Fuel system tester - KLI 9210- is connected to vehicle via
adapter hose - KLI 9210/55-1- .
– Connect fuel system tester - KLI 9210- to vehicle battery.
– Remove rear right wheel housing liner.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Clamp off hose between fuel system diagnostic pump - V144-

and air filter -arrow-.

(20 mbar).
– If the pressure no longer drops, renew fuel system diagnostic
pump - V144- .
If the pressure is not held for at least 5 minutes or does not build
up, localise leak as follows:
– Fill fuel system with smoke, set valve -D- again to “Test” for
this.
– While fuel system is being filled, press button -I- for smoke
generator for approx. one minute.
The fuel system is now pressurised and filled with smoke.
– Check whether smoke escapes from any fuel system line or
hose. Also check fuel tank cap.
Note
♦ Light up the components and hoses with a strong floodlight. In

the floodlight, smoke is more visible.
♦ For leak detection in accessible areas, also use ultrasonic de‐
tector or commercially available leak detecting spray.
♦ Depending on how long the fault finding takes, it may be nec‐
essary to press the smoke generator button from time to time.
This ensures that sufficient smoke is present in the fuel sys‐
tem.
♦ To inspect flanges for fuel pump and fuel filter, open assembly
opening in vehicle interior.
– Renew leaking hoses or components.

10.5.2 Schematic overview of activated charcoal filter system

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

2 - Location of adapter hose -
KLI 9210/55-1-
❑ For leak detection in fuel
system
4 - Breather line
❑ Throttle valve module -
J338-
5 - Solenoid valve
sis pump - V144- .
6 - Vacuum line
7 - Air filter
sis pump - V144- .
pump - V144-
9 - Fuel tank
10 - Sealing cover
10.5.3 Checking vacuum supply of fuel system

diagnostic pump - V144-
♦ T-piece - 251 201 346-

♦ Hose ∅ 6mm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
The fuel system diagnostic pump - V144- is fitted in the rear right
wheel housing behind the wheel housing liner.
– Remove rear right wheel and wheel housing liner.

V144- .
– Switch on measuring range I (absolute pressure measure‐
ment).
– Connect vehicle diagnostic tester and start engine.
functions .

leaks”.
– Initiate test.
– Observe display on turbocharger tester - V.A.G 1397A- while
test is running.
• Pressure must pulsate and must not exceed 0.7 bar (absolute
pressure) during test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.
Note
A throttle is fitted in the vacuum hose on the intake manifold

-arrow-. Disconnect the cable -A- and the hose -B- and check the
throttle.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
21 – Turbocharging/supercharging
1 Exhaust turbocharger
Note
♦ Secure all hose connections with hose clips which conform to

production standard.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. The oil seals and seal‐
ing surfaces must be oiled lightly only for plug-in connectors
⇒ page 243 .
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Hose clip pliers - VAS 6499- or hose clip pliers - V.A.G 1921-
are recommended for installation of spring-type clips.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed and do not rev up immediately. This ensures that
the turbocharger is fully primed with oil.
Fitting hose connections with plug-in connectors ⇒ page 243

Assembly overview - turbocharger ⇒ page 244 .
Removing and installing turbocharger ⇒ page 248 .
Checking turbocharger vacuum unit ⇒ page 256 .
Adjusting vacuum unit for turbocharger ⇒ page 257 .
Removing and installing vacuum unit for turbocharger
⇒ page 257 .
1.1 Fitting hose connections with plug-in

connectors
Caution
The seal for the push-on coupling can be damaged if the re‐
taining clip is in the locked position during installation. This
would result in leaking. Observe installation instructions.
Removing:
– Release plug-in connector by pulling out retaining clip
-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place seal in groove of charge air hose. Make sure
that the seal is correctly seated in the groove all around the
complete circumference and that it is not twisted.
– Lubricate sealing surface and seal with oil.
1. Exhaust turbocharger 243

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Bring retaining clip to release position -1-.

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

When working on the turbocharger, pay careful attention to the
following “5 rules” for cleanliness:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.
1.3 Assembly overview - turbocharger

♦ Part I ⇒ page 244
♦ Part II ⇒ page 246
♦ Part III ⇒ page 247
1.3.1 Part I
244 Rep. gr.21 - Turbocharging/supercharging

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Seal
❑ Renew
2 - 20 Nm
❑ Renew
❑ Coat studs of exhaust
manifold with high-tem‐
perature paste.
❑ High-temperature paste
⇒ Electronic Parts
Catalogue (ETKA)
3 - 35 Nm
4 - Sealing ring
❑ Renew
5 - 9 Nm
6 - 23 Nm
❑ On coolant return line
only fitted with two re‐
tainers
7 - Coolant return line
❑ Gradual introduction of
coolant return lines with
one retainer
⇒ page 248
9 - Bracket
10 - 30 Nm
❑ Coat bolt with high-tem‐
perature paste
❑ High-temperature paste
⇒ Electronic Parts
Catalogue (ETKA)
11 - 30 Nm
❑ Coat bolt with high-temperature paste
❑ High-temperature paste ⇒ Electronic Parts Catalogue (ETKA)
12 - Bracket
13 - 23 Nm
14 - 30 Nm
❑ Do not loosen to remove turbocharger
❑ Renew
❑ Coat studs of exhaust manifold with high-temperature paste.
❑ High-temperature paste ⇒ Electronic Parts Catalogue (ETKA)
15 - Clamping rail

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.3.2 Part II
1 - Sealing ring
❑ Renew
2 - 30 Nm
3 - Oil supply line
⇒ page 248
5 - 9 Nm
6 - 30 Nm
7 - Sealing ring
❑ Renew
8 - 35 Nm
9 - Sealing ring
❑ Renew
10 - Coolant supply line
11 - 23 Nm
12 - 35 Nm
13 - 9 Nm
14 - Sealing ring
❑ Renew
15 - Seal
❑ Renew
16 - Oil return line
17 - 9 Nm
18 - Seal
❑ Renew

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.3.3 Part III
⇒ page 248
2 - Seal
❑ Renew
3 - 9 Nm
4 - Crankcase breather line
5 - Heat shield
6 - Connection hose
7 - Pressure canister
⇒ page 257
❑ Adjusting ⇒ page 257
8 - Banjo union
9 - Sealing ring
❑ Renew
10 - Hose
11 - Hose
12 - 3 Nm
13 - Charge pressure control
solenoid valve - N75-
14 - 8 Nm
15 - Sealing ring
16 - Connection
17 - Retaining clip
18 - 7 Nm
19 - Hose
20 - 7 Nm
21 - Bracket
22 - 7 Nm
23 - Turbocharger air recirculation valve - N249-
❑ Note installation position ⇒ page 248
24 - Sealing ring

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Installation location of turbocharger air recirculation valve - N249-

– Observe installation position -arrows-
1.4 Removing and installing turbocharger

♦ Tensioning strap - T10038-
Caution
If a mechanical fault is found on the turbocharger, e.g. a de‐

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

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing:
– Remove engine cover panel/air filter ⇒ page 273 and remove
intake hose ⇒ Item 11 (page 273) from turbocharger.
– Remove right front part of wheel housing liner.
– Pull charge air hose -arrow- off charge air cooler.
– Pull off connectors -1 and 2- and unclip wire.

– Unscrew bolts -arrows- and remove union from turbocharger.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Disconnect connector for Lambda probe - G39- -arrow- and

lay cable to side.
Golf, Eos:
– Remove wiper arms, plenum chamber cover and plenum bulk‐
head ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper
system; Removing and installing windscreen wiper system .
All vehicles:
– Pull connectors off ignition coils and lay wiring harness to side.
– Disconnect coolant line to coolant expansion tank -arrow-.
– Pull off coolant hoses -1- and -2-.

– Disconnect coolant line -3-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull upper coolant hose off heat exchanger -arrows-.
– Remove heat shield and coolant pipe -arrows-.
– Unbolt crankcase breather line with heat shield from turbo‐

charger -1-.
– Disconnect crankcase breather line from cylinder head cover
-2- and remove.
– Remove activated charcoal filter line to turbocharger from cyl‐
inder head cover -3-.
– Loosen turbocharger oil supply line -4-.
– Remove the two upper securing nuts for front exhaust pipe/
turbocharger.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unbolt heat shield for right-hand drive shaft -arrows-.

– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Removing and installing drive shafts .
– Remove the two lower securing nuts for front exhaust pipe/
turbocharger.
– Unbolt bracket for exhaust system -arrows-.
– Separate exhaust system at clamp -arrows-.

– Pull front exhaust pipe off turbocharger and slightly push to
rear.
Note
The catalytic converter is not removed and the Lambda probe

connector is not separated.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unbolt oil supply line and coolant supply line from turbocharg‐
er -arrows-.
– Remove oil return line -arrows- at turbocharger.
– Remove bolts -1- and -2- and remove support for turbocharg‐
er.
Note
The following procedure is necessary to provide more space be‐

tween the cylinder head and plenum chamber bulkhead.
– Remove bolts -2 and 3-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull engine approx. 20 mm to rear using tensioning strap -

T10038- .
– Disconnect coolant pipe -arrow-.
Note
♦ The clamping strip nuts need not be loosened.

♦ Bolt -1- is only fitted on coolant pipes with two retainers.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unscrew bolt -1- for coolant pipe and remove upper nuts
-arrows-.
– Remove turbocharger/exhaust manifold upwards.
Installing:
Caution
If a mechanical fault is found on the turbocharger, e.g. a de‐

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

note the following:
♦ Fitting hose connections with plug-in connectors ⇒ page 243
♦ Renew seals, gaskets and self-locking nuts.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ The coolant return line ⇒ Item 7 (page 245) must be installed
together with the turbocharger.
free of oil and grease before assembly. The oil seals and seal‐
ing surfaces must be oiled lightly only for plug-in connectors
⇒ page 243 .
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ EKTA (Electronic parts cata‐
logue) .
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
Specified torques ⇒ page 244
Component Nm
Pendulum support to gearbox ⇒ page 13
Exhaust manifold/turbocharger to cylinder 201)
head
Oil supply line to turbocharger 30
Oil return line to turbocharger 9
Coolant supply line to turbocharger 35
Turbocharger bracket to cylinder block 302)
Turbocharger bracket to turbocharger 302)
Air intake pipe (right side) to sump 10
1) Renew nuts.
2)Use high-temperature paste ⇒ ETKA (Electronic parts cata‐
logue) .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.5 Checking vacuum unit for turbocharger

Test specification:
♦ Hose from turbocharger via charge pressure control solenoid
valve - N75- to vacuum unit must have through-flow (not
blocked).
♦ Charge pressure control solenoid valve - N75- OK.
Procedure
– Connect hand-operated vacuum pump - VAS 6213- to vacuum
unit -arrow-.
sition -B- for “pressure”.
Caution
The pressure must not exceed 750 mbar! If the pressure is

exceeded, the vacuum unit can be damaged.
– Operate hand vacuum pump - VAS 6213- several times and

observe the linkage.
The linkage -A- should start to move at a pressure of approx.
300 mbar and be at its limit stop at a pressure of approx.
700 mbar.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
The stroke of the rod is approx. 10 mm.
Note
If no pressure can be built up using hand vacuum pump - VAS

6213- , or if the pressure drops immediately again, check hand
vacuum pump - VAS 6213- and connecting hoses for leaks. If no
fault is found: renew vacuum unit ⇒ page 257 .
1.6 Removing and installing vacuum unit for

turbocharger
Removing:
– Remove turbocharger ⇒ page 248 .
– Detach locking plate above turbocharger linkage.
– Loosen lock nut -2-.
– Separate rod from turbocharger -3-.
– Remove vacuum unit -1- from turbocharger -arrows-.
Installing:
note the following:
– Adjust turbocharger vacuum unit ⇒ page 257 .
– Install turbocharger ⇒ page 248 .
Specified torques
Component Nm
Vacuum unit to turbocharger 10
1.7 Adjusting vacuum unit for turbocharger

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

equipment required
♦ Universal dial gauge holder - VW 387-

♦ Pressure regulating valve - VAS 6342-
♦ Dial gauge - VAS 6341/1-
♦ Extension, 30 mm - VAS 6341/3-
♦ Flat probe - VAS 6341/4-
Note
♦ This procedure is used to adjust the vacuum unit. When check‐

ing already adjusted vacuum units the values can differ.
♦ The vacuum unit must be adjusted only if the linkage has been
loosened.
♦ Adjustment is carried out when turbocharger is removed.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull hose -arrow- from vacuum unit on turbocharger.

– Detach locking plate above turbocharger linkage.
– Loosen lock nut -2-.
– Pre-adjust bypass flap -1- above rod of vacuum unit -arrow-,

so that the bypass flap can just be turned by hand.
– Tighten lock nut hand-tight.
– Connect up hand-operated vacuum pump - VAS 6213- , tur‐

bocharger tester - V.A.G 1397A- (connection II) and pressure
control valve - VAS 6342- as shown in illustration.
– Close pressure control valve - VAS 6342- at lever -1-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
sition -B- for “pressure”.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position II.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Secure universal dial gauge bracket - VW 387- to turbocharger

-arrows-.
– Secure dial gauge - VAS 6341/1- with dial gauge extension,
30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to uni‐
versal dial gauge bracket - VW 387- .
– With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm
preload.
– Turn dial of dial gauge - VAS 6341/1- to 0.
– Make sure that dial gauge can move freely.
– Operate vacuum pump - VAS 6213- until turbocharger tester
- V.A.G 1397A- indicates 350 +/- 5 mbar.
– The dial gauge must indicate between 4.1 mm and 4.3 mm;
otherwise, turn rod of vacuum unit until the value is indicated.
– Tighten lock nut hand-tight.
– Repeat adjustment.
Note
The values in mm refer to the read value (includes 1 mm preten‐

sion).
– Vent system via pressure control valve - VAS 6342- so that

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

sequence. Do not allow the pressure to drop to 0 between meas‐
urements.
– Operate vacuum pump - VAS 6213- until turbocharger tester

- V.A.G 1397A- indicates 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Actuate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 650 mbar to 700 mbar.
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5 +/- 0.25 mm.
– Correct setting if the result (average) is not 5 +/- 0.25 mm,
tighten lock nut hand-tight and repeat measurement.
– If the result (mean value) is 5 +/- 0.25 mm, tighten the lock nut
to 5 Nm and secure with sealing paint.
– Secure locking plate above turbocharger linkage.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2 Charge air system

Assembly overview - charge air cooling, Golf ⇒ page 262 .
Assembly overview - sound amplifier; Golf ⇒ page 263
Assembly overview - charge air cooling, Eos, Passat
⇒ page 264 .
Removing and installing charge air cooler, Golf, Eos
⇒ page 264 .
Removing and installing charge air cooler (Passat) ⇒ page 266 .
Fitting hose connections with plug-in connectors ⇒ page 243
Schematic diagram of turbocharging system ⇒ page 267 .
Checking charge air system for leaks ⇒ page 268
2.1 Assembly overview - charge air cooling,

Golf
Note
Assembly overview - sound amplifier ⇒ page 263 .
1 - 5 Nm
2 - Mounting
❑ For charge air cooler.
3 - Intercooler
⇒ page 264
4 - Charge air pipe
5 - 8 Nm
6 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 243
7 - Charge air pipe
❑ To sound amplifier
8 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 243
9 - Hose clamp
10 - Charge air hose
❑ To throttle valve module
- J338- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

12 - Charge air pipe
14 - 8 Nm
15 - Sound amplifier
❑ Fasteners ⇒ page 263
❑ Fitting hose connections with plug-in connectors ⇒ page 243
18 - Charge air pressure sender - G31-
19 - 5 Nm
2.2 Assembly overview - sound amplifier, Golf
1 - Cover
2 - 8 Nm
3 - Plenum chamber bulkhead
4 - Trim
❑ For feed-through in ple‐
num chamber bulkhead
5 - Charge air pipe
6 - Clip
7 - Charge air hose
8 - 8 Nm
9 - Spacer sleeve
10 - Rubber mounting
11 - Sound amplifier
❑ Before removing, re‐
move cover
⇒ Item 1 (page 263) .
12 - Bracket
❑ For sound amplifier
13 - 8 Nm
2. Charge air system 263

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2.3 Assembly overview - charge air cooling, Eos, Passat
1 - 5 Nm
2 - Mounting
❑ For charge air cooler.
3 - Intercooler
charge air cooler (Pas‐
sat) ⇒ page 266 .
charge air cooler, Eos
⇒ page 264 .
4 - Charge air pipe
5 - 8 Nm
6 - From turbocharger
7 - Charge air hose
❑ Note installation instruc‐
tions ⇒ page 243
8 - To throttle valve module -
J338- .
9 - Charge air hose
10 - 10 Nm
11 - 5 Nm
12 - Charge air pressure send‐
er - G31-
❑ Note installation instruc‐
tions ⇒ page 243
2.4 Removing and installing charge air cool‐

er (Golf, Eos)
Removing:
– Remove bumper cover ⇒ Bumpers; Rep. gr. 63 ; Removing
and installing front bumper cover .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove right air hose -arrows-.

– Remove radiator cowl ⇒ page 134 .
– Removing radiator ⇒ page 134 .
Pipes of condenser are bolted to right-hand side of charge air
cooler. To unscrew securing bolts, proceed as follows:
– Make a paper template with the specified dimensions.
– Fit the template on the plastic bracket at the front right so that
it rests against the edges at the top and left.
– Mark the intersection on the template -arrow- with a centre
punch.
– Drill a hole into the plastic bracket with a 5-mm drill bit.
– Drill or cut the hole to 16 mm.
– Unscrew securing bolt -arrow- for condenser pipes.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unscrew bolts -1- for charge air cooler mountings.
Note
The securing bolts of the condenser are difficult to access. With

the aid of a second mechanic, lift the charge air cooler out of the
radiator mountings. The charge air cooler can now be moved
»back and forth« to allow access to the securing bolts.
– Unbolt condenser from charge air cooler -arrows-.

– Attach condenser to lock carrier using cable ties.
– Take out charge air cooler from underneath.
Installing:
note the following:
free of oil and grease before assembly. The seal and sealing
surface must be oiled lightly only for plug-in connectors
⇒ page 243 .
2.5 Removing and installing charge air cool‐

er, Passat
Removing:
– Remove bumper cover ⇒ Bumpers; Rep. gr. 63 ; Removing
and installing front bumper cover .
– Remove right air hose -arrows-.
– Remove radiator cowl ⇒ page 134 .
– Removing radiator ⇒ page 136 .
– Remove air deflector elements on lock carrier ⇒ Body - front;
Rep. gr. 50 ; Assembly overview - air deflector elements on
lock carrier .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Unscrew bolts -1- for charge air cooler mountings.
Note
The securing bolts of the condenser are difficult to access. With

the aid of a second mechanic, lift the charge air cooler out of the
radiator mountings. The charge air cooler can now be moved
»back and forth« to allow access to the securing bolts.
– On the right-hand side of the charge air cooler unscrew pipes

of condenser -arrow-.
– Unbolt condenser from charge air cooler -arrows-.

– Attach condenser to lock carrier using cable ties.
– Take out charge air cooler from underneath.
Installing:
note the following:
free of oil and grease before assembly. The seal and sealing
surface must be oiled lightly only for plug-in connectors
⇒ page 243 .
2.6 Schematic diagram of turbocharging system

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Pressure canister
⇒ page 257
❑ Adjusting ⇒ page 257
2 - Charge pressure control
solenoid valve - N75-
3 - Turbocharger air recircula‐
tion valve - N249-
5 - Brake servo
8 - Vacuum pump
10 - Oil filter bracket
solenoid valve 1 - N80-
13 - Intercooler
14 - Throttle valve module -
J338-
15 - Pressure regulating valve
17 - Air mass meter - G70-
2.7 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/5-


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Release clip -A- and detach hose -B- from charge air pipe.
– Fit adapter - V.A.G 1687/5- onto charge air hose -A- and turn
adapter through approx. 90° -B-.
Prepare charge air system tester - V.A.G 1687- as follows:
– Turn pressure control valve -2- anti-clockwise onto stop.

– Close valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect charge air system tester - V.A.G 1687- as shown.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by hearing, touching,
with commercially available leak detector spray or using ultra‐
sonic tester - V.A.G 1842- .
Note
♦ Fitting hose connections with plug-in connectors ⇒ page 243

♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/5- before removing adapter.
free of oil and grease before assembly.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
24 – Mixture preparation - injection

1 Injection system
General notes on injection ⇒ page 271 .
Safety precautions ⇒ page 140 .
Technical data ⇒ page 272 .
Assembly overview - intake manifold ⇒ page 275 .
Assembly overview - fuel rail (vehicles up to 05.2007)
⇒ page 282
Assembly overview - fuel rail (vehicles from 05.2007)
⇒ page 282
Assembly overview - air filter ⇒ page 272
Removing and installing engine cover panel/air filter
⇒ page 273
Removing and installing air filter element ⇒ page 274
Removing and installing throttle valve module - J338-
⇒ page 286
Removing and installing intake manifold ⇒ page 277 .
Removing and installing intake manifold flap motor - V157- along
with intake manifold flap potentiometer - G336- ⇒ page 280
Removing and installing fuel rail ⇒ page 285 .
Removing and installing fuel pressure sender - G247-
⇒ page 290 .
Checking fuel pressure sender - G247- ⇒ page 292 .
Removing and installing injectors ⇒ page 295 .
Renew Teflon seal on injector ⇒ page 296
1.1 General notes on injection

♦ Fuel hoses in engine compartment must be secured only with
spring-type clips which conform to production standard. The
use of crimp-type or screw-type clips is not permissible.
♦ The battery must be disconnected only with ignition switched
off. If a coded radio is installed, ascertain code before discon‐
necting battery.
♦ Observe required procedures after connecting battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Disconnecting and reconnecting
battery.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted.
♦ After completing work, read fault memory of engine control
unit, clear all fault entries that have been stored during checks
and repairs. If the fault memory was cleared, the readiness
1. Injection system 271

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
code must be generated ⇒ Vehicle diagnostic tester.“Guided

functions”.
♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
reduces the danger of a fire in a crash as the fuel pump is
switched off via the fuel pump relay.
♦ When driver door is opened, fuel pump is activated for 2 sec‐
onds to generate pressure in fuel system. This improves the
quality of the start behaviour.
Technical data ⇒ page 272 .
1.2 Technical data

Engine code AXX, BWA, BPY
Idling check
Idling speed 1) rpm 620…800
Engine control unit 2)
System designation Motronic MED 9.1
Part number ⇒ ETKA (Electronic parts catalogue)
Governed speed rpm approx. 6800
1) If voltage supply to engine control unit drops below 12 volt,

idling speed will be raised incrementally up to 990 rpm. The idling
speed cannot be adjusted.
2) Renew engine control unit ⇒ page 300 .
1.3 Assembly overview - engine cover panel/air filter
272 Rep. gr.24 - Mixture preparation - injection

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Air mass meter - G70-

2 - 3 Nm
3 - Upper part of air filter/en‐
gine cover panel
5 - Intake air guide
6 - Filter element
7 - Air filter lower part
8 - 3 Nm
9 - Heat shield
10 - Rubber grommet
❑ Observe fitting marks
11 - Intake hose
❑ Observe fitting marks
1.4 Removing and installing engine cover

panel/air filter
Removing:
– Remove intake hose -1-.
– Pull off connector -2-.
– Unscrew bolts -3-.
– Pull engine cover panel off upwards in sequence -A…D- at
points indicated.
Installing:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Ensure that the four rubber mountings -arrows- are inserted in

engine cover panel.
– Position engine cover panel in installation position and at the
same time push the rubber mountings onto retaining pins.
Further assembly is carried out in the reverse order.
1.5 Removing and installing air filter ele‐

ment
Removing:
– Remove intake air duct -arrow-.
– Remove all bolts -arrows-.
– Detach engine cover panel (note retainers -arrows-).

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull air filter element out of engine cover panel.

Installing air filter element:
Note
♦ Always use genuine part for air filter element.

♦ The air filter housing must be clean.
♦ When blowing out the air filter housing with compressed air
note the following: to prevent malfunctions, cover air mass
meter - G70- with a clean cloth.
– Check air mass meter - G70- and intake air duct

⇒ Item 5 (page 273) for salt deposits, dirt and leaves.
– When installing the air filter element, check that it is properly
centred in the retainer in the lower part of air filter.
– Place upper part of air filter carefully on lower part of air filter
without exerting excessive force. Make sure the upper part of
the air filter is fitted straight on the air filter element (note po‐
sition of sealing lip on air filter element).
Further assembly is carried out in the reverse order.
1.6 Assembly overview - intake manifold

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - 10 Nm
2 - Clamp
3 - 3 Nm
4 - Stud, 10 Nm
5 - Seal
❑ Renew
6 - Intake manifold
❑ With intake manifold
flaps
⇒ page 277
7 - Coupling rod
8 - Intake manifold flap motor -
V157- and intake manifold flap
potentiometer - G336-
⇒ page 280
9 - 7 Nm
11 - Hose
solenoid valve 1 - N80-
13 - Hose
15 - Intake manifold support
16 - 25 Nm
17 - 10 Nm
18 - Bonded rubber mounting
19 - Throttle valve module - J338-
❑ Including throttle valve drive (electric throttle operation) - G186- , angle sender 1 for throttle valve drive
(electric throttle operation) - G187- and angle sender 2 for throttle valve drive (electric throttle operation)
- G188- .
20 - 7 Nm
21 - Sealing ring
22 - 5 Nm
23 - Intake air temperature sender - G42-
24 - 10 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.7 Removing and installing intake manifold

Removing:
WARNING
Observe safety precautions when releasing fuel pressure in

high-pressure section ⇒ page 141
Note

♦ If an injector was pulled out of the cylinder head when the in‐
take manifold was removed, the Teflon seal must be renewed
⇒ page 296 .
♦ Assembly overview - intake manifold ⇒ page 275 .
– Remove throttle valve module - J338- ⇒ page 286 .

– Disconnect all electrical connectors as necessary.
– Disconnect vacuum hose between intake manifold and vac‐
uum pump at intake manifold.
WARNING

off line.
Engine code BPY:

buttons.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

– Disconnect fuel supply line -2-.
– Disconnect breather line -2-.

Pull vacuum lines -arrows- off intake manifold and cylinder head
cover.
WARNING

off line.
Vehicles up to 05.2006:
– Unscrew fuel pipe -4- from connection -3-. At the same time
counterhold connection -3-.
– Unscrew banjo bolt -2-, at the same time counterhold connec‐
tion -1-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Vehicles from 05.2006:

– Open hose clip -1- and pull fuel hose off.
– Unscrew fuel pipe -3-, at the same time counterhold connec‐
tion -2-.
– Disconnect coolant pipe and oil dipstick tube from intake mani‐
fold -arrows- and remove oil dipstick tube from engine by
pulling it upwards.
– Remove intake manifold support -arrows- and disconnect con‐

nector -1- from fuel pressure sender - G247- .
– Unscrew all bolts from intake manifold.
– Carefully pull intake manifold and fuel rail off cylinder head.
Installing:
note the following:
If an injector was pulled out of the cylinder head when the intake
manifold was removed, renew the Teflon seal of the injector
⇒ page 296 .
Renew O-rings between injector and fuel rail and moisten slightly
with clean engine oil.
Fit intake manifold with fuel rail on cylinder head and evenly press
onto injectors.
If the intake manifold flap motor - V157- or the intake manifold
was renewed, the intake manifold flap potentiometer - G336- must
be adapted to the engine control unit ⇒ Vehicle diagnostic tester
“guided functions”.
Specified torque Nm
Securing bolts for intake mani‐ 10
fold
Bolt for intake manifold support 23
Nut for intake manifold support 10
Fuel lines on high-pressure ⇒ page 287
pump
Bolts for intake manifold flap 7
motor - V157-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.8 Removing and installing intake manifold

flap motor - V157- and intake manifold
flap potentiometer - G336-
♦ Commercially available 1/4" drive ratchet handle e.g.. Hazet

2264
♦ T30 bit insert

Removing:
– Unscrew air duct on lock carrier -arrows-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull off vacuum lines -arrows-.

– Remove connectors as follows:
Note
Use assembly tool - T10118- to facilitate release of connectors

which are less accessible
♦ Connector for intake manifold flap motor - V157-

♦ Connector for activated charcoal filter system solenoid valve
1 - N80-
♦ Connector for intake manifold pressure sender - G71- .
♦ Connector for throttle valve module - J338-
♦ Connector for fuel pressure sender for low pressure - G410-
– Disconnect additional electrical connectors -arrows-.

– Loosen cable retainer -A- and place complete wiring harness
to side.
– Unbolt retainer for connectors -arrows- from coolant pipe.
Note
♦ Only loosen the nut with the left arrow until the retainer can be
moved to the side.
♦ Plastic retainers are clipped.
♦ For clarity, the illustration shows the intake manifold removed
from the engine.
– Prise coupling rod -arrow- off intake manifold flap motor -

V157- .
– Unscrew bolts -1- and -2- using 1/4" drive ratchet handle and
T30 bit insert .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Note
The rear bolt -arrow - can only be unscrewed with a ratchet han‐
dle . The space between the bolt and the coolant pipe is very
constricted.
– Remove intake manifold flap motor - V157- from intake mani‐

fold.
Installing:
note the following:
– Insert bolts -1- and -2- by hand to prevent damage to the

thread.
If the intake manifold flap motor - V157- or the intake manifold
were renewed, the intake manifold flap potentiometer - G336-
must be adapted to the engine control unit ⇒ vehicle diagnostic
tester “guided functions”.
1.9 Assembly overview - fuel rail (vehicles

up to 05.2006)
WARNING


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Injector, cylinder 1 - N30- to

injector, cylinder 4 - N33-
⇒ page 295
2 - 8 Nm
3 - Fuel distributor
⇒ page 285
4 - Panel nut
5 - Pressure limiting valve
❑ 30 Nm
remove intake manifold
⇒ page 277 .
6 - Low pressure pipe
❑ When removing, coun‐
terhold pressure limiting
valve
❑ Before installing, check
pressure of pressure
limiting valve.
❑ Install free of tension.
❑ Tighten union nut to
22 Nm.
7 - Bracket
8 - High-pressure pipe
❑ Tighten high-pressure
pump union nuts to
27 Nm.
❑ Tighten fuel rail union
nuts to 33 Nm.
9 - Connector
❑ For injectors.
10 - 5 Nm
11 - Fuel pressure sender - G247-
❑ 22 Nm
❑ Coat thread and sealing taper with clean engine oil.
1.10 Assembly overview - fuel rail (vehicles

from 05.2006)
WARNING


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Injector, cylinder 1 - N30- to

injector, cylinder 4 - N33-
⇒ page 295
2 - 8 Nm
3 - Fuel distributor
⇒ page 285
4 - Low pressure fuel hose
❑ To high-pressure pump
5 - Pressure limiting valve
❑ 30 Nm
remove intake manifold
⇒ page 277 .
6 - Panel nut
7 - Low pressure pipe
❑ Counterhold pressure
limiting valve when loos‐
ening union nut.
pressure of pressure
limiting valve.
❑ Tighten union nut to
22 Nm.
8 - Bracket
❑ Counterhold threaded
connection when loos‐
ening union nut.
❑ Before installing, check torque of threaded connection
❑ Tighten union nuts to 27 Nm.
10 - 3 Nm
11 - Connector
❑ For injectors.
12 - Connector
❑ For ⇒ Item 16 (page 284) and ⇒ Item 17 (page 284)
13 - Connector
❑ For ⇒ Item 11 (page 284)
14 - Cable channel
15 - Clip
❑ Attach on lower right sleeve of intake manifold
16 - Connector
❑ For Hall sender - G40- .
17 - Connector
❑ For fuel pressure sender - G247- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
18 - 5 Nm
19 - Fuel pressure sender - G247-
❑ 22 Nm
❑ Coat thread and sealing taper with clean engine oil.
20 - Connecting union
❑ 30 Nm
1.11 Removing and installing fuel rail

Removing:
– Remove hoses from activated charcoal filter.
– To do this, open hose clip -1-.
– Unscrew two bolts -arrows- on fuel rail.
– Disconnect hose connection -1- from intake manifold and loos‐

en the two bolts -arrows-.
– Disconnect union nuts of the two fuel pipes -2 and 3-. At the
same time counterhold pressure limiting valve.
– Carefully pry off linkage from intake manifold flap motor -
V157- -4-.
– Unbolt intake manifold flap motor - V157- -5-.
– Remove fuel rail from intake manifold.

Installing:
– Install in reverse order of removal.
Specified torques (vehicles to 05.2006) ⇒ page 282 .
Specified torques (vehicles from 05.2006) ⇒ page 283 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.12 Removing and installing throttle valve

module - J338-
Removing:
Golf:
– Remove pipe -A- and hose -B- -arrows-.
All vehicles:
– Release hose clip -1-.

– Unscrew bolt -2-.
– Separate electrical connector -3-.
– Remove bolt -4- pull air pipe off charge air cooler and take
downwards.
– Remove four bolts of throttle valve module - J338- and remove
throttle valve module - J338- .
Installing:
note the following:
– If a new throttle valve module - J338- was installed, adapt the
engine control unit to throttle valve module - J338- ⇒ Vehicle
diagnostic tester “guided functions”.
1.13 Cleaning throttle valve module - J338-

♦ Acetone
Note
♦ Observe all relevant safety precautions ⇒ page 140 .

♦ When cleaning the throttle valve housing it must not be
scratched.
Procedure
– Remove throttle valve module ⇒ page 286 .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Open throttle valve by hand and block throttle valve in open

position with a suitable object -arrow-.
WARNING
Acetone is highly inflammable. Please comply with the acci‐

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

closed throttle valve, using commercially available acetone
and a cleaning brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Adapt the engine control unit to throttle valve module ⇒ Vehicle
diagnostic tester “Guided Functions”.
1.14 Assembly overview - high-pressure

pump
Note
From 05.2006 on the low pressure line on high-pressure pump,

the pipe with banjo bolt was replaced by a hose connection with
spring-type clip.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - Plunger
2 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
3 - High-pressure pump with
fuel pressure regulating valve -
N276-
⇒ page 289
4 - 10 Nm
5 - Union nut
❑ 27 Nm
❑ When loosening, coun‐
terhold threaded con‐
nection
torque of threaded con‐
nection in high-pressure
pump
❑ Install fuel pipe free of
tension.
❑ Observe safety precau‐
tions when releasing
fuel pressure in high-
pressure section
⇒ page 141
❑ Vehicles from 05.2006
❑ 30 Nm
❑ Only renew if loosened.
❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed
at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with
a »grip edge«.
8 - Low pressure fuel hose
❑ Vehicles from 05.2006
❑ Secure with spring-type clip.
9 - Banjo bolt with conical sealing seat
❑ 15 Nm
❑ Renew
❑ Install fuel pipe free of tension.
❑ When loosening, counterhold threaded connection
❑ Vehicles up to 05.2006
10 - Fuel line
❑ Low pressure
❑ 30 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
❑ Only renew if loosened.
❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed
at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with
a »grip edge«.
12 - Threaded connection for high-pressure pipe
❑ 40 Nm
❑ Do not loosen threaded connection, only retighten
13 - Fuel pressure sender for low-pressure - G410-
❑ 15 Nm
14 - Sealing ring
❑ Renew
1.15 Removing and installing high-pressure

pump
WARNING
♦ Observe safety precautions when releasing fuel pressure

in high-pressure section ⇒ page 141
Note
♦ The high-pressure pump must not be dismantled.

Removing:
– Set engine to TDC.
– Pull off connectors -1 and 2-.
WARNING

off line.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Vehicles up to 05.2006:
– Unscrew fuel pipe -4- from connection -3-. At the same time
counterhold connection -3-.
– Unscrew banjo bolt -2-, at the same time counterhold connec‐
tion -1-.
Vehicles from 05.2006:

– Open hose clip -1- and pull fuel hose off.
– Unscrew fuel pipe -3-, at the same time counterhold connec‐
tion -2-.
– Remove bolts -arrows- and carefully remove high-pressure

pump.
Note
Under certain circumstances, the plunger ⇒ Item 1 (page 288)

may become stuck in the cylinder head.
Installing:
– Renew O-ring for high-pressure pump (lubricate lightly with
clean engine oil before fitting).
– Check plunger ⇒ Item 1 (page 288) for damage and insert in
cylinder head.
– Carefully place high-pressure pump in position on cylinder

head and tighten bolts -arrows- hand tight.
– Bolt on fuel pipes hand-tight.
Note
Before installing fuel pipes, check torque for threaded unions.
– Then tighten all bolts and fuel pipes to specified torque

⇒ page 287 .
Further assembly is performed in the reverse order of removal.
1.16 Removing and installing fuel pressure

sender - G247-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Double hexagon socket, 27 mm - VAS 5301/7-
WARNING
♦ Observe safety precautions when releasing fuel pressure

in high-pressure section ⇒ page 141
Removing:
– Detach coolant pipe and oil dipstick tube from intake manifold
-arrows-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Push oil dipstick tube downwards to right -arrow-.

– Release connector from fuel pressure sender - G247- using
assembly tool - T10118- .
WARNING
The fuel rail is pressurized. Wear protective goggles and pro‐

tective clothing to avoid injury and contact with the skin. Before
loosening the fuel pressure sender - G247- wrap a cloth around
the connection. Then release pressure by carefully loosening
the connection.
– Unscrew fuel pressure sender - G247- using deep hexagon

socket, 27 mm - VAS 5301/7- .
Installing:
note the following:
Specified torques ⇒ Item 19 (page 285) .
1.17 Checking fuel pressure sender - G247-

♦ Double hexagon socket, 27 mm - VAS 5301/7-

♦ Pressure sensor tester - VAS 6394-
♦ Test adapter - VAS 5570-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Procedure
WARNING
♦ The fuel pressure sender is under pressure! Wear protec‐

tive goggles and protective clothing to avoid injury and
contact with the skin. Before loosening fuel pressure send‐
er, wrap a cloth around the connection. Then release
pressure by carefully loosening the connection.
– Remove fuel pressure sender - G247- ⇒ page 290

– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester - VAS 6394/1- . Specified torque: 22 Nm
– Moisten tapered seal of adapter - VAS 6294/2- with clean en‐

gine oil and screw into fuel rail. Specified torque: 22 Nm
– Connect pressure line of tester - VAS 6394/1- to adapter - VAS

6394/2- .
– Connect fuel pressure sender -1- and electrical connector of
fuel pressure sender using test instrument adapter - VAS
5570- .
– Install engine cover panel/air filter again and reconnect the air
mass meter - G70- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Switch on tester - VAS 6394/1- to do this, press button -A- once

briefly.
Note
♦ When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.
♦ If the pressure tester - VAS 6394/1- reading is not 0 bar, carry
out a zero point procedure ⇒ operating instructions .
– Connect vehicle diagnostic tester to diagnostic connection.

– Press following buttons on display of diagnostic tester one af‐
ter the other:
Vehicle self-diagnosis
Self-diagnosis ►
01 - Engine electronics ►
011 - Measured values ►
– Select measured value block 1 4 0 and confirm with Q .

The actual fuel pressure value is shown in display zone 3, meas‐
ured by the fuel pressure sender - G247- .
– Start engine.
– Compare the displayed pressure of pressure tester - VAS
6394/1- with the displayed actual value on vehicle diagnostic
tester .
• A maximum pressure deviation of 5 bar is permissible.
– If the deviation is greater than 5 bar, renew fuel pressure
sender - G247- .
WARNING
The tester - VAS 6394- is under extreme fuel pressure! With

engine running, pull connector off fuel pressure sender -
G247- . This reduces fuel pressure to approx. 6 bar. Switch off
ignition. Place a cleaning cloth around fuel pressure sender -
G247- , then reduce residual pressure by carefully loosening
fuel pressure sender - G247- .
– Repeat the test with the new fuel pressure sender - G247- and
compare both measured values.
If measured values again fail to correspond:
– Check wiring ⇒ Vehicle diagnostic tester.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.18 Removing and installing injectors

Special tools and work‐
shop equipment re‐
quired
♦ Tool set - T10133-
Injector components
1- Radial compensa‐
tion element (re‐
new)
2- Combustion cham‐
ber ring seal (Tef‐
lon ring seal), re‐
new; when fitting,
do not grease ring
or use any other lu‐
bricant.
3- Groove in injector.
4- Support washer
(renew).
5- O-ring (renew; to
install, lightly lubri‐
cate with clean en‐
gine oil).
6- Support ring
Removing:
– Remove intake mani‐
fold ⇒ page 277 .
– Seal intake ports with
a clean cloth.
– Use a screwdriver to bend retaining hooks of radial compen‐

sation element to side, and pull support ring off injector.
Note
The retaining hooks of radial compensation element are damaged

by this action (retaining hooks bend or break). The radial com‐
pensation element must be renewed before injector is refitted.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Screw slide hammer - T10133/3- to puller - T10133/2- . Then

guide puller - T10133/2- into groove in injector and carefully
hammer injector out.
Installing:
Note
♦ The Teflon seal on the injector must not be oiled or greased.

♦ It is possible that an open inlet valve hinders cleaning. In this
case, turn engine by hand at crankshaft using a spanner.
– Thoroughly clean holes of high-pressure injectors in cylinder

head using a nylon brush - T10133/4- .
– Renew O-ring, radial compensation element, support washer
and Teflon seal of injector ⇒ page 296 .
– Insert injector in hole in cylinder head to stop using drift -

T10133/9- .
– Ensure correct position of injectors in cylinder head.
1.19 Renewing Teflon seal on injector


Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Tool set - T10133-
Note
The Teflon ring must not be lubricated.
– Carefully clean injector in area of seal -arrow-. Remove coking

deposits using a brass wire brush.
– Carefully cut open seal with a knife.
– Clean groove for seal.
– Fit new seal onto assembly cone - T10133/5- . Push seal as

far as possible onto assembly cone - T10133/6- using assem‐
bly sleeve - T10133/5- .
– Turn assembly sleeve - T10133/6- around and push seal to

end of assembly cone - T10133/5- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Fit assembly cone - T10133/5- onto injector and push seal on‐
to injector using assembly sleeve - T10133/6- .
– Remove assembly cone - T10133/5- and push seal into
groove using assembly sleeve - T10133/6- .
– Push calibration sleeve - T10133/7- onto injector as far as it

will go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve - T10133/7- off again by turning it in the
opposite direction.
– Now press calibration sleeve - T10133/8- onto injector to stop

by turning gently (approx. 180°).
– Pull calibration sleeve - T10133/8- off again by turning it in the
opposite direction.
– Renew O-ring on injector and on support washer.
– Attach support ring -1- to injector and clip radial compensation

-2- into support ring.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
2 Checking components
Checking double non-return valve
– Remove connectors from activated charcoal filter solenoid

valve 1 - N80- and fuel pressure sender for low-pressure -
G410- -arrows-.
– Remove activated charcoal filter solenoid valve 1 - N80- -B-
from hose -A-.
sition -A- (vacuum).
– Connect hand vacuum pump - VAS 6213- to hose to double

non-return valve -arrow-.
– Operate hand vacuum pump - VAS 6213- several times, vac‐
uum must build up.
If no vacuum builds up, renew double non-return valve.
2. Checking components 299

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
3 Engine control unit - J623- , Golf, Eos

Removing and installing engine control unit - J623- ⇒ page 300
Removing and installing anti-theft engine control unit - J623-
⇒ page 300
3.1 Removing and installing engine (motor)

control unit - J623-
Note
If you wish to renew the engine control unit, connect the vehicle
diagnostic tester and perform the guided function “Renewing en‐
gine control unit”.
Removing
chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing windscreen
wiper system .
– Release front connector -1- from engine control unit and pull
it off.
– Lever up catch -2- slightly.
– Then push engine control unit out of retainer -arrow-.
– Then release rear connector on engine control unit and pull it
off.
Installing
– Fit rear connector to engine control unit and lock in position.
– Push engine control unit onto bracket.
– Fit front connector to engine control unit and lock it in position.
– Install plenum chamber bulkhead, plenum chamber cover and
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys‐
tem .
3.2 Removing and installing anti-theft en‐

gine control unit - J623-
♦ Electric cutter - V.A.G 1561 A-
♦ Saw set - V.A.G 1561/14-

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
♦ Grip pliers
♦ Hot air blower from wiring harness repair set - VAS 1978-
Note
If the engine control unit is to be renewed, connect vehicle diag‐

nostic, testing and information system - VAS 5051B- and perform
“Renewing engine control unit” in guided functions.
Removing:
chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing windscreen
wiper system .
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat (scorching/
melting of plastics etc.).
Perform settings on hot air blower -4- as shown:
3. Engine control unit J623 , Golf, Eos 301

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Turn temperature setting potentiometer -2- to maximum heat

output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat the bolts.
– Remove bolts with grip pliers .
Note
If the bolts will not move, saw into heads of shear-head bolts so
that two parallel slots are created -arrows- and then remove the
bolts.
– Insert a screwdriver between protective housing -A- and

bracket -arrow-.
– Lever up protective housing using screwdriver -A- and pull to

side off bracket -arrow-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Release front connector -1- from engine control unit and pull
it off.
– Lever up catch -2- slightly.
– Then push engine control unit out of retainer -arrow-.
– Then release rear connector on engine control unit and pull it
off.
Installing:
– Fit rear connector to engine control unit and lock in position.
– Push engine control unit onto bracket.
– Fit front connector to engine control unit and lock it in position.
– Push protective housing onto bracket.
– Tighten new shear-head bolts -1- evenly until heads shear off.
– Install plenum chamber bulkhead, plenum chamber cover and
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys‐
tem .
3. Engine control unit J623 , Golf, Eos 303

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
4 Engine control unit - J623- (Passat)
Note
From November 2006 a modified anti-theft protection has been

introduced. Identification: Locking clip instead of locking plate
Removing and installing engine control unit - J623- ⇒ page 304

Removing and installing anti-theft engine control unit - J623- (with
locking plate) ⇒ page 305
Removing and installing anti-theft engine control unit - J623- (with
locking plate) ⇒ page 309
4.1 Removing and installing engine (motor)

control unit - J623-
Note
DANGER!
For vehicles with heavy duty running gear; vehicle must be re‐
stricted to a maximum of 210 km/h via the engine control unit.
Drive shafts can be damaged at speeds above 210 km/h. Per‐
form function “Restricting maximum speed” in Guided function
using ⇒ Vehicle diagnostic tester.
Removing:
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐
view - plenum chamber cover .
– Pull connector -1- off heated windscreen control unit - J505- .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
– Remove retainer frame with engine control unit from plenum
chamber.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Press locking device -1- outwards and slide engine control unit
-2- from retaining frame.
Installing:
– Slide engine control unit -1- into retaining frame in direction of

arrow.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer: 6 Nm.
– Tighten securing bolts -3- to 7 Nm.
– Fit connectors to engine control unit and slide locking devices
-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Flush-bonded windows; Assembly overview
- plenum chamber cover .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms.

gine control unit - J623- (with locking
plate)
Note
DANGER!
4. Engine control unit J623 (Passat) 305

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

♦ Grip pliers
Removing:
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat (scorching/
melting of plastics etc.).
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat the bolts.
– Unscrew shear-head bolt -2- using pliers on bolt head.
The procedure for the second shear-head bolt is exactly the
same.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Pull connector -1- off heated windscreen control unit - J505- .
– Lift cover -1- and pull it forwards.

– Remove retainer frame with engine control unit from plenum
chamber.
– Press locking device -1- outwards and slide engine control unit
-2- from retaining frame.
Installing:

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Slide engine control unit -1- into retaining frame in direction of

arrow.
– Fit retainer frame with engine control unit onto retainer in ple‐
num chamber.
Specified torque of securing nuts for retainer: 6 Nm.

-1- inwards.
– Slide cover -1- over engine control unit and press it down‐
wards.
– Tighten new shear-head bolts -2- evenly until bolt head shears
off.
– Fit connector -1- to heated windscreen control unit - J505- .

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

gine control unit - J623- (with locking
clip)
Note
DANGER!

♦ Grip pliers
– If the engine control unit is to be renewed, connect vehicle
diagnostic, testing and information system - VAS 5051 B- and
perform “Renewing engine control unit” in guided functions.
Removing:
Note
In some vehicles covers are installed to protect the engine control

unit from water. These are tightened to the engine control unit by
bolts -1-.
– Unscrew bolts -1-.

– Remove cover, if fitted.
– Cover the plenum chamber with a clean cloth so that it is not
scratched.
– Raise engine control unit with control unit bracket slightly.
– Release engine control unit -arrows- and pull out slightly.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.

– Remove engine control unit.
Installing:
– Slide engine control unit -1- in direction of -arrow- into control

unit retainer until it engages.

-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Tighten control unit bracket and, if fitted, the cover to bracket

with bolts -1-.
Specified torque
Control unit bracket to bracket 6 Nm

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ Do not bend the decoupling element in the front exhaust pipe

by more than 10° because it might otherwise be damaged.
♦ 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 clamp and align silencers and
exhaust pipe so that sufficient clearance is maintained to the
bodywork at all points and the mountings are evenly loaded.
♦ The exhaust manifold and the turbocharger are one compo‐
nent, removing and installing ⇒ page 248 .
Assembly overview - exhaust system ⇒ page 312 .

Separating centre and rear silencers ⇒ page 316
Removing and installing front exhaust pipe with catalytic convert‐
er ⇒ page 318
Aligning exhaust system free of tension ⇒ page 320 .
1.1 Assembly overview - exhaust system; Golf, Eos
312 Rep. gr.26 - Exhaust system

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1 - 40 Nm
❑ Renew
perature paste.
2 - Catalytic converter
❑ With front exhaust pipe
❑ Protect from damage by
knocks and impact.
❑ With decoupling ele‐
ment.
❑ Do not bend flexible joint
more than 10° - other‐
wise it can be damaged.
⇒ page 318
❑ Aligning exhaust sys‐
tem free of tension
⇒ page 320 .
3 - Lambda probe after catalyt‐
ic converter - G130-
❑ 55 Nm
❑ Bank 1, probe 2
❑ Grease only the threads
with high-temperature
paste. The paste must
not penetrate into the
slots on the probe body
4 - Retainer
5 - 25 Nm
6 - Rear silencer
❑ In initial equipment,
component with centre silencer. Can be renewed individually for repair purposes.
❑ Aligning exhaust system free of tension ⇒ page 320 .
❑ Separate exhaust system ⇒ page 316
7 - Mounting
8 - 25 Nm
9 - Rear clamp
❑ For separate replacement of centre and rear silencers
❑ Tighten bolted connections evenly.
10 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Aligning exhaust system free of tension ⇒ page 320 .
11 - 25 Nm
12 - Front clamp
❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 320
1. Removing and installing parts of exhaust system 313

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
13 - 25 Nm
14 - Mounting
15 - Mounting
16 - Seal
❑ Renew
17 - Lambda probe - G39-
❑ 55 Nm
❑ Bank 1, probe 1
❑ Grease only the threads with high-temperature paste. The paste must not penetrate into the slots on the
probe body
1.2 Assembly overview - exhaust system, Passat
1 - Seal
❑ Renew
2 - Lambda probe - G39-
❑ Bank 1, probe 1
❑ 55 Nm
with high-temperature
paste. The paste must
not penetrate into the
slots on the probe body
3 - 40 Nm
❑ Renew
perature paste.
4 - Heat shield
5 - Catalytic converter
❑ With front exhaust pipe
❑ Protect from damage by
knocks and impact.
❑ With decoupling ele‐
ment.
❑ Do not bend flexible joint
more than 10° - other‐
wise it can be damaged.
⇒ page 318
6 - Lambda probe after catalyt‐
ic converter - G130-
❑ 55 Nm
❑ Bank 1, probe 2
with high-temperature paste. The paste must not penetrate into the slots on the probe body
7 - Retainer

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
8 - 25 Nm
9 - Mounting
10 - Rear silencer
❑ In initial equipment, component with centre silencer. Can be renewed individually for repair purposes.
11 - Rear clamp
❑ For separate replacement of centre and rear silencers
12 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
13 - Front clamp
14 - Mounting
❑ For centre silencer
15 - Mounting
❑ For catalytic converter
1.3 Clamps
Installation position of front clamp
– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Bolted connection faces to right.
Installation position of rear clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolted connection faces to right (Passat) or to rear (Golf, Eos).

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
1.4 Separating centre and rear silencers,

Golf, Eos
Note
♦ The connecting pipe can be cut through at the cutting location

in order to renew the centre and rear silencers separately.
♦ The cutting point is marked by indentations on the periphery
of the exhaust pipe.

♦ Chain-type pipe cutter - VAS 6254-
Or
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.
– Cut through exhaust pipe at cutting point -arrow 2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position clamp -4- centrally at side marks when installing, ar‐
rows -1- and -3-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Install clamp so that bolt ends do not protrude beyond lower

edge of clamp -arrow-.
• Threaded connection faces to rear.
– Align exhaust system free of stress ⇒ page 320 .
Specified torques
Component Nm
Clamping sleeve 25
1.5 Separating centre and rear silencers,

Passat
Note
♦ The connecting pipe can be cut through at the cutting location

in order to remove and install or renew the centre and rear
silencers separately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.

♦ Pneumatic sabre saw - V.A.G 1523 A-
Or
♦ Chain-type pipe cutter - VAS 6254-
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Cut through exhaust pipe at right angles using e.g. body saw
- V.A.G 1523 A- at separating point -arrow-.
– Position clamping sleeve between side markings when instal‐
ling.
– Install clamp so that ends of bolts do not protrude beyond bot‐

tom of clamp.
– Align exhaust system so that the distance -a- on left and right
is even.
1.6 Removing and installing front exhaust

pipe with catalytic converter
Removing:
– Disconnect connector for Lambda probe - G39- -arrow- and
lay cable to side.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove securing nuts -arrows- for front exhaust pipe/turbo‐

charger.
– Remove right underbody panel -arrows-.
– Disconnect connector for Lambda probe after catalytic con‐

verter - G130- -arrow- and lay cable to side.
Note
The flexible joint in front exhaust pipe must not be bent more than
10° - risk of damage.
– Separate exhaust system at clamp -arrows-.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Remove front cross member for underbody -arrows-.
– Unbolt bracket for exhaust system -arrows-.

– Remove catalytic converter with front exhaust pipe.
Installing:
note the following:
♦ Coat turbocharger studs with high-temperature paste; high-
temperature paste ⇒ ETKA (Electronic Parts Catalogue) .
♦ Align exhaust system free of stress ⇒ page 320 .
Specified torques
Component Nm
Front exhaust pipe to turbocharger 40
Tunnel cross-piece to body 25
Mounting to subframe 25
Clamping sleeve 25
1.7 Aligning exhaust system free of stress

• The exhaust system must be aligned when cold.
– Loosen bolts -3 and 4- on front clamp -1-.
– Align front clamp -1- to marking -A- on front exhaust pipe -2-
(-arrow- points forwards).
• Dimension -a- = 5 mm
• The bolts must be on the right and the ends of the bolts must
not protrude beyond the lower edge of the clamp.
– Tighten front clamp bolts -3- hand-tight.

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
– Push exhaust system forward until preload on rear silencer

retainer is dimension -a- 15…17 mm.
– In this position, tighten bolts -3 and 4- on front clamp evenly

to 25 Nm.
Installation position of front clamp

• Threaded connection faces right
Installation position of rear clamp

• Bolted connection faces to right (Passat) or to rear (Golf, Eos).

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
28 – Ignition system
1 Repairing ignition system
General notes on ignition system ⇒ page 322 .
Assembly overview - ignition system ⇒ page 322 .
Removing and installing ignition coils with output stage
⇒ page 323 .
Test data, spark plugs ⇒ page 324
1.1 General notes on ignition system

♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ To complete work, read fault memory of engine control unit.
Delete all fault entries which may have occurred during tests
and repairs. If the fault memory was cleared, the readiness
code must be generated ⇒ Vehicle diagnostic tester.“Guided
functions”.
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted ⇒ Vehicle diag‐
nostic tester “Guided Functions”.
1.2 Safety precautions

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
1.3 Assembly overview - ignition system
Note
The engine speed sender - G28- can be found on the cylinder

block ⇒ Item 14 (page 22) .
322 Rep. gr.28 - Ignition system

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

❑ To remove, the coolant
thermostat housing
must be removed
⇒ page 133
❑ To remove, the oil filter
bracket must be re‐
moved ⇒ page 111
3 - Ignition coil with output
stage - (N70, N127, N291,
N292)-
⇒ page 323
4 - Spark plug
❑ 25 Nm
❑ Type and electrode gap
⇒ page 324 .
❑ Remove and install with
spark plug socket and
extension - 3122 B-
5 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
6 - 10 Nm
8 - O-ring
1.4 Removing and installing ignition coils

with output stage
♦ Puller - T40039-
1. Repairing ignition system 323

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤
Removing ignition coils with output stages
Note
♦ Observe all relevant safety precautions ⇒ page 322 .

♦ Assembly overview - ignition system ⇒ page 322 .
♦ To pull off spark plugs, fit puller - T40039- onto uppermost,
thick rib -arrow- of ignition coils with final output stages.
♦ If the lower ribs are used, they could be damaged.
– Release connectors and pull all connectors off ignition coils at

the same time.
– Pull all ignition coils out of spark plug recess using puller -
T40039- .
Installing ignition coils with output stages
– Fit all ignition coils loosely into spark plug recess.
– Align the ignition coils with the connectors and attach all con‐
nectors onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand with uniform
pressure.
1.5 Test data, spark plugs

Firing order 1-3-4-2
Spark plugs
VW/Audi 101 905 631 H1)
324 Rep. gr.28 - Ignition system

Eos 2006 ➤ , Golf 2004 ➤ , Passat 2006 ➤

Electrode gap 0.7…0.8 mm
Specified torque 25 Nm
Change interval ⇒ Maintenance ; Booklet ; Service tables
1)For current part numbers, please see ⇒ Electronic Parts Cata‐

logue (ETKA)
1. Repairing ignition system 325

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Copyright © 2017 Volkswagen AG, Wolfsburg K0058992820

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

7.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

1.10 Assembly overview - fuel rail (vehicles from 05.2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

Special tools and workshop

♦ Torque wrench - V.A.G 1331-

1. Removing and installing engine 3

1.1 Removing engine

♦ The battery earth must be disconnected for the remaining pro‐

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

– Disconnect earth strap at battery with ignition switched off ⇒

4 Rep. gr.10 - Removing and installing engine

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

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

– Unscrew cable from alternator at fuse holder -arrow-.

– Unscrew earth cable from longitudinal member -arrow-.

1. Removing and installing engine 5

– Open wiring guide catches on longitudinal member -arrows-.

The fuel system is pressurised!

– Disconnect lines -1, 2 and 3-. Do this by operating release

The fuel system is pressurised!

– Disconnect breather line -1- and fuel supply line -2-.

– Disconnect breather line -2-. Pull activated charcoal filter with

6 Rep. gr.10 - Removing and installing engine

– Remove left and right wheel housing liner front part.

– Remove charge air hoses -arrows-.

– Unbolt heat shield for right-hand drive shaft -arrows-.

– Disconnect refrigerant line -arrow- from air conditioner com‐

1. Removing and installing engine 7

– Remove refrigerant line from condenser -arrow-.

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

– Clamp-off hose for pipe/hose line -A- to slave cylinder using

Do not operate clutch pedal any more.

Vehicles with automatic gearbox:

– Unscrew coolant circulation pump - V50- -arrows-.

8 Rep. gr.10 - Removing and installing engine

– Place engine bracket - T10012- on engine as shown and tight‐

– Unscrew assembly mounting on engine side from engine

– Unscrew assembly mounting on gearbox side from gearbox

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

– Carefully lower engine with gearbox.

1.2 Securing engine to assembly stand

1. Removing and installing engine 9

Special tools and workshop

♦ Lifting tackle - 2024 A-

10 Rep. gr.10 - Removing and installing engine

– Attach lifting tackle - 2024 A- as follows and lift from engine

1.3 Installing engine

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