Engine Cjza CJZB CJZC CJZD Cyva Cyvb Cyvd Repair Manual Eng
Engine Cjza CJZB CJZC CJZD Cyva Cyvb Cyvd Repair Manual Eng
Engine Cjza CJZB CJZC CJZD Cyva Cyvb Cyvd Repair Manual Eng
Workshop Manual
Golf 2013 ➤ , Golf 2017 ➤ ,
Golf Cabriolet 2012 ➤ ,
Golf Sportsvan 2015 ➤ ,
Golf Variant 2014 ➤ ,
Golf Variant 2017 ➤ , Polo 2014 ➤ ,
Touran 2016 ➤
4-cylinder direct injection engine (1.2 l engine, 4V, EA
211, turbocharger)
Engine ID CJZA CJZB CYV CYV CJZC CJZD CYV
A B D
Edition 04.2020
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Contents i
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 209
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.2 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 217
4.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
ii Contents
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.7 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 250
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 251
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 252
2.10 Removing and installing radiator fan thermal switch F18 . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.4 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 276
4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.6 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 298
1.4 Removing and installing connection for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
2.5 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Contents iii
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
iv Contents
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
00 – Technical data
1 Safety information
(VRL014138; Edition 04.2020)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with start/stop
system”, page 1
⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
⇒ “1.4 Safety precautions when working on the cooling system”,
page 2
⇒ “1.5 Safety precautions when working on ignition system”, page
2
1. Safety information 1
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
Or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
2 Identification
⇒ “2.1 Engine number/engine data”, page 3
Note
2. Identification 3
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
3 Repair notes
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 General information”, page 5
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Foreign objects in engine”, page 6
⇒ “3.5 Contact corrosion”, page 6
⇒ “3.6 Routing and attachment of lines”, page 6
⇒ “3.7 Fitting radiator and condensers”, page 6
⇒ “3.8 Checking vacuum system”, page 6
3. Repair notes 5
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
Sequence of operations
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
– If an entry is stored in the event memory, check all vacuum
lines leading to the corresponding component and also check
the remaining vacuum lines leading to other components.
– If pressure cannot be built-up using hand vacuum pump - VAS
6213- or pressure immediately drops again, check hand vac‐
uum pump and connecting hoses for leaks.
3. Repair notes 7
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
– Loosen bolt -1- until clamp -2- can be pushed over catalytic
converter.
– Release and pull off fuel lines -1- and -2- ⇒ Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .
Note
For the work steps below use removal lever - 80 - 200- to unclip
the binding clips.
Manual gearbox
– Disconnect connectors -1- and -2-.
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Remove clutch slave cylinder and lay aside with hydraulic line
still connected ⇒ Rep. gr. 30 ; Clutch mechanism; Removing
and installing clutch slave cylinder .
– Do not open hydraulic system when doing this. Lay clutch
slave cylinder to one side.
Dual clutch gearbox
– Remove selector lever cable, pull connector off mechatronic
unit, and remove all retainers from gearbox ⇒ Rep. gr. 34 ;
Removing and installing gearbox; Removing gearbox .
– Unscrew nuts for coupling rod -arrow- on left and right of anti-
roll bar.
– Remove pendulum support
⇒ “2.4 Removing and installing pendulum support”,
page 60 .
– Remove drive shaft heat shield ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive
shaft heat shield .
Note
Note
CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
Note
For the work steps below use removal lever - 80 - 200- to unclip
the binding clips.
– Loosen bolt -1- until clamp -2- can be pushed over catalytic
converter.
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
– Disconnect coolant hoses -1- and -2- from heat exchanger for
heater.
– To do this, lift securing clips in -direction of arrow-.
Note
♦ Safety glasses
♦ Safety gloves
Removing
Note
– Release and pull off lower connector -1- on engine control unit
- J623- . Separate connection -4-.
– Unscrew bolts -2- and -3- on fuse box, and pull off lines.
– Place wiring harness on engine.
– Loosen bolt -1- until clamp -2- can be pushed over catalytic
converter.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation .
– Remove front right and front left wheel housing liners ⇒ Rep.
gr. 66 ; Wheel housing liner; Removing and installing front
wheel housing liner .
– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– Move clear electrical wiring harness, and lay it to one side.
– Remove right and left drive shafts ⇒ Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
– If fitted, unbolt front left vehicle level sender - G78- on trans‐
verse link ⇒ Running gear, axles, steering; Rep. gr. 43 ;
Vehicle level sender; Assembly overview - front vehicle level
sender .
– Remove radiator cowl.
⇒ “4.5 Removing and installing radiator cowl”, page 285
– Open spring-type clip -arrow- and pull off coolant hose down‐
wards.
– Open spring-type clips -arrows-.
Note
Sequence of operations
• Engine/gearbox assembly removed and attached to engine
bracket - T10497- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Attach shackle - 10-222 A/12- to gearbox and screw in pin to
stop.
– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /
2- to lifting tackle.
Sequence of operations
• Gearbox detached from engine
⇒ “1.2 Separating engine and gearbox”, page 37 .
Note
Note
– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
– Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.
– Install gearbox support.
– Take up engine/gearbox assembly with engine support -
T10497- .
– Guide engine/gearbox assembly into body.
– Bring engine/gearbox assembly into position on mountings.
– Install engine mounting
⇒ “2.2 Removing and installing engine mounting”, page 52 .
– First screw in bolts for mountings to stop by hand.
– The bolts are tightened to final torque only after adjusting the
assembly mountings
⇒ “2.6 Adjusting assembly mountings”, page 80 .
– Tighten bolts
⇒ “2.1 Assembly overview - assembly mountings”,
page 44 .
– Remove - T10497- from engine.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐
sembly overview - starter .
Vehicles with manual gearbox
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;
Removing and installing clutch slave cylinder .
– Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐
lector mechanism; Assembly overview - selector cables .
Vehicles with dual clutch gearbox
– Install selector lever cable, fit connector of mechatronic and
install all retainers on gearbox:⇒ Rep. gr. 34 ; Removing and
installing gearbox
Continued for all vehicles
– Install catalytic converter
⇒ “2.2 Removing and installing catalytic converter”,
page 400 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Assembly overview - drive shaft .
– Install transverse link, swivel joint and coupling rod ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Lower transverse link,
swivel joint; Assembly overview - lower transverse link, swivel
joint .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Install poly V-belt
⇒ “1.2 Removing and installing poly-V belt”, page 88 .
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, electron‐
ics boxes and ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Install engine control unit - J623-
⇒ “8 Engine control unit”, page 360 .
– Connect coolant hoses with plug-in connector ⇒ page 264 .
Note
Note
Specified torques
Note
♦ The specified torques are only valid for nuts and bolts which
have been slightly greased, oiled, phosphate-treated or black-
oxided.
♦ Additional lubricant such as engine oil or gear oil may be used,
but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ The tolerance for specified torques varies by ± 15%.
Component Nm
Bolts and nuts 9
15
20
M10 40
M12 65
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”,
page 44 .
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
page 265
♦ ⇒ “2.1 Assembly overview - emission control”, page 397
♦ ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Assembly
overview - vacuum pump
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower sus‐
pension link, swivel joint; Assembly overview - lower suspen‐
sion link, swivel joint .
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Assembly overview - drive shaft
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Installing
gearbox
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified
torques for gearbox
♦ ⇒ Electrical system; Rep. gr. 27 ; Starter; Assembly overview
- starter
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Assembly overview - drive unit of air conditioner
compressor
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 44
⇒ “2.2 Removing and installing engine mounting”, page 52
⇒ “2.3 Removing and installing gearbox mountings”, page 56
⇒ “2.4 Removing and installing pendulum support”, page 60
⇒ “2.5 Supporting engine in installation position”, page 63
⇒ “2.6 Adjusting assembly mountings”, page 80
⇒ “2.7 Checking adjustment of assembly mountings (engine and
gearbox mountings)”, page 82
2.1.1 Assembly overview - assembly mountings, Golf, Golf Estate, Golf SV, Tour‐
an
1 - Bolt
❑ Renew
❑ Tightening sequence
⇒ Fig. ““Engine support
- specified torque and
installation sequence”“ ,
page 95
2 - Engine support
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling engine support”,
page 92
❑ Specified torque and
tightening sequence
⇒ Fig. ““Engine support
- specified torque and
installation sequence”“ ,
page 95
3 - Engine mounting
❑ With support arm
❑ Removing and installing
⇒ “2.2.1 Removing and
installing engine mount‐
ing, Golf, Golf Estate,
Golf SV, Touran”,
page 52
4 - Bolt
❑ Renew
❑ 40 Nm +90°
5 - Bolt
❑ Renew
❑ 23 Nm +90°
6 - Bolt
❑ 8 Nm
7 - Bracket
8 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
9 - Pendulum support
❑ Removing and installing
⇒ “2.4.1 Removing and installing pendulum support, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet”,
page 60
10 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence
⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
11 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence
⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
12 - Bolts
❑ Renew after removal
❑ Specified torque and tightening sequence
⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
2. Assembly mountings 45
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
13 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
14 - Bolt
❑ Renew
❑ 60 Nm +90°
15 - Bolt
❑ Renew
❑ 50 Nm +90°
16 - Gearbox mounting
❑ With support arm
❑ Removing and installing
⇒ “2.3.1 Removing and installing gearbox mounting, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet”,
page 56
1 - Connection
2 - Bolt
❑ Connection to engine
mounting and body
❑ Renew after removal
❑ 20 Nm +90°
3 - Bolt
❑ Connection to engine
mounting and body
❑ Renew after removal
❑ 20 Nm +90°
4 - Bolts
❑ Engine mounting to en‐
gine support
❑ Renew after removal
❑ 60 Nm +90°
5 - Bolt
❑ For bracket for activated
charcoal filter
❑ Renew after removal
❑ 20 Nm +90°
6 - Centre hex stud
❑ Engine mounting to
body
❑ Renew after removal
❑ 40 Nm +90°
7 - Bolt
❑ Engine mounting to
body
❑ Renew after removal
❑ 40 Nm +90°
8 - Engine mounting
❑ Removing and installing ⇒ “2.2.2 Removing and installing engine mounting, Golf Cabriolet”, page 52
9 - Bracket
❑ For activated charcoal filter
10 - Bolt
❑ Engine support to engine
❑ Renew after removal
❑ Specified torque and tightening sequence
⇒ Fig. ““Engine support - specified torque and installation sequence”“ , page 95
11 - Engine support
❑ Removing and installing ⇒ “1.5 Removing and installing engine support”, page 92
❑ Specified torque and tightening sequence
⇒ Fig. ““Engine support - specified torque and installation sequence”“ , page 95
12 - Bolt
❑ Gearbox mounting to gearbox support
❑ Renew after removal
❑ 60 Nm +90°
13 - Bolt
❑ Gearbox mounting to body
❑ Renew after removal
❑ 40 Nm +90°
14 - Gearbox mounting
❑ Illustration shows version for dual clutch gearbox.
15 - Bolt
❑ Gearbox support to gearbox
Specified torques:
❑ Vehicles with manual gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques for
gearbox
❑ Vehicles with dual clutch gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques
for gearbox
16 - Centre hex stud
❑ Gearbox support to gearbox
Specified torques:
❑ Vehicles with manual gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques for
gearbox
❑ Vehicles with dual clutch gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques
for gearbox
17 - Gearbox support
18 - Pendulum support
❑ Removing and installing
⇒ “2.4.1 Removing and installing pendulum support, Golf, Golf Estate, Golf SV, Touran, Golf Cabriolet”,
page 60
❑ Bolt pendulum support to gearbox and then to subframe.
19 - Bolt
❑ Pendulum support to subframe
❑ Renew after removal
❑ Specified torque: ⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
20 - Bolts
❑ Pendulum support to gearbox
2. Assembly mountings 47
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
❑ Renew after removal
❑ Specified torque: ⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“ , page 61
2.1.3 Assembly overview - assembly mountings, Polo with dual clutch gearbox
1 - Engine support
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling engine support”,
page 92
❑ Specified torque and
tightening sequence
⇒ Fig. ““Engine support
- specified torque and
installation sequence”“ ,
page 95
2 - Bolt
❑ Renew after removal
❑ Specified torque and
tightening sequence
⇒ Fig. ““Engine support
- specified torque and
installation sequence”“ ,
page 95
3 - Engine mounting
❑ Removing and installing
⇒ “2.2.3 Removing and
installing engine mount‐
ing, Polo”, page 54
❑ Aligning engine mount‐
ing
⇒ Fig. ““Aligning engine
mountings:”“ ,
page 55
4 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
❑ Qty. 4
5 - Nut
❑ The securing nut must
not be loosened.
6 - Centre hex stud
❑ With mounting for earth wire; specified torque ⇒ Fig. ““Earth strap on engine mounting”“ , page 49
❑ Renew after removal
❑ 30 Nm +90°
7 - Bolt
❑ Qty. 2
❑ Renew after removal
❑ 30 Nm +90°
8 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
❑ Tightening sequence
⇒ Fig. ““Tightening sequence - gearbox mounting, dual clutch gearbox”“ , page 49
9 - Gearbox mounting
❑ Removing and installing
❑ Tightening sequence - gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, dual clutch gearbox”“ , page 49 .
10 - Bolt
❑ Renew after removal
❑ 50 Nm +90°
❑ Tightening sequence - gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, dual clutch gearbox”“ , page 49 .
11 - Bolt
❑ Renew after removal
❑ 50 Nm +90°
❑ Qty. 2
❑ Tightening sequence - gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, dual clutch gearbox”“ , page 49 .
12 - Pendulum support
❑ Removing and installing ⇒ “2.4.2 Removing and installing pendulum support, Polo”, page 61
13 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
14 - Bolt
❑ Renew after removal
❑ 30 Nm +90°
❑ Qty. 2
2. Assembly mountings 49
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
1 - Engine support
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling engine support”,
page 92
❑ Specified torque and
tightening sequence
⇒ Fig. ““Engine support
- specified torque and
installation sequence”“ ,
page 95
2 - Bolt
❑ Renew after removal
❑ Specified torque and
tightening sequence
⇒ Fig. ““Engine support
- specified torque and
installation sequence”“ ,
page 95
3 - Engine mounting
❑ Removing and installing
⇒ “2.2.3 Removing and
installing engine mount‐
ing, Polo”, page 54
❑ Aligning engine mount‐
ing
⇒ Fig. ““Aligning engine
mountings:”“ ,
page 55
4 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
❑ Qty. 4
5 - Nut
❑ The securing nut must
not be loosened.
6 - Centre hex stud
❑ With mounting for earth wire ⇒ Fig. ““Earth strap on engine mounting”“ , page 52
❑ Renew after removal
❑ 30 Nm +90°
7 - Bolt
❑ Qty. 2
❑ Renew after removal
❑ 30 Nm +90°
8 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
❑ Tightening sequence ⇒ Fig. ““Tightening sequence - gearbox mounting, manual gearbox”“ , page 51
9 - Gearbox mounting
❑ Removing and installing ⇒ “2.3 Removing and installing gearbox mountings”, page 56
❑ Tightening sequence - gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, manual gearbox”“ , page 51 .
10 - Bolt
❑ Renew after removal
❑ 50 Nm +90°
❑ Tightening sequence - gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, manual gearbox”“ , page 51 .
11 - Bolt
❑ Renew after removal
❑ 50 Nm +90°
❑ Qty. 2
❑ Tightening sequence - gearbox mounting
⇒ Fig. ““Tightening sequence - gearbox mounting, manual gearbox”“ , page 51 .
12 - Pendulum support
❑ Removing and installing ⇒ “2.4.2 Removing and installing pendulum support, Polo”, page 61
13 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
14 - Bolt
❑ Renew after removal
❑ 30 Nm +90°
❑ Qty. 3
15 - Bolt
❑ Renew after removal
❑ 50 Nm +90°
Note
2. Assembly mountings 51
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
♦ Socket - T40055-
Removing
– Support engine in its installation position
⇒ “2.5 Supporting engine in installation position”, page 63 .
– Pull off breather line -arrow- ⇒ Rep. gr. 20 ; Plug-in connec‐
tors .
– Release locking lug -3- in direction of arrow, and remove ac‐
tivated charcoal filter -1- upwards.
– Place activated charcoal filter -1- on engine with line -2- con‐
nected.
– Unscrew bolt -4- and turn filler neck for washer fluid reservoir
-2- towards front.
– Open clip -3- and pull connector -5- off coolant expansion tank
-1-.
– Unscrew bolts -arrows- and place coolant expansion tank -1-
on engine with coolant hoses connected.
2. Assembly mountings 53
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Removing
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 323 .
– Release connectors -2- and pull off.
– Unscrew securing bolts -3-.
– Place coolant expansion tank -1- on top of engine.
– Support engine in installation position
⇒ “2.5.4 Supporting engine in installation position, Polo”, page
78 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
Note
Note
2. Assembly mountings 55
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
Golf Cabriolet:
– Remove resonator for intake air
⇒ “2.3 Removing and installing resonator for intake air”, page
324 .
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 323 .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
2. Assembly mountings 57
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
Removing
– Remove resonator for intake air
⇒ “2.3 Removing and installing resonator for intake air”, page
324 .
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 323 .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Release fastener, detach engine control unit - J623- , and
place it to one side.
– Release and pull off lower connector -1- on engine control unit
- J623- . Separate connection -4-.
– Unscrew bolts -2- and -3- on fuse box, and pull off lines.
– Support engine in installation position
⇒ “2.5.4 Supporting engine in installation position, Polo”, page
78 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
2. Assembly mountings 59
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
2. Assembly mountings 61
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
Vehicles with dual clutch gearbox:
– Unscrew bolts -arrows- for pendulum support.
Note
Note
Note
Specified torques
♦ ⇒ “2.1.3 Assembly overview - assembly mountings, Polo with
dual clutch gearbox”, page 48
♦ ⇒ “2.1.4 Assembly overview - assembly mountings, Polo with
manual gearbox”, page 50
♦ Adapter - T40091/3-
2. Assembly mountings 63
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
♦ Adapter - T40093/3-
♦ Adapter - T40093/3-6-
♦ Adapter - 10-222A/29-
2. Assembly mountings 65
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
2. Assembly mountings 67
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
♦ Adapter - T40091/3-
♦ Adapter - T40093/3-
♦ Adapter - T40093/3-6-
2. Assembly mountings 69
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
♦ Adapter - 10-222A/29-
2. Assembly mountings 71
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
2. Assembly mountings 73
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
♦ Spindles - 10-222A-
♦ Joints - T40091/3-
♦ Adapter - 10-222A/13-
♦ Adapter - 10-222A/28-
♦ Adapter - 10-222A/28-2-
♦ Shackle - 10 - 222 A /12-
2. Assembly mountings 75
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
2. Assembly mountings 77
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
2. Assembly mountings 79
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
– Fit adapter - 10 - 222 A /8- behind the hole -arrow- and align
it.
– Mount adapter - 10 - 222 A /32- to mountings on engine as
shown in illustration.
– Secure with tensioning strap - T10038- on both sides of bonnet
hinges.
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
Note
– On the gearbox side, ensure that the edges of the support arm
-2- and gearbox support -1- are parallel.
• Distance -x- = distance -x-.
– Tighten bolts for gearbox mounting.
Install in reverse order.
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 44
♦ ⇒ “2.1 Assembly overview - charge air system”, page 302
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 320
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 44
2. Assembly mountings 81
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
2. Assembly mountings 83
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4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 84
⇒ “1.2 Removing and installing poly-V belt”, page 88
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 90
⇒ “1.4 Removing and installing vibration damper”, page 91
⇒ “1.5 Removing and installing engine support”, page 92
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 95
1.1.1 Assembly overview - poly V-belt drive, vehicles without air conditioner com‐
pressor
1 - Bolt
❑ Renew
❑ Use counter-hold tool -
T10475- to loosen and
tighten
❑ 150 Nm +180°
2 - Vibration damper
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling vibration damp‐
er”, page 91
3 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen
❑ For allocation, refer to ⇒
Electronic parts cata‐
logue .
❑ Do not kink
❑ Poly V-belt routing
⇒ page 89
❑ Removing and installing
⇒ “1.2 Removing and in‐
stalling poly-V belt”,
page 88
❑ When installing, make
sure it is properly seated
on pulleys.
4 - Bolt
❑ Renew
❑ 20 Nm +90°
5 - Tensioning device for poly
V-belt
❑ Pivot with socket to slacken poly V-belt
❑ Lock with locking pin - T10060 A- .
❑ Removing and installing ⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 90
6 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
❑ With freewheel
❑ Various versions of the overrunning alternator pulley, -A- or -B-, may be fitted depending on the type and
version of alternator. Allocation ⇒ Fig. ““Allocation of overrunning alternator pulley”“ , page 86 .
❑ Determine length of poly V-belt according to ⇒ Electronic parts catalogue depending on version of over‐
running alternator pulley
1.1.2 Assembly overview - poly V-belt drive, vehicles with air conditioner com‐
pressor
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen
❑ Determine length of poly
V-belt according to ⇒
Electronic parts cata‐
logue depending on ver‐
sion of overrunning al‐
ternator pulley
❑ Do not kink
❑ Poly V-belt routing
⇒ Fig. ““Fit poly V-belt as
shown in illustration.”“ ,
page 90
❑ Removing and installing
⇒ “1.2.1 Removing and
installing poly V-belt, ve‐
hicles without air condi‐
tioner compressor”,
page 88
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Specified torque
⇒ Item 1 (page 85)
3 - Vibration damper
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling vibration damp‐
er”, page 91
4 - Tensioning device for poly
V-belt
❑ Pivot with socket to slacken poly V-belt
Removing
– To slacken poly V-belt, turn tensioner anti-clockwise -arrow-.
– Lock tensioning device in place with locking pin - T10060 A- .
Note
Note
Removing
– If poly V-belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen before removing.
– Fit tool -3- onto hexagon of tensioner -1-.
– To slacken poly V-belt push tool -3- in -direction of arrow-.
– Lock tensioner -1- in place with locking pin - T10060 A- -2-.
– Remove poly V-belt -4-.
Installing
Install in reverse order of removal, observing the following:
– Push tool -3- in -direction of arrow-, and pull out locking pin -
T10060 A- -2-.
– Release tension from tensioner -1-.
– Check that poly V-belt -4- is properly seated.
– Start engine and check that poly V-belt runs properly.
Note
Version 1
– Convert counterhold tool - T10475- -1- with inserts -T10475/2-
-2-.
Version 2
– Convert counterhold tool - T10475- with inserts -T10475/1-
and -T10475/2- as shown in illustration.
• To do this, use hole -A- or -B- of counterhold tool - T10475-
-1- depending on type of vibration damper.
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove poly V-belt
⇒ “1.2 Removing and installing poly-V belt”, page 88 .
– Set piston in cylinder no. 1 to »TDC« position
⇒ “4.7 Setting piston to TDC position”, page 119 .
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
Installing
Install in reverse order of removal, observing the following:
Note
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 227 .
– Remove resonator for intake air
⇒ “2.3 Removing and installing resonator for intake air”, page
324 .
– Remove air filter housing
⇒ “2.2 Removing and installing air filter housing”, page 323 .
– Remove tensioner for poly V-belt.
⇒ “1.3 Removing and installing tensioner for poly V-belt”, page
90
– Remove upper part of toothed belt guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”,
page 139 .
– Unscrew bolt -1-.
– Loosen hose clip -2- and pull off coolant hose.
– Unscrew bolts -1- and remove bracket -2- for catalytic con‐
verter.
– Pull off connector -1-.
– Open retaining clips on pipes of air conditioning system.
Note
Sequence of operations
– Remove toothed belt
⇒ “2.5 Removing and installing toothed belt”, page 148 .
– Detach crankshaft pulley -1- -arrow-.
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
Note
– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
– Draw in seal -3- to stop using thrust piece - T10485/4- -2- and
pulley bolt -1-.
Note
1 - Bolt
❑ Renew
❑ 60 Nm +90°
2 - Flywheel
❑ Removing and installing
⇒ “2.2 Removing and in‐
stalling flywheel”,
page 99
❑ Can only be fitted in one
position
3 - Engine speed sender -
G28-
❑ Removing and installing
⇒ “1.5 Removing and in‐
stalling engine speed
sender G28 ”,
page 412
4 - Bolt
❑ Specified torque
⇒ “1.1 Assembly over‐
view - ignition system”,
page 408
5 - Dowel pin
❑ Qty. 2
6 - Intermediate plate
❑ Do not damage or bend
when assembling.
❑ Installing
⇒ Fig. ““Install inter‐
mediate plate:”“ ,
page 99
7 - Bolt
❑ Specified torque and
tightening sequence
⇒ Fig. ““Sealing flange on gearbox side - specified torque and tightening sequence”“ , page 99
8 - Sealing flange with sender wheel and oil seal
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 100
Removing
• Gearbox removed
Note
♦ Three M6 × 35 bolts
♦ Spark plug socket , e.g. -3122 B-
♦ Screwdriver with a shaft length of at least 250 mm
♦ Hexagon key
Sequence of operations
Note
– Remove flywheel
⇒ “2.2 Removing and installing flywheel”, page 99 .
– Remove intermediate plate -1- from dowel sleeves
-arrows A-.
– Guide intermediate plate -1- upwards.
– While doing so, pull retaining lug -arrow B- of intermediate
plate -1- out of recess behind sealing flange.
– Turn crankshaft to “TDC” position
⇒ “4.7 Setting piston to TDC position”, page 119 .
– Remove sump
⇒ “1.3 Removing and installing sump”, page 201 .
– Remove engine speed sender - G28- -arrow-
⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 412 .
Note
The sealing flange -1- is pressed off crankshaft -3- together with
the sender wheel -2-.
– Screw bolts alternately into sealing flange not more than 1/2
turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
Pressing in sealing flange with sender wheel
Note
Note
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.
– Place sealing flange -1- with front side facing downwards onto
assembly tool - T10134- so that locating pin -D- is seated in
hole -3- in sender wheel hole -2-.
– If necessary, rotate sender wheel with support ring so that lo‐
cating pin and hole align.
• The sealing flange must rest flat against the assembly tool.
Note
The guide pin for diesel engines (black knob) must not be inserted
in threaded hole of crankshaft.
3 Crankshaft
⇒ “3.1 Crankshaft dimensions”, page 109
⇒ “3.2 Measuring axial clearance of crankshaft”, page 109
⇒ “3.3 Renewing needle bearing in crankshaft”, page 110
Note
♦ If the bearing cap bolts are loosened, the cylinder block must
be renewed complete with the crankshaft.
♦ Measuring the crankshaft bearing clearance is not possible
with normal workshop equipment.
3. Crankshaft 109
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Sequence of operations
– Screw dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder block as shown in the illustration.
– Position dial gauge against crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off measured
value.
• Axial clearance: 0.066 to 0.233 mm
♦ Pin - VW 207 C-
Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Condition:
• The front edges of the inner puller must be free of chips.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .
3. Crankshaft 111
Golf 2013 ➤ , Golf 2017 ➤ , Golf Cabriolet 2012 ➤ , Golf Sportsvan 2015 ...
4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger) - Edition 04.2020
Note
If the needle bearing has been accidentally driven in too far, the
bearing must be renewed because it will be damaged when it is
pulled out.
1 - Bolts
❑ Renew
❑ Oil threads and contact
surface
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ The conrod bearing cap
only fits in one position
and only on the appro‐
priate conrod due to the
breaking procedure
(cracking) separating
the cap from the conrod.
❑ Mark allocation to cylin‐
der and conrod in colour
-B-.
❑ Installation position: Lug
-A- on conrod bearing
cap faces towards pul‐
ley end
3 - Bearing bushes
❑ Fitting position
⇒ Fig. ““Bearing shells -
installation position”“ ,
page 115
❑ Renew worn bearing
shells
❑ Ensure firm seating
4 - Connecting rod
❑ With industrially
cracked conrod bearing
cap
❑ Renew as set only.
❑ Mark allocation to cylin‐
der and conrod bearing cap in colour -B-.
❑ Measuring radial clearance ⇒ “4.5 Checking radial clearance of conrods”, page 118
❑ Separate new conrod ⇒ “4.4 Separating new conrod”, page 117 .
❑ Installation position: Lug -A- on conrod bearing cap faces towards pulley end
5 - Retaining ring
❑ Qty. 2
❑ Renew
6 - Piston pin
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 115
7 - Piston
❑ With combustion chamber.
❑ Mark installation position and cylinder number
⇒ Fig. ““Installation position and allocation of piston to cylinder”“ , page 114 .
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 115
❑ Checking piston and cylinder bore ⇒ “4.3 Checking pistons and cylinder bores”, page 116
8 - Piston rings
❑ Compression rings
❑ Measuring ring gap ⇒ page 116
❑ Measuring ring-to-groove clearance ⇒ page 117
❑ Use commercially available piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gaps by 120°
9 - Piston ring
❑ Oil scraper ring
❑ Measuring ring gap ⇒ page 116
❑ Measuring ring-to-groove clearance ⇒ page 117
❑ Use piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gap 120° relative to lower compression ring
♦ Commercially available
Removing
– Removing cylinder head.
⇒ “1.3 Removing and installing cylinder head”, page 126
– Remove sump
⇒ “1.3 Removing and installing sump”, page 201 and baffle
plate.
– Mark piston installation position and corresponding cylinder
number.
– Mark installation position and matching of cylinder and conrod
bearing cap to conrod ⇒ Item 4 (page 113) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
Note
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
Note
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
Note
NOTICE
Risk of damage to oil spray jets.
– Do not bend oil spray jets.
– Check clearance of oil jets after reinstallation of pistons.
– Bent oil spray jets must be renewed.
Note
Note
Setting piston from cylinder no. 1 to TDC position for repair work
on toothed belt drive and for setting valve timing
– Remove resonator for intake air
⇒ “2.3 Removing and installing resonator for intake air”, page
324 .
– Remove air intake pipe
⇒ “2.5 Removing and installing air pipe”, page 308 .
– Press release tabs and disconnect hose -1- for activated char‐
coal filter.
– Unscrew bolts -arrows- and pull off crankcase breather hose.
Note
Note
9 - Bolt
❑ Renew
❑ Sequence when loosening ⇒ page 129 .
❑ Specified torque and tightening sequence
⇒ Fig. ““Cylinder head - specified torque and sequence”“ , page 124
Note
1 - Bolt
❑ Specified torque and
tightening sequence
⇒ Fig. ““Camshaft hous‐
ing - specified torque
and tightening se‐
quence”“ , page 126
2 - Inlet camshaft control valve
1 - N205-
❑ Removing and installing
⇒ “3.6 Removing and in‐
stalling camshaft control
valve 1 N205 ”,
page 185
❑ Check O-ring for dam‐
age.
❑ O-ring not available as a
separate part; renew to‐
gether with camshaft
control valve 1 - N205- if
damaged.
3 - Bolt
❑ 8 Nm
4 - Camshaft case
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling camshaft hous‐
ing”, page 131
5 - Hall sender - G40-
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling Hall sender”,
page 411
6 - Bolt
❑ 8 Nm
7 - Seal
❑ For exhaust camshaft, gearbox end
❑ Renewing ⇒ “3.5.3 Removing and installing exhaust camshaft oil seal, gearbox end”, page 182
8 - Crankshaft
❑ For coolant pump
❑ Removing and installing
⇒ “2.7 Removing and installing toothed belt pulley for coolant pump”, page 250
9 - Bolt
❑ Specified torque ⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 235
10 - Bolt
❑ 8 Nm
11 - Cap
12 - O-ring
❑ Renew
13 - Seal
❑ Renew
14 - Dowel pin
15 - Seal
❑ With oil strainer
❑ Inserted into cylinder head
Note
16 - Seal
❑ For inlet camshaft
❑ Renewing
⇒ “3.5.1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end”, page 178
17 - Seal
❑ For exhaust camshaft (pulley end)
❑ Renewing ⇒ “3.5.2 Removing and installing exhaust camshaft oil seal, pulley end”, page 180
18 - Cap
Note
Note
– Unscrew bolts -arrows- and detach oil supply pipe -1- and oil
return pipe -2-.
– Disconnect connectors:
1 - For coolant temperature sender - G62-
2 - For charge pressure positioner - V465-
Note
Note
Note
Note
– Disconnect connectors:
2 - For camshaft adjuster valve 1 - N205-
4 - for Hall sender - G40-
– Remove bolt -3-, move wiring harness clear and place to left
side.
– Pull out dipstick -1-.
Note
Note
– Fit seal with oil strainer -2- into cylinder head -1-.
– Fit gasket onto dowel pins -arrows-.
Note
Note
♦ Puller - T10530-
Sequence of operations
• Engine oil temperature at least 30 °C.
• Battery voltage at least 12.5 V.
– Remove fuse for fuel pump control unit from fuse holder. Fuse
assignment ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
Note
Note
Entries will have been made in the event memory of the engine
control unit because connectors were separated and the engine
was started.
1 - Toothed belt
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
❑ Check for wear
❑ Removing and installing
⇒ “2.5 Removing and in‐
stalling toothed belt”,
page 148
2 - Bolt
❑ 25 Nm
❑ When setting specified
torque on torque wrench
- VAS 6583- , length
must be entered in tor‐
que wrench.
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
⇒ “1.5 Removing and in‐
stalling engine support”,
page 92 .
4 - Bolt
❑ Renew
❑ 50 Nm +90°
5 - Exhaust camshaft toothed
belt pulley
❑ Removing and installing
⇒ “3.4 Removing and in‐
stalling toothed belt pul‐
ley”, page 176
6 - Inlet camshaft toothed belt
pulley
❑ With camshaft adjuster
❑ Removing and installing camshaft adjuster
⇒ “3.3 Removing and installing camshaft adjuster”, page 172
7 - Guide sleeve
8 - Bolt
❑ Renew
❑ 50 Nm +135°
9 - O-ring
❑ Renew
10 - Plug
❑ 20 Nm
11 - O-ring
❑ Captive, supplied with “item 13”.
12 - Spacer sleeve
❑ Supplied with item “13”.
13 - Idler roller
14 - Bolt
❑ 40 Nm
15 - Crankshaft pulley
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
Note
Sequence of operations
Test tool - VAS 611 007-
– Secure clamping ring - VAS 611 007/3- -C- in groove -a- from
adapter for angle sensor - VAS 611 007/9- and adapter for
angle sensor - VAS 611 007/10- -E-.
– Insert angle sensor - VAS 611 007/1- -A- with red colour cod‐
ing on side marked red -arrows a- of adapter for camshaft
housing - VAS 611 007/8- -D-. To do this, release locking pins
-c- by pulling them upwards.
– Insert angle sensor - VAS 611 007/1- -A-, and push it in until
locking pin can be heard to engage.
– Repeat procedure with angle sensor - VAS 611 007/1- -A- with
blue colour coding -arrows b-.
– Screw in locking ring - VAS 611 007/2- red and blue -B- ap‐
prox. 2 turns. Note colour coding -arrows a- and -arrows b-
when doing this.
– Screw in lock ring - VAS 611 007/2- -B- max. 2 turns by hand.
– Make sure that the shaft is free to move.
• Adapter for angle sensor - VAS 611 007/9- and adapter for
angle sensor - VAS 611 007/10- should turn easily.
– Remove resonator
for intake air
⇒ “2.3 Removing and
installing resonator
for intake air”,
page 324 .
– Remove air pipe
⇒ “2.5 Removing and
installing air pipe”,
page 308 .
– Remove connection
for turbocharger
⇒ “1.4 Removing and
installing connection
for turbocharger”,
page 299 .
– Set piston for cylinder
no. 1 to TDC position
⇒ “4.7 Setting piston
to TDC position”,
page 119 .
– Drain coolant
⇒ “1.3 Draining and
adding coolant”, page
227 .
Note
Before positioning the test tool - VAS 611 007- against the cam‐
shaft housing, the grooves of the camshafts must be checked for
damage.
– Fit adapter for camshaft housing - VAS 611 007/8- -D- to cam‐
shaft housing, and slide it on.
– Tighten knurled screws -arrows a- alternately by hand.
– Make sure that adapter for camshaft housing - VAS 611 007/8-
-D- is properly seated.
Note
• Test tool - VAS 611 007- must rest flush against camshaft
housing.
– Make sure that brakes on angle sensor - VAS 611 007/1- are
released on both sides ⇒ page 141 .
– Tighten locking ring - VAS 611 007/2- -B- on both sides evenly
by hand. When doing this, ensure that camshaft housing
adapter - VAS 611 007/8- -D- always lies flat against camshaft
housing -1-.
• Camshaft housing adapter - VAS 611 007/8- -D- should not lift
off of camshaft housing -1-.
Note
Sequence of operations
– Connect electronic measuring equipment of test tool - VAS
611 007- ⇒ Operating manual .
– Perform software installation of test tool - VAS 611 007- ⇒
Operating manual .
– Start test program ⇒ Operating manual .
If angle sensors are not connected, message shown in illustration
is displayed.
– Connect test tool - VAS 611 007- , and press CONNECT .
– Turn adapter for angle sensor - VAS 611 007/10- red -E- for
exhaust camshaft.
If »OK« is displayed, teach-in of exhaust camshaft is successful.
– Turn adapter for angle sensor - VAS 611 007/9- blue -E- for
inlet camshaft.
If display is as follows:
– Check valve timing
⇒ “2.6 Checking valve timing”, page 154 .
NOTICE
Risk of damage to toothed belt by bending it excessively. The
toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
– Never bend toothed belt to a radius less than r = 25 mm.
– Fit toothed belt -1- together with crankshaft pulley -2- onto
crankshaft journal.
– Renew bolt -1- for camshaft adjuster on inlet side, and screw
it in to stop by hand.
– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in to stop by hand.
• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
Note
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviations do not affect the
toothed belt tension or the timing.
Sequence of operations
– Preassemble test tool - VAS 611 007-
⇒ “2.4.1 Preassembling test tool VAS 611 007 ”, page 139 .
– Install test tool - VAS 611 007-
⇒ “2.4.2 Installing test tool VAS 611 007 ”, page 143 .
– Make sure that brakes -a- are released on both sides.
Specifications
Inlet camshaft Exhaust camshaft
-1.5° ±1.5° +1.0° ±1.5°
NOTICE
Adjust valve timing as precisely as possible. The settings must
be as close to the specifications as possible.
The valve timing must not be outside the tolerance limits.
Sequence of operations
• Toothed belt installed.
– Check valve timing ⇒ “2.6 Checking valve timing”, page 154 .
– Set piston for cylinder no. 1 to TDC position
⇒ “4.7 Setting piston to TDC position”, page 119 .
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
Note
– Make sure that bolts -a- for brakes are released on both sides.
– Seal camshaft adjuster -2- using suitable plugs -A- from en‐
gine bung set - VAS 6122- .
– Fit a piece of paper -A- into plugs to catch the engine oil.
– Insert plugs into camshaft adjusters with the open side facing
towards front, as shown in illustration.
– Turn crankshaft 2 turns in direction of rotation of engine.
Determining correction angle
– Screw in locking pin - T10340- .
– Set piston for cylinder no. 1 to TDC position
⇒ “4.7 Setting piston to TDC position”, page 119 .
– Read valve timing on display and write down values.
Note
Example
Index Explanation
e Inlet camshaft - actual value (after 2 full revolutions
of the engine)
f Inlet camshaft - specification (+/- tolerance)
c Direction of correction (+/-)
d Correction value - correction angle
a Exhaust camshaft - actual value (after 2 full revolu‐
tions of the engine)
b Exhaust camshaft - specification (+/- tolerance)
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
– Seal camshaft adjusters -1- and -2- using suitable plugs -A-
from engine bung set - VAS 6122- .
– Fit a new piece of paper into plugs -A- to catch the engine oil.
– The plug for the camshaft adjuster -1- on exhaust side must
be pushed in slightly.
– Turn crankshaft 2 turns in direction of rotation of engine.
– Screw in locking pin - T10340- .
– Set piston for cylinder no. 1 to TDC position
⇒ “4.7 Setting piston to TDC position”, page 119 .
– Check valve timing ⇒ “2.6 Checking valve timing”, page 154 .
NOTICE
Adjust valve timing as precisely as possible. The settings must
be as close to the specifications as possible.
The valve timing must not be outside the tolerance limits.
Specified angle in °
Inlet camshaft Exhaust camshaft
-1.5° ±1.5° +1.0° ±1.5°
NOTICE
If the radius/diameter is not reached, the toothed belt could be‐
come damaged.
– The toothed belt is made of glass fibre fabric.
– Never kink any toothed belts, regardless of whether they are
used or new.
– The bend radius -r- of the toothed belt -2- may therefore
never exceed 25 mm. Approx. half of pulley diameter -1- on
crankshaft ⇒ page 166 .
Note
– Renew bolt -1- for camshaft adjuster on inlet side, and screw
it in to stop by hand.
– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in to stop by hand.
• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
– Pull toothed belt upwards and fit on idler pulley -1-, tensioning
roller -2- and camshaft toothed belt pulleys -3- and -4-.
Note
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviation does not affect the
toothed belt tension or the timing.
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 169
⇒ “3.2 Measuring axial play of camshaft”, page 171
⇒ “3.3 Removing and installing camshaft adjuster”, page 172
⇒ “3.4 Removing and installing toothed belt pulley”, page 176
⇒ “3.5 Removing and installing camshaft oil seal”, page 178
⇒ “3.6 Removing and installing camshaft control valve 1 N205 ”,
page 185
⇒ “3.7 Removing and installing valve stem seals”, page 185
1 - Inlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 195
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 194
2 - Outlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 195
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 194
3 - Cylinder head
4 - Valve stem seal
❑ Renewing
⇒ “3.7 Removing and in‐
stalling valve stem
seals”, page 185
5 - Valve springs
❑ Fitting position
⇒ Fig. ““Installation po‐
sition of valve spring”“ ,
page 170
6 - Valve spring plate
7 - Valve cotters
8 - Roller rocker fingers
❑ Removing and installing
⇒ “1.4 Removing and installing camshaft housing”, page 131
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.
9 - Retaining clip
❑ For hydraulic compensation element.
Preparing tools
– Bolt on counter-hold tool - T10172- and counter-hold tool -
T10554/1- using knurled screws - T10554/2- -arrows-.
Note
Note
– Renew bolt -1- for camshaft adjuster on inlet side, and screw
it in to stop by hand.
– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in loosely to stop by hand.
• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
– Fit toothed belt onto camshafts ⇒ page 166 .
– Adjust valve timing ⇒ “2.7 Adjusting valve timing”, page 156 .
Sequence of operations
Sequence of operations
– Remove upper toothed belt guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”,
page 139 .
Note
– Renew bolt -1- for camshaft adjuster on inlet side, and screw
it in to stop by hand.
– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in to stop by hand.
• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
– Fit toothed belt onto camshafts ⇒ page 166 .
Removing
Note
Note
– Fit seal -1- over fitting sleeve -T10478/3- onto guide sleeve -
T10478/2- .
• Installation position: closed end of seal faces fitting sleeve.
– Separate fitting sleeve and guide sleeve.
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
Removing
– Remove toothed belt pulley.
⇒ “3.4 Removing and installing toothed belt pulley”,
page 176
– Remove seal -1- using extractor hook -T20143/1- .
Installing
Note
– Fit seal -1- over fitting sleeve -T10478/3- onto guide sleeve -
T10478/2- .
• Installation position: closed end of seal faces fitting sleeve.
– Separate fitting sleeve and guide sleeve.
Removing
– Remove toothed belt pulley for coolant pump
⇒ “2.7 Removing and installing toothed belt pulley for coolant
pump”, page 250 .
Note
Note
– Fit seal -1- over fitting sleeve -T10479/3- onto guide sleeve -
T10479/2- .
• Installation position: closed end of seal faces fitting sleeve.
– Separate fitting sleeve and guide sleeve.
– Fit guide sleeve -T10479/2- with oil seal -2- centrally to cam‐
shaft.
– Secure guide sleeve onto camshaft using bolt -1- for coolant
pump drive sprocket.
– Push seal onto camshaft and unbolt guide sleeve.
– Draw in seal -2- to stop using thrust piece -T10479/1- and bolt
-1- for toothed belt pulley for coolant pump.
– Install toothed belt pulley for coolant pump
⇒ “2.7 Removing and installing toothed belt pulley for coolant
pump”, page 250 .
Note
Specified torques
♦ Specified torque
⇒ “1.2 Assembly overview - camshaft housing”, page 125
Note
– Fit guide plate -VAS 5161A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Screw adapter - VAS 5161A/35- into the respective spark plug
thread hand-tight.
– Connect adapter to compressed air supply using a commer‐
cially available union and apply pressure continuously.
• Minimum pressure: 6 bar.
– Insert punch -VAS 5161/3A- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Sequence of operations
– Remove cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 126 .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.
– Fit guide plate -VAS 5161A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Insert punch -VAS 5161/3A- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Note
Test sequence
– Insert valve in guide. Valve stem end must be flush with guide.
On account of differing stem diameters, only use inlet valve in
inlet valve guide and exhaust valve in exhaust valve guide.
– Determine rock.
• Wear limit: 0.5 mm.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Note
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 196
⇒ “1.2 Engine oil:”, page 200
⇒ “1.3 Removing and installing sump”, page 201
⇒ “1.4 Removing and installing oil pump”, page 206
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 209
Note
1 - Dipstick
❑ Oil capacities
⇒ “1.2 Engine oil:”, page
200
❑ Minimum and
⇒ Fig. ““Markings on oil
dipstick”“ , page 199
2 - Cap
3 - Breather valve
❑ Observe installation po‐
sition
4 - O-ring
❑ Renew
❑ Moisten with oil before
installing
5 - Shield
❑ For oil separator
6 - Oil pressure switch for re‐
duced oil pressure
❑ Screw in by hand 3 full
turns
❑ 20 Nm
❑ Checking
⇒ “4.3 Checking oil
pressure and oil pres‐
sure switch”, page 218
❑ Removing and installing
⇒ “4.2 Removing and in‐
stalling oil pressure
switch for reduced oil
pressure F378 ”,
page 217
7 - Sump
❑ Removing and installing ⇒ “1.3 Removing and installing sump”, page 201
8 - Oil filter
❑ 20 Nm
❑ Moisten seal with oil before installing
❑ Renew oil filter if outer surface is damaged
❑ If connecting union for oil filter in sump became loose
⇒ Fig. ““Tightening connecting union for oil filter”“ , page 200
9 - Seal
❑ Renew
10 - Oil level and oil temperature sender - G266-
❑ Removing and installing
⇒ “1.5 Removing and installing oil level and oil temperature sender G266 ”, page 209
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ Specified torques and tightening sequence
⇒ Fig. ““Sump (one-piece design) – specified torque and tightening sequence”“ , page 199
13 - Seal
❑ Renew
Note
Note
Oil drain plug with renewable seal (all future oil change services)
– Unscrew oil drain plug -2-, and dispose of old seal -3-.
– New oil seal -1- can be renewed individually when oil is
changed in the future.
Note
♦ After adding oil, always check correct oil level on oil dipstick
⇒ Fig. ““Markings on oil dipstick”“ , page 199 .
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter! Markings
⇒ Fig. ““Markings on oil dipstick”“ , page 199 .
♦ Multi-point bit -
T10058-
♦ Torque wrench -
V.A.G 1331-
♦ Wedges - T10383/2-
Note
– Cut through seal between oil sump -4- and engine -1-.
– Use cutting tool - T10561- to do this.
Note
Note
Note
Note
– Fill oil filter with engine oil and tighten it with oil filter tool -
3417- .
– Replenish engine oil.
Engine oil capacity ⇒ “1.2 Engine oil:”, page 200 .
– Install air conditioner compressor: ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
Install poly V-belt
⇒ “1.2 Removing and installing poly-V belt”, page 88 .
Further assembly is basically a reverse of the dismantling se‐
quence.
Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 196
♦ ⇒ Fig. ““Sump (one-piece design) – specified torque and tight‐
ening sequence”“ , page 199
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified
torques for gearbox
Note
Renew oil seal -2-. Moisten seal with oil before installing.
3 Crankcase ventilation
⇒ “3.1 Assembly overview - crankcase breather system”,
page 212
⇒ “3.2 Removing and installing oil separator”, page 213
1 - Hose
❑ For crankcase ventila‐
tion.
2 - Cover
❑ For oil separator
3 - Oil separator
❑ Removing and installing
⇒ “3.2 Removing and in‐
stalling oil separator”,
page 213
❑ Renew if damaged
4 - O-ring
❑ Renew
❑ Moisten with oil before
installing
5 - Union
❑ Check for correct posi‐
tioning
6 - Hose
❑ For crankcase ventila‐
tion.
7 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
Note
Note
Note
1 - Oil filter
❑ Observe notes
⇒ Item 8 (page 197)
❑ Removing and installing
⇒ Maintenance ; Book‐
let
❑ 20 Nm
❑ If connecting union for
oil filter in sump became
loose
⇒ Fig. ““Tightening con‐
necting union for oil fil‐
ter”“ , page 217
2 - Oil pressure switch for re‐
duced oil pressure - F378-
❑ Switch pressure 0.3 to
0.6 bar
❑ Insulation, green
❑ Checking
⇒ “4.3 Checking oil
pressure and oil pres‐
sure switch”, page 218
❑ Removing and installing
⇒ “4.2 Removing and in‐
stalling oil pressure
switch for reduced oil
pressure F378 ”,
page 217
❑ 20 Nm
3 - Seal
❑ Must be renewed after
removal of oil pressure
switch ⇒ Electronic
parts catalogue
Note
Removing
– Pull activated charcoal filter solenoid valve 1 - N80- -3- off in‐
take manifold and push it downwards slightly.
– Disconnect connector -2-.
– Place a cloth underneath to catch escaping engine oil.
– Unscrew oil pressure switch for reduced oil pressure - F378-
-1-.
– Snip off encapsulated seal, renew seal.
Installing
Install in reverse order of removal, observing the following:
Note
Sequence of operations
• Oil level OK. Checking ⇒ Maintenance ; Booklet .
• Engine oil temperature at least 80°C (radiator fan must have
run once)
– Remove oil pressure switch for reduced oil pressure - F378-
⇒ “4.2 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 217 .
Note
– Screw oil pressure tester - V.A.G 1342- into hole for oil pres‐
sure switch.
– Screw oil pressure switch for reduced oil pressure - F378- into
hole in oil pressure tester - V.A.G 1342- in order to seal hole.
– Start engine.
• Oil pressure at idling speed: at least 0.6 bar.
• Oil pressure at 2000 rpm: at least 1.5 bar.
• Minimum oil pressure at 4,500 rpm: 2.8 bar.
Note
If no fault is found:
– Renew oil pump
⇒ “1.4 Removing and installing oil pump”, page 206 .
Check oil pressure switch for reduced oil pressure - F378-
(brown):
– Switch off engine.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive and
oil pressure switch for reduced oil pressure - F378- using ca‐
bles from auxiliary test set - V.A.G 1594C- .
• LED must not light up.
– If LED lights up, renew oil pressure switch for reduced oil
pressure - F378- .
If LED does not light up:
– Start engine. At 0.3 to 0.6 bar the LED must light up. Other‐
wise, renew oil pressure switch
⇒ “4.2 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 217 .
Removing
– Drain engine oil.
– Remove oil filter -arrow- with oil filter tool - 3417- .
Installing
– Fill oil filter with engine oil and moisten seal with oil.
– Tighten oil filter to specified torque of 20 Nm using oil filter tool
- 3417- .
• If connecting union for oil filter in sump became loose
⇒ Fig. ““Tightening connecting union for oil filter”“ , page 217
– Fill engine oil ⇒ “1.2 Engine oil:”, page 200 .
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 221
⇒ “1.2 Checking cooling system for leaks”, page 225
⇒ “1.3 Draining and adding coolant”, page 227
Note
1.1.2 Connection diagram - coolant hoses, vehicles with engine preheating ele‐
ment - Z97-
Note
Sequence of operations
Note
CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
Note
Note
– Screw cap -1- into adapter for cooling system tester - V.A.G
1274/9- -2-.
– Connect adapter for cooling system tester - V.A.G 1274/9- to
cooling system tester - V.A.G 1274 B- using connecting hose
supplied.
– Build up pressure using hand pump of cooling system tester.
Blue cap
♦ The pressure relief valve must open at a pressure of 1.4 bar.
Black cap
♦ The pressure relief valve must open at a pressure of 1.6 to
1.8 bar.
If the pressure relief valve opens prematurely:
– Renew cap.
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Safety glasses
♦ Safety gloves
CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
– Pull out retaining clip -1-, remove lower left coolant hose from
radiator and drain off coolant.
Polo:
– Open spring-type clips -arrows-.
– Pull hoses -1- off water radiator for charge air cooling circuit
-2-.
– Open spring-type clip -arrow- and pull off coolant hose down‐
wards.
– Drain coolant from radiator.
Continued for all vehicles
Filling
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- or refractometer - T10007B-
must be used to determine the current anti-freeze value.
♦ The scale -1- of the refractometer is calibrated for the coolant
additives G12++ and G12evo.
♦ The scale -2- of the refractometer is calibrated for the coolant
additive G13.
♦ If it is not possible to ensure that the same type of coolant
additive is filled: always determine anti-freeze protection using
the scale for G13.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
♦ The temperature reading on the refractometer corresponds to
the »ice flocculation point«. Flakes of ice may start forming in
the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Sequence of operations
– Connect coolant hoses ⇒ Fig. ““”“ , page 264 .
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ If the vacuum drops, the cooling system must be checked for
leaks.
Coolant level:
Golf, Golf Estate, Golf SV, Touran:
– Fill coolant up to “max.” mark.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
– Tighten cap of coolant expansion tank until it engages.
– Start engine and run alternately at approx. 1500 rpm to max‐
imum of 2800 rpm until radiator fan starts operating.
1 - Thermostat housing
❑ Removing and installing
⇒ “2.6 Removing and in‐
stalling thermostat”,
page 248
❑ Observe tightening se‐
quence when tightening
to coolant pump
⇒ “2.5 Removing and in‐
stalling coolant pump”,
page 243 .
2 - Thermostat
❑ For cylinder block cool‐
ant circuit
❑ Up to 07.2016: Starts to
open at approx. 87 °C
❑ From 07.2016 onwards:
Starts to open at approx.
97 °C
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue .
❑ Removing and installing
⇒ “2.6.2 Removing and
installing thermostat for
cylinder block coolant
circuit”, page 249
3 - Seal
❑ Renew
❑ Ensure proper seating
of seal
❑ Lightly coat with coolant
before installing.
4 - Coolant pump
❑ Vehicles manufactured
as of June 2013 are fitted with a modified coolant pump ⇒ page 221
❑ Removing and installing ⇒ “2.5 Removing and installing coolant pump”, page 243
❑ If coolant pump is renewed, also renew toothed belt
5 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified torque.
❑ Specified torque and tightening sequence
⇒ Fig. ““Thermostat housing to coolant pump - specified torque and sequence”“ , page 238
6 - Seal
❑ Renew
❑ Ensure proper seating of seal
❑ Lightly coat with coolant before installing.
7 - Toothed belt guard
❑ For toothed belt for coolant pump
8 - Bolt
❑ Renew
❑ 20 Nm +90°
9 - Toothed belt
❑ Renew after removal
2.3.1 Assembly overview - coolant temperature sender, Golf, Golf Estate, Golf
SV, Touran, Golf Cabriolet
1 - O-ring
❑ Renew after removal
2 - Radiator outlet coolant tem‐
perature sender - G83-
❑ Removing and installing
⇒ “2.9 Removing and in‐
stalling radiator outlet
coolant temperature
sender G83 ”,
page 252
3 - Support ring
4 - O-ring
❑ Renew after removal
5 - Radiator outlet coolant -
G62-
❑ Removing and installing
⇒ “2.8 Removing and in‐
stalling coolant temper‐
ature sender G62 ”,
page 251
6 - Bolt
❑ 8 Nm
7 - Retaining clip
❑ Check for firm seating
Removing
CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
Note
Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Torque wrench - VAS 6583-
– Move clear electrical wiring harness -1- and coolant hose -2-.
– Release hose clips -arrows- and detach coolant hoses.
Note
Note
– Apply torque wrench -VAS 6583- with hexagon key (10 mm)
-item 6- to coolant pump.
– Using hexagon on coolant pump, preload coolant pump in
clockwise direction to 30 Nm using 10 mm hexagon socket
-6-, extension and torque wrench - VAS 6583- .
– For ease of use, fit torque wrench - VAS 6583- on vertically.
Note
Removing
– Remove coolant pump
⇒ “2.5 Removing and installing coolant pump”, page 243 .
Note
Note
Installing
Install in reverse order of removal, observing the following:
– Renew O-ring.
– Check coolant level ⇒ page 233 .
Specified torque
♦ ⇒ “2.3 Assembly overview - coolant temperature sender”,
page 240
Note
– Renew O-ring.
– Install front noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Check coolant level ⇒ page 233 .
Note
3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 254
⇒ “3.2 Removing and installing coolant pipes”, page 254
1 - Coolant hose
2 - Coolant pipe
❑ Clipped onto intake
manifold (bottom)
❑ Carefully lever it out of
catches using a screw‐
driver when removing.
3 - Bolt
❑ 8 Nm
4 - Coolant hose
5 - Coolant hose
6 - Coolant line
❑ Clipped onto intake
manifold (top)
7 - Coolant hose
8 - Coolant hose
Note
Removing
CAUTION
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
Skin and other parts of the body may be scalded.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
Note
To avoid damaging the intake manifold and coolant pipe, this pro‐
cedure must be carried out very carefully!
– First push the coolant pipe onto mounting -1- until coolant pipe
engages.
– Then push coolant pipe onto mounting -2- until coolant pipe
engages.
– Check that the coolant pipe has properly engaged by pulling
on it.
Further installation is carried out in reverse order of removal, ob‐
serving the following:
Note
4.1.1 Assembly overview - radiator/radiator fan, Golf, Golf Estate, Golf SV, Tour‐
an, version 1
17 - Coolant hose
❑ Pull out retaining clip to remove
❑ Connect ⇒ Fig. ““”“ , page 264
18 - O-ring
❑ Renew
4.1.2 Assembly overview - radiator/radiator fan, Golf, Golf Estate, Golf SV, Tour‐
an, version 2
1 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect
⇒ Fig. ““”“ , page 264
2 - O-ring
❑ Renew after removal
❑ Moisten with coolant
3 - Radiator for charge air cool‐
ing circuit
❑ Removing and installing
⇒ “4.4.2 Removing and
installing water radiator
for charge air cooling
circuit, Golf, Golf Estate,
SV, Touran version 2”,
page 280
4 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect
⇒ Fig. ““”“ , page 264
5 - O-ring
❑ Renew after removal
❑ Moisten with coolant
6 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect
⇒ Fig. ““”“ , page 264
7 - O-ring
❑ Renew after removal
❑ Moisten with coolant
8 - Radiator for engine coolant
❑ Removing and installing
⇒ “4.3.2 Removing and installing radiator, Golf, Golf Estate, Golf SV, Touran version 2”, page 270
❑ Renew coolant after replacing
9 - Air duct
10 - Air duct
11 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser
12 - Rubber mounting
❑ For radiator
13 - Rubber mounting
❑ For radiator
14 - O-ring
❑ Renew after removal
❑ Moisten with coolant
15 - Coolant hose
❑ Pull out retaining clip to remove
❑ Connect ⇒ Fig. ““”“ , page 264
Note
1 - Condenser
❑ Removing and installing
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ;
Refrigerant circuit; Re‐
moving and installing
condenser
2 - Radiator mounting
❑ Renew if damaged
3 - Radiator for charge air cool‐
ing circuit
❑ Removing and installing
⇒ “4.4.3 Removing and
installing water radiator
for charge air cooling
circuit, Golf Cabriolet”,
page 280
4 - Rubber mounting
❑ Bottom of radiator in
lock carrier
5 - Refrigerant line
❑ To condenser
6 - O-ring
❑ For refrigerant line
❑ Renew after removal
7 - O-ring
❑ Connection, radiator for
charge air cooling circuit
❑ Renew after removal
8 - Retaining clip
❑ Connection for coolant
hose, charge air cooler
9 - Coolant hose
❑ On radiator for charge air cooling circuit
❑ Lift retaining clip to remove
❑ Connect ⇒ Fig. ““”“ , page 264
10 - Bolts
❑ 5 Nm
11 - Radiator for engine coolant
❑ Removing and installing ⇒ “4.3.3 Removing and installing radiator, Golf Cabriolet”, page 272
❑ Renew coolant after replacing
12 - O-ring
❑ Connection, radiator
❑ Renew after removal
13 - Coolant hose
❑ Lift retaining clip to remove
❑ Connect ⇒ Fig. ““”“ , page 264
14 - Retaining clip
15 - Coolant hose
❑ Lift retaining clip to remove
❑ Connect ⇒ Fig. ““”“ , page 264
16 - O-ring
❑ Renew after removal
17 - Retaining clip
18 - Radiator outlet coolant temperature sender - G83-
❑ Removing and installing ⇒ “2.10 Removing and installing radiator fan thermal switch F18 ”, page 252
19 - Coolant hose
❑ On radiator for charge air cooling circuit
❑ Lift retaining clip to remove
❑ Connect ⇒ Fig. ““”“ , page 264
1 - Radiator mounting
❑ Lower radiator mount‐
ing in front end
2 - Radiator for charge air cool‐
ing circuit
❑ Removing and installing
⇒ “4.4.4 Removing and
installing water radiator
for charge air cooling
circuit, Polo”, page 282
3 - Radiator fan thermal switch
- F18-
❑ Removing and installing
⇒ “2.10 Removing and
installing radiator fan
thermal switch F18 ”,
page 252
❑ Assembly overview
⇒ “2.3.2 Assembly over‐
view - coolant tempera‐
ture sender, Polo”, page
241
❑ 35 Nm
4 - O-ring
❑ Renew if damaged
5 - Bolt
❑ 5 Nm
❑ Qty. 2
6 - Radiator mounting
❑ Top
7 - Radiator/cooler
❑ Removing and installing
⇒ “4.3.4 Removing and
installing radiator, Polo”, page 273
❑ After renewing, renew entire coolant.
8 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 221
9 - Expansion tank
❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling
system tester - V.A.G 1274/8-
10 - Cap
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
❑ Checking ⇒ “1.2 Checking cooling system for leaks”, page 225
11 - Bolt
❑ 2 Nm
❑ Qty. 2
12 - Connector
13 - Radiator cowl with radiator fan - V7-
❑ Assembly overview ⇒ “4.2.3 Assembly overview - radiator cowl and radiator fan, Polo”, page 268
❑ Removing and installing ⇒ “4.5.3 Removing and installing radiator cowl, Polo”, page 288
Open clip:
– Press together spring-type clips using hose clip pliers until clip
engages.
– The clip is now open and coolant hose can be pulled off.
– It is not possible to detach clip from coolant hose.
Close clip:
– Install coolant hose.
– Carefully release pretensioned spring-type clips. Insert re‐
lease tool - VAS 531 001- as shown -1- and engage in direction
of -arrow-.
– Depending on available space, use appropriate release hook.
4.2.1 Assembly overview - radiator cowl and radiator fan, Golf, Golf Estate, Golf
SV, Touran
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
❑ Removing and installing
⇒ “4.5.1 Removing and
installing radiator cowl,
Golf, Golf Estate, Golf
SV, Touran”, page 285
3 - Radiator fan - V7-
❑ Removing and installing
⇒ “4.6.1 Removing and
installing radiator fan,
Golf, Golf Estate, Golf
SV, Touran”, page 290
4.2.2 Assembly overview - radiator cowl and radiator fan, Golf Cabriolet
1 - Radiator cowl
❑ Removing and installing
⇒ “4.5.2 Removing and
installing radiator cowl,
Golf Cabriolet”,
page 286
2 - Bolt
❑ Radiator cowl to radiator
❑ 5 Nm
3 - Bolt
❑ Radiator cowl to radiator
❑ 5 Nm
4 - Radiator fan 2 - V177-
❑ Removing and installing
⇒ “4.6.2 Removing and
installing radiator fan,
Golf Cabriolet”,
page 290
5 - Radiator fan - V7-
❑ Removing and installing
⇒ “4.6.2 Removing and
installing radiator fan,
Golf Cabriolet”,
page 290
6 - Bracket
❑ Coupling point
7 - Bolt
❑ Radiator cowl to radiator
❑ 5 Nm
8 - Bolt
❑ 5 Nm
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
– Release locking tabs -arrow- for radiator on left and right. Then
pull top of radiator backwards.
Note
Note
Radiator and water radiator for charge air cooling circuit are re‐
moved together.
Removing
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 227 .
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
– Remove centre guide on lock carrier ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Assembly overview - lock
carrier .
– Unclip air ducts -1- on both sides from lock carrier -2-
-arrows-.
– To do this, release catches -3- in -direction of arrow-, and pull
off air ducts.
– Pull left and right air duct -2- upwards off condenser.
– Release catches on both sides -arrow A- and detach con‐
denser -3- from water cooler for charge air cooling circuit -1-.
Note
Removing
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 227 .
– Remove radiator cowl
⇒ “4.5 Removing and installing radiator cowl”, page 285 .
– Release retaining clip -arrow-.
– Pull off coolant hose -1- from top of radiator.
Note
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 227 .
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.
Note
Note
Note
Specified torques
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 258
– Unclip air ducts -1- on both sides from lock carrier -2-
-arrows-.
Note
– Lift water radiator for charge air cooling circuit -1- at bottom
out of radiator mountings -arrows-.
– Remove both radiators.
Note
– Insert radiator for charge air cooling circuit -1- at bottom into
radiator mountings -arrows-.
– Attach radiator to radiator for charge air cooling circuit.
– Fit radiator mountings -1- on left and right onto radiator. When
doing so, note the installation position -arrow-.
– Swing water radiator for charge air cooling circuit into lock
carrier. Ensure proper seating of radiator mountings in lock
carrier.
Note
– Removing radiator
⇒ “4.3 Removing and installing radiator”, page 268 .
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
– Lift retaining clip -arrow- and disconnect coolant hose (top
right) from radiator for charge air cooling circuit.
Note
Note
Removing
– Removing radiator
⇒ “4.3 Removing and installing radiator”, page 268 .
Note
– Lower water radiator for charge air cooling circuit -1- further in
-direction of arrow A-. At the same time, push it in direction of
-arrow B-.
– Detach water radiator for charge air cooling circuit -1- on right
from mounting -arrow- on radiator -2-.
– Remove water radiator for charge air cooling circuit -1- down‐
wards.
Installing
Install in reverse order. Observe the following:
– Insert water radiator for charge air cooling circuit -2- into right
mounting.
– Properly engage water radiator for charge air cooling circuit
-2- in -direction of arrow- in mountings on radiator -1-.
– Check firm seating by pulling on it.
Note
Note
Specified torques
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 258
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
page 265
CAUTION
Risk of injury to hands caused radiator fan which may start au‐
tomatically at any time.
– Do not grasp into the radiator fan when disconnecting con‐
nector.
Removing
– Release hose clip -1- and detach air intake hose.
– Remove bolt -2- on both sides.
– Unclip air duct at lock carrier and detach.
Removing
– Release spring-type clips -3-, and remove intake hose -1-.
– Unclip cover of intake air duct -2- -arrows-, and remove it.
– Press catches of lower part of intake air duct, and remove in‐
take air duct towards rear.
CAUTION
Danger of injury; the radiator fans can run at any time.
– Disconnect electrical connectors:
Note
Removing
– Loosen clamps -3-, and detach intake hose -1-.
– Release retaining lugs -1-, and pull off intake hose -2-.
CAUTION
Risk of injury to hands caused radiator fan which may start au‐
tomatically at any time.
– Do not grasp into the radiator fan when disconnecting con‐
nector.
Note
Note
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 293
⇒ “1.2 Removing and installing turbocharger”, page 295
⇒ “1.3 Removing and installing charge pressure positioner V465
”, page 298
⇒ “1.4 Removing and installing connection for turbocharger”,
page 299
1 - Turbocharger
❑ Removing and installing
⇒ “1.2 Removing and in‐
stalling turbocharger”,
page 295
2 - Bolt
❑ 8 Nm
3 - Connection
4 - O-ring
❑ Renew after removal
❑ Before installing, coat
lightly with engine oil.
5 - Seal
❑ Renew after removal
6 - Heat shield
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 8 Nm
9 - Bolt/nut
❑ 8 Nm
10 - Nut
❑ Renew after removal
❑ 14 Nm
11 - Bolt
❑ Renew after removal
❑ 8 Nm +45°
12 - Operating lever
13 - Retaining clip
❑ Renew after removal
1. Turbocharger 293
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15 - Seal
❑ Renew
16 - Coolant lines
❑ Supply and return
17 - Bolt
❑ 8 Nm
18 - O-ring
❑ Renew after removal
❑ Before installing, coat lightly with engine oil.
19 - Bolt
❑ 8 Nm
Note
1. Turbocharger 295
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• Check air filter housing, air filter element and air inlet hoses
for contamination.
• Check the whole charge air path and charge air cooler for for‐
eign objects.
• If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the charge
air cooler.
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 227 .
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
– Remove bolts -arrows- and detach oil supply line -1- and oil
return line -2-.
– Press release tabs and disconnect hose -1- for activated char‐
coal filter.
– Unscrew bolts -arrows- and pull off crankcase breather hose.
Note
1. Turbocharger 297
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Note
Removing
– Switch off ignition.
– Disconnect connector -1-.
– Pull off securing clip -2- using locking tool - T40265- .
– Remove bolts -arrows- and detach charge pressure positioner
- V465- .
Installing
Install in reverse order of removal, observing the following:
• Renew securing bolts for charge pressure positioner
-arrows-.
• Renew circlip -2-.
– Adapt engine control unit - J623- to charge pressure positioner
- V465- using ⇒ Vehicle diagnostic tester; “Guided functions”
0001 - Calibration of boost press. actuator -
V465 .
Specified torques
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 293
1. Turbocharger 299
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– Open hose clip -1- and push coolant hose -2- to one side.
Note
– Renew seals.
– Before installing, lightly moisten O-rings with clean engine oil.
– If bolts are tightened with insert - T10572- , Torx bit T 30 -
T10573- and torque wrench - V.A.G 1783- , observe torque.
– Set torque wrench - V.A.G 1783- to 4.2 Nm.
Specified torques
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 293
1. Turbocharger 301
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1 - O-ring
❑ Renew after removal
❑ Before installing, lightly
moisten O-ring with
clean engine oil
2 - Union
3 - O-ring
❑ Renew after removal
❑ Before installing, lightly
moisten O-ring with
clean engine oil
4 - Air intake pipe
❑ Removing and installing
⇒ “2.5 Removing and in‐
stalling air pipe”,
page 308
5 - Charge air pressure sender
- GX26-
❑ Consisting of
Charge pressure sender
- G31-
Intake air temperature
sender - G42-
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling charge pressure
sender GX26 ”,
page 306
6 - O-ring
❑ Renew after removal
7 - O-ring
❑ Renew after removal
❑ Before installing, lightly moisten O-ring with clean engine oil
8 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified torque
❑ 7 Nm
9 - Retaining clip
❑ For air pipe
Throttle valve drive angle sender 1 for electronic power control - G187-
Throttle valve drive angle sender 2 for electronic power control - G188-
❑ Removing and installing ⇒ “3.3 Removing and installing throttle valve module GX3 ”, page 329
11 - O-ring
❑ Renew after removal
❑ Before installing, lightly moisten O-ring with clean engine oil
12 - Intake manifold
Removing and installing ⇒ “3.2 Removing and installing intake manifold”, page 327
13 - Seal
❑ Renew after removal
14 - Sealing lip
❑ Renew after removal
❑ Before installing, coat lightly with engine oil.
15 - Coolant hose
16 - Hose clamp
17 - Charge air cooler
❑ Removing and installing ⇒ “2.2 Removing and installing charge air cooler”, page 304
❑ Change coolant after renewing
18 - Bolt
❑ Specified torque and tightening sequence ⇒ “3.1 Assembly overview - intake manifold”, page 325
19 - Coolant hose
20 - Hose clamp
21 - Coolant hose
22 - Hose clamp
23 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified torque
❑ 7 Nm
24 - O-ring
❑ Renew
25 - Intake manifold sender - GX9-
❑ Consisting of
Intake air temperature sender 2 - G299-
Removing
– Open clip -1- and push hose -arrow- to one side.
– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor; Re‐
moving and installing air conditioner compressor from and to
bracket .
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Remove radiator cowl
⇒ “4.5 Removing and installing radiator cowl”, page 285 .
– Fit sealing lip -1- in -direction of arrow- onto charge air cooler
-2-.
– Insert new gasket into groove on intake manifold.
Note
Note
Torque
Component Specified torque
Charge pressure sender - GX26- 3 Nm
Sequence of operations
– Remove resonator for intake air
⇒ “2.3 Removing and installing resonator for intake air”, page
324 .
– Press release buttons and remove hose -1-. Seal hose -1- us‐
ing suitable plugs from engine bung set - VAS 6122- .
Note
Note
If there is water in the inspection window, drain it via the drain plug
-6-.
Note
Note
Installing
Assembly is carried out in reverse sequence; note the following:
Note
Note
The catch -arrow- for the vacuum hose -1- does not need to be
released for this procedure.
Polo:
– Release hose clips -arrows-, and unclip air duct from mount‐
ings -1-.
– Remove air duct -2-.
Golf Cabriolet:
– Loosen hose clips -3-, and detach air intake hose -1-.
1.1.1 Overview of fitting locations - engine compartment, Golf, Golf Estate, Golf
SV, Touran
Throttle valve drive angle sender 1 for electronic power control - G187-
Throttle valve drive angle sender 2 for electronic power control - G188-
❑ Assembly overview ⇒ “3.1 Assembly overview - intake manifold”, page 325
9 - Charge air pressure sender - GX26-
❑ Consisting of
Charge pressure sender - G31-
Throttle valve drive angle sender 1 for electronic power control - G187-
Throttle valve drive angle sender 2 for electronic power control - G188-
Throttle valve drive angle sender 1 for electronic power control - G187-
Throttle valve drive angle sender 2 for electronic power control - G188-
❑ Assembly overview ⇒ “3.1 Assembly overview - intake manifold”, page 325
2 Air filter
⇒ “2.1 Assembly overview - air filter housing”, page 320
⇒ “2.2 Removing and installing air filter housing”, page 323
⇒ “2.3 Removing and installing resonator for intake air”,
page 324
2.1.1 Assembly overview - air filter housing, Golf, Golf Estate, Golf SV, Touran
1 - Union
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling connection for
turbocharger”,
page 299
2 - Spring-type clip
3 - Resonator for intake air
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling resonator for in‐
take air”, page 324
4 - Spring-type clip
5 - Air filter upper part
❑ Remove dirt, leaves and
salt residues
6 - Air filter element
❑ Use only genuine air fil‐
ter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance ta‐
bles
❑ Removing and installing
⇒ Maintenance ; Book‐
let
7 - Bump stop
8 - Air filter lower part
❑ Remove dirt, leaves and
salt residues
9 - Bolt
❑ 3 Nm
10 - Water drain hose
❑ Clean water drain hose.
11 - Spring-type clip
12 - Intake hose
13 - Spring-type clip
14 - Cover
❑ For upper part of air duct
1 - Connection hose
2 - Cold air intake
❑ On lock carrier
3 - Bolt
❑ 2 Nm
4 - Water drainage pipe
❑ Clean if soiled.
5 - Bolt
❑ 1.5 Nm
6 - Bump stop
7 - Air filter lower part
❑ Remove dirt, leaves and
salt residues
8 - Air filter element
❑ Use only genuine air fil‐
ter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance ta‐
bles
❑ Removing and installing
⇒ Maintenance ; Book‐
let
9 - Air filter upper part
❑ Remove dirt, leaves and
salt residues
10 - Hose
❑ For crankcase ventila‐
tion.
11 - Resonator for intake air
❑ Removing and installing ⇒ “2.3 Removing and installing resonator for intake air”, page 324
12 - Clip
– Press air filter housing -1- on ball studs -A- and -B-.
– Finally, press air filter housing on ball stud -C-.
Note
– Remove salt residues, dirt and leaves from top and bottom part
of air filter housing using a vacuum cleaner.
– Blow out water drain with compressed air.
Specified torque
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 320 .
Note
3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 325
⇒ “3.2 Removing and installing intake manifold”, page 327
⇒ “3.3 Removing and installing throttle valve module GX3 ”, page
329
⇒ “3.4 Cleaning throttle valve module GX3 ”, page 330
1 - Coolant pipe
❑ Clipped onto intake
manifold.
2 - Intake manifold
❑ Combined with charge
air cooler
❑ Removing and installing
⇒ “3.2 Removing and in‐
stalling intake manifold”,
page 327
3 - Coolant pipe
❑ Clipped onto intake
manifold.
4 - Bolt
❑ Specified torque and
tightening sequence
⇒ Fig. ““Intake manifold
- specified torque and
tightening sequence”“ ,
page 326
5 - O-ring
❑ Renew after removal
6 - Intake manifold sender -
GX9-
❑ Consisting of
Intake air temperature
sender 2 - G299-
9 - O-ring
❑ Renew after removal
10 - Union
11 - O-ring
❑ Renew after removal
❑ Moisten with engine oil before installing
12 - Air intake pipe
❑ Removing and installing ⇒ “2.5 Removing and installing air pipe”, page 308
13 - O-ring
❑ Renew after removal
❑ Moisten with engine oil before installing
14 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified torque.
❑ 7 Nm
15 - Retaining clip
❑ For air intake pipe
16 - Throttle valve module - GX3-
❑ Consisting of
Throttle valve module - J338-
Throttle valve drive angle sender 1 for electronic power control - G187-
Throttle valve drive angle sender 2 for electronic power control - G188-
❑ Removing and installing ⇒ “3.3 Removing and installing throttle valve module GX3 ”, page 329
❑ Cleaning ⇒ “3.4 Cleaning throttle valve module GX3 ”, page 330
17 - Seal
❑ Renew after removal
18 - Vacuum line
19 - O-ring
❑ Renew after removal with vacuum line
20 - Vacuum line
21 - O-ring
❑ Renew after removal with vacuum line
– Pull activated charcoal filter solenoid valve 1 - N80- -3- off in‐
take manifold and push it downwards slightly.
– Disconnect connector -2- on oil pressure switch for reduced
oil pressure - F378- -1-.
Note
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.
– Wear protective goggles.
– Wear protective gloves.
4 Injectors
⇒ “4.1 Assembly overview - fuel rail with injectors”, page 331
⇒ “4.2 Removing and installing fuel rail”, page 332
⇒ “4.3 Removing and installing injectors”, page 333
⇒ “4.4 Cleaning injectors”, page 343
4. Injectors 331
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6 - O-ring
❑ Renew
❑ Lubricate with clean engine oil
7 - Spacer ring
❑ Renew if damaged
8 - Injection valve
❑ Removing and installing ⇒ “4.3 Removing and installing injectors”, page 333
9 - Combustion chamber seal
❑ Do not treat with grease or other lubricant.
❑ Renewing ⇒ “4.3 Removing and installing injectors”, page 333
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Release high pressure.
Note
4. Injectors 333
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Removing
Note
Note
Note
4. Injectors 335
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Note
Note
Take care not to damage the groove of injector. The injector must
be renewed if the groove is damaged.
Installing
– Clean hole in cylinder head with nylon brush - T10133/4- .
Note
Note
4. Injectors 337
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– Before installing injector -1- moisten new O-ring -3- with clean
engine oil.
Note
Note
Removing
Note
Note
Note
4. Injectors 339
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Note
Note
Note
Take care not to damage the groove of injector. The injector must
be renewed if the groove is damaged.
4. Injectors 341
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Installing
– Clean hole in cylinder head with nylon brush - T10133/4- .
Note
Note
– Before installing injector -1- moisten new O-ring -3- with clean
engine oil.
Note
Note
4. Injectors 343
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Note
Note
Cleaning
– Remove injectors
⇒ “4.3 Removing and installing injectors”, page 333 .
– Insert injectors -1- all the way into mounting plate - VAS
6418/1- -item 2-.
– Immerse injectors together with mounting plate - VAS 6418/1-
into cleaning fluid - VAS 6418/2- .
– Set rotary knob -4- to a temperature of 50°C.
– Set a cleaning time of 30 minutes with the rotating knob -5-.
– Press button -3- to switch on ultrasonic unit.
Note
4. Injectors 345
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Note
If the retaining tabs broke off during removal, the sender can be
mounted using two securing bolts ⇒ Electronic parts catalogue .
Specified torque ⇒ page 346 .
Removing
– Disconnect connector -1-.
Note
Note
Moisten thread and taper of fuel pressure sender with engine oil
before installing.
Specified torque
♦ ⇒ “4.1 Assembly overview - fuel rail with injectors”, page 331
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
6 High-pressure pump
⇒ “6.1 Assembly overview - high-pressure pump”, page 350
⇒ “6.2 Removing and installing high-pressure pump”, page 352
⇒ “6.3 Removing and installing high-pressure pipe”, page 353
1 - Roller tappet
❑ When installing lubri‐
cate lightly with clean
engine oil
2 - O-ring
❑ Renew
❑ When installing lubri‐
cate lightly with clean
engine oil
3 - High-pressure pump
❑ With fuel pressure regu‐
lating valve - N276- .
❑ Do not dismantle.
❑ Removing and installing
⇒ “6.2 Removing and in‐
stalling high-pressure
pump”, page 352
4 - High-pressure pipe
❑ Does not need to be re‐
placed
❑ Before installing used
high-pressure pipes,
check thoroughly for
leaks
❑ Removing and installing
⇒ “6.3 Removing and in‐
stalling high-pressure
pipe”, page 353
❑ Do not alter shape.
❑ Unions must be free of
damage
❑ Lubricate thread of un‐
ion nuts with clean en‐
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ Renew
❑ Specified torque and tightening sequence ⇒ page 352
6 - Hose clamp
7 - Fuel supply line
8 - Electrical connector
Version 2, Continental
1 - Roller tappet
❑ When installing lubri‐
cate lightly with clean
engine oil
2 - O-ring
❑ Renew
❑ When installing lubri‐
cate lightly with clean
engine oil
3 - High-pressure pump
❑ With fuel pressure regu‐
lating valve - N276- .
❑ Do not dismantle.
❑ Removing and installing
⇒ “6.2 Removing and in‐
stalling high-pressure
pump”, page 352
4 - High-pressure pipe
❑ Does not need to be re‐
placed
❑ Before installing used
high-pressure pipes,
check thoroughly for
leaks
❑ Removing and installing
⇒ “6.3 Removing and in‐
stalling high-pressure
pipe”, page 353
❑ Do not alter shape.
❑ Unions must be free of
damage
❑ Lubricate thread of un‐
ion nuts with clean en‐
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ Renew
❑ Specified torque and tightening sequence ⇒ page 352
6 - Hose clamp
7 - Fuel supply line
8 - Electrical connector
Removing
• Engine cold.
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Release high pressure.
Note
Note
Renew O-ring.
Removing
– Remove throttle valve module - GX3-
⇒ “3.3 Removing and installing throttle valve module GX3 ”,
page 329 .
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Release high pressure.
Note
7 Lambda probe
⇒ “7.1 Assembly overview - Lambda probe”, page 356
⇒ “7.2 Removing and installing Lambda probe”, page 357
Note
Removing
– Disconnect connector -2- for Lambda probe 1 before catalytic
converter - GX10- .
Note
Specified torques
♦ ⇒ “7.1 Assembly overview - Lambda probe”, page 356
Removing
– Disconnect connector -1- for Lambda probe 1 after catalytic
converter - GX7- .
Note
Specified torques
♦ ⇒ “7.1 Assembly overview - Lambda probe”, page 356
Removing
– If engine control unit is renewed, select “Guided Function”
0001 - Replace engine control module on vehicle diag‐
nostic tester .
– Switch off ignition and remove key from ignition lock.
Note
♦ If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence.
♦ Therefore, disconnect the battery before removing the engine
control unit ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
– Release retaining clip -arrow- and take out engine control unit
- J623- .
Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle -2- from
wiring harness repair set - VAS 1978 B-
Note
♦ If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence.
♦ Therefore, disconnect the battery before removing the engine
control unit ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
Note
Cover the area around the engine control unit, and protect it from
flying sparks.
Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
Installing
– Fit connectors to engine control unit.
– Push locking devices to stop in -direction of arrow-.
– Insert engine control unit into retaining frame and push retain‐
ing frame upwards in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Removing and installing
bulkhead .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
– Switch on ignition and continue with the following menu op‐
tions on vehicle diagnostic tester :
♦ 0001 - Renew engine control unit
♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle -2- from
wiring harness repair set - VAS 1978 B-
– Bend locking bar -1- in -direction of arrow- until locking bar can
be pulled off connector.
Installing
– Fit connectors to engine control unit.
– Push locking devices to stop in -direction of arrow-.
– Insert engine control unit into retaining frame and push retain‐
ing frame upwards in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Removing and installing
bulkhead .
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
– Switch on ignition and continue with the following menu op‐
tions on vehicle diagnostic tester :
♦ 0001 - Renew engine control unit
Note
Removing
– Switch off ignition.
– Release catches of holder -1- from engine control unit - J623- .
– Press down tab -2-, and remove engine control unit - J623-
upwards.
Engine control unit with protective housing
– Disconnect engine control unit from protective housing
⇒ “8.1.6 Disconnecting engine control unit J623 from protec‐
tive housing, Polo”, page 370 .
All versions
Note
Removing
– Remove engine control unit from holder
⇒ “8.1 Removing and installing engine control unit J623 ”, page
360 .
– Move clear wiring harness, and push it to one side as far as
possible.
– Remove bolts -A-. Remove retainer -B-.
– Remove engine control unit from protective housing.
Installing
Install in reverse order. Observe the following:
– Push engine control unit into protective housing as far as it will
go.
– Fit locking element -B- onto protective housing, and secure it
with new shear bolts -A- ⇒ Electronic parts catalogue (ETKA) .
1 - Bracket
2 - Engine control unit - J623-
❑ Removing and installing
⇒ “8.1 Removing and in‐
stalling engine control
unit J623 ”, page 360
3 - Locking bar
❑ Removing and installing
⇒ “8.1.6 Disconnecting
engine control unit J623
from protective housing,
Polo”, page 370
4 - Bolt
❑ Tighten shear-head
screws evenly until
head shears off.
❑ For securing bracket to
engine control unit
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
5 - Bolt
❑ Tighten shear-head
screws evenly until
head shears off.
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
6 - Protective housing
7 - Bolt
❑ Tighten shear-head
screws evenly until
head shears off.
❑ For securing bracket to
engine control unit
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 373
⇒ “1.2 Separating exhaust pipes from silencers”, page 383
⇒ “1.3 Removing and installing silencer”, page 389
⇒ “1.4 Aligning exhaust system free of stress”, page 395
⇒ “1.5 Checking exhaust system for leaks”, page 395
⇒ “1.6 Installation position of clamp”, page 396
1 - Retaining loop
❑ Renew if damaged
2 - Bolt
❑ 20 Nm
3 - Mounting »A«
❑ Renew if damaged
❑ Only for rear silencer
❑ Aligning ⇒ page 375
4 - Rear silencer
❑ Combined in one unit
with front silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling silencer”,
page 389
❑ Separating exhaust
pipes from silencers
⇒ “1.2 Separating ex‐
haust pipes from silenc‐
ers”, page 383
❑ Aligning exhaust sys‐
tem free of tension
⇒ “1.4 Aligning exhaust
system free of stress”,
page 395 .
5 - Rear clamp
❑ Align exhaust system
free of tension before
tightening
⇒ “1.4 Aligning exhaust
system free of stress”,
page 395 .
❑ Fitting position ⇒ “1.6 Installation position of clamp”, page 396
❑ Tighten threaded connections evenly.
6 - Nut
❑ 30 Nm
7 - Retaining loop
❑ Renew if damaged
8 - Bolt
❑ 20 Nm +90°
❑ Renew
9 - Mounting »B«
❑ Renew if damaged
❑ Only for front silencer
❑ Aligning ⇒ page 375
10 - Front silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Removing and installing ⇒ “1.3 Removing and installing silencer”, page 389
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 383
1 - Front silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling silencer”,
page 389
❑ Separating exhaust
pipes from silencers
⇒ “1.2 Separating ex‐
haust pipes from silenc‐
ers”, page 383
❑ Aligning exhaust sys‐
tem free of tension
⇒ “1.4 Aligning exhaust
system free of stress”,
page 395 .
2 - Retaining loop
❑ Renew if damaged
3 - Mounting »A«
❑ Renew if damaged
❑ Aligning ⇒ page 377
4 - Bolt
❑ x 25
❑ 20 Nm
5 - Nut
❑ 30 Nm
6 - Rear clamp
❑ Align exhaust system
free of tension before
tightening ⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
❑ Fitting position ⇒ “1.6 Installation position of clamp”, page 396
❑ Tighten threaded connections evenly.
7 - Mounting »B«
❑ Renew if damaged
❑ Aligning ⇒ page 377
8 - Bolt
❑ x 25
❑ 20 Nm
9 - Rear silencer
❑ Combined in one unit with front silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Removing and installing ⇒ “1.3 Removing and installing silencer”, page 389
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 383
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
10 - Mounting »B«
❑ Renew if damaged
Mounting »C«
– Pre-tighten bolt.
– Align mounting at elongated hole as necessary.
– Align holes -arrows- of mounting -C-.
– Use a commercially available 8 mm drill bit for this purpose.
– Then tighten to specified torque.
5 - Bolt
❑ x 25
❑ 20 Nm
6 - Nut
❑ 30 Nm
7 - Rear clamp
❑ Align exhaust system free of tension before tightening
⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
❑ Fitting position ⇒ “1.6 Installation position of clamp”, page 396
❑ Tighten threaded connections evenly.
8 - Retaining loop
❑ Renew if damaged
9 - Retaining loop
❑ Renew if damaged
10 - Mounting »A«
❑ Renew if damaged
❑ Aligning ⇒ page 380
11 - Bolt
❑ x 25
❑ 20 Nm
12 - Rear silencer
❑ Combined in one unit with front silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Removing and installing ⇒ “1.3 Removing and installing silencer”, page 389
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 383
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
13 - Retaining loop
❑ Renew if damaged
14 - Mounting »A«
❑ Renew if damaged
❑ Aligning ⇒ page 380
15 - Bolt
❑ x 25
❑ 20 Nm
1 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling silencer”,
page 389
❑ Separating exhaust
pipes from silencers
⇒ “1.2.4 Separating ex‐
haust pipes/silencers,
Golf Cabriolet”,
page 386
❑ Aligning exhaust sys‐
tem free of tension
⇒ “1.4 Aligning exhaust
system free of stress”,
page 395 .
2 - Mounting
❑ Renew if damaged
3 - Bolt
❑ 20 Nm
4 - Retaining loop
❑ Renew if damaged
5 - Rear clamp
❑ Align exhaust system
free of tension before
tightening
⇒ “1.4 Aligning exhaust
system free of stress”,
page 395 .
❑ Fitting position
⇒ “1.6 Installation position of clamp”, page 396
❑ Specified torque ⇒ Fig. ““Specified torque for clamp”“ , page 382
6 - Mounting
❑ Renew if damaged
7 - Retaining loop
❑ Renew if damaged
8 - Bolt
❑ 20 Nm
9 - Nut
❑ 20 Nm
10 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Removing and installing ⇒ “1.3 Removing and installing silencer”, page 389
❑ Separating exhaust pipes from silencers
⇒ “1.2.4 Separating exhaust pipes/silencers, Golf Cabriolet”, page 386
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
1 - Clamping sleeve
❑ Removing and installing
⇒ “1.6 Installation posi‐
tion of clamp”,
page 396
❑ 23 Nm
2 - Tunnel cross-piece
❑ Note installation posi‐
tion (mark before re‐
moval, if necessary).
• Depending on version, re‐
move underbody cladding
on left and right sides ⇒
General body repairs, exte‐
rior; Rep. gr. 66 ; Under‐
body cladding .
❑ Removing and installing
⇒ Rep. gr. 66 ; Under‐
body cladding; Remov‐
ing and installing tunnel
cross-piece
3 - Securing nuts
❑ 20 Nm
4 - Front silencer
5 - Mounting
❑ Renew if damaged
6 - Bracket
7 - Bolts
❑ 23 Nm
8 - Coupling point
❑ ⇒ “1.2 Separating ex‐
haust pipes from silenc‐
ers”, page 383
9 - Rear silencer
❑ Removing and installing ⇒ “1.3 Removing and installing silencer”, page 389
10 - Bracket
❑ With mounting
❑ Renew if damaged
11 - Securing bolts
❑ 23 Nm
Sequence of operations
– Cut through exhaust pipe at right angles at separating point
-arrow- using chain pipe cutter - VAS 6254- .
Sequence of operations
– Cut through exhaust pipe at right angles at separating point
-arrow- using chain pipe cutter - VAS 6254- .
Sequence of operations
– Remove rear left underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding .
– Cut through exhaust pipe at right angles at separating point
-arrow- using chain pipe cutter - VAS 6254- .
– Remove rear silencer
⇒ “1.3.3 Removing and installing rear silencer, Touran”, page
391 .
Install in reverse order of removal, observing the following:
– Attach rear silencer.
♦ Safety glasses
Disconnecting
CAUTION
Danger of severe burns from hot exhaust system.
Risk of burns to hands and other parts of body.
– Allow exhaust system to cool.
Note
Note
CAUTION
Risk of injury from swarf being flung into air.
Irritation and injury to skin and eyes possible.
– Wear protective goggles.
– Wear protective gloves.
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
Note
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
Note
Removing
– If fitted, remove rear left underbody cladding ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody cladding .
– Remove rear tunnel cross-piece ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody cladding .
– Remove cross brace -3- for subframe ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Rear axle .
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
– Loosen clamp -1-, and push it to one side towards front si‐
lencer -2-.
– Remove rear silencer.
Installing
Note
2 Emission control
⇒ “2.1 Assembly overview - emission control”, page 397
⇒ “2.2 Removing and installing catalytic converter”, page 400
2.1.1 Assembly overview - emission control, Golf, Golf Estate, Golf SV, Touran,
Golf Cabriolet
1 - Bolt
❑ 20 Nm
2 - Mounting
❑ Renew if damaged
3 - Nut
❑ Specified torque and
tightening sequence
⇒ Fig. ““Installing cata‐
lytic converter - speci‐
fied torque and se‐
quence”“ , page 398
4 - Bolt
❑ 20 Nm
5 - Nut
❑ Specified torque and
tightening sequence
⇒ Fig. ““Installing cata‐
lytic converter - speci‐
fied torque and se‐
quence”“ , page 398
6 - Bracket
7 - Bracket
8 - Bolt
❑ Specified torque and
tightening sequence
⇒ Fig. ““Installing cata‐
lytic converter - speci‐
fied torque and se‐
quence”“ , page 398
9 - Bolt
❑ Specified torque and
tightening sequence
⇒ Fig. ““Installing cata‐
lytic converter - specified torque and sequence”“ , page 398
10 - Front exhaust pipe with catalytic converter
❑ Do not bend flexible joint more than 10°. Otherwise, it can be damaged.
❑ Install flexible joint so that it is not under tension
❑ Take care not to damage wire mesh on decoupling element.
❑ Protect catalytic converter from damage by knocks and impact
1 - Bracket
❑ Renew if damaged
2 - Bracket
❑ Renew if damaged
3 - Retaining bracket
4 - Bolt
❑ 20 Nm
5 - Bracket
6 - Nut
❑ Specified torque and
tightening sequence
⇒ Fig. ““Installing cata‐
lytic converter - speci‐
fied torque and tighten‐
ing sequence”“ ,
page 400
7 - Turbocharger
8 - Screw-type clamp
❑ Renew
❑ Specified torque and
tightening sequence
⇒ Fig. ““Installing cata‐
lytic converter - speci‐
fied torque and tighten‐
ing sequence”“ ,
page 400
9 - Seal
❑ Renewing
⇒ Fig. ““Renewing
seal”“ , page 400
10 - Front exhaust pipe with
catalytic converter
❑ Do not bend flexible joint more than 10° - otherwise it can be damaged.
❑ Install flexible joint so that it is not under tension
❑ Take care not to damage wire mesh on flexible joint.
❑ Protect catalytic converter from damage by knocks and impact
❑ Removing and installing ⇒ “2.2.2 Removing and installing catalytic converter, Polo”, page 403
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
11 - Clamping sleeve
❑ Align exhaust system free of tension before tightening
⇒ “1.4 Aligning exhaust system free of stress”, page 395 .
❑ Fitting position ⇒ “1.6 Installation position of clamp”, page 396
❑ Tighten threaded connections evenly.
❑ 23 Nm
Renewing seal
– Fit screwdriver -2- in recess -arrow- on turbocharger.
– Lever out seal -1-.
– Renew oil seal -1-.
Note
Removing
Note
Note
Note
Clamp position
Note
Removing
– Release and pull off connectors -3-.
– Lay wires -2- to one side.
– Unclip wires -4- from retainer -1-.
Note
Note
Clamp position
Note
The illustrations show the left-hand side. Adapt the procedure ac‐
cordingly for the right-hand side.
Specified torques
♦ ⇒ “1.1.5 Assembly overview - silencers, Polo”, page 382
♦ ⇒ Fig. ““Installing catalytic converter - specified torque and
tightening sequence”“ , page 400
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding
28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 408
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 409
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 411
⇒ “1.4 Removing and installing Hall sender”, page 411
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
412
1 - Bolt
❑ The specified torque in‐
fluences the function of
the knock sensor.
❑ 20 Nm
2 - Knock sensor 1 - G61-
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling knock sensor 1
G61 ”, page 411
3 - Spark plug
❑ Remove and install with
spark plug socket and
extension - 3122 B-
⇒ Maintenance ; Book‐
let 819
❑ Specified torque: 22 Nm
❑ Change interval ⇒
Maintenance tables
4 - Ignition coil with output
stage
♦ Ignition coil 1 with output
stage - N70-
♦ Ignition coil 2 with output
stage - N127-
♦ Ignition coil 3 with output
stage - N291-
♦ Ignition coil 4 with output
stage - N292-
❑ To remove, use puller -
T10530- .
❑ Observe notes on disas‐
sembly
⇒ “1.2 Removing and installing ignition coils with output stage”, page 409
❑ Removing and installing ⇒ “1.2 Removing and installing ignition coils with output stage”, page 409
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
7 - Hall sender - G40-
❑ Removing and installing ⇒ “1.4 Removing and installing Hall sender”, page 411
8 - O-ring
9 - Sender wheel
❑ For engine speed sender - G28-
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 100
10 - Sealing flange, gearbox side
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 100
11 - Engine speed sender - G28-
❑ Removing and installing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 412
12 - Bolt
❑ 4.5 Nm
Note
Removing
Ignition coils “cyl. 2, 3 and 4”:
– Remove resonator for intake air
⇒ “2.3 Removing and installing resonator for intake air”, page
324 .
Note
The spark plug connectors are removed from the ignition coils by
hand.
Installing
Install in reverse order of removal, observing the following:
Removing
– Remove noise insulation -1- ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Unscrew bolt -arrow-, and push charge air cooling pump -
V188- to one side.
Note