Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
1Removing and installing engine
31 Removing and installing engine
31.1 Removing engine
31.2 Separating gearbox from engine and assembling
161.3 Securing engine on engine and gearbox support VAS 6095
191.4 Notes on installing
202 Assembly mounting, except Jetta 2011 ▶
242.1 Assembly overview - assembly mountings
242.2 Checking adjustment of engine assembly mountings
272.3 Adjusting assembly mountings
273 Assembly mounting, Jetta 2011 ▶
333.1 Assembly overview - assembly mountings
333.2 Removing and installing engine mounting
353.3 Removing and installing gearbox mounting
403.4 Removing and installing pendulum support
423.5 Supporting engine in installation position
433.6 Adjusting assembly mountings
483.7 Checking adjustment of assembly mountings
49Crankshaft group
511 Dismantling and assembling engine
511.1 Assembly overview - poly V-belt drive
511.2 Removing and installing poly-V belt
521.3 Removing and installing poly V-belt tensioner
541.4 Removing and installing bracket for ancillaries
561.5 Assembly overview - toothed belt drive
571.6 Removing and installing engine bracket
601.7 Assembly overview - cylinder block
632 Removing and installing sealing flange and flywheel
662.1 Renewing crankshaft sealing flange - flywheel end
672.2 Renewing crankshaft oil seal - pulley end
782.3 Removing and installing sealing flange - pulley end
812.4 Removing and installing engine speed sender G28
853 Pistons and conrods
883.1 Assembly overview - pistons and conrods
883.2 Separating new conrods
923.3 Bearing shells - installation position
933.4 Piston and cylinder dimensions
933.5 Checking piston projection at TDC
934 Crankshaft
964.1 Assembly overview - crankshaft
964.2 Crankshaft dimensions
974.3 Pulling needle bearing out of and driving into crankshaft
98Cylinder head, valve gear
1011 Cylinder head
1011.1 Assembly overview - cylinder head cover
1011.2 Removing and installing Hall sender G40
1031.3 Removing and installing engine cover
1061.4 Removing and installing cylinder head cover
1071.5 Assembly overview - cylinder head
1131.6 Removing, installing and tensioning toothed belt
1161.7 Removing and installing cylinder head
1251.8 Removing and installing vacuum pump
1501.9 Checking compression
1522 Valve gear
1542.1 Assembly overview - valve gear
1542.2 Removing and installing camshafts
1562.3 Removing and installing camshaft oil seal
1652.4 Renewing valve stem seals (with cylinder head installed)
1672.5 Checking valve guides
171Lubrication
1731 Engine oil:
1731.1 Oil capacities
1731.2 Checking engine oil level
1732 Parts of lubrication system (engine codes CBEA)
1752.1 Assembly overview - oil pump, sump, balance shaft module
1752.2 Removing and installing oil sump
1782.3 Removing and installing oil pump
1822.4 Removing and installing balance shaft module
1832.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear
1913 Parts of lubrication system (engine codes CBDA, CBDB, CEGA, CJAA)
1953.1 Assembly overview - oil pump, sump
1953.2 Removing and installing oil sump
1973.3 Removing and installing oil pump
2024 Oil filter bracket, oil cooler, oil pressure and oil supply line
2034.1 Assembly overview - oil filter bracket and oil cooler
2034.2 Removing and installing oil filter bracket together with oil cooler
2054.3 Removing and installing oil supply line to turbocharger
2084.4 Checking oil pressure and oil pressure switch F1
211Cooling
2151 Parts of cooling system
2151.1 Assembly overview - parts of cooling system, body side
2161.2 Parts of cooling system - engine side
2181.3 Coolant hose connection diagram
2241.5 Removing and installing radiator
2301.6 Removing and installing coolant pump
2311.7 Removing and installing thermostat
2331.8 Removing and installing 4/2-way valve with thermostat
2341.9 Draining and adding coolant
2371.10 Checking cooling system for leaks
2421.11 Checking oil cooler for leaks
2441.12 Engine preheater (engine codes CBEA, CJAA)
247Fuel supply system
2501 Safety regulations for working on fuel supply
2502 Rules for cleanliness
2513 Procedure in event of misfuelling
2523.1 Step 1 (Engine was started with incorrect fuel)
2523.2 Step 2 (Engine was not started with incorrect fuel)
2533.3 Step 3 (There are filings in fuel delivery unit and fuel tank)
2553.4 Step 4 (There are no filings in fuel delivery unit and fuel tank)
2553.5 Step 5 (There are filings in high-pressure pump)
2563.6 Step 6 (There are no filings in high-pressure pump)
2564 Parts of fuel supply system
2584.1 Assembly overview - fuel tank, all vehicles apart from Jetta from MY 2011
2594.2 Assembly overview - fuel tank, only Jetta from MY 2011
2614.3 Emptying fuel tank
2634.4 Removing and installing fuel tank
2674.5 Removing and installing fuel delivery unit
2724.6 Removing and installing fuel gauge sender G
2765 Separating plug-in connectors
2786 Repairing fuel supply
2846.1 Assembly overview - fuel filter
2846.2 Removing and installing fuel filter
2856.3 Checking fuel system pressurisation pump G6
2876.4 Checking supplementary fuel pump V393 (inline electronic fuel pump)
2937 Electronic power control (EPC)
2997.1 Function of EPC system
2997.2 Assembly overview - accelerator module
2997.3 Removing and installing accelerator pedal module
300Turbocharging/supercharging
3031 Safety precautions when working on charge air system and turbocharger
3032 Rules for cleanliness
3043 Turbocharger
3053.1 Assembly overview - turbocharger with exhaust manifold and attachments
3053.4 Changing vacuum unit with position sender for charge pressure positioner G581
3173.5 Removing and installing exhaust gas temperature sender G235
3254 Charge air system
3294.1 Assembly overview - parts of charge air cooling
3304.3 Checking charge air system for leaks
3344.4 Vacuum hose schematic diagram (engine codes CBEA, CJAA)
3374.5 Vacuum hose schematic diagram, (engine codes CBDA, CBDB, CEGA)
3384.6 Checking vacuum system
339Mixture preparation - injection
3441 Observe safety precautions when working on diesel direct injection fuel system
3442 Rules for cleanliness
3463 Diesel direct injection system
3473.1 System layout
3483.2 Assembly overview - fuel system
3513.3 Removing and installing injector (piezo injector)
3543.4 Checking fuel pressure regulating valve N276
3613.5 Removing and installing fuel pressure regulating valve N276
3623.6 Removing and installing fuel pressure sender G247
3643.7 Removing and installing fuel system high-pressure pump
3663.8 Filling/bleeding fuel system
3713.9 Checking for leaks in the fuel system
3723.10 Checking pressure retention valve in fuel return line
3723.11 Assembly overview - intake manifold with attachments
3743.12 Removing and installing intake manifold
3753.13 Assembly overview - air filter
3793.14 Removing and installing air filter housing
3823.15 Removing and installing air filter element
3833.16 Checking changeover flap for intake air preheating
3853.17 Removing and installing changeover flap for intake air preheating
3873.18 Removing and installing air mass meter G70
3894 Engine control unit (engine codes CBEA, CJAA)
3914.3 Removing and installing engine control unit J623, only Jetta from MY 2011
3975 Engine control unit (engine codes CBDA, CBDB, CEGA)
4005.1 Removing and installing engine control unit J623 with no theft protection
4005.2 Removing and installing engine control unit J623 with theft protection
402Exhaust system
4061 Exhaust system (engine codes CBEA, CJAA)
4061.1 Assembly overview - particulate filter with NOx storage catalytic converter
4061.2 Note installation position of securing clamps and exhaust gas temperature sender
4131.3 Removing and installing particulate filter with NOx storage catalytic converter
4151.4 Assembly overview - exhaust flap control unit J883 with SCR catalytic converter
4261.5 Routing cables/lines of components for exhaust system
4281.6 Assembly overview - silencers
4291.7 Separating and joining exhaust system
4331.8 Aligning exhaust system free of stress
4351.9 Checking exhaust system for leaks
4371.10 Installation position of clamp
4372 Exhaust system (engine codes CBDA, CBDB, CEGA)
4402.1 Assembly overview - front exhaust pipe with particulate filter
4402.2 Removing and installing particulate filter
4432.3 Assembly overview - silencers
4492.4 Cutting exhaust pipe
4492.5 Aligning exhaust system free of stress
4503 Exhaust gas recirculation
4523.1 Assembly overview – exhaust gas recirculation
4523.2 Removing and installing exhaust gas recirculation filter
4563.4 Removing and installing exhaust gas recirculation cooler, engine code CJAA
4633.5 Checking exhaust gas recirculation cooler for leaks
4653.6 Removing and installing temperature sensor for exhaust gas recirculation
4703.7 Cleaning exhaust gas recirculation system
475Glow plug system
4831 Glow plugs
4831.1 Removing and installing glow plug
4831.2 Removing and installing connectors for glow pin plugs
487