Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
1Removing and installing engine
21 Removing and installing engine (Golf, Golf Plus)
21.1 Removing engine
31.2 Securing engine to assembly stand
81.3 Installing engine
81.4 Specified torques
91.5 Assembly mountings
101.6 Additional information and assembly work for vehicles with air conditioner
112 Removing and installing engine (Touran)
122.1 Removing engine
132.2 Securing engine to assembly stand
162.3 Installing engine
162.4 Specified torques
182.5 Assembly mountings
192.6 Additional information and assembly work for vehicles with air conditioner
203 Removing and installing engine (Passat)
213.1 Removing engine
223.2 Securing engine to assembly stand
263.3 Installing engine
263.4 Specified torques
273.5 Assembly mountings
283.6 Notes on repairs to air conditioning system
284 Removing and installing engine (Eos)
304.1 Removing engine
314.2 Securing engine to assembly stand
354.3 Installing engine
354.4 Assembly mountings
38Crankshaft group
401 Dismantling and assembling engine
401.1 Assembly overview - parts l and ll
401.2 Assembly overview - part I, belt drive
421.3 Assembly overview - part II, cylinder block
431.4 Removing and installing poly-V belt
451.5 Removing and installing valve timing housing (timing case)
461.6 Removing and installing valve timing housing (Touran)
502 Sealing flange and flywheel or drive plate
552.1 Assembly overview
562.2 Removing and installing engine speed sender G28
572.3 Renewing crankshaft oil seal - belt pulley end
582.4 Poly V-belt pulley securing bolt tightening procedure
612.6 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
642.7 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
722.8 Renewing crankshaft sealing flange at flywheel end (Eos)
802.9 Crankshaft dimensions
883 Dismantling and assembling pistons and conrods
893.1 Assembly overview
893.2 Checking piston
913.3 Piston and cylinder dimensions
92Cylinder head, valve gear
931 Cylinder head
931.1 Assembly overview
931.2 Checking valve timing
961.3 Adjusting valve timing
971.6 Removing and installing camshaft housing
1161.7 Removing and installing cylinder head
1211.8 Checking compression
1242 Repairing valve gear
1272.1 Assembly overview
1272.2 Checking camshaft axial clearance
1292.3 Reworking valve seats
1292.4 Checking valve guides
1312.5 Renewing valve stem seals
131Lubrication
1341 Removing and installing parts of lubrication system
1341.1 Engine oil:
1341.2 Assembly overview
1341.3 Removing and installing sump
1371.4 Removing and installing oil pump
1381.5 Checking oil pressure and oil pressure switch
140Cooling
1431 Removing and installing parts of cooling system
1431.4 Assembly overview - parts of cooling system, body side, radiator with two fans (Touran)
1481.7 Assembly overview - parts of cooling system, engine side
1521.8 Coolant hose connection diagram
1551.9 Draining and adding coolant
1551.10 Removing and installing radiator fan V7 and radiator fan 2 V177
1591.11 Removing and installing radiator
1601.12 Removing and installing coolant pump
1621.13 Checking cooling system for leaks
163Fuel supply system
1661 Safety precautions
1661.1 Safety regulations for working on fuel supply
1661.2 Releasing pressure in high-pressure area
1662 Rules for cleanliness
1683 Fuel tank (Golf, Golf Plus)
1693.1 Fuel tank - assembly overview (Golf, Golf Plus)
1693.2 Emptying fuel tank
1703.3 Removing and installing fuel tank
1734 Fuel tank (Touran)
1764.1 Assembly overview - fuel tank
1764.2 Emptying fuel tank
1784.3 Removing and installing fuel tank
1805 Fuel tank (Passat)
1835.1 Assembly overview - fuel tank
1835.2 Emptying fuel tank
1845.3 Removing and installing fuel tank
1866 Fuel tank (Eos)
1906.1 Assembly overview - fuel tank
1906.2 Emptying fuel tank
1926.3 Removing and installing fuel tank
1947 Repairing fuel supply system (Golf, Golf Plus, Eos)
1977.1 Removing and installing fuel delivery unit
1977.2 Removing and installing fuel gauge sender G
2007.3 Crash fuel shut-off
2027.4 Checking fuel pump
2028 Repairing fuel supply (Touran)
2148.1 Removing and installing fuel delivery unit
2148.2 Removing and installing fuel gauge sender G
2168.3 Crash fuel shut-off
2188.4 Checking fuel pump
2189 Repairing fuel supply (Passat)
2309.1 Removing and installing fuel delivery unit
2309.2 Removing and installing fuel gauge sender G
2339.3 Checking fuel pump
23410 Electronic power control; EPC (Golf, Golf Plus, Passat, Eos)
24410.1 Assembly overview - accelerator module
24410.2 Removing and installing accelerator pedal module
24411 Electronic power control; EPC (Touran)
24711.1 Assembly overview - accelerator module
24711.2 Removing and installing accelerator pedal module
24712 Activated charcoal filter system (Golf, Golf Plus, Eos)
24912.1 Assembly overview - activated charcoal filter system
24912.2 Checking fuel tank breather
24913 Activated charcoal filter system (Touran)
25213.1 Checking fuel tank breather
25214 Activated charcoal filter system (Passat)
25414.1 Assembly overview - activated charcoal filter system
25414.2 Checking fuel tank breather
254Mixture preparation - injection
2561 Injection system
2561.1 General notes on injection
2561.2 Technical data
2571.3 Assembly overview - air filter
2571.4 Removing and installing air filter
2581.5 Assembly overview - intake manifold (engine codes BAG, BKG)
2591.6 Assembly overview - intake manifold (engine codes BLF, BLN, BLP)
2621.7 Assembly overview - fuel rail with injectors
2641.8 Cleaning throttle valve module J338
2651.9 Removing and installing high-pressure pump (engine codes BAG, BKG)
2651.10 Removing and installing high-pressure pump (engine codes BLF, BLN, BLP)
2671.11 Removing and installing injectors
2712 Checking components
2762.1 Checking function of intake manifold flap
2762.2 Checking vacuum reservoir in intake manifold for leaks
2762.3 Checking intake air preheating
2773 Engine control unit J623 (Golf, Eos)
2783.1 Removing and installing engine (motor) control unit J623
2784 Engine control unit J623 (Golf Plus, Touran)
2824.1 Removing and installing engine (motor) control unit J623
2825 Engine control unit J623 (Passat)
2865.1 Removing and installing engine (motor) control unit J623
2865.2 Removing and installing engine control unit J623 with locking plate
2875.3 Removing and installing engine control unit J623 with locking clip
290Exhaust system
2921 Parts of exhaust system (Golf, Golf Plus, Touran)
2921.2 Assembly overview - catalytic converters and attachments, engine codes BLN, BLP, BLF
2941.3 Assembly overview - silencers with mountings
2962 Parts of exhaust system (Passat)
2972.1 Assembly overview - catalytic converters and attachments
2972.2 Assembly overview - silencers with mountings
2983 Parts of exhaust system (Eos)
3003.1 Assembly overview - catalytic converters and attachments
3003.2 Assembly overview - silencers with mountings
3023.3 Separating centre and rear silencers
3024 Exhaust gas recirculation system
3044.1 Assembly overview - exhaust gas recirculation system
3044.2 Removing and installing exhaust gas recirculation valve N18
305Ignition system
3071 Repairing ignition system
3071.1 General notes on ignition system
3071.2 Safety precautions
3071.3 Assembly overview - ignition system
3071.4 Removing and installing ignition coils with output stage
3081.5 Test data, spark plugs
310