Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
12 Safety caution
32.1 Precautions for fuel supply system working
32.2 Safety measures when using testing and measuring devices in trail running
42.3 Safety measure when the ignition system is in working
42.4 Safety measure when the cooling system is in working
52.5 Reduce fuel pressure in high pressure area
53 Maintenance instruction
73.1 Clean requirements
73.2 Foreign objects in engine
73.3 Rusting due to contact
73.4 Pipe arrangement and fixing
73.5 Installation of radiator and condenser
8Removal and installation of engine
91.1 Engine removal
101.2 Disengage the engine and 5-speed manual gearbox PCM
201.3 Disengage engine and 7-gear dual-clutch gearbox PGR/QPH
201.4 Fix the engine on assembly bracket
231.5 Install the engine
242.1 Engine removal
312.2 Disengage engine and 7-gear dual-clutch gearbox QFP/QJM
412.3 Fix the engine on assembly bracket
442.4 Engine removal
453 Removal and installation of engine (Lamando)
503.1 Engine removal
513.2 Disengage the engine and 5-speed manual gearbox 0A4
633.3 Disengage engine and 7-gear dual-clutch gearbox 0CW
633.4 Fix the engine on assembly bracket
653.5 Engine removal
664 Removal and installation of engine (Passat 2016)
714.1 Engine removal
724.2 Disengage the engine and 5-speed manual gearbox 0A4
834.3 Disengage engine and 7-gear dual-clutch gearbox 0AM
844.4 Fix the engine on assembly bracket
864.5 Engine removal
875 Removal and installation of the engine (All New Touran L 2016)
925.1 Engine removal
935.2 Disengage the engine and 5-speed manual gearbox 0A4
1055.3 Disengage engine and 7-gear dual-clutch gearbox 0CW
1055.4 Fix the engine on assembly bracket
1075.5 Engine removal
1086 Removal and installation of the engine (New Tiguan 2013)
1136.1 Engine removal
1156.2 Disengage engine and 6-gear dual-clutch gearbox 02E
1256.3 Fix the engine on assembly bracket
1276.4 Engine removal
1297.1 Unit support-assembly overview (models equipped with 5-speed automatic gearbox PCM)
1347.3 Remove and install engine mounting
1387.4 Remove and install engine mounting
1397.5 Removal and installation of gearbox base
1427.6 Adjust unit support
1448 Unit support (applicable for New Santana, New Polo GTI and Gran Santana)
1478.1 Unit support - assembly overview
1478.2 Removal and installation of engine mounting
1498.3 Removal and installation of engine supporting device
1518.4 Remove and install gearbox mounting
1558.5 Adjust unit support
1599 Unit support (Lamando, All New Touran L 2016)
1619.1 Unit support-assembly overview (models equipped with 5-speed automatic gearbox 0A4)
1619.3 Removal and installation of engine mounting (Lamando)
1649.4 Remove and install engine mounting (All New Touran L 2016)
1689.5 Remove and install engine mounting (Lamando)
1729.6 Remove and install engine mounting (All New Touran L 2016)
1789.7 Remove and install gearbox mounting
1849.8 Remove and install gearbox bracket (All New Touran L 2016)
1889.9 Adjust unit support (Lamando)
1929.10 Adjust unit support (All New Touran L 2016)
19810 Unit support (Passat 2016)
20310.1 Unit support-assembly overview (models equipped with 5-speed automatic gearbox 0A4)
20310.3 Removal and installation of engine mounting
20610.4 Remove and install engine mounting
21010.5 Remove and install gearbox mounting
21610.6 Adjust unit support
22011 Unit support (New Tiguan 2013)
22611.1 Unit support - assembly overview
22611.2 Removal and installation of engine mounting
22811.3 Remove and install engine mounting
23111.4 Remove and install gearbox mounting
23611.5 Adjust unit support
240Crank connecting rod mechanism
2451 Disassembly and assembly of engine
2451.1 Belt driven - assembly overview
2451.2 Sealing flange at pulley side- assembly overview
2471.3 Removal and installation of V-ribbed belt
2481.6 Remove and install crankshaft pulley
2541.7 Replace the sealing ring of crankshaft at the pulley belt’s side
2582 Cylinder block on gearbox side
2692.3 Removal and installation
2722.4 Remove and install sealing flange on gearbox side
2733 Crankshaft
2813.2 Crankshaft size
2823.3 Measure the crankshaft axial clearance
2824 Piston and connecting rod
2844.1 Piston and connecting rod - assembly overview
2844.2 Remove and install piston
2864.3 Check the piston
2884.4 Check the cylinder inner bore
288Valve mechanism
2901 Belt driven
2901.1 Belt protective cover - assembly overview
2901.2 Toothed belt - assembly overview
2911.3 Inspect timing
2921.4 Disengage timing toothed belt from the camshaft
2981.5 Removal and installation of timing toothed belt
3112 Cylinder head
3252.1 Cylinder head - Assembly Overview
3252.2 Removal and installation of cylinder head
3262.3 Check cylinder pressure
3313 Valve mechanism
3353.1 Camshaft housing - assembly overview
3353.2 Valve - Assembly Overview
3371 N318
3383.4 Check the axial clearance of the camshaft
3383.5 Removal and installation of camshaft seal ring
3393.6 Removal and installation of camshaft housing
3443.7 Remove and install sealing element of valve stem
3484 Intake valve and exhaust valve
3534.1 Valve guide pipe
3534.2 Check the valve
3534.3 Valve size
354Lubrication system
3551 Components of lubrication system
3551.1 Engine oil
3551.2 Oil pan and oil pump - assembly Overview
3551.3 Removal and installation of oil pan lower parts
3581.4 Removal and installation oil pump
3601.5 Remove and install oil pump drive sprocket
3621.6 Removal and installation of the upper parts of oil pan
3632 Engine oil cooler
3662.1 Engine oil cooler - assembly overview
3662.2 Removal and installation of engine oil cooler
3663 Crankcase exhaust system
3683.1 Crankcase exhaust system - assembly overview
3683.2 Removal and installation of oil/air separator
3694 Oil filter / oil pressure switch
3714.1 Oil filter / oil pressure switch - assembly overview
3714.2 Removal and installation of the oil pressure switch F1
3714.3 Remove and install oil pressure switch for reduced oil pressure F378
3734.4 Remove and install engine oil pressure control valve N428
3754.5 Test engine oil pressure and engine oil pressure switch
377Cooling System
3801 Components of cooling System
3801.1 Coolant hose connection diagram
3801.2 Discharge and add coolant
3821.3 Check the tightness of cooling system
3872 Coolant pump / coolant adjusting unit
3902.1 Coolant pump / coolant adjusting unit - assembly overview
3902.2 Coolant circulating pump - assembly overview
3922.6 Coolant temperature sensor - assembly overview (Passat 2016)
3962.7 Coolant temperature sensor - assembly overview (New Tiguan 2013)
3972.8 Removal and installation of coolant pump
3982.9 Remove and install coolant pump toothed belt pulley
4022.10 Remove and install thermostat for large coolant circulation
4042.11 Remove and install thermostat for small coolant circulation
4062.12 Remove and install coolant circulating pump V51
4072.13 Remove and install coolant temperature sensor G62
4083 Coolant pipe
4173.1 Coolant pipe - assembly overview
4173.2 Removal and installation of coolant pipe
4174.1 Radiator - Assembly Overview
4194.2 Radiator fan - Assembly Overview
4204.3 Remove and install fan shield
4214.4 Removal and installation of radiator
4214.5 Remove and install radiator fan V7 and radiator fan control unit J293
4234.6 Removal and installation of the radiator of turbocharger system
4245 Radiator and radiator fan (Applicable for New Santana, New Polo GTI and Gran Santana)
4265.1 Radiator and radiator fan - Assembly Overview
4265.2 Remove and install fan shield
4275.3 Remove and install radiator fan V7
4285.4 Removal and installation of radiator
4295.5 Removal and installation of the radiator of turbocharger system
4326 Radiator and radiator fan (Lamando, All New Touran L 2016)
4346.1 Radiator - Assembly Overview
4346.2 Radiator fan - Assembly Overview
4366.3 Remove and install fan shield
4366.4 Remove and install radiator fan VX57
4376.5 Removal and installation of radiator (Lamando)
4386.6 Removal and installation of radiator (All New Touran L 2016)
4406.7 Removal and installation of the turbocharged radiator
4427 Radiator and radiator fan (Passat 2016, New Tiguan 2013)
4457.1 Radiator - Assembly Overview
4457.2 Radiator fan - Assembly Overview
4467.3 Remove and install fan shield
4477.4 Remove and install radiator fan V7 and radiator fan 2 V177
4487.5 Removal and installation of radiator
4487.6 Removal and installation of the radiator of turbocharger system
450Fuel supply system
4521 Safety measures
4521.1 Safety measures when operating fuel supply system
4521.2 Clean requirements
4531.3 Release the pressure of high pressure area
4532.1 Fuel tank and installation part - assembly overview
4552.3 Drain the fuel tank
4602.5 Removal and installation of secondary beam (Applicable for New Polo GTI)
4652.6 Fuel pump and fuel quantity transducer - assembly overview
4682.7 Removal and installation of the fuel pump
4702.8 Remove and install fuel quantity transducer G
4722.9 Check fuel pump
4742.10 Fuel filter and installation part - assembly overview
4862.11 Remove and install fuel filter
4873 Fuel tank (Lamando, All New Touran L 2016)
4883.1 Fuel tank and installation part - assembly overview (Lamando)
4883.2 Fuel tank and installation part - assembly overview (All New Touran L 2016)
4903.3 Drain the fuel tank
4923.4 Removal and installation of the fuel tank (Lamando)
4973.5 Removal and installation of fuel tank (All New Touran L 2016)
5033.6 Fuel pump and fuel quantity transducer - assembly overview (Lamando)
5083.8 Removal and installation of the fuel pump (Lamando)
5113.9 Remove and install fuel pump (All New Touran L 2016)
5133.10 Remove and install fuel quantity transducer G
5163.11 Check fuel pump
5164 Fuel tank (Passat 2016)
5304.1 Fuel tank and installation part - assembly overview
5304.2 Drain the fuel tank
5314.3 Removal and installation of the fuel tank
5374.4 Fuel pump and fuel quantity transducer - assembly overview
5414.5 Removal and installation of the fuel pump
5434.6 Remove and install the flange with fuel filter
5464.7 Remove and install fuel quantity transducer G
5474.8 Check fuel pump
5485 Fuel tank (New Tiguan 2013)
5615.1 Fuel tank and installation part - assembly overview
5615.2 Drain the fuel tank
5635.3 Removal and installation of the fuel tank
5655.4 Removal and installation of the fuel pump
5695.5 Remove and install the flange with fuel filter
5725.6 Remove and install fuel quantity transducer G
5735.7 Remove and install fuel quantity transducer G169
5735.8 Check fuel quantity transducer G
5755.9 Check fuel quantity transducer 2 G169
5775.10 Check fuel pump
5795.11 Check fuel suction jet pump
5905.12 Fuel filter and installation part - assembly overview
5905.13 Remove and install fuel filter
5916 Electronic accelerator (EPC)
5936.1 Electronic accelerator
5936.4 Accelerator pedal - assembly overview (Lamando、All New Touran L 2016)
5966.5 Accelerator pedal - assembly overview (Passat 2016, New Tiguan 2013)
5987 Activated carbon canister
6037.1 Functions
6037.5 Activated carbon canister - assembly overview (applicable to New Polo GTI)
6077.9 Remove and install activated carbon canister (Lamando, All New Touran L 2016)
6107.13 Check exhaust of fuel tank (Applicable for New Santana and Gran Santana)
6157.14 Check fuel tank exhaust (Lamando, All New Touran L 2016)
6187.15 Check fuel tank exhaust (applicable to New Polo GTI)
6227.16 Check the exhaust of fuel tank (Passat 2016, New Tiguan 2013)
625Turbocharger System
6301 Turbocharger
6301.3 Removal and installation of the turbocharger
6341.7 Adjust the boost pressure regulator of exhaust gas turbocharger
6442 Turbocharged air intake system
6492.1 Turbocharged air intake system – assembly overview
6492.2 Remove and install boost pressure sensor G31 / air intake temperature sensor 2 G299
6502.3 Removal and installation of the inter-cooler
650Mixed gas preparation and injection system
6531 Injection system
6531.1 Installation position overview:
6532 Air filter
6602.3 Air filter - Assembly Overview (Passat 2016)
6622.4 Remove and install the air filter housing
6633 Intake manifold assembly
6643.1 Intake manifold assembly - assembly overview
6643.2 Remove and install intake manifold assembly
6663.3 Remove and install the throttle valve module J338
6703.4 Clean throttle control unit J338
6723.5 Technical data
6734 Fuel nozzle
6744.1 Fuel distributor with fuel nozzle - assembly overview
6744.2 Remove and install fuel distributor with fuel nozzle
6754.3 Removal and installation of the fuel nozzle
6764.4 Clean fuel nozzle
6815 Sensor
6845.1 Remove and install intake temperature sensor G42 / intake manifold pressure sensor G71
6845.2 Remove and install fuel pressure sensor G247
6845.3 Check fuel pressure sensor signal G247
6866 High pressure pump
6916.1 High pressure pump - assembly overview
6916.2 Removal and installation of HP pump
6926.3 Removal and installation of high-pressure pipe
6947 Oxygen sensor
6978 Engine control unit
7038.1 Use test box V.A.G 1598/42 to inspect conducting wires and parts
7038.4 Removal and installation of engine control unit J623 (Lamando, All New Touran L 2016)
7068.5 Remove and install engine control unit J623 (Passat 2016)
7078.6 Remove and install engine control unit J623 (New Tiguan 2013)
7088.7 Matching function and components
7098.8 Inquire and clear the fault memory of engine control unit
710Exhaust system
7111.1 Emission-catalytic purifier and installation part - assembly overview
7121.2 Install the front exhaust pipe with exhaust catalytic converter
7141.3 Silencer and suspension system - assembly overview
7171.4 Remove and install silencer
7191.5 Separate the silencer
7201.6 Install the exhaust system in non-stress state
7212 Components of exhaust system (Applicable for New Santana and Gran Santana)
7232.1 Emission-catalytic purifier and installation part - assembly overview
7232.2 Install the front exhaust pipe with exhaust catalytic converter
7242.3 Silencer and suspension system - assembly overview
7282.4 Remove and install silencer
7302.5 Separate the silencer
7312.6 Install the exhaust system in non-stress state
7333.1 Emission-catalytic purifier and installation part - assembly overview
7343.2 Remove and install front exhaust pipe with emission-catalytic purifier
7363.3 Silencer and suspension system - assembly overview (Lamando)
7403.4 Silencer and suspension system - assembly overview (Passat 2016)
7413.5 Silencer and suspension system - assembly overview (All New Touran L 2016)
7423.6 Silencer and suspension system - assembly overview (New Tiguan 2013)
7443.7 Remove and install silencer (Lamando)
7443.8 Remove and install silencer (Passat 2016)
7463.9 Remove and install silencer (All New Touran L 2016)
7483.10 Remove and install silencer (New Tiguan 2013)
7503.11 Separate the silencer (Lamando, Passat 2016)
7523.12 Separate the silencer (All New Touran L 2016)
7533.13 Separate the silencer (New Tiguan 2013)
7553.14 Install the exhaust system in non-stress state (Lamando and Passat 2016)
7573.15 Install the exhaust system in non-stress state (All New Touran L 2016)
7583.16 Check the tightness of exhaust system (New Tiguan 2013)
7594 Components of exhaust system (Applicable for New Polo GTI)
7614.1 Emission-catalytic purifier and installation part - assembly overview
7614.2 Remove and install front exhaust pipe with emission-catalytic purifier
7634.3 Silencer and suspension system - assembly overview
7674.4 Remove and install silencer
7684.5 Separate the silencer
7694.6 Install the exhaust system in non-stress state
771Ignition system
7721 Ignition equipment
7721.1 Ignition device - assembly overview
7721.2 Test data, spark plugs
7731.3 Remove and install ignition coil with power output stage
7741.4 Remove and install knock sensor 1 G61
7761.5 Remove and install the light sensor G40
7771.6 Remove and install Hall sensor 2 G163
7791.7 Remove and install engine speed sensor G28
781