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 and installing engine cover
31.2 Removing engine
41.3 Separating engine from gearbox
131.4 Separating engine from dual clutch gearbox
151.5 Securing engine to assembly stand
181.6 Installing engine
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
393.4 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 Poly V-belt drive with tensioning element and air conditioner compressor
511.2 Poly V-belt drive with tensioning roller and air conditioner compressor
551.3 Poly V-belt drive without air conditioning compressor
591.4 Removing and installing bracket for ancillaries
611.5 Assembly overview - toothed belt drive
631.6 Removing and installing engine bracket
651.7 Assembly overview - crankcase
692 Removing and installing sealing flange and flywheel
712.1 Assembly overview - Sealing flange, belt pulley end
712.2 Renewing crankshaft oil seal, pulley end
732.3 Removing and installing sealing flange - pulley end
752.4 Assembly overview - Dual-mass flywheel and sealing flange
792.5 Removing and installing dual-mass flywheel
802.6 Renewing crankshaft sealing flange, flywheel end
812.7 Removing and installing engine speed sender G28
923 Pistons and conrods
943.1 Assembly overview - pistons and conrods
943.2 Piston and cylinder dimensions
983.3 Separating new conrods
983.4 Bearing shells - installation position
993.5 Piston and cylinder dimensions
1003.6 Checking piston projection at TDC
1003.7 Measuring radial clearance of conrods
1024 Crankshaft
1034.1 Assembly overview - crankshaft
1034.2 Crankshaft dimensions
1034.3 Pulling needle bearing out of and driving into crankshaft
104Cylinder head, valve gear
1071 Cylinder head
1071.1 Assembly overview - cylinder head
1071.2 Assembly overview - cylinder head cover
1111.3 Assembly overview - toothed belt
1131.4 Removing and installing cylinder head cover
1161.5 Removing, installing and tensioning toothed belt
1191.6 Removing and installing cylinder head
1281.7 Removing and installing vacuum pump
1401.8 Compression test
1412 Valve gear
1432.1 Assembly overview - valve gear
1432.2 Removing and installing camshafts
1452.3 Measuring axial clearance of camshaft
1542.4 Measuring radial clearance of camshafts
1552.5 Removing and installing camshaft oil seal
1562.6 Checking hydraulic compensation elements
1612.7 Renewing valve stem seals with cylinder head installed
1622.8 Renewing valve stem seals with cylinder head removed
1662.9 Valves
171Lubrication
1741 Engine oil:
1741.1 Oil capacities
1741.2 Checking engine oil level
1742 Parts of lubrication system
1752.1 Assembly overview - oil pump, sump
1752.2 Removing and installing oil level and oil temperature sender G266
1782.3 Removing and installing oil sump
1782.4 Removing and installing oil pump
1843 Oil filter bracket and engine oil cooler
1863.1 Assembly overview - oil filter bracket and engine oil cooler
1863.2 Removing and installing oil filter bracket with engine oil cooler
1883.3 Removing and installing oil pressure switch F1
1913.4 Checking oil pressure switch F1
1923.5 Checking oil pressure
194Cooling
1961 Parts of cooling system
1961.1 Assembly overview - parts of cooling system, body side
1961.2 Assembly overview - parts of cooling system, engine side
1971.3 Assembly overview - coolant pump and thermostat
1991.4 Coolant hose connection diagram
1992 Repairing cooling system
2022.2 Removing and installing radiator
2032.3 Removing and installing coolant pump
2042.4 Removing and installing 4/2-way valve with thermostat
2062.5 Draining and adding coolant
2162.6 Coolant pipes, coolant temperature sender
2222.7 Checking cooling system for leaks
236Fuel supply system
2391 Safety regulations for working on fuel supply
2392 Rules for cleanliness
2403 Procedure in event of misfuelling
2413.1 Procedure for 1st scenario
2413.2 Procedure for 2nd scenario
2424 Parts of fuel supply system
2454.1 Fuel tank, vehicles with front-wheel drive
2454.2 Fuel tank, vehicles with four-wheel drive
2544.3 Emptying fuel tank
2634.4 Removing and installing fuel delivery unit
2674.5 Removing and installing fuel gauge sender
2695 Repairing fuel supply
2705.1 Assembly overview - fuel filter
2705.2 Removing and installing upper part of fuel filter
2735.3 Removing and installing fuel filter
2765.4 Checking fuel system pressurisation pump G6
2775.7 Assembly overview - accelerator mechanism
288Turbocharging/supercharging
2921 Turbocharger
2921.1 Safety precautions
2921.2 Rules for cleanliness
2921.3 Assembly overview - turbocharger
2931.4 Removing and installing turbocharger
2951.5 Changing vacuum unit with position sender for charge pressure positioner G581
2992 Charge air system
3072.1 Installing hose connections with corrugated pipe and hose clips
3072.2 Assembly overview - parts of charge air cooling
3082.4 Removing and installing charge air cooler
3102.5 Checking charge air system for leaks
3122.6 Vacuum hose connection diagram
3162.7 Checking vacuum system
316Mixture preparation - injection
3211 Diesel direct injection system
3211.1 Safety precautions
3211.2 Rules for cleanliness
3211.3 System layout
3222 High-pressure pump
3242.1 Assembly overview – high-pressure pump
3242.2 Removing and installing high-pressure pump
3262.3 Filling/bleeding fuel system
3302.4 Checking for leaks in the fuel system
3313 Injectors
3323.1 Assembly overview - injectors
3323.2 Carrying out adaptation for injector delivery calibration
3353.3 Checking for injectors sticking open
3363.4 Checking return flow rate of injectors with engine running
3373.5 Checking return flow rate of injectors at starter speed
3403.6 Removing and installing injectors
3423.7 Installing high-pressure lines
3463.8 Checking fuel pressure regulating valve N276
3483.9 Checking low pressure fuel system
3493.10 Removing and installing fuel pressure regulating valve N276
3523.11 Removing and installing fuel pressure sender G247
3543.12 Removing and installing fuel rail
3564 Intake manifold
3604.1 Assembly overview - intake manifold with attachments
3604.2 Removing and installing throttle valve module J338
3624.3 Removing and installing intake manifold
3635 Air filter
3685.1 Assembly overview - air filter
3685.2 Removing and installing air filter housing
3705.3 Removing and installing air mass meter G70
3725.4 Checking changeover flap for intake air preheater
3735.5 Removing and installing changeover flap for intake air preheater
3746 Lambda probe and pressure differential sender
3776.1 Removing and installing Lambda probe G391 with Lambda probe heater Z191
3776.2 Removing and installing pressure difference sender G5051
3787 Engine control unit J623
3807.1 Reading and clearing engine control unit fault memory
3807.2 Adapting functions and components
3807.5 Removing and installing engine control unit J623, only Jetta from MY 2011
387Exhaust system
3901 Front exhaust pipe with particulate filter
3901.1 Assembly overview - front exhaust pipe with particulate filter
3901.2 Removing and installing particulate filter
3932 Silencer
4002.1 Silencer, Jetta, Golf Variant
4002.2 Aligning exhaust system free of stress
4012.3 Installation position and specified torque of clamp
4023 Exhaust gas temperature regulation
4053.1 Assembly overview - exhaust gas temperature regulation
4053.2 Removing and installing exhaust gas temperature sender 1 G235
4063.3 Removing and installing exhaust gas temperature sender 3 G495
4083.4 Removing and installing exhaust gas temperature sender 4 G648
4104 Exhaust gas recirculation
4134.1 Assembly overview – exhaust gas recirculation
4134.2 Removing and installing exhaust gas recirculation cooler
4154.3 Checking changeover for exhaust gas recirculation cooler
4184.4 Checking exhaust gas recirculation cooler for leaks
4194.5 Cleaning exhaust gas recirculation system
424Glow plug system
4321 Checking glow plug system
4321.1 Automatic glow period control unit J179
4321.2 Removing and installing glow plugs
4321.3 Removing and installing automatic glow period control unit J179
435