Manual VW Polo 2018+ PDF

AG.
Volkswagen AG d
agen oes
olksw not
V
Service
by gu
d ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Workshop Manual
l purpos
Golf 2013 ➤ , Golf 2017 ➤ ,
nform
ercia
Golf Sportsvan 2015 ➤ ,

m
at
om
ion
c
Golf Variant 2014 ➤ , Polo 2014 ➤ ,
in t
or
his
ate
Polo 2018 ➤ , Polo Lim RUS 2016 ➤
do
priv
cum
for
en
g
4-cylinder injection engine (1.6 l engine, 4 V, EA 211)

n
t.
yi Co
Cop py
t. rig
CWV CWV
gh ht
yri by
Engine ID
p Vo
A B
co lksw
by
cted agen
Prote AG.
Edition 11.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
AG. Volkswagen AG d
00 - Technical data olksw
agen oes
not
y V gu
10 - Removing and installing enginerised b ara
nte
ho eo
13 - Crankshaft group ut ra
s a c
s
15 - Cylinder head, valve gear
ce
le
un
pt
an
d
itte
17 - Lubrication
y li
rm
ab
pe
19 - Cooling
ility
ot
wit
, is n
24 - Mixture preparation - injection
h re
hole
spec
26 - Exhaust system
es, in part or in w
t to the co
28 - Ignition system
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B8042C9AB

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Variant 2014 ➤ ...
4-cylinder injection engine (1.6 l engine, 4 V, EA 211) - Edition 11.2018
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 a 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 ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . .n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . 5
ge d
3.1 Rules for cleanliness . . . . . . . . . . . . . .Vo. lk.s.w.a . . . . . . . . . . . . . . . . o.e.s n. o.t .g . . . . . . . . . . . . . . . 5
y u
3.2 General information . . . . . . . . . . i.se.d.b . . . . . . . . . . . . . . . . . . . . . . . . . . . a.ra.nt. . . . . . . . . . . . 5
r e
3.3 General repair instructions . . a.ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.o.r a. . . . . . . . . 5
3.4 Foreign objects in engine . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . 6
ce
le
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

un
pt
an
d
itte
3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
y li
rm
ab
3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
pe
ility
ot
3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
wit
, is n
h re
hole
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
spec
es, in part or in w
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
t to the co
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
rrectness of i
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
l purpos
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
nform
ercia
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
m
a
com
ti
2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
on in
r
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

te o
thi
s
iva
2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

do
r
rp
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 63

um
fo
en
g
2.7 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

n
t.
yi Co
Cop py
t. rig
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
gh ht
pyri by
Vo
co lksw
by
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
67
agen
Prote AG.
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.4 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Contents i
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.7 Setting piston to TDC position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.4 Removing and installing AG. Volkscamshaft
wagen AG housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
agen d
1.5 Checking Vol
compression
ksw . . . . . . . .oe. s.n.ot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
y g
2 Toothed d b belt drive . . . . . . . . . . . . . . . . .ua.ra. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
rise nte
tho
2.1 auAssembly
e
overview - toothed belt cover . . . . .or.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
s c
2.2 s Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ce
le
un
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

pt
an
d
itte
2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

y li
rm
ab
2.5 Preassembling and installing valve timing tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
pe
ility
ot
2.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wit
141
, is n
h re
2.7 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
hole
spec
2.8 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
es, in part or in w
t to the co
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.2 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
rrectness of i
3.3 Removing and installing toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

l purpos
3.4 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
nform
ercia
3.6 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 176

3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
m
a
com
tio
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

n in
r
te o
thi
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

s
iva
do
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

r
rp
cum
fo
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

en
ng
t.
yi Co
op
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
C py
t. rig
gh ht
pyri by
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
co Vo
by lksw
cted agen
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
187
AG.
1.2 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.4 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.5 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.3 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
ii Contents
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.2 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.4 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 227
2.5 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 231
2.7 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 232
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4 Radiator,wradiator
agen
AG. Vfan . g.e.n.A.G.d.oe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
olkswa 237
ks s no
4.1 Assembly
by
Vol
overview - radiator/radiator t gufan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ara
237
d
4.2 oriAssembly
se overview - radiator cowl and radiator nte
eo
fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
th
4.3s au Removing and installing radiator . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
s
4.4 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
ce
e
nl
pt
du
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

an
itte
y li
erm
ab
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

ility
ot p
wit
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

, is n
h re
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

hole
spec
1.2 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

es, in part or in w
t to the co
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
rrectness of i
2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

l purpos
2.4 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

2.5 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
nf
ercia
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

rm
m
atio
3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

om
n in
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

or c
thi
e
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

t
sd
iva
o
r
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

rp
cu
o
m
f
en
ng
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yi
t.
Co 272
op
4.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
C py
t. rig
gh
4.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
ht
pyri by
Vo
o
by c lksw
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
277
agen
Prote AG.
5.1 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
6.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 278
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
7.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Contents iii
1.3 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.5 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
iv Contents
00 – Technical data
1 Safety information
(VRL012423; Edition 11.2018)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with a 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 ignition system”, page
2
⇒ “1.5 Safety precautions when working on exhaust system”,
page 2
⇒ “1.6 Safety precautions when working on the cooling system”,
page 3
1.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system: AG. Volkswagen AG d
agen oes
olksw not
– Wear protective goggles. d byV gu
ara
ise nte
r
– Wear protective gloves. ut
ho eo
ra
s a c
s
– To release pressure, wrap a clean cloth around the connection
ce
le
un
and carefully loosen the connection.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Danger of fire caused by escaping fuel
spec
urposes, in part or in wh
When the battery is connected and the driver door opens, the door
t to the co
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
rrectne
– Disconnect voltage supply to fuel pump before opening the
fuel system. ss o
cial p
f inform
mer
atio
om
1.2 Safety measures when working on vehicles with a start/stop system

c
i
or
n thi
te
sd
a
Risk of injury due to unexpected motor start

iv
o
pr
cum
r
fo
If the vehicle's start/stop system is activated, the engine could

en
ng
t.
yi
start unexpectedly. A message in the dash panel insert indicates
Co
op py
whether the start/stop system is activated.
. C rig
ht ht
rig by
opy Vo
– Deactivate start/stop system by switching off the ignition. by c lksw
cted agen
Prote AG.
1. Safety information 1
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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
1.4 Safety precautions when working on ignition system ss c
ce
e
nl
pt
du
an
Risk of injury due to electric shock
itte
y li
erm
ab
The ignition system is under high voltage when the engine is run‐
ility
ot p
ning. Touching the ignition system may result in an electric shock.
wit
, is n
h re
– Do not touch or disconnect ignition cables when the engine is
hole
spec
running or being turned at starter speed.
es, in part or in w
t to the co
rrectness of i
l purpos
Risk of damage to components

Connecting or disconnecting electric cables or washing the en‐
nf
ercia
gine while it is running may damage components.
orm
m
– Switch off the ignition before connecting or disconnecting elec‐
atio
m
tric cables.
o
n in
or c
thi
e
– Switch off the ignition before washing the engine.

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
1.5 Safety precautions when working on exhaust system
by lksw
cted agen
Prote AG.
Risk of poisoning due to chemical substances

Exhaust gas temperature senders may contain chemical sub‐
stances. There is a risk of poisoning or injuries to respiratory
system.
– Never open an exhaust gas temperature sender by cutting,
sawing or any other means.
Risk of injury due to hot condensate and particles in the exhaust
system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation.
2 Rep. gr.00 - Technical data

1.6 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Safety information 3
2 Identification
⇒ “2.1 Engine number/engine data”, page 4
2.1 Engine number/engine data

The engine code and the engine number are located on the stick‐
er -arrow- on the upper toothed belt guard.
The engine code is also on the vehicle data sticker and on the
AG. Volkswagen AG d
crankcase above the gearbox.
lkswagen oes
n o ot g
yV u
The engine number consists
ris
ed
b
of up to 9 characters (alphanumeric).
ara
nte
The first part (3 code
ut
ho letters max.) represents the “engine code”. eo
ra
The second part ss a (six-characters) represents the “serial number”. c
After 999,999 engines with the same code letters have been pro‐
ce
le
un
pt
duced, the first of the six digits is replaced by a letter.
an
d
itte
y li
Vehicles with four digit engine codes
rm
ab
pe
ility
ot
Four-place engine codes are being introduced, starting with letter
wit
, is n
“C”. The first 3 places show the mechanical design of engine and
h re
hole
are stamped on the engine as previously. The fourth digit denotes
spec
the performance and torque rating of the engine and depends on
es, in part or in w
t to the co
the engine control unit - J623- . The four-digit engine code can be
found on the type plate, the vehicle data label and on the engine
control unit.
rrectness of i
l purpos
Note
Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

nform
ercia
Vehicle data sticker .

m
a
com
tion in
r
te o
thi
Engine code CWVA CWVB

s
iva
do
r
Manufactured 02.14 ► 02.14 ►

rp
cum
fo
en
g
Exhaust emission standard EU5 EU5

n
t.
yi Co
op
Displacement cm3 1598 1598
C py
t. rig
gh ht
yri by
Power kW at 81/5800 66/4250-6000
op Vo
by c lksw
cted
rpm
agen
Prote AG.
Torque Nm at 155/3800-4000 155/3800-4000
rpm
Bore ∅ mm 76.5 76.5
Stroke mm 86.9 86.9
Compression ratio 10.5 10.5
Cylinders/valves per cylinder 4/4 4/4
RON At least 95 unleaded1) 95 unleaded1)
Injection, ignition Bosch ME 17 Bosch ME 17
Firing order 1-3-4-2 1-3-4-2
1)In exceptional circumstances min. 91 RON, however with re‐
duced performance.

. Volkswagen AG
gen AG
waGolf 2013 ➤ , Golf 2017
does ➤ , Golf Sportsvan 2015 ➤ , Golf Variant 2014 ➤ ...
olks not
byV 4-cylinder injection engine
gu
ara (1.6 l engine, 4 V, EA 211) - Edition 11.2018
ed
ris nte
tho eo
au ra
c
ss
3 Repair instructions
ce
e
nl
pt
du
an
itte
⇒ “3.1 Rules for cleanliness”, page 5
y li
erm
ab
⇒ “3.2 General information”, page 5
ility
ot p
wit
, is n
⇒ “3.3 General repair instructions”, page 5
h re
hole
spec
⇒ “3.4 Foreign objects in engine”, page 6
es, in part or in w
t to the co
⇒ “3.5 Contact corrosion”, page 6
⇒ “3.6 Routing and attachment of lines”, page 6
rrectness of i
⇒ “3.7 Fitting radiator and condensers”, page 6
l purpos
⇒ “3.8 Checking vacuum system”, page 6
3.1 Rules for cleanliness
nform
mercia
When working on the fuel supply/injection system, carefully follow
at
om
io
the “7 rules” below:
n
c
in t
or
his
e
♦ Thoroughly clean all joints and surrounding areas before dis‐

at
do
riv
mantling.
p
cum
for
en
g
♦ Place removed parts on a clean surface and cover them over.

n
t.
yi Co
Use lint-free cloths only. t. Cop py
rig
gh ht
yri
♦ Carefully cover opened components or seal them if repairs
p by
co Vo
cannot be carried out immediately.
by lksw
cted agen
Prote AG.
♦ Install clean components only: do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
♦ Make sure that no fuel gets onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned immediately.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
3.2 General information

♦ The engine/motor control unit has a self-diagnosis capability.
Interrogate the event memory before performing repairs and
before fault finding. Also check the vacuum hoses and con‐
nections (unmetered air).
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. The risk of
a fire after a crash is diminished by the fuel pump relay switch‐
ing off the fuel pump.
♦ The system also improves the starting characteristics of the
engine. When the driver door is opened, the fuel pump is ac‐
tivated for 2 seconds in order to build up pressure in the fuel
system, observe safety precautions
⇒ “1.1 Safety regulations for working on fuel supply”, page 1 .
3.3 General repair instructions

♦ Clean tools and workbench etc. before working on injection
system.
3. Repair instructions 5
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Golf 2013 ➤ , Golf 2017 ➤ , Golforis Sportsvan 2015 ➤ , Golf Variant 2014 n➤
tee ...
th or
4-cylinder injection engine s(1.6 l engine, 4 V, EA 211) - Edition 11.2018
au ac
s
ce
le
un
pt
♦ If the high-pressure lines are not renewed, the existing high-
an
d
itte
pressure lines must be labelled before removal.
y li
rm
ab
pe
ility
♦ High-pressure fuel lines must always be re-installed in their
ot
wit
original positions (i.e. on the same cylinder).
, is n
h re
hole
♦ Align high-pressure lines so that they are not subjected to
spec
stress . First tighten all unions hand-tight and then tighten to
es, in part or in w
t to the co
torque.
♦ Never attempt to reshape high-pressure lines.
rrectness of i
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
l purpos
ions. All other components must always be removed and

installed by hand without using tools or other equipment.
nform
ercia
♦ All cable ties that are opened or cut through during removal
m
must be fitted/renewed in the same position during installation.
a
com
tion in
♦ Fuel hoses in engine compartment must be secured only with
r
te o
thi
spring-type clips. The use of crimp-type or screw-type clips is
s
iva
do
not permissible.
r
rp
cum
fo
3.4 Foreign objects in engine
en
ng
t.
yi Co
Cop py
.
To prevent the ingress of foreign bodies during work on the en‐
ht rig
rig ht
by
gine, seal open channels of the intake and exhaust sections with copy Vo
by lksw
suitable plugs, for example from the engine bung set - VAS 6122- . cted agen
Prote AG.
3.5 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic Parts Catalogue .
3.6 Routing and attachment of lines

♦ In order to ensure that lines are all installed in their original
position, the lines for the fuel, hydraulic and vacuum systems
and for the activated charcoal filter system as well as electrical
wires must be marked appropriately before they are removed.
Make sketches or take photographs if necessary.
♦ Because of the lack of space in the engine compartment, make
sure that there is sufficient clearance between lines and all
moving or hot components. This is to avoid damage to lines.
3.7 Fitting radiator and condensers

Even when correctly installed, radiator and condenser may show
slight marks on plates. This does not mean that these compo‐
nents have been damaged. Minor indentations such as these are
not a reason to renew either the radiator or condenser.
3.8 Checking vacuum system

Special tools and workshop equipment required

♦ Hand operated vacuum pump - VAS 6213-
Procedure
– 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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Repair instructions 7
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 8
⇒ “1.2 Separating engine and gearbox”, page 26
⇒ “1.3 Securing engine on engine and gearbox support”, AG. Volkswagen AG d
page 30 agen oes
olksw not
y V gu
d b ara
⇒ “1.4 Installing engine”, page 32 orise nte
th eo
u ra
1.1 Removing engine s a c
s
ce
e
nl
pt
du
⇒ “1.1.1 Removing engine, Golf 2013>, Golf SV 2015>, Golf Es‐
an
itte
y li
tate 2014>, Golf 2017>, Polo 2018>”, page 8 erm
ab
ility
ot p
⇒ “1.1.2 Removing engine, Polo 2014>, Polo Saloon RUS
wit
2016>”, page 18
, is n
h re
hole
1.1.1 Removing engine, Golf 2013>, Golf SV 2015>, Golf Estate 2014>, Golf
spec
es, in part or in w
2017>, Polo 2018>
t to the co
rrectness of i
Special tools and workshop
equipment required
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8 Rep. gr.10 - Removing and installing engine

♦ Release lever - 80 - 200-

♦ Extension -2024 A /1- of lifting tackle - 2024 A-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine support - T10497-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Spring-type clip pliers - VAS 6362-
♦ Locking pin - T10060 A-
♦ Commercially available stepladder

♦ Safety glasses
♦ Safety gloves
Procedure
AG. Volkswagen AG d
agen oes
ksw
Note by
Vol not
gu
ara
e d
ris nte
o eo
♦ The engine is removed downwards
aut
h
together with the gearbox. ra
ss c
♦ Reinstall all cable ties in the same locations when installing.
ce
le
un
pt
an
d
itte
y li
– Heed the safety precautions

erm
ab
⇒ “1 Safety information”, page 1 .

ility
ot p
wit
is n
– Observe rules for cleanliness

h re
ole,
⇒ “3.1 Rules for cleanliness”, page 5 .

spec
– Note repair instructions ⇒ “3 Repair instructions”, page 5 .

t to the co
Note
rrectne
The coolant expansion tank may differ in design depending on

s
the type and version of the vehicle.

s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Removing and installing engine 9

– Open filler cap -arrow- for coolant expansion tank.
CAUTION
Skin and other parts of the body may be scalded.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.

gr. 44 ; Wheels, tyres; Wheel change .
– Remove front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Assembly overview
- front wheel housing liner .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove underbody cladding at front. ⇒ Rep. gr. 66 ; Under‐
body cladding; Removing and installing underbody cladding
– Drain coolant
⇒ “1.2 Draining and adding coolant”, page 212 .
– Remove air filter housing
⇒ “3.2 Removing and installing air filter housing”, page 268 .
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
– Remove radiator cowl gen AG. Volkswagen AG d
⇒ “4.4 Removing and
Vol
ksinstalling
wa radiator cowl”,oepage
s no 248 .
t y gu
db ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Open retainer for coolant hose -2-.

es, in part or in w
t to the co
– Separate coolant hose -3- from bracket -1-.

rrectness of i
Note
l purpos
Disregard position -4-.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG . Volkswagen AG
Vehicles with air conditioner compressor:
ksw
agen does
not
Vol
y gu
– Remove poly V-belt ise d b ara
nte
⇒ “1.2.3 Removing uthoand
r
installing poly-V belt, vehicles with air eo
conditioner compressor,
ss a Golf 2013>, Golf Estate 2014>, Golf ra
c
SV 2015, Golf 2017>”, page 76 .
ce
e
nl
pt
du
an
– Release and pull off connector -1- on air conditioner compres‐
itte
y li
sor regulating valve - N280- .
erm
ab
ility
ot p
wit
CAUTION
, is n
h re
hole
Risk of freezing injury caused by refrigerant.
spec
es, in part or in w
– Do not open refrigerant circuit of air conditioning system.
t to the co
NOTICE
rrectness of i
Risk of damage to refrigerant lines from rupture of inner foil.
l purpos
– Never bend refrigerant lines to a radius sharper than r =

100 mm.
nform
mercia
at
– Unscrew bolts -arrows- for air conditioning compressor.
om
ion
c
in t
– Remove air conditioner compressor with refrigerant lines con‐
or
his
e
nected, and tie it up towards outside.

at
do
priv
cum
Continued for all vehicles:
for
en
ng
t.
yi
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Co
Cop py
Disconnecting and reconnecting battery .
t. rig
gh ht
pyri by
Vo
o
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
c by lksw
cted agen
27 ; Battery; Removing and installing battery tray .
Prote AG.
– Release retaining tab -arrow-, and pull off hose connection

-1- for vacuum hose -2-.
Version with hose clips
– Loosen hose clips -arrows-, and pull coolant hoses off heat
exchanger for heater.
Version with retaining clips

– Release retaining clips -arrows-.

– Pull coolant hoses -1- off heat exchanger for heater unit.
Golf 2013>, Golf Estate 2014>, Golf SV 2015, Golf 2017>
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
– Unscrew nuts -1- for securing front exhaust pipe
horis to cylinder nte
eo
head. s aut ra
c
s
– Unscrew bolts -2- and exhaust system bracket, and tie up ex‐
ce
le
un
pt
haust system.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Polo 2018>
l purpos
– Unscrew nuts -4-, and detach and tie up -5- flexible pipe.
nform
ercia
Continued for all vehicles

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Loosen hose clips -arrows-, and pull off coolant hoses.
Note
Place a cloth underneath to catch any escaping coolant.

– Release and pull off fuel lines -1- and -2-. Disconnect plug-in
connectors ⇒ Rep. gr. 20 ; Plug-in connectors; Disconnecting
plug-in connectors .
CAUTION
The fuel system is pressurised. wage
es n
lks
Danger of injury caused by V by fuel spray.
o ot g
ua
ed ran
– Wear protectivethor goggles.
is tee
or
u
– Wear protective
ss
a
gloves. ac
ce
le
– To release pressure, wrap a clean cloth around the connec‐

un
pt
tion and carefully loosen the connection.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
For the work steps below use removal lever - 80 - 200- to unclip
the binding clips.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
– Unplug upper electrical connector -1- at engine control unit -
thi
te
J623- ⇒ “6 Engine control unit”, page 278 .

sd
iva
o
pr
cum
r
– Remove connectors -2- and -3- from retainer, release them,

fo
en
ng
and pull them off.

t.
yi Co
Cop py
– Move electrical lines free.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release and unplug electrical connector -2-.
Note
Cover for positive battery terminal -1- does not need to be de‐
tached.
– Unbolt earth wire from body.

Golf 2013>, Golf Estate 2014, Golf SV 2015, Golf 2017>

– Release catches -arrows- and detach cover -1- for electronics

box in engine compartment.
– Release catch using a screwdriver -arrow- and detach cover

-1- for electronics box in engine compartment upwards.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Remove nut -arrow-, detach electrical wiring and move clear.

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
Continued for all vehicles with manual gearbox

i
o
pr
cum
r
fo
en
ng
– Release and pull off connectors -1-.

t.
yi Co
op py
– If fitted, release and pull off connector -2-.
. C rig
ht ht
rig by
py Vo
– Remove gear selector cable from gearbox ⇒ Rep. gr. 34 ;
co lksw
by
cted agen
Selector mechanism; Removing and installing selector mech‐ Prote AG.
anism .
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐
nism; Removing and installing clutch slave cylinder .
– Do not remove clutch line from clutch slave cylinder while do‐
ing so.

Vehicles with automatic gearbox:

– Remove selector lever cable from gearbox ⇒ Rep. gr. 37 ;
Selector mechanism; Removing and installing selector lever
cable .
– Release connector -4- and pull off.
– Move wiring harness on retainer -2- clear to one side.
– Release and pull off connectors -1- and -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -arrows- on engine mounting approx. 2 turns.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
– Unscrew bolts -arrows- on gearbox mounting approx. 2 turns.

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Unscrew nuts -1- for coupling rod -3- on leftAG

and
. Voright
lkswagfrom
en AGanti-
roll bar -2-. lkswagen does
n o ot g
yV ua
– Remove pendulum supportrised b ran
tee
⇒ “2.5 Removing and installing
tho pendulum support”, or
page 59 . s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew nuts on both sides -arrows-.
– Pull suspension link out of swivel joint and turn wheel bearing
rrectness of i
housing outwards to relieve suspension link.
l purpos
Vehicles with manual gearbox:

– Unbolt drive shafts on both sides from gearbox ⇒ Running
nform
ercia
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly

overview - drive shaft , and tie them up.
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
Make sure not to damage the surface protection of the drive shaft.
en
ng
t.
yi Co
Cop py
t. rig
Vehicles with automatic gearbox: opyri
gh by
Vo
ht
by c
– Remove drive shafts on left and right ⇒ Running gear, axles,
lksw
cted agen
Prote
steering; Rep. gr. 40 ; Drive shaft; Assembly overview - drive
AG.
shaft , and tie them up.

– Swivel front left suspension strut outwards and support with
extension -2024 A /1- , as shown in illustration.
– Secure locking pin and swivel joint with locating pin -arrow-
and nut -1-.
– Secure swivel joint -2- (right-side) to transverse link -1- with

nut -arrow-, as shown in illustration.
– Apply clamping piece T10497/2 at housing rib on cylinder
block, as shown in illustration.

olkswagen AG
g en AG. V
Golf 2013 ➤ , Golf 2017 ➤ o,lkGolf
swa Sportsvan 2015 ➤ , Golf
does
not Variant 2014 ➤ ...
yV g
4-cylinder injection
s ed engine (1.6 l engine, 4 V, EA 211)ua-raEdition 11.2018
b
n
ri tee
ho
ut or
– Position engine support T10497 withsspin T10497/1 on cylinder
a ac
block.
ce
e
nl
pt
du
an
– Screw in bolt -1- through hole “B” in engine support T10497
itte
y li
and tighten it to 20 Nm.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Fit adapter - T10497/3- to engine support - T10497- and tight‐

p
cum
or
en bolt -1- to 20 Nm.

f
en
ng
t.
yi Co
op
– Insert engine and gearbox jack - V.A.G 1383 A- in engine sup‐ C py
ht. rig
port T10497 , and raise engine/gearbox assembly slightly. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
To unscrew bolts for assembly mounting use commercially avail‐

able stepladder.
– Remove bolts -arrows- for engine mounting.

– Remove bolts -arrows- securing gearbox mounting.
Note
♦ Risk of damage to the vacuum lines or electrical wiring as well

as damage to the engine compartment.
♦ Check that all vacuum lines and electrical wiring between en‐
gine, gearbox, subframe and body have been detached.
♦ When lowering, carefully guide engine/gearbox assembly with
assembly carrier out of engine compartment.
– First lower engine/gearbox assembly slightly.

– Then push gearbox end of engine/gearbox assembly forwards
and only then lower further.
1.1.2 Removing engine, Polo 2014>, Polo Saloon RUS 2016>

swage es n
Special tools and workshop byV
olk ot g
ua
equipment required ir se
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Release lever - 80 - 200-

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine support - T10497-


♦ Commercially available stepladder

♦ Safety glasses
♦ Safety gloves AG. Volkswagen AG d
agen oes
olksw not
Procedure d by V gu
ara
rise nte
tho eo
au ra
s c
s Note
ce
le
un
pt
an
d
♦ The engine is removed downwards together with the gearbox.

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Vehicles with automatic gearbox
ss
– Remove gearbox control unit ⇒ Rep. gr. 39 ; Gearbox control
o
cial p
f i
system, Removing and installing gearbox control unit .
nform
mer
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.

atio
m

o
n
c
i
or
n thi
Vehicles with manual gearbox

te
sd
iva
o
r
– Pull vacuum line -1- off brake servo -2-.

p
cum
r
fo
en
ng
t.
yi Co
– If fitted, release and disconnect connector on vacuum sender Cop py
t. rig
on vacuum line. opyri
gh by
Vo
ht
c lksw
by
cted agen
Prote AG.
– Remove air filter

– Carefully loosen wiring harness at its fastening points

-arrows-.

– Release connector -arrow-, pull off and unclip from bracket.

– Release connector from engine control unit and pull off
⇒ “6 Engine control unit”, page 278 .
– Place wiring harness on engine.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .
Rep. gr. 50 ; Noise insulation .
– Remove left and right drive shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Remove radiator cowl
⇒ “4.4 Removing and installing radiator cowl”, page 248 .
– Drain coolant
Note
Do not reuse coolant which has been drained off.

– Remove poly V-belt
⇒ “1.2 Removing and installing poly-V belt”, page 73 .
– Separate connector -1- on air conditioning compressor regu‐
lating valve - N280- . olks
wage es n
o
yV t gu
db ara
CAUTION rise nte
tho eo
au ra
ss c
ce
e
nl
– Do not open refrigerant circuit of air conditioning system. pt

du
an
itte
y li
erm
ab
ility
ot p
NOTICE
wit
, is n
h re

hole
spec

es, in part or in w
100 mm.
t to the co

rrectness of i
nected and tie it up on the right side.

l purpos
– Loosen clamp -arrow-, and push it to rear.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Detach exhaust hangers -3- in -direction of arrow- from sub‐

frame -2-.
– Lower exhaust system -1- until it rests on subframe -2-.
– Unscrew bolt -2-.

– Remove screw-type clip -1-.
– Unscrew nuts -arrows- and tie up catalytic converter -3-.
lkswage es n
o ot g
– Unscrew bolts -arrows- and remove bracket -1-. d byV ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Open spring-type clip -arrow- and pull off coolant hose down‐
rrectne
wards.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Open spring-type clips -arrows-.

– Pull coolant hose -1- off radiator -2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
– Release retaining clips -arrows-.
s aut ra
c
s
– Pull coolant hoses -1- off heat exchanger for heater unit.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Release and pull off connector -2- on starter -1-.

– Pull off protective cap -3-.
nform
ercia
– Unscrew nut -arrow- and remove line from starter -1-.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release and pull off connectors -2-.
– Unclip connectors -2- from bracket -1-.
– Unclip wires -3- and -4- from bracket -1-.
– Unscrew nut -arrow-.
– Remove bracket -1- from gearbox.

AG. Volkswagen AG d
agen o
– Release and pullVoff
olks connector -3- on alternator
w es n
ot-2-.
g
by ua
ed ran
– Remove nuts
ho
ris -4-. tee
t or
au ac
– Remove
ss wire -1- from alternator -2-.
ce
le
un
– Lay wiring harness -1- on coolant hose to one side.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Lay lower wiring harness on intake manifold to one side.
rrectness of i
– Use removal lever - 80 - 200- to do this.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Release retaining tab -arrow-, and pull off hose connection
rig ht
py by
o Vo
-1- for vacuum hose -2-. by c lksw
cted agen
Prote AG.
– Release and pull off connector -1- on gearbox.

– If fitted, release and pull off connector -2-.
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐
nism; Removing and installing clutch slave cylinder .


– Remove selector lever cable from gearbox ⇒ Rep. gr. 37 ;
Selector mechanism; Removing and installing selector lever
cable .
– Release connector -4- and pull off.
– Move wiring harness clear at bracket -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Pull vacuum line -2- in direction of -arrow- off vacuum pump
ss
ce
le
for brakes - V192- -1-.

un
pt
an
d
itte
y li
– Lay vacuum line -1- to one side.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Release connectors -2- and pull off.

m
a
– Unscrew securing bolts -3-.
com
tion in
– Place coolant expansion tank -1- on engine.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect fuel supply line -1- and line to activated charcoal

filter solenoid valve 1 - N80- -2-. Separate plug-in connectors
⇒ Rep. gr. 20 ; Plug-in connectors .

– Unscrew earth wire -1-.

– Unscrew bolts -arrows- on engine mounting approx. 2 turns.
– Unscrew securing bolts -arrows- on gearbox mounting by ap‐

prox. 2 turns.
– Remove pendulum support
⇒ “2.5 Removing and installing pendulum support”,
page 59 .
– Apply clamping piece T10497/2 at housing rib on cylinder
block, as shown in illustration.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
– Position engine support T10497 with pin T10497/1rison
e cylinder
d
nte
block. ut
ho eo
ra
s a c
s
– Screw in bolt -1- through hole “B” in engine support T10497
ce
e
nl
and tighten it to 20 Nm.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Fit adapter - T10497/3- to engine support - T10497- and tight‐

thi
te
en bolt -1- to 20 Nm.

sd
iva
o
r
rp
cu
– Insert engine and gearbox jack - V.A.G 1383 A- in engine sup‐

o
m
f
en
ng
port T10497 , and raise engine/gearbox assembly slightly.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Note by c lksw
cted agen
Prote AG.
To unscrew bolts for assembly mounting use commercially avail‐

able stepladder.

– Remove bolts -arrows- for engine mounting.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
– Unscrew securing bolts -arrows- from gearboxss mounting.
a ra
c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
♦ Risk of damage to the vacuum lines or electrical wiring as well
wit
, is n
as damage to the engine compartment.
h re
hole
spec
♦ Check that all vacuum lines and electrical wiring between en‐
es, in part or in w
gine, gearbox, subframe and body have been detached.
t to the co
♦ When lowering, carefully guide engine/gearbox assembly with
assembly carrier out of engine compartment.
rrectness of i
– First lower engine/gearbox assembly slightly.
l purpos
– Then push gearbox end of engine/gearbox assembly forwards

and only then lower further.
nform
mercia
at
om
1.2 Separating engine and gearbox
ion
c
in t
or
his
e
⇒ “1.2.1 Separating engine and gearbox, vehicles with manual

at
do
riv
gearbox”, page 26
p
cum
for
en
⇒ “1.2.2 Separating engine and gearbox, vehicles with automatic
ng
t.
yi Co
gearbox”, page 28 ht. Cop py
rig
rig ht
1.2.1 Separating engine and gearbox, vehi‐
py by
co Vo
by lksw
cted
cles with manual gearbox
agen
Prote AG.

♦ Shackle - 10 - 222 A /12-

♦ Hook - 10 - 222 A /2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
♦ Workshop hoist - VAS 6100- rise d ara
nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Procedure
s
• Engine/gearbox assembly removed and attached to engine
s o
support T10497 .
cial p
f inform
mer
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
atio
Removing and installing starter .
om
n
c
i
– Bolt shackle - 10 - 222 A /12- to gearbox.
or
n thi
te
sd
va
– Attach hook - 10 - 222 A /2- to workshop hoist - VAS 6100- .

i
o
pr
cum
r
fo
– Attach hook - 10 - 222 A /2- to shackle - 10 - 222 A /12- .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove bolts -1, 2, 3, 6, 7, 8, 9- securing gearbox to engine.

– Pull gearbox off engine.
lkswage es n
1.2.2 Separating engine and gearbox, vehi‐
o ot g
byV ua
d ran
ir se
cles with automatic gearbox o tee
th or
au ac
ss
ce
le
un
pt
an
d
♦ Shackle - 10 - 222 A /12-
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Hook - 10 - 222 A /2-

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Workshop hoist - VAS 6100-
♦ Hose clamps - 3094- and -3093-

• Engine/gearbox assembly removed and attached to engine

support T10497 .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Open clamps for coolant hoses on gear oil cooler, and pull off
coolant hoses.
– Unscrew upper bolts -arrows- securing gearbox to engine us‐
ing e.g. 12-point hexagon flex head socket -A-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
– Using insert - V/175- , remove the 3 torque converter nuts

un
pt
through opening -arrow- in gearbox.
an
d
itte
y li
erm
ab
– To do this, turn engine in direction of engine rotation using
ility
ot p
wrench - T03003- .
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
– Bolt shackle - 10 - 222 A /12- to gearbox.
inform
mer
– Attach hook - 10 - 222 A /2- to workshop hoist - VAS 6100- .

atio
m
– Attach hook - 10 - 222 A /2- to shackle - 10 - 222 A /12- .

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove remaining engine/gearbox connecting bolts ⇒ Rep.

gr. 37 ; Removing and installing gearbox; Specified torques
for gearbox .
– Press gearbox off engine while simultaneously pressing tor‐

que converter out of drive plate of engine.
– Secure the torque converter against falling out.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1.3 Securing engine on engine and gearbox

support
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
30
Prote AG.
Rep. gr.10 - Removing and installing engine
♦ Engine and gearbox support - VAS 6095-
♦ Workshop hoist - VAS 6100- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Procedure
rrectne
• Gearbox detached from engine
⇒ “1.2.1 Separating engine and gearbox, vehicles with manual
gearbox”, page 26 .
ss o
cial p
f
– Secure lifting tackle - 2024 A- on engine, and attach it to work‐
inform
shop hoist - VAS 6100- as shown in illustration.
mer
atio
om
n
c
i
or
n
Note
thi
te
sd
iva
o
r
♦ In order to match the lifting tackle to the centre of gravity of the

p
cum
r
fo
engine, the holes in the hook rail must be allocated as shown

en
ng
t.
yi
in the illustration.
Co
Cop py
t. rig
gh
♦ The support hooks and retaining pins on the lifting tackle must
ht
pyri by
Vo
be secured with locking pins -arrows-.
o
by c lksw
cted agen
Prote AG.
– The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– Lift engine off T10497 using workshop hoist - VAS 6100- .

– Secure engine to engine and gearbox bracket - VAS 6095-

using pins -arrows- as shown in illustration.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
1.4 Installing engine
an
d
itte
y li
erm
ab
⇒ “1.4.1 Installing engine, Golf 2013>, Golf SV 2015>, Golf Estate
ility
ot p
2014>, Golf 2017>, Polo 2018>”, page 32
wit
is n
h re
ole,
⇒ “1.4.2 Installing engine, Polo 2014>, Polo Saloon RUS 2016>”,
spec
page 35
t to the co
1.4.1 Installing engine, Golf 2013>, Golf SV
2015>, Golf Estate 2014>, Golf 2017>,
rrectne
Polo 2018>
s
Procedure
s o
cial p
f in
• Engine secured to engine support T10497 ⇒ page 17 .
form
mer
atio
om
Note
c
i
or
n thi
te
sd
va
♦ Renew bolts that are tightened with turning further angle.

i
o
pr
cum
r
fo
♦ Renew self-locking nuts and bolts, and seals, O-rings and

en
ng
t.
yi
gaskets.
Co
Cop py
t. rig
gh ht
♦ Secure all hose connections with hose clips corresponding to yri
p by
o Vo
the series equipment ⇒ Electronic Parts Catalogue .
c by lksw
cted agen
Prote AG.
Installing gearbox to engine, vehicles with manual gearbox

– Install intermediate plate ⇒ page 89 .
– If there are no dowel sleeves -A- in cylinder block for centring
engine and gearbox, insert new ones ⇒ Item 5 (page 88) .
– Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9- ⇒ Rep.
gr. 34 ; Removing and installing gearbox; Installing gearbox .
– Install gearbox support ⇒ Rep. gr. 34 ; Assembly mountings;
Assembly overview - assembly mountings .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐
sembly overview - starter .

Installing gearbox to engine, vehicles with automatic gearbox

– 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- to -4- ⇒ Rep. gr. 37 ;
Removing and installing gearbox; Installing gearbox .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
Installing engine/gearbox assembly:
– Support engine/gearbox assembly on engine support -
T10497- ⇒ page 17 .
AG . Volkswage
– Insert engine/gearbox assembly into body using
agen engine sup‐AG does
n
lksw not
port - T10497- and engine and gearbox
by jack - V.A.G 1383 A- .
Vo gu
a
ed ran
ris tee
ho
– First screw bolts -arrows- fors aengine
ut
mountings into stop by or
ac
hand. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– First screw bolts -arrows- for gearbox mountings into stop by

hand.
Note
♦ The bolts are tightened to final torque only after adjusting the
assembly mountings
⇒ “2.7 Adjusting assembly mountings”, page 64 .
♦ Route lines of any kind and cables so that original routing is
restored.
♦ Ensure that there is sufficient clearance to all moving
swa
orn Ahot
ge G. Volkswagen AG d
oes
components. yV
olk not
gu
edb ara
ris nte
ho eo
– Detach engine support T10497 from engine.
aut ra
ss c
ce
le
un
pt
an
d
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;

itte
y li
rm
Removing and installing clutch slave cylinder .
ab
pe
ility
ot
– Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐
wit
, is n
lector mechanism; Assembly overview - selector cables .
h re
hole
spec
Vehicles with dual clutch gearbox
es, in part or in w
t to the co
– Install selector lever cable, fit connector of mechatronic and
install all retainers on gearbox:⇒ Rep. gr. 34 ; Removing and
installing gearbox
rrectness of i
l purpos
– Attach selector lever cable to gearbox ⇒ Rep. gr. 37 ; Selector

mechanism; Removing and installing selector lever cable .
nform
ercia
– Connect all connectors to gearbox.

m
a
com
tio
n in
r
te o
– Install catalytic converter thi

s
iva
do
⇒ “2.2 Removing and installing catalytic converter”,

r
rp
cum
page 308 .
fo
en
ng
t.
yi Co
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. . Cop py
40 ; Drive shaft; Assembly overview - drive shaft .
ht rig
rig ht
py by
co Vo
– Install transverse link, swivel joint and coupling rod ⇒ Running
by lksw
cted agen
Prote
gear, axles, steering; Rep. gr. 40 ; Lower transverse link,
AG.
swivel joint; Assembly overview - lower transverse link, swivel

joint .
– If present, install vehicle level sender ⇒ Electrical system;
Rep. gr. 94 ; Automatic headlight range control; Assembly
overview - automatic headlight range control .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Install poly V-belt
– Install all wires ⇒ Electrical system; Rep. gr. 97 ; Relay car‐
riers, fuse carriers, electronics boxes; Overview of fitting lo‐
cations - relay carriers, fuse carriers, electronics boxes and
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
– Install engine control unit - J623-
⇒ “6 Engine control unit”, page 278 .
– Connect coolant hoses with plug-in connector ⇒ page 238 .

– Install pendulum support

⇒ “2.5 Removing and installing pendulum support”,
page 59 .
– Install front wheel housing liners ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Assembly overview
- front wheel housing liner .
– Install front wheels ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres; Changing wheel .
– Adjust assembly mountings
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
– Install air filter housing
AG. Volkswagen AG d
– Add coolant ⇒ page 213 . ksw
agen oes
not
ol
byV gu
ara
ed
ris nte
o eo
Note aut
h
ra
ss c
ce
e

nl
pt
du
an
itte
y li
erm
ab
Specified torques
ility
ot p
wit
, is n
h re
Retainer for coolant hose on engine 20 Nm
hole
spec
es, in part or in w
t to the co
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 39
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 267 rrectness of i
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 237
l purpos
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,

page 239
nform
ercia
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 67

m
at
om
ion
♦ ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified

c
in t
or
torques for gearbox

his
ate
do
riv
♦ ⇒ Electrical system; Rep. gr. 27 ; Starter; Assembly overview

p
cum
or
- starter
f
en
ng
t.
yi Co
op
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing C py
ht. rig
liner; Assembly overview- front wheel housing liner rig ht
py by
co Vo
by lksw
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview cted agen
Prote AG.
- battery
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview - subframe
1.4.2 Installing engine, Polo 2014>, Polo Sa‐

loon RUS 2016>
Install in reverse order of removal. During this procedure, observe
the following:
• Attach engine/gearbox assembly to engine support T10497 .

Note

♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Secure all hose connections with hose clips corresponding to
When the gearbox has been separated from the engine:

G. Volkswagen AG d
ksw
agen
A
oes
not
y Vol
⇒ “1 Safety information”, page 1. gu
b d ara
ise nte
– Observe rulesut
h or
for cleanliness eo
⇒ “3.1 Rules
ss a for cleanliness”, page 5 . ra
c
ce
e

nl
pt
du
an
itte
y li
Installing gearbox to engine, vehicles with manual gearbox
erm
ab
ility
ot p
wit
, is n
h re
– If there are no dowel sleeves -A- in cylinder block for centring
hole
engine and gearbox, insert new ones ⇒ Item 5 (page 88) .

spec
es, in part or in w
– Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9- ⇒ Rep. t to the co

gr. 34 ; Removing and installing gearbox; Installing gearbox . rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Installing gearbox to engine, vehicles with automatic gearbox

– 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- ⇒ Rep. gr.
37 ; Removing and installing gearbox; Installing gearbox .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
Installing engine/gearbox assembly in vehicle:
– Take up engine/gearbox assembly with engine support
T10497 .
– Guide engine/gearbox assembly into body.
– Install engine mounting
⇒ “2.3 Removing and installing engine mounting”, page 53 .
– Install gearbox mounting
⇒ “2.4 Removing and installing gearbox mounting”,
page 56 .
– Detach engine support T10497 from engine.
– Install pendulum support wagen AG. Volkswagen AG does
⇒ “2.5 Removing and olks
Vinstalling pendulum support”,not gu
by
page 59 . ris
ed ara
nt ee
tho or
Vehicles with manual
sa
u gearbox ac
s
ce
e
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;

nl
pt
du
Removing and installing clutch slave cylinder .

an
itte
y li
erm
ab
– Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐

ility
ot p
lector mechanism; Assembly overview - selector cables .

wit
, is n
h re

hole
spec

es, in part or in w
t to the co

stalling air conditioner compressor .
rrectness of i

l purpos
– Connect wires to engine control unit - J623- ⇒ page 278 .

– Connect wires to alternator ⇒ Electrical system; Rep. gr. 27 ;
nform
ercia
Alternator; Assembly overview - alternator .

m
at
om
– Ensure proper electrical connections and routing ⇒ Electrical

ion
c
system; Rep. gr. 97 ; Relay carriers, fuse carriers, electronics

in t
or
his
e
boxes; Overview of fitting locations – relay carriers, fuse car‐

at
do
riv
riers, electronics boxes and ⇒ Current flow diagrams, Electri‐

p
cum
cal fault finding and Fitting locations.

for
en
ng
t.
yi Co
– Install catalytic converter Cop py
⇒ “2.2 Removing and installing catalytic converter”,
t. rig
gh ht
yri
page 308 .
p by
co Vo
by lksw
cted agen
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
Prote AG.
40 ; Drive shaft; Removing and installing drive shaft .

– Install coolant expansion tank
⇒ “4 Radiator, radiator fan”, page 237 .
– Install radiator cowl


– Install gearbox control unit ⇒ Rep. gr. 39 ; Gearbox control
system, Removing and installing gearbox control unit .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .
– Install front wheels ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres; Specified torque for wheel bolts .
– Add coolant ⇒ page 213 .
Specified torques
AG. Volkswagen AG d
agen
Note olksw
oes
not
byV gu
ara
ed
is nte
♦ The specified torques are only valid for nuts and ut
h bolts which
or eo
have been slightly greased, oiled, phosphate-treated
ss a or black- ra
c
oxided.
ce
le
un
pt
an
d
♦ Additional lubricant such as engine oil or gear oil may be used,

itte
y li
but do not use lubricant containing graphite.
rm
ab
pe
ility
♦ Do not use degreased parts.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Securing gearbox on engine ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Specified torques for gearbox .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 39
⇒ “2.2 Supporting engine in installation position”, page 46
⇒ “2.3 Removing and installing engine mounting”, page 53
⇒ “2.4 Removing and installing gearbox mounting”, page 56
⇒ “2.5 Removing and installing pendulum support”, page 59
⇒ “2.6 Checking adjustment of assembly mountings (engine and
gearbox mountings)”, page 63
⇒ “2.7 Adjusting assembly mountings”, page 64 AG. Volkswagen AG d
agen oes
lksw not
2.1 Assembly overview - assembly mount‐ Vo gu
d by ara
ise nte
ings aut
hor eo
ra
ss c
⇒ “2.1.1 Assembly overview - assembly mountings, Golf 2013>,
ce
le
un
Golf Estate 2014>, Golf SV 2015>, Polo 2018>, Golf 2017>”,
pt
an
d
itte
page 39
y li
erm
ab
⇒ “2.1.2 Assembly overview - assembly mountings, Polo 2014>,
ility
ot p
Polo Saloon RUS 2016>, manual gearbox”, page 42
wit
is n
h re
ole,
⇒ “2.1.3 Assembly overview - assembly mountings, Polo 2014>,
spec
Polo Saloon RUS 2016>, automatic gearbox”, page 44
t to the co
2.1.1 Assembly overview - assembly mountings, Golf 2013>, Golf Estate 2014>,
Golf SV 2015>, Polo 2018>, Golf 2017>
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Assembly mountings 39
lkswage es n
o ot g
byV ua
ed ran
Golf 2013 ➤ho,r Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf
is tee Variant 2014 ➤ ...
t or
4-cylinders ainjection
u engine (1.6 l engine, 4 V, EA 211) - Edition ac 11.2018
s
ce
le
un
1 - Bolt
pt
an
d
itte
y li
❑ Renew after removal
rm
ab
pe
ility
❑ Tightening sequence
ot
wit
⇒ page 41
, is n
h re
hole
2 - Engine support
spec
es, in part or in w
❑ Specified torque and
t to the co
tightening sequence
⇒ page 41
rrectness of i
3 - Engine mounting
❑ With support arm
l purpos
❑ Removing and installing

⇒ “2.3 Removing and in‐
nform
ercia
stalling engine mount‐

ing”, page 53
m
a
com
tion in
4 - Bolt
r
te o
thi
s
iva
do
r
❑ 40 Nm +90°
rp
cum
fo
en
ng
5 - Bolt
t.
yi Co
Cop py
t. rig
gh ht
yri by
❑ 20 Nm +90° cop Vo
by lksw
cted agen
Prote AG.
6 - Bolt
❑ 8 Nm
7 - Bracket
8 - Bolt
❑ 60 Nm +90°
9 - Pendulum support
stalling pendulum sup‐
port”, page 59
10 - Bolt
❑ Specified torque and tightening sequence ⇒ page 41
11 - Bolt
12 - Bolts
13 - Bolt
❑ 60 Nm +90°
14 - Bolt
❑ 60 Nm +90°
15 - Bolt
❑ 50 Nm +90°

16 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ “2.4 Removing and installing gearbox mounting”, page 56
AG. Volkswagen AG d
agen oes
olksw not
V gu
Engine support - specified torqueedandby installation sequence ara
nte
ris
ho eo
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
Renew bolts that are tightened with turning further angle.
y li
erm
ab
ility
ot p
– Tighten bolts in stages in the sequence shown.
wit
is n
h re
ole,
Stage Bolts Specified torque/turning further angle
spec
1 -1 … 3- 7 Nm
t to the co
2 -1 … 3- 40 Nm
3 -1 … 3- Turn 90° further
rrectne
Install pendulum support
ss o
cial p
f inform
Note
mer
atio
om
n
Replace bolts that are tightened with specified tightening angle.
c
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
1 -2, 3- 50 Nm
t. rig
gh ht
pyri by
Vo
2 -1- 130 Nm
o
by c lksw
cted agen
Prote AG.
2.1.2 Assembly overview - assembly mountings, Polo 2014>, Polo Saloon RUS
2016>, manual gearbox
1 - Engine support
stalling engine support”,
page 82
tightening sequence
⇒ page 43
2 - Bolt
tightening sequence
⇒ page 43
3 - Engine mounting
stalling engine mount‐ n AG. Volkswagen AG do
lkswage es n
ing”, page 53 byV
o ot g
ua
d ran
❑ Aligning engine mount‐ ir se tee
ho
ing ⇒ page 43 aut or
ac
ss
4 - Bolt
ce
le
un
pt
an
d

itte
y li
erm
ab
❑ 20 Nm +90°
ility
ot p
❑ Qty. 4
wit
is n
h re
ole,
5 - Nut
spec
6 - Centre hex stud
t to the co
❑ With mounting for earth
wire.
rrectne
❑ 30 Nm +90°
ss o
7 - Bolt
cial p
❑ Qty. 2 f inform
mer

atio
om
❑ 30 Nm +90°
c
i
or
n thi
te
8 - Bolt
sd
iva
o
pr

um
r
fo
en
ng
❑ 40 Nm +90°
t.
yi Co
Cop py
❑ Tightening sequence ⇒ page 44
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
❑ Tightening sequence - gearbox mounting ⇒ page 44 .
10 - Bolt
❑ 50 Nm +90°
11 - Bolt

. Volkswage
Golf 2013 wag➤
en,AGolf
G
2017 ➤ , Golf
n AG d
oes Sportsvan 2015 ➤ , Golf Variant 2014 ➤ ...
olks not
by 4-cylinder injection engine (1.6
V gul engine, 4 V, EA 211) - Edition 11.2018
ar
d an
ise tee
or
❑ 50 Nm +90°auth or
ac
ss
❑ Qty. 2
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
❑ Removing and installing ⇒ “2.5 Removing and installing pendulum support”, page 59
wit
is n
h re
13 - Bolt
ole,
spec
t to the co
❑ 40 Nm +90°
14 - Bolt
rrectne
❑ 30 Nm +90°
ss
❑ Qty. 3
o
cial p
f inform
15 - Bolt
mer
atio
om
n
❑ 50 Nm +90°
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Aligning engine mountings
en
ng
t.
yi Co
op
– Fit engine mounting on longitudinal member. C py
ht. rig
rig ht
by
• The positioning holes -arrows- must be in line; check with ap‐ copy Vo
by lksw
propriate drill if necessary. cted agen
Prote AG.
Engine support - specified torque and tightening sequence

1 -1 … 3- 7 Nm
2 -1 … 3- 40 Nm
lkswage es n
o ot g
b yV ua
Golf 2013ris➤ed , Golf 2017 ➤ , Golf Sportsvan 2015ra➤ nte , Golf Variant 2014 ➤ ...
o
4-cylinder
auth injection engine (1.6 l engine, 4 V, EA 211)e o-r Edition 11.2018
ac
ss
ce
e
Tightening sequence - gearbox mounting nl
pt
du
an
itte
y li
Ite Procedure Specified torque
erm
ab
m
ility
ot p
wit
, is n
B Start bolts before tightening hand-tight
h re
an them
hole
spec
dC
es, in part or in w
t to the co
B Tighten bolts 50 Nm +90°
C Tighten bolt. 50 Nm +90°
rrectness of i
A Start bolts before tightening hand-tight
them
l purpos
A Bolts 40 Nm +90°
nform
ercia
2.1.3 Assembly overview - assembly mountings, Polo 2014>, Polo Saloon RUS
m
at
om
2016>, automatic gearbox
ion
c
in t
or
his
ate
do
riv
1 - Engine support
p
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
page 82 p by
co Vo
by lksw
cted
agen
Prote AG.
tightening sequence
⇒ page 46
2 - Bolt
tightening sequence
⇒ page 46
3 - Engine mounting
stalling engine mount‐
ing”, page 53
❑ Aligning engine mount‐
ing ⇒ page 45
4 - Bolt
❑ 20 Nm +90°
❑ Qty. 4
5 - Nut
6 - Centre hex stud
❑ With mounting for earth
wire.
❑ 30 Nm +90°
7 - Bolt
❑ Qty. 2
❑ 30 Nm +90°
8 - Bolt
❑ 40 Nm +90°

10 - Bolt
❑ 50 Nm +90°
11 - Bolt
❑ 50 Nm +90°
❑ Qty. 2
❑ Removing and installing ⇒ “2.5 Removing and installing pendulum support”, page 59
13 - Bolt
❑ 40 Nm +90°
olkswagen AG
en AG. V
14 - Bolt ksw
ag does
not
y Vol gu
ed
b ara
nte
oris
❑ 30 Nm +90°auth eo
ra
ss c
❑ Qty. 2
ce
le
un
pt
15 - Bolt
an
d
itte
y li
erm

ab
ility
ot p
❑ 50 Nm +90°
wit
is n
h re
ole,
spec
Aligning engine mountings

t to the co
– Fit engine mounting on longitudinal member.

• The positioning holes -arrows- must be in line; check with ap‐
rrectne
propriate drill if necessary.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Engine support - specified torque and tightening sequence

1 -1 … 3- 7 Nm
2 -1 … 3- 40 Nm
Tightening sequence - gearbox mounting

Ite Procedure Specified torque
m
B Start bolts before tightening hand-tight
an them
dC
B Tighten bolts 50 Nm +90°
C Tighten bolt. 50 Nm +90°
A Start bolts before tightening hand-tight
them n AG. Volkswagen AG do
lkswage es n
A Bolts 40 Nm +90° byV
o ot g
ua
d ran
ir se tee
tho
u or
2.2 Supporting engine in installation posi‐ ss
a ac
ce
e
tion
nl
pt
du
an
itte
y li
⇒ “2.2.1 Supporting engine in installation position, Golf 2013>,
erm
ab
Golf Estate>, Golf SV>, Golf 2017>, Polo 2018>”, page 46
ility
ot p
wit
, is n
⇒ “2.2.2 Supporting engine in installation position, Polo 2014>,
h re
hole
Polo Saloon RUS 2016>”, page 50
spec
es, in part or in w
2.2.1 Supporting engine in installation posi‐
t to the co
tion, Golf 2013>, Golf Estate>, Golf SV>,
Golf 2017>, Polo 2018>
Special tools and workshop equipment required rrectness of i
l purpos
♦ Support - 10 - 222 A-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Shackle - 10 - 222 A /12-

♦ Adapter - 10 - 222 A /18-
♦ Adapter - 10 - 222 A /29-

lkswage es n
o ot g
byV ua
d ran
ir se
♦ Adapter - T40091/1-
tho tee
or
au ac
♦ Adapter s-s T40091/3-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Adapter - T40093/3-
♦ Adapter - T40093/3-6-
Procedure
– Remove air filter housing.
⇒ “3.2 Removing and installing air filter housing”, page 268
Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>
– Remove filler pipe for washer fluid reservoir of windscreen
washer system ⇒ Electrical system; Rep. gr. 92 ; Windscreen
washer system; Removing and installing washer fluid reser‐
voir .
– On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐
tween upper wheel housing longitudinal member and mount‐
ing plate for wing located underneath.
Adapter - 10 - 222 A /29- -L- is to be inserted on right side of
vehicle:
– Adapter -arrow- is engaged in recess of wing.
Adapter - 10 - 222 A /29- -R- is to be inserted on left side of vehicle:
– Adapter -arrow- is engaged in recess of wing.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
• Arrow -2- on adapter - 10 - 222 A /29- always points in direction
ility
ot p
of normal travel.
wit
, is n
h re
hole
• Fit adapter - 10 - 222 A /29- onto the load-bearing part of the
spec
upper wheel housing longitudinal member.
es, in part or in w
t to the co
Polo 2018>
– Push connecting piece - T40091/3- -8- onto support bracket -
rrectness of i
10-222 A- -1-.
l purpos
– Insert -T40091/1- - 5- into connecting piece - T40091/3- -8-.

– Slide 2 spindles - 10 - 222 A /32- -3 - and -4- onto support
nf
ercia
bracket - 10-222 A- -1-.

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Secure shackle - 10-222 A /12- -10- to camshaft housing.

– Bolt support bracket - 10-222 A- -1- to adapters - 10 - 222 A /
29- -2- and -7-.
– Release air conditioning line from securing element on right
longitudinal member.
– Place adapter - T40093/3- -6- on right longitudinal member.
– Install adapter - T40093/3-6- -A- as follows.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Check adapters - T40093/3-6- and modify as necessary
wit
, is n
h re
hole
– If necessary, cut off the marked area.
spec
es, in part or in w
– Round off front edges.
t to the co
– Protect adapter against corrosion.
– Then, mark adapters - T40093/3-6- as -T40093/3-6A- .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
Adapter -A- corresponds to adapter - T40093/3-6- and is fitted as

o
his
e
follows:
at
do
priv
cum
• To prevent damage to the longitudinal members, wrap the

for
en
g
front section of the adapters - T40093/3-6A- with textile-rein‐

n
t.
yi Co
op
forced adhesive tape ⇒ Electronic parts catalogue (ETKA C py
t. rig
chemical substances) . gh ht
pyri by
Vo
o
by c lksw
• Each of the adapters - T40093/3-6- locks with pin -A- behind Prote
cted AG.
agen
the web of the longitudinal member -arrow-.
– Bolt on spindles - T40093 /3- .
– Connect spindles - T40093 /3- via square tubes - T40091/1-
to engine support bracket - 10-222 A- , and fasten the con‐
nection (⇒ previous illustration).
– Attach spindle - 10 - 222 A /32- to shackle - 10-222 A /12- .
– Position support bracket according to dimension -a- = 1 cm.
– Push adapter - 10 - 222 A /18- and two connecting pieces -

T40091/3- onto support bracket - 10-222 A- .
– Insert -T40091/1- into connecting pieces - T40091/3- .
– Slide spindle - 10 - 222 A /11- onto -T40091/1- .
– Fit spindle - 10 - 222 A /11- on adapter - 10 - 222 A /18- as
shown in illustration.
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
– Install shackle - 10 - 222 A /12- to engine as shown in illustra‐
tion.
– Attach spindle - 10 - 222 A /11- to shackle - 10 - 222 A /12- .
– Install adapter - T40093/3-6- -A- as follows.
Adapter -A- corresponds to adapter - T40093/3-6- and is fitted as

follows:
– If present, pull off wires in front area of flange on both longi‐
tudinal members -arrow-. Do not disconnect pipe/hose sys‐
tem.
– Place adapters - T40093/3-6- onto both longitudinal members
(the figure shows the right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect
Volkswagepipe/hose system ⇒
Heating, air conditioning; en AG.gr.
wagRep. 87 ; Refrigerant
n AG d
oes circuit;
lks n
System overviewb-y Vrefrigerant
o circuit . ot g
ua d ran
ise
• Each of theuthadapters
or - T40093/3-6- locks with pin -A- behind
tee
or
the web of
ss
a the longitudinal member -arrow-. ac
ce
e
– Bolt on spindles - T40093 /3- .

nl
pt
du
an
itte
y li
– Connect spindles - T40093 /3- via square tubes - T40091/1-

erm
ab
to engine support bracket - 10-222 A- , and fasten the con‐

ility
ot p
nection (⇒ previous illustration).

wit
, is n
h re
– Then, attach spindles in lifting eyes of engine. If necessary,

hole
spec
use the shackles - 10 - 222 A /12- for this.

es, in part or in w
t to the co
All versions
– Take up weight of engine/gearbox assembly and support
bracket on spindles .
rrectness of i
l purpos
2.2.2 Supporting engine in installation posi‐

tion, Polo 2014>, Polo Saloon RUS
nf
ercia
2016>
rm
m
atio
om
n in

or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10 - 222 A /32-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Tensioning strap - T10038-

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
To prevent damage to edges of wings, cover lower areas of both

adapters - 10 - 222 A /8- with woven adhesive tape -arrow- ⇒
Electronic Parts Catalogue (ETKA) .
Procedure
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove seals from upper edge of wing.

– Slide adapter - 10 - 222 A /32- onto engine support bracket -
10 - 222 A- as shown in illustration.
– Mount adapter - 10 - 222 A /8- on engine support bracket - 10
- 222 A- .

– Lift up plenum chamber cover at sides.

– Position engine support bracket - 10 - 222 A- on left and right
onto longitudinal members as shown in illustration.
– Fit adapter - 10 - 222 A /8- behind the hole -arrow- and align
it.
– Mount adapter - 10 - 222 A /32- to mountings on engine as
– Secure engine support bracket - 10 - 222 A- using tensioning
straps - T10038- on both sides of bonnet hinges.
– Take up weight of engine/gearbox assembly slightly with spin‐
dle; do not lift.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.3 Removing and installing engine mount‐
rrectness of i
ing
l purpos
⇒ “2.3.1 Removing and installing engine mounting, Golf 2013>,

Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>”,
nf
ercia
page 53
orm
m
atio
m
⇒ “2.3.2 Removing and installing engine mounting, Polo 2014>,

o
n in
Polo Saloon RUS 2016>”, page 54
or c
thi
te
sd
a
2.3.1 Removing and installing engine mount‐

iv
o
r
rp
cu
ing, Golf 2013>, Golf Estate 2014>, Golf
o
m
f
en
ng
t.
yi
SV 2015>, Golf 2017>, Polo 2018>
Co
Cop py
ht. rig
rig ht
Removing
py by
co Vo
by lksw
cted agen
– Separate connector -1-.
Prote AG.
– Move clear hose -2- from activated charcoal filter.

– Using a screwdriver, release fasteners -arrow- and move cool‐
ant expansion tank to one side.
– Support engine in its installation position
⇒ “2.2 Supporting engine in installation position”, page 46 .
– Tighten spindles slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew bolts -arrows- and remove engine mounting -1-.

Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings
⇒ “2.6 Checking adjustment of assembly mountings (engine
and gearbox mountings)”, page 63 .
Specified torques
wage
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 39 olks es n
ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
2.3.2 Removing and installing engine mount‐
un
pt
an
d
itte
ing, Polo 2014>, Polo Saloon RUS
y li
erm
ab
2016>
ility
ot p
wit
is n
h re
ole,
spec
♦ Torque wrench - V.A.G 1331-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing


– Pull vacuum line -2- in direction of -arrow- off vacuum pump
for brakes - V192- -1-.
– Lay vacuum line -1- to one side.
lkswage es n
o ot g
byV ua
d ran
ir se
Continued for all vehicles tho tee
or
au ac
– Release connectors -2- and pull off. ss
ce
e
nl
pt
– Unscrew securing bolts -3-. du
an
itte
y li
erm
ab
– Place coolant expansion tank -1- on engine.
ility
ot p
– Support engine in installation position
wit
, is n
h re
hole
spec
– Tighten spindle slightly to take up weight of engine/gearbox
es, in part or in w
t to the co
rrectness of i
– Unscrew nut -3-.
l purpos
– Remove earth wire.
nform
mercia
Note
at
om
ion
c
in t
or
Nut -4- must not be loosened.
his
ate
do
priv
cum
or
– Unscrew bolts -2- between engine mounting and engine.

f
en
ng
t.
yi Co
– Unscrew bolts -arrows- and remove engine mounting. t. Cop py
rig
gh ht
Installing pyri by
Vo
co lksw
by
cted agen
Install in reverse order of removal. During this procedure, observe Prote AG.
the following:
– Place assembly mounting on longitudinal member.

– Remove support bracket - 10 - 222 A- from engine.
Specified torques
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 267
2.4 Removing and installing gearbox

mounting
⇒ “2.4.1 Removing and installing gearbox mounting, Golf 2013>,
Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>”, AG. Volkswagen AG d
page 56 lksw
agen oes
not
Vo gu
by
⇒ “2.4.2 Removing and installing gearbox mounting, Polo 2014>, rised ara
nte
Polo Saloon 2016>”, page 58 ut
ho eo
ra
s a c
s
2.4.1 Removing and installing gearbox
ce
le
un
pt
mounting, Golf 2013>, Golf Estate
an
d
itte
y li
erm
2014>, Golf SV 2015>, Golf 2017>, Polo
ab
ility
ot p
2018>
wit
is n
h re
ole,
spec
t to the co
– Remove engine control unit
⇒ “6.1 Removing and installing engine (motor) control unit
J623 ”, page 278 .
rrectne
– Unscrew nuts -arrows-, and remove bracket -1-.
ss o
cial p
f in
Note
form
mer
atio
m
Different types of brackets are fitted depending on version.

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Unclip wire guide -1- upwards -arrows-, and push it slightly to

one side.
– Support engine in its installation
wage
nposition
AG. Volkswagen AG d
oes
⇒ “2.2 Supporting engineyV
oin installation position”, page
lks no46
t gu .
b ara
ed
– Tighten spindle tohtake
or
is up weight of engine/gearbox assembly;
nte
eo
do not lift. s aut ra
c s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Unscrew bolts -arrows-.
o
cial p
f inform
– Lower engine/gearbox assembly slightly.
mer
atio
m
– Remove gearbox mounting -1-.

o
n
c
i
or
n
Installing
thi
te
sd
iva
o
pr
cum
r
fo
the following:
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
♦ Risk of damage to threads in gearbox support by starting bolts
at an angle.
♦ Gearbox support and support arm of gearbox mounting must
be perfectly parallel to each other before screwing in bolts
-arrows 1-. If necessary, lift gearbox at rear using trolley jack.
♦ Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.
♦ Replace bolts that are tightened with specified tightening an‐
gle.
– Lift gearbox with spindle of support bracket until gearbox sup‐

port makes contact with support arm of gearbox mounting.
Specified torques
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
2.4.2 Removing and installing gearbox

mounting, Polo 2014>, Polo Saloon
2016>
Removing
n AG. Volkswagen A
– Remove battery tray ⇒ Electrical system;
olks
Rep.
wage gr. 27 ; Battery; does n
G
ot g
Removing and installing battery tray
db .
y V ua
r e an
ris tee
– Support engine in its installation
tho position or
au
⇒ “2.2 Supporting engine ins s installation position”, page 46 . ac
ce
e
nl
– Take up weight of engine/gearbox assembly slightly with spin‐
pt
du
an
dle; do not lift.
itte
y li
erm
ab
– Carefully loosen wiring harness at its fastening points
ility
ot p
-arrows-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Unscrew securing bolts -arrows- from gearbox mounting.

AG. Volkswagen AG d
Installing lksw
agen oes
not
Vo gu
y
rise
d b ara
nte
the following: utho eo
ra
s a c
s
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
♦ Risk of damage to threads in gearbox support by starting bolts
pe
ility
ot
at an angle.
wit
, is n
h re
♦ Do not remove support bracket - 10 - 222 A- until the bolts
hole
spec
securing the assembly mounting have been tightened to
es, in part or in w
specified torque.
t to the co
♦ Replace bolts that are tightened with specified tightening an‐
gle.
rrectness of i
l purpos
– Remove support bracket - 10 - 222 A- from engine.

Specified torques
nform
ercia

m
a
com
t
♦ Tightening sequence for gearbox mounting ⇒ page 44 .
ion in
r
te o
thi
s
iva
do
r

rp
cum
fo
- battery
en
ng
t.
yi Co
Cop py
t. rig
2.5 Removing and installing pendulum sup‐
gh ht
pyri by
Vo
o
port
c by lksw
cted agen
Prote AG.
⇒ “2.5.1 Removing and installing pendulum support, Golf 2013>,

Golf Estate 2014>, Golf SV 2015>, Golf 2017>, Polo 2018>”,
page 59
⇒ “2.5.2 Removing and installing pendulum support, manual
gearbox, Polo 2014>, Polo Saloon 2016>”, page 60
⇒ “2.5.3 Removing and installing pendulum support, automatic
gearbox, Polo 2014>, Polo Saloon 2016>”, page 61
2.5.1 Removing and installing pendulum sup‐

port, Golf 2013>, Golf Estate 2014>,
Golf SV 2015>, Golf 2017>, Polo 2018>
sulation .
– Unscrew bolts -1- to -3-, and remove pendulum support.
Installing
Note
♦ There are threaded inserts, e.g. “Heli coil” in the bolting holes
for the pendulum support.
♦ This can be identified via the shoulder in the first thread pitch
-arrow-.
Specified torques
♦ ⇒ Fig. ““Install pendulum support”“ , page 41 olkswagen AG
en AG. V wag does
olks not
byV gu
ara
ed nte
ris
2.5.2 Removing and installing pendulum sup‐ au
tho eo
ra
c
ss
port, manual gearbox, Polo 2014>, Polo
ce
le
un
pt
Saloon 2016>
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi

te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing

– Unscrew bolts -arrows- for pendulum support -1-.
Note
Bolt -3- must not be loosened.
– Pull pendulum support -1- out of assembly carrier -2-.

Installing agen
AG. Volkswagen AG d
oes
olksw not
yV gu
Install in reverse order of removal. During thiseprocedure,
db observe ara
nte
is
the following: hor eo
aut ra
ss c
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ Identification: shoulder along beginning of thread -arrow-.
t to the co
Specified torques
rrectness o
cial p
f
2.5.3 Removing and installing pendulum sup‐
inform
mer
port, automatic gearbox, Polo 2014>,
atio
m
Polo Saloon 2016>

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
ksw not
Golf 2013 ➤ , Golf 2017 ➤ , Golf by Sportsvan
Vol
2015 ➤ , Golf Variant gu2014 ➤ ...
ara
d
4-cylinder injection engine (1.6
orise l engine, 4 V, EA 211) - Edition 11.2018 nte
eo
th
au ra
s c
Removing s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
⇒ “3.1 Rules for cleanliness”, page 5 . , is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -arrows- for pendulum support.
rrectness of i
l purpos
Note
nform
ercia
Bolt -1- must not be loosened.

m
at
om
io
– Pull pendulum support -1- out of assembly carrier -2-.
n
c
in t
or
his
e
Installing
at
do
priv
cum
or

f
en
g
the following:
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.
♦ Identification: shoulder along beginning of thread -arrow-.
Specified torques

2.6 Checking adjustment of assembly

mountings (engine and gearbox mount‐
ings)
⇒ “2.6.1 Checking adjustment
gen AG
. Volkof assembly
swagen AG
doemountings, Golf
swa s no
2013>, Golf EstateVolk 2014>, Golf SV 2015>, Golft g2017>, Polo
by ua
2018>”, page
ris
ed 63 ran
t ee
tho o
⇒ “2.6.2au Checking adjustment of assembly mountings, rPolo
ac
ss
2014>, Polo Saloon RUS 2016>”, page 64
ce
le
un
pt
2.6.1 Checking adjustment of assembly
an
d
itte
y li
rm
ab
mountings, Golf 2013>, Golf Estate
pe
ility
ot
2014>, Golf SV 2015>, Golf 2017>, Polo
wit
, is n
h re
2018>
hole
spec
es, in part or in w
Procedure
t to the co
The following specifications must be obtained:
rrectness of i
• There must be a distance -a- of 10 mm between engine sup‐
port -2- and engine mounting -1-.
l purpos
• Side surface of engine support -2- must be located parallel to

support arm of engine mounting -1-.
nform
ercia
• Dimension -b- must be identical on both sides.

m
a
com
tion in
r
te o
Note
thi
s
iva
do
r
rp
cum
Distance -a- (10 mm) can also be checked with a metal rod of
fo
en
g
suitable size, or similar.

n
t.
yi Co
Cop py
ht. rig
rig ht
– If the dimension is too small or too high, adjust assembly
py by
co Vo
mountings
by lksw
cted agen
Prote AG.
– On the gearbox side, ensure that the edges of the support arm
-2- and gearbox support -1- are parallel.
2.6.2 Checking adjustment of assembly

mountings, Polo 2014>, Polo Saloon
RUS 2016>
Procedure AG. Volkswagen AG d
agen oes
lksw not
– Fit engine mounting on longitudinald by V member.
o gu
ara
ise nte
or eo
h
aut ra
Note s s c
ce
le
un
pt
an
d
Risk of damage to threads by starting bolts at an angle.

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Specified torques
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
2.7 Adjusting assembly mountings

m
a
com
tion in
Procedure
r
te o
thi
s
iva
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; do

r
rp
c
um
fo
en
ng
t.
yi
– Remove air filter housing ⇒ page 268 .
Co
Cop py
ht. rig
– Remove engine control unit ⇒ page 278 . rig ht
py by
co Vo
by lksw
– Unscrew nuts -arrows-, and remove bracket -1-. cted agen
Prote AG.
Note
Different types of brackets are fitted depending on version.

– Unclip wire guide -1- upwards -arrows-, and push it slightly to

one side.
– Support engine in its installation position ⇒ page 46 .
– Unscrew engine mounting bolts -arrows- one after the other

and renew them (if not already renewed when installing en‐
gine).
– First screw bolts in loosely.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
– Unscrew bolts -arrows- for gearbox mounting -1- in succes‐

nl
pt
du
an
sion and renew (if not already carried out on installing engine).
itte
y li
erm
ab
– First screw bolts in loosely.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Using assembly lever, adjust engine/gearbox assembly so

that specifications listed below are attained:
There must be a distance -a- of 10 mm between engine support
-2- and engine mounting -1-.
Side surface of engine support -2- must be located parallel to
support arm of engine mounting -1-.
Dimension -b- must be identical on both sides.
Note
Distance -a- = 10 mm can also be checked with a metal rod of

suitable size, or similar.
– Tighten bolts for engine mounting.
– On the gearbox side, ensure that the edges of theagsupport

en AG. V armagen AG doe
olksw
-2- and gearbox support -1- are parallel. Volksw s no
tg
by ua
ed ran
• Distance -x- = distance -x-. oris tee
th or
au
– Tighten bolts for gearbox mounting.
ss
ac
ce
le
un
Install in reverse order of removal.
pt
an
d
itte
y li
Specified torques
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
- battery
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 67
⇒ “1.2 Removing and installing poly-V belt”, page 73
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 79
⇒ “1.4 Removing and installing vibration damper”, page 80
⇒ “1.5 Removing and installing engine support”, page 82
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 84
1.1 Assembly overview - poly V-belt drive

⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles without
air conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf
SV 2015>, Golf 2017>”, page 67
⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles without
air conditioner compressor, Polo 2014, Polo Saloon RUS 2016>,
Polo 2018>”, page 69
⇒ “1.1.3 Assembly overview - poly V-belt drive, vehicles with air
conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf SV
2015, Golf 2017>”, page 71
⇒ “1.1.4 Assembly overview - poly V-belt drive, vehicles with air
conditioner compressor, Polo 2014>, Polo Saloon RUS 2016>,gen AG. Volkswagen AG d
a
Polo 2018>”, page 73 Vol
ksw
oes
not
g by ua
ed ra
1.1.1 Assembly overview - poly V-belt
ut
ho
ris drive, vehicles without air conditioner
nte
eo com‐
ra
pressor, Golf 2013>, Golf sEstate 2014>, Golf SV 2015>, Golf 2017>
s a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder block (pulley end) 67

1 - Bolt
❑ Use counter-hold tool -
T10475- to loosen and
tighten
❑ 150 Nm +180°
2 - Vibration damper
stalling vibration damp‐
er”, page 80
3 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen
❑ Do not kink
❑ The length of the poly V-
belt must be determined
according to the ⇒ Elec‐
tronic Parts Catalogue
depending on the ver‐
sion of overrunning al‐
ternator pulley.
❑ Poly V-belt routing
⇒ page 75 AG. Volkswagen AG d
agen oes
olksw not
❑ Removing and installing ed by
V gu
ara
⇒ “1.2 Removing and in‐ horis nte
eo
stalling poly-V belt”, aut ra
c
page 73 ss
ce
e
nl
❑ When installing, make

pt
du
an
itte
sure it is properly seated

y li
erm
ab
on pulleys.
ility
ot p
4 - Bolt
wit
, is n
h re

hole
spec
❑ 20 Nm +90°
es, in part or in w
t to the co
5 - Tensioning device for poly V-belt

❑ Pivot with socket to slacken poly V-belt
rrectness of i
❑ Lock with locking pin - T10060 A- .

l purpos
❑ Removing and installing ⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 79
6 - Bolt
nform
ercia
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
m
at
7 - Alternator
om
ion
c
in t
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
or
his
ate
❑ With freewheel
do
priv
cum
❑ Various versions of the overrunning alternator pulley, -A- or -B-, may be fitted depending on the type and
for
en
g
version of alternator ⇒ page 69 .

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
68 Rep. gr.13 - Crankshaft group

Allocation of alternator decoupler pulley

The length of the poly V-belt must be determined according to the Volkswa
⇒ Electronic Parts Catalogue depending on the version of over‐
agen
AG. gen AG
does
ksw
running alternator pulley. by Vol not
gu
a
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.1.2 Assembly overview - poly V-belt drive, vehicles without air conditioner com‐
nf
ercia
o
pressor, Polo 2014, Polo Saloon RUS 2016>, Polo 2018>
rm
m
atio
om
n in
or c
1 - Bolt
thi
te
sd
iva
o
r
rp
cu
o
m
❑ Use counter-hold tool -
f
en
ng
t.
yi
T10475- to loosen and
Co
op py
tighten
t. C rig
gh ht
yri by
❑ 150 Nm +180° cop Vo
by lksw
cted agen
Prote
AG.

er”, page 80
3 - Poly V-belt
❑ Check for wear
❑ Do not kink
ternator pulley.
⇒ “1.2.1 Removing and
installing poly-V belt, ve‐
hicles without air condi‐
tioner compressor, Golf
2013>, Golf Estate
2014>, Golf SV 2015>,
Golf 2017>”, page 73
❑ When installing, make
sure it is properly seated
on pulleys.
4 - Bolt
❑ Specified torque ⇒
Electrical system; Rep.
gr. 27 ; Alternator; Assembly overview - alternator

5 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. n AGgr.
. Vol27
ksw;aAlternator;
gen AG Removing and installing alternator
swage does
❑ With freewheel by
Volk not
gu
ara
ed
❑ Various versions of the overrunningh oris alternator pulley, -A- or -B-, may be fitted ntedepending on the type and
eo
version of alternator ⇒ page 70
aut . ra
c
ss
ce
le
un
pt
an
d
Allocation of alternator decoupler pulley itte
y li
rm
ab
pe
ility
The length of the poly V-belt must be determined according to the
ot
wit
, is n
h re
running alternator pulley.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.1.3 Assembly overview - poly V-belt drive, vehicles with air conditioner com‐
pressor, Golf 2013>, Golf Estate 2014>, Golf SV 2015, Golf 2017>
1 - Poly V-belt
❑ Check for wear
chalk or felt-tipped pen
❑ Do not kink
ternator pulley.
❑ Poly V-belt routing
⇒ page 77
installing poly-V belt, ve‐
hicles without air condi‐
tioner compressor, Golf
2013>, Golf Estate AG. Volkswagen AG d
2014>, Golf SV 2015>, agen oes
olksw not
Golf 2017>”, page 73 d by
V gu
ara
ise nte
❑ When installing, make hor eo
ut
sure it is properly seated ss a ra
c
on pulleys.
ce
e
nl
pt
du
an
2 - Bolt
itte
y li
erm
ab
❑ Specified torque
ility
ot p
⇒ Item 1 (page 68) .
wit
, is n
h re
hole
spec
es, in part or in w

t to the co
er”, page 80 rrectness of i
4 - Tensioning device for poly

V-belt
l purpos
❑ Pivot with socket to slacken poly V-belt

❑ Lock with locking pin - T10060 A- .
nform
ercia
❑ Removing and installing ⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 79
m
at
om
io
5 - Bolt
n
c
in t
or

his
ate
do
riv
❑ 20 Nm +90°
p
cum
for
en
g
6 - Bolt
n
t.
yi Co
op
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
C py
t. rig
gh ht
yri by
7 - Alternator
op Vo
by c lksw
cted agen
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
Prote AG.
❑ With freewheel
❑ Various versions of the overrunning alternator pulley, -A- or -B-, may be fitted depending on the type and
version of alternator ⇒ page 72 .
8 - Dowel sleeve
❑ For air conditioner compressor.

9 - Air conditioner compressor

❑ Do not unscrew or disconnect refrigerant lines
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing air conditioner compressor from and to bracket
10 - Bolt
AG. Volkswagen AG d
❑ Specified torque ⇒ Heating, lkswair conditioning; Rep. gr.
agen oes 87 ; Air conditioner compressor; Assembly over‐
not
view - drive unit of aird conditioner
by Vo
compressor . gu
a
e ran
ris tee
utho or
a ac
ss
Allocation of alternator decoupler pulley
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.1.4 Assembly overviewlks-wapoly

gen AG V-belt drive,
. Volkswagen AG
doesvehicles with air conditioner com‐
not
pressor, Poloise2014>, Polo Saloon RUS 2016>, Polo 2018>
Vo gu
y
db ara
n r tee
ho
aut or
ac
ss
1 - Bolt
ce
e
nl
pt
❑ Renew
du
an
itte
y li
❑ 150 Nm +180° further
erm
ab
ility
ot p
wit
, is n
h re
❑ For crankshaft
hole
spec
❑ Do not cant when instal‐
es, in part or in w
ling
t to the co
❑ To remove and install,
use counterhold tool -
T10475- .
rrectness of i
3 - Bolt
l purpos
❑ Renew
nf
ercia
orm
m
4 - Cap
atio
om
n in
c
5 - Bolt
or
thi
te
❑ 30 Nm
sd
iva
o
r
rp
cu
6 - Tensioning element
o
m
f
en
ng
t.
yi Co
7 - Bolt t. Cop py
rig
gh
❑ 23 Nm
ht
pyri by
Vo
co lksw
by
8 - Alternator
cted agen
Prote AG.
9 - Guide bush
10 - Air conditioner compres‐
sor
11 - Bolt
❑ 23 Nm
12 - Poly V-belt
❑ Mark direction of rota‐
tion before removing
poly V-belt ⇒ “1.2 Removing and installing poly-V belt”, page 73
1.2 Removing and installing poly-V belt

⇒ “1.2.1 Removing and installing poly-V belt, vehicles without air
2015>, Golf 2017>”, page 73
⇒ “1.2.2 Removing and installing poly V-belt, vehicles without air
conditioner compressor, Polo 2014> Polo Saloon RUS 2016>,
⇒ “1.2.3 Removing and installing poly-V belt, vehicles with air
2015, Golf 2017>”, page 76
⇒ “1.2.4 Removing and installing poly V-belt, vehicles with air
conditioner compressor, Polo 2014> Polo Saloon RUS 2016>,
1.2.1 Removing and installing poly-V belt, ve‐

hicles without air conditioner compres‐

sor, Golf 2013>, Golf Estate 2014>, Golf

SV 2015>, Golf 2017>
Removing
– Before removing, mark direction of rotation of poly V-belt with
chalk or felt-tipped pen for re-installation.
– To slacken poly V-belt, turn tensioning device in anti-clockwise
direction -arrow-.
– Lock tensioning device in place with locking pin - T10060 A- .
– Remove poly V-belt.
Installing
the following:
Various versions of the overrunning alternator pulley, -A- or -B-,

may be fitted depending on the type and version of alternator.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
74
cop Vo
by lksw
Rep. gr.13 - Crankshaft group Prote
cted AG.
agen

– Fit poly V-belt as shown in illustration.
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
– Turn tensioning device in -direction of arrow-, and pull out

locking pin - T10060 A- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
1.2.2 Removing and installing poly V-belt, ve‐

. Volkswagen AG
hicles withoutolks
wa air conditioner
gen AG does
compres‐
not
yV
sor, e Polo 2014> Polo Saloon RUS
b gu
d ara
ris nte
2016>, Polo 2018>
tho eo
u ra
sa
s c
ce

le
un
pt
an
d
itte
♦ Poly V-belt repair kit with assembly tools ⇒ Electronic Parts

y li
rm
ab
Catalogue (ETKA)
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
The poly V-belt repair kit with assembly tool contains the assem‐
bly tool -T10367/2- and instructions.
rrectness of i
Removing
l purpos
– Cut through poly V-belt.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installing
Proceed as described in the instructions provided with the repair
kit.
Poly V-belt routing

wage
1 - Vibration damper/crankshaft yV
olks es n
ot g
d b ua
ran
2 - Poly V-belt ir se tee
tho
u or
a ac
3 - Alternator pulley ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.2.3 Removing and installing poly-V belt, ve‐
hicles with air conditioner compressor,
rrectness of i
Golf 2013>, Golf Estate 2014>, Golf SV
l purpos
2015, Golf 2017>

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Before removing, mark direction of rotation of poly V-belt with

AG. Volkswagen A
Golf 2013 ➤ , Golf 2017 agen
ksw➤ , Golf Sportsvan 2015es n ➤ , Golf Variant 2014 ➤ ...
G do
Vol ot g
4-cylinder einjection
db
y engine (1.6 l engine, 4 V, EA ua 211) - Edition 11.2018
ra
ris nte
tho eo
– Fit tool -3- onto hexagon of tensioner
ss
au
-1-. ra
c
ce
e
– To slacken poly V-belt push tool -3- in -direction of arrow-.
nl
pt
du
an
itte
y li
– Lock tensioning device using locking pin - T10060 A- -2-.
erm
ab
ility
ot p
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Fit poly V-belt as shown in illustration.
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
– Turn tensioner anti-clockwise -direction of arrow- and remove

locking pin - T10060 A- -2-.
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.

1.2.4 Removing and installing poly V-belt, ve‐

hicles with air conditioner compressor,
Polo 2014> Polo Saloon RUS 2016>,
Polo 2018>
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
Removing
ce
le
un
pt
an
d
– Mark the direction of rotation of the poly V-belt with a marker.

itte
y li
rm
ab
– Lever off belt tensioner cap -arrow- using a screwdriver.
pe
ility
ot
wit
, is n
– Loosen securing bolt -1-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
– Turn belt tensioner -2- in -direction of arrow- past TDC using
on in
a socket.
r
te o
thi
s
iva

do
r
rp
cum
fo
Installing
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note
py by
co Vo
by lksw
cted agen
Prote AG.
When installing the poly V-belt, ensure that the belt is properly
seated in the vibration damper and the pulleys.
– Fit poly V-belt over vibration damper pulley and pulleys of al‐
ternator and air conditioner compressor.
– Push belt onto belt tensioner.

– Turn belt tensioner -2- in -direction of arrow- past TDC using

a socket.
– Tighten securing bolt -1- to 30 Nm.
Poly V-belt routing

1 - Vibration damper/crankshaft
2 - Tensioning pulley
3 - Alternator pulley
4 - Poly V-belt
AG. Volkswagen AG d
agen
5 - Air conditioner compressor pulley olksw
oes
not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
1.3 Removing and installing tensioner for
erm
ab
ility
poly V-belt
ot p
wit
is n
h re
⇒ “1.3.1 Removing and installing tensioner for poly V-belt, vehi‐
ole,
spec
cles without air conditioner compressor”, page 79
t to the co
⇒ “1.3.2 Removing and installing tensioner for poly V-belt, vehi‐
cles with air conditioner compressor”, page 80
1.3.1 Removing and installing tensioner for
rrectne
poly V-belt, vehicles without air condi‐
ss
tioner compressor
o
cial p
f inform
Removing
mer
atio
m
– Remove poly V-belt from tensioner

o
n
c
⇒ “1.2.1 Removing and installing poly-V belt, vehicles without

i
or
n thi
air conditioner compressor, Golf 2013>, Golf Estate 2014>,

te
sd
a
Golf SV 2015>, Golf 2017>”, page 73 .

iv
o
pr
cum
r
fo
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.

en
ng
t.
yi Co
op
Installing
C py
ht. rig
rig ht
py by
Install in reverse order of removal. During this procedure, observe co Vo
by lksw
the following:
cted agen
Prote AG.

⇒ “1.2.1 Removing and installing poly-V belt, vehicles without
air conditioner compressor, Golf 2013>, Golf Estate 2014>,
Golf SV 2015>, Golf 2017>”, page 73 .
Specified torques
♦ ⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles with‐
out air conditioner compressor, Golf 2013>, Golf Estate
2014>, Golf SV 2015>, Golf 2017>”, page 67

1.3.2 Removing and installing tensioner for

poly V-belt, vehicles with air conditioner
compressor
Removing
– Remove poly V-belt from tensioner
conditioner compressor, Golf 2013>, Golf Estate 2014>, Golf
SV 2015, Golf 2017>”, page 76 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
SV 2015, Golf 2017>”, page 76 .
Specified torques
Volkswagen AG
♦ ⇒ “1.1.3 Assembly overview - poly V-belt drive, vehiclesswwith
agen
AG. does
air conditioner compressor, Golf 2013>, Golf Estate by
V2014>,
olk not
gu
ara
Golf SV 2015, Golf 2017>”, page 71 ris
ed nte
tho eo
s au ra
c
1.4 Removing and installing vibration damp‐ s
ce
le
un
pt
er
an
d
itte
y li
erm
ab
ility
ot p
wit
♦ Counter-hold tool - T10475-
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Preparing counterhold tool - T10475-

t
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
♦ Different types of vibration damper can be installed. pyri by
Vo
co lksw
by
cted
♦ For this reason, the counterhold tool - T10475- must be adap‐
agen
Prote AG.
ted to the holes of the respective vibration damper.

Version 1 n AG. Volkswagen AG do

lkswage es n
– Convert counterhold tool - T10475- -1- with inserts -T10475/2-
byV
o ot g
ua
-2-. ir se
d ran
tee
tho
u or
Version 2 ss
a ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Convert counterhold tool - T10475- with inserts -T10475/1-
rrectness of i
and -T10475/2- as shown in illustration.
l purpos
• To do this, use hole -A- or -B- of counterhold tool - T10475-

-1- depending on type of vibration damper.
nf
ercia
o
Removing
rm
m
atio
m

o
n in
c

or
thi
sulation .
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
– Set crankshaft to »TDC« of cylinder no. 1. t. C rig
gh ht
⇒ “2.6 Checking valve timing”, page 141 yri
p by
co Vo
by lksw
cted agen
Prote AG.
– Loosen bolt -arrow- for vibration damper using counterhold -
T10475- .
– Unscrew bolt and remove vibration damper.
Note
To avoid disturbing valve timing, do not turn the crankshaft when

the vibration damper has been removed.
Installing
Note

♦ All contact surfaces between bolt, vibration damper and crank‐
shaft toothed belt pulley must be free of oil and grease.

– Fit vibration damper, oil threads of bolt for vibration damper

and screw it in to stop by hand.
– Tighten bolt -arrow- for vibration damper using counterhold -
T10475- .
Further installation is carried out in reverse order of removal, ob‐
serving the following:
Specified torques
1.5 Removing and installing engine support

Removing
– Drain coolant
– Remove tensioner for poly V-belt.
⇒ “1.3 Removing and installing tensioner for poly V-belt”, page
79
swage es n
– Detach hoses from retainer -3-. byV
olk ot g
ua
d ran
ir se
– Unscrew bolt -2-. tho tee
or
au ac
– Release clips -arrows- and remove upper toothed belt guard
ss ce
le
-1-.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect fuel line -1-. Disconnect plug-in connectors ⇒ Rep.

rrectness of i
gr. 20 ; Plug-in connectors; Disconnecting plug-in connectors .

l purpos
Note
nform
ercia
Any open lines, pipes, hoses and connections must be sealed

m
a
com
ti
immediately with a suitable cap or plug.

on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Release hoses from retainer -2-, and lay them to one side.
– Unplug connector -1-.
– Using a screwdriver, release catches -arrow-, and lay coolant
expansion tank to one side.
– Open retaining clips on pipes of air conditioning system.
– Loosen bolt -1-, but do not unscrew it completely.

olkswagen AG
en AG. V
– Swivel alternator -3- in -direction
olks
wag of arrow- towards
does
front.
not
yV gu
db ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Unscrew bolts -arrows- from bracket for front exhaust pipe.
t to the co
– Remove pendulum support
⇒ “2.5 Removing and installing pendulum support”, page 59 . rrectne
– Support engine in its installation position

ss

o
cial p

inform
mer
– Removing engine mounting

atio
⇒ “2.3 Removing and installing engine mounting”, page 53 .

om
n
c
i
or
n thi
te
sd
iva
o
pr

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se te
o
Golf 2013 ➤ , Golf 2017 ➤ , GolfauSportsvan 2015 ➤ , Golf Variant 2014 ➤ ... e or a
th
c
4-cylinder injection engine (1.6 l engine, 4 V, EA 211) - Edition 11.2018 ss
ce
e
nl
pt
du
an
– Unscrew bolts -1, 2, 3-.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
rm
m
atio
m
– Push engine/gearbox assembly slightly towards left, and de‐

o
n in
c
tach engine support.

or
thi
te
sd
a
Installing
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 126
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 234
♦ ⇒ “2.1 Assembly overview - emission control”, page 305
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view
- alternator
- battery
1.6 Renewing crankshaft oil seal - belt pul‐

ley end
♦ Assembly tool - T10485-

♦ Extractor hook - T20143-
Procedure
– Remove toothed belt
⇒ “2.4 Removing and installing toothed belt”, page 129 .
– Detach crankshaft pulley -1- -arrow-.
Note
To avoid disturbing valve timing, do not turn crankshaft out of

“TDC” position when vibration damper is removed.
– Pry out seal using extractor hook -T20143/2- -arrow-.

– Clean contact surface and sealing surface.
swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
ris
Note utho eo
ra
a c
ss
ce
e
Do not lubricate new seal.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit new seal in -direction of arrow- onto assembly sleeve -

T10485/2- .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull off assembly sleeve - T10485/3- in -direction of arrow-.

• Installation position: closed end of seal faces fitting sleeve.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Use fitting sleeve -T10485/1- and bolt -1- for poly V-belt pulley
o
cial p
f
to pull in oil seal -2- onto stop.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Fit crankshaft sprocket onto crankshaft.

• The contact surface between vibration damper and crankshaft
toothed belt pulley must be free of oil and grease.
• The machined surface -arrow- of crankshaft pulley must be
positioned over the machined surface of the crankshaft jour‐
nal.
– Install toothed belt ⇒ page 131 .

2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 87
⇒ “2.2 Removing and installing flywheel”, page 90
⇒ “2.3 Removing and installing drive plate”, page 91
⇒ “2.4 Removing and installing sealing flange on gearbox side”,
page 93
2.1 Assembly overview - cylinder block,

gearbox end
⇒ “2.1.1 Assembly overview - cylinder block, gearbox end, vehi‐
cles with manual gearbox”, page 87
⇒ “2.1.2 Assembly overview - cylinder block, gearbox end, vehi‐
cles with automatic gearbox”, page 89
2.1.1 Assembly overview - cylinderageblock,

n AG. Volkgearbox
swagen AG end, vehicles with manual
does
gearbox lksw not
Vo gu
by a
ed ran
ris tee
tho or
au ac
Note ss
ce
le
un
pt
an
d
For assembly work, secure engine to engine and gearbox support

itte
y li
⇒ “1.3 Securing engine on engine and gearbox support”, page 30 .
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Cylinder block, gearbox end 87

4-cylinder injection engine
agen
AG. Vol(1.6
kswagl eengine,
n AG d 4 V, EA 211) - Edition 11.2018
o
w es n
olks ot g
yV ua
1 - Bolt ris
ed
b ran
tee
ho
❑ Renew au after removal
t or
ac
ss
❑ 60 Nm +90°
ce
le
un
pt
an
2 - Flywheel
d
itte
y li
rm
ab
pe
ility
ot
wit
stalling flywheel”,
, is n
h re
page 90
hole
spec
❑ Can only be fitted in one
es, in part or in w
position
t to the co
3 - Engine speed sender -
G28-
rrectness of i
l purpos

stalling engine speed
sender G28 ”,
nform
ercia
page 316
m
a
4 - Bolt
com
tion in
❑ Specified torque
r
te o
thi
⇒ “1.1 Assembly over‐
s
iva
view - ignition system”, do

r
rp
cum
page 311
fo
en
ng
t.
yi Co
5 - Dowel pin Cop py
ht. rig
❑ Qty. 2
rig ht
py by
co Vo
by lksw
cted
6 - Adapter
agen
Prote AG.
❑ Do not damage or bend

when assembling.
❑ Installing ⇒ page 89
7 - Bolt
tightening sequence
⇒ page 88
8 - Sealing flange with sender wheel and oil seal
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Removing and installing ⇒ “2.4 Removing and installing sealing flange on gearbox side”, page 93
Sealing flange on gearbox side - specified torque and tightening

sequence
– Tighten bolts in 2 stages as follows.
Stage Tightening se‐ Specified torque
quence
1 -1- to -6- Screw in by hand as far as stop
2 -1- to -6- Tighten to 10 Nm

Install intermediate plate.

– Attach intermediate plate -1- to sealing flange -2- -arrow B-.
– Slide intermediate plate onto dowel sleeves -arrows A-.
2.1.2 Assembly overview - cylinder block, gearbox end, vehicles with automatic
gearbox
1 - Dual mass flywheel/drive

plate
drive plate
stalling drive plate”,
page 91 AG. Volkswagen AG d
agen oes
❑ Can only be installed in olksw not
V gu
by
one position (holes are rised ara
nte
offset). ut
ho eo
ra
s a c
2 - Dowel sleeve s
ce
le
un
pt
3 - Sealing flange, gearbox
an
d
itte
y li
side
erm
ab
ility
❑ With seal
ot p
wit
is n
❑ Renew only as com‐

h re
ole,
plete unit
spec
❑ Removing and installing t to the co

stalling sealing flange
on gearbox side”,
rrectne
page 93
❑ Do not oil or grease oil
s
seal sealing lip.

s o
cial p
❑ Before installing, re‐

inform
move oil residue from

mer
crankshaft journal using

atio
m
a clean cloth.
o
n
c
i
or
❑ Do not remove guide

thi
te
sd
sleeve until sealing

iva
o
r
flange has been slid on‐

p
cum
r
fo
to crankshaft journal.
en
ng
t.
yi Co
op
4 - Cylinder block C py
t. rig
gh ht
yri by
5 - Bolt
op Vo
by c lksw
cted agen
❑ Specified torque and Prote AG.
tightening sequence
⇒ page 90
6 - Adapter
❑ Illustration does not show version installed in vehicle.
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
❑ Is fitted onto sealing flange ⇒ page 90

7 - Dowel sleeve
8 - Bolt
❑ For dual-mass flywheel/drive plate
❑ 60 Nm +90°
Sealing flange on gearbox side - specified torque and tightening

sequence
– Tighten bolts in 2 stages as follows.
Stage Tightening se‐ Specified torque
quence
2 -1- to -6- Tighten to 10 Nm
Install intermediate plate.

– Attach intermediate plate -1- to sealing flange -2- -arrow B-.
– Slide intermediate plate onto dowel sleeves -arrows A-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
2.2 Removing and installing flywheel

ility
ot p
wit
, is n

h re
hole
spec
♦ Counter-hold tool - 3067-

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Removing
f
en
ng
t.
yi Co
op
• Gearbox removed ⇒ Rep. gr. 34 ; Removing and installing C py
ht. rig
gearbox . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Insert counterhold tool - 3067- into hole in cylinder block

-item B-.
– Loosen and remove flywheel bolts.
Installing
Note

♦ Flywheel with sender wheel can only be fitted in one position.
– Insert counterhold - 3067- in hole in cylinder block -item A-.

Specified torques
♦ ⇒ “2.1.1 Assembly overview - cylinder block, gearbox end, ve‐
hicles with manual gearbox”, page 87
torques for gearbox
2.3 Removing and installing drive plate

n AG. Volkswagen A ge G do
swa es n
♦ Counter-hold tool - VWb558-
yV
olk ot g
ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Depth gauge - VAS 6082-

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
♦ Hexagon bolt M8×40 and hexagon nut M8 Prote
cted AG.
agen
– Removing gearbox ⇒ Rep. gr. 37 ; Removing and installing

gearbox .

Preparing counter hold tool - VW 558- :

– Tighten hexagon bolt M8x40 -A- with hexagon nut on clutch
counter-hold tool - VW 558- .
Loosening and tightening drive plate:

– Insert counter hold - VW 558- in cylinder block and drive plate
as shown.
Stellung A - To loosen
Stellung B - To tighten
Installing drive plate:

– Fit drive plate without washer -A- first.
– Fit used securing bolts -3- and tighten to 30 Nm.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Check dimension between drive plate and cylinder block at

an
d
itte
y li
three points and calculate average.

rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Measure through hole in drive plate to milled surface of cylinder

es, in part or in w
t to the co
block. When measuring to intermediate plate, the plate thickness

must be taken into account.
rrectness of i
• Specification measured without intermediate plate: 19.5…

21.1 mm
l purpos
• Specification measured with intermediate plate: 18.8…

nform
20.4 mm
mercia
If the specification is not reached, replace all securing bolts and

a
com
tio
tighten.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
92
Prote AG.
Rep. gr.13 - Crankshaft group
If specification is not attained:

– Remove drive plate again and fit shim -A-. Tighten bolts -3-
again to 30 Nm.
– Repeat measurement. If the specification is not reached, re‐
place all securing bolts and tighten.
Specified torques
♦ ⇒ “2.1.2 Assembly overview - cylinder block, gearbox end, ve‐
hicles with automatic gearbox”, page 89
2.4 Removing and installing sealing flange

on gearbox side
♦ Flared ring spanner tool insert AF 24 - V.A.G 1332/11-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
♦ Depth gauge - VAS 6082-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

olksw AG. V agen AG
agen does
lksw not
♦ Locating bolt - T10340- db
yV
o gu
ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Bolt M6x35 (3x)
l purpos
♦ Spark plug socket , e.g. -3122 B-

♦ Hexagon key
nf
ercia
or
Procedure
m
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
For reasons of clarity, illustration shows work procedure with en‐
o
m
f
en
ng
gine removed.
t.
yi Co
Cop py
t. rig
gh ht
– Remove noise insulation ⇒ General body repairs, exterior; yri
p by
o Vo
by c lksw
cted agen
sulation .
Prote AG.
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing

gearbox .
Vehicles with manual gearbox:
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
clutch .
– Remove flywheel
⇒ “2.2 Removing and installing flywheel”, page 90 .
– Remove drive plate
⇒ “2.3 Removing and installing drive plate”, page 91 .
– 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.
– Set piston of cylinder no. 1 to “TDC” position
⇒ “4.7 Setting piston to TDC position”, page 111 .
– Remove sump (bottom section)
⇒ “1.2 Removing and installing lower part of sump”,
page 190 .
– Remove upper part of sump
⇒ “1.4 Removing and installing upper part of sump”,
page 196 .
– Remove engine speed sender - G28-
⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 316 .

– Unscrew bolts -arrows- for sealing flange -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
– To press off, screw 3 bolts M6 x 35 into sealing flange -1-
erm
ab
-arrows-.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
The sealing flange -1- is pressed off crankshaft -3- together with
the sender wheel -2-.
rrectness of i
– Screw bolts alternately into sealing flange not more than 1/2
l purpos
turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
nform
ercia
Pressing in sealing flange with sender wheel

m
at
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
♦ The sealing flange with a PTFE seal is equipped with a sealing

n
t.
yi Co
lip support ring -2-. This support ring serves as a fitting sleeve
Cop py
t. rig
and must not be removed prior to installation.
opyri
gh by
Vo
ht
c lksw
♦ Sealing flange and sender wheel -1- must not be separated
by
cted agen
Prote
after removal from packaging.
AG.
♦ The sender wheel -1- is held in its installation position on the

locating pin of the assembly tool - T10134- ⇒ page 96 .
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly tool - T10134- is held in its position relative to
the crankshaft by a guide pin inserted into a hole in the crank‐
shaft ⇒ page 96 .

Set-up of assembly tool - T10134- :

A - Clamping surface
B - Nut
C - Assembly housing
D-
Locating pin
E - Hexagon socket head bolt (qty. 2)
F-
Guide pin for petrol engines (red knob)
G - Guide pin for diesel engines (black knob)
H - Knurled screws (qty. 3)
I - Inner part
Fitting sealing flange with sender wheel on assembly tool -

T10134- :
– Screw on nut -B- until just before it touches the clamping sur‐
face -A- of the threaded spindle.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Clamp assembly device - T10134- at clamping surface -A- of

wit
, is n
threaded spindle in a vice -1-.

h re
hole
spec
– Push assembly housing -C- downwards until it rests against

es, in part or in w
nut -B-.
t to the co
• Inner part of assembly tool and assembly housing must be at

same height.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
– If fitted, remove securing clip -arrow- from new sealing flange.

or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
Cop py
Do not take the sender wheel and support ring out of the sealing
t. rig
gh ht
yri
flange. p by
o Vo
by c lksw
cted agen
Prote AG.

– Place sealing flange -1- with front side facing downwards on

a clean level surface.
– Push sealing lip support ring -2- downwards in
-direction of arrow- until it rests against flat surface.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
• Upper edge of sealing lip support ring -1- and front edge of
, is n
h re
sealing flange -2- must align -arrows-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Place sealing flange -1- with front side facing downwards onto
thi
te
assembly tool - T10134- so that locating pin -D- is seated in

sd
iva
o
r
hole -3- in sender wheel hole -2-.

rp
cu
o
m
f
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
♦ The sealing flange can be supplied in different versions.
cted agen
Prote AG.
♦ On some versions, the »TDC position hole« -3- is not in the

requisite TDC position -D-.
– If the position -3- is not correct in relation to the locating pin

-D-, carefully rotate the sender wheel -2- with support ring.
• The sealing flange must rest flat against the assembly tool.
– Screw knurled screws -H- into sealing flange -1-.

– Press sealing flange -1- and sealing lip support ring -2- against
surface of assembly tool - T10134- whilst tightening knurled
screws.
– This prevents the locating pin from slipping out of the sender
wheel hole.
– When installing sealing flange, ensure that sender wheel re‐
mains fixed in assembly tool.

Mounting assembly tool - T10134- with sealing flange -1- on

crankshaft flange:
• The crankshaft flange must be free of grease and oil.
• Engine is at “TDC” position
– Screw on nut -B- until it reaches end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in
-direction of arrow-, until nut -B- rests against assembly hous‐ n AG. Volkswagen AG do
swage es n
ing -C-. byV
olk ot g
ua
d ran
ir se
– Align flat side of assembly housing to sealing surface of cyl‐
tho tee
or
inder block on sump side. ss
au ac
ce
e
nl
pt
du
– Attach assembly tool - T10134- together with sealing flange
an
itte
y li
-1- to crankshaft flange -2-.
erm
ab
ility
ot p
– To do this, screw hexagon socket head bolts -E- into crank‐
wit
shaft flange (approx. 5 full turns) using a hexagon key.
, is n
h re
hole
– Push guide pin for petrol engines (red knob) -F- into crankshaft
spec
flange.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– To guide sealing flange -1-, screw two M6×35 mm bolts -2-
orm
into cylinder block.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Bolting assembly tool - T10134- onto crankshaft flange:

– Push assembly housing -C- by hand in -direction of arrow- until
sealing lip support ring -1- rests against crankshaft flange
-2-.
– Make sure that guide pin for petrol engines (red knob) -F- is
properly seated in hole in crankshaft. This ensures that the
sender wheel reaches its final installation position.
Note
The guide pin for diesel engines (black knob) must not be inserted
in threaded hole of crankshaft.
– Tighten the two hexagon socket head bolts of assembly tool

hand-tight.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly housing -C-.

Pressing sender wheel onto crankshaft flange using assembly

tool - T10134- :
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.
• After nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block -2- and sealing flange
-1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
Checking sender wheel installation position on crankshaft:
an
d
itte
y li
rm
ab
– Screw on nut -B- until it reaches end of threaded spindle.
pe
ility
ot
– Unscrew the two bolts -2- from cylinder block.
wit
, is n
h re
hole
– Pull guide pin for petrol engines (red knob) -F- out of crank‐
spec
shaft flange.
es, in part or in w
t to the co
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange, un‐
rrectness of i
screwing hexagon socket head bolts -E- from crankshaft
flange.
l purpos
– Remove sealing lip support ring.

nform
ercia
– Position depth gauge - VAS 6082- on crankshaft flange -2-.

m
a
com
ti
– Measure distance between crankshaft flange -2- and sender

on in
wheel -1-.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: dimension -a- = 0.5 mm
– If specification is not achieved, press sender wheel further in
⇒ page 100 .
– If specification is achieved, proceed with subsequent work
steps ⇒ page 101 .

Re-pressing sender wheel:

– Secure assembly tool - T10134- on crankshaft flange -2-.
– Make sure that locating pin of assembly tool - T10134- is prop‐
erly seated in sender wheel hole.
– Tighten hexagon socket head bolts -E- by hand.
– Push assembly tool - T10134- by hand against sealing flange
-1-.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly tool - T10134- .
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
– Screw knurled screws -H- into sealing flange -1-.
– To guide sealing flange, screw two M6×35 mm bolts -2- into AG. Volkswagen AG d
agen oes
ksw
cylinder block. by
Vol not
gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Tighten nut -B- of assembly tool - T10134- to 40 Nm.

– Check sender wheel installation position on the crankshaft
again ⇒ page 99 .
– If the specification is not achieved, tighten nut of assembly tool
- T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 99 .
Installing
– Tighten bolts for sealing flange (vehicles with manual gearbox)
. Volkswagen AG
⇒ page 88 . sw agen AG does
k not
Vol g
– Tighten bolts by
edfor sealing flange (vehicles with automatic gear‐
ua
ran
box) ⇒ page
oris 90 . tee
th o
au ra
c
– Installssupper part of sump
ce
e

nl
pt
du
an
page 196 .
itte
y li
erm
ab
– Install bottom section of sump
ility
ot p
wit
, is n
page 190 .
h re
hole
spec
– Install intermediate plate (vehicles with manual gearbox)
es, in part or in w
⇒ page 89 .
t to the co
– Install intermediate plate (vehicles with automatic gearbox)
⇒ page 90 .
– Install flywheel (vehicles with manual gearbox) rrectness of i
l purpos
⇒ “2.2 Removing and installing flywheel”, page 90 .

– Install drive plate (vehicles with automatic gearbox)
nform
ercia
⇒ “2.3 Removing and installing drive plate”, page 91 .

m
Specified torques
at
om
ion
c
♦ ⇒ Fig. ““Sealing flange on gearbox side - specified torque and

in t
or
his
e
tightening sequence”“ , page 88

at
do
priv
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page

um
for
en
g
87
n
t.
yi Co
op py
♦ ⇒ “1.1 Assembly overview - ignition system”, page 311
. C rig
ht ht
rig by
py Vo
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 187
co lksw
by
cted agen
Prote AG.
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation
torques for gearbox

3 Crankshaft
⇒ “3.1 Measuring axial clearance of crankshaft”, page 102
3.1 Measuring axial clearance of crankshaft

Risk of deformation of bearing seats.
Note
♦ The crankshaft must not be removed. Just loosening the main

bearing caps will cause deformation of the cylinder block bear‐
ing seats.
♦ This deformation will cause a reduction of the bearing clear‐
ance. Even if the bearing shells are not renewed, bearing
damage could occur due to a different
gen AG
. Vbearing
olkswagenclearance.
AG d a oes
lksw n
♦ If the bearing cap boltsd bare
y V loosened, the cylinder block must
o ot g
ua
be replaced complete
or
isewith the crankshaft.
ran
tee
th or
♦ Measuring the smain
s bearing clearance is not possible with au ac
normal workshop equipment.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Universal dial gauge holder - VW 387-

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
♦ Dial gauge - VAS 6079-

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Procedure
– Screw dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- onto cylinder block and set against crank web with
projection of approx. 2 mm.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
AG. Volkswagen AG d
• Axial clearance: 0.066 to 0.233 mm agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Crankshaft 103
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 104
⇒ “4.2 Removing and installing pistons”, page 106
⇒ “4.3 Checking pistons and cylinder bores”, page 108
⇒ “4.5 Checking radial clearance of conrods”, page 109
⇒ “4.4 Separating new conrod”, page 109
⇒ “4.6 Removing and installing oil spray jets”, page 110
⇒ “4.7 Setting piston to TDC aposition”,
gen AG
. Volkpage
swage111
n AG d
o
ksw es n
Vol ot g
4.1 Assembly
ris
ed
by overview - pistons and uconrods
ara
nt ee
tho or
s au ac
s
1 - Bolt
ce
e
nl
pt
du
an
itte
y li
❑ Oil threads and contact
erm
ab
ility
surface
ot p
wit
, is n
h re
hole
spec
2 - Conrod bearing cap
es, in part or in w
❑ The conrod bearing cap

t to the co
only fits in one position
and only on the appro‐
priate conrod due to the
rrectness of i
breaking procedure
l purpos
(cracking) separating
the cap from the conrod.
❑ Mark allocation to cylin‐
nf
ercia
der and conrod in colour

rm
m
-A-
atio
om
n in
❑ Installation position: ori‐

or c
entation nubs -B- on

thi
te
sd
a
conrod bearing cap

iv
o
r
rp
cu
must face in the same

o
m
f
direction for all caps

en
ng
t.
yi Co
Cop py
t. rig
Note gh ht
pyri by
Vo
co lksw
by
cted
Upon assembly in the factory, the
agen
Prote AG.
nubs -B- are oriented towards gear‐
box. The orientation of the conrods
may be changed during repair work,
but only if the orientation of all con‐
rods is changed. The orientation
nubs -A- on conrod bearing cap
must face in the same direction for
all caps.
3 - Bearing bushes
❑ Fitting position
⇒ page 106
❑ Renew worn bearing shells
❑ Ensure firm seating
4 - Pressure relief valve
❑ 27 Nm
❑ Removing and installing ⇒ “4.6 Removing and installing oil spray jets”, page 110

5 - Oil spray jet

❑ For piston cooling
❑ Removing and installing ⇒ “4.6 Removing and installing oil spray jets”, page 110
6 - Retaining ring
❑ Qty. 2
7 - Piston pin
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 106
8 - Piston
❑ Mark installation position and cylinder number ⇒ page 106 .
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 106
❑ Checking piston and cylinder bore ⇒ “4.3 Checking pistons and cylinder bores”, page 108
9 - Piston rings
❑ Compression rings
❑ Measuring ring gap ⇒ page 108
❑ Measuring ring-to-groove clearance ⇒ page 108
❑ 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°
10 - Piston rings
❑ Oil scraper rings
❑ Carefully remove and install 3-part oil scraperAG. Volkswagen AG d
agen rings by hand. oes
olksw not
❑ Measuring ring gap ⇒ page 108 ed by V gu
ara
is nte
❑ Ring-to-groove clearance not
ut
h measurable.
or eo
ra
sa c
11 - Connecting rod s ce
e
nl
pt
❑ With industrially cracked conrod bearing cap
du
an
itte
y li
❑ Renew as set only.

erm
ab
ility
❑ Mark allocation to cylinder and conrod bearing cap in colour -A-

ot p
wit
, is n
❑ Separating new conrod ⇒ “4.4 Separating new conrod”, page 109 .

h re
hole
❑ Installation position: orientation nubs -B- on conrod bearing cap must face in the same direction for all
spec
caps
es, in part or in w
t to the co
Note
rrectness of i
Upon assembly in the factory, the

nubs -A- are oriented towards gear‐
l purpos
box. The orientation of the conrods

may be changed during repair work,
nf
ercia
but only if the orientation of all con‐

or
rods is changed. The orientation

m
m
atio
nubs -A- on conrod bearing cap

om
n in
must face in the same direction for

or c
all caps.
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Pistons and conrods 105

4-cylinder injection engine (1.6 l engine, 4 V, eEA
n AG211)
. Volks-wEdition
agen AG 11.2018
ag does
ksw not
y Vol gu
Installation position and allocation of pistonsetod b cylinder ara
nte
ori eo
th
au ra
c
ss
Note
ce
e
nl
pt
du
an
itte
♦ If worn pistons are to be reinstalled, mark their allocation to
y li
erm
ab
the cylinder on the piston crown.
ility
ot p
wit
♦ Use paint for this.
, is n
h re
hole
♦ Do not use indentation, scratches, notches, or similar to mark
spec
piston crown.
es, in part or in w
t to the co
• Arrow on piston crown points to pulley end -arrow-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Bearing shells - installation position

or
thi
te
sd
a
• Ensure that crankshaft bearing shell is correctly positioned in

iv
o
r
rp
cu
conrod and conrod bearing cap.
o
m
f
en
ng
t.
yi
• Dimension -a- must be the same as dimension -a-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 27 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
Note
♦ Do not bend oil spray jets.

♦ Check clearance of oil jets after reinstallation of pistons.
♦ Bent oil spray jets must be renewed.
4.2 Removing and installing pistons


♦ Drift - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
– Removing cylinder head.
⇒ “1.3 Removing and installing cylinder head”, page 117
page 196 .
– Mark piston installation position and corresponding cylinder
number.
– Mark installation position and matching of cylinder and conrod
bearing cap to conrod ⇒ Item 11 (page 105) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
Note
AG. Volkswagen AG d
agen oes
ksw
If the piston pin is difficult to move, heat the piston to approx. by V 60°
ol not
gu
C. rised ara
nte
ho eo
aut ra
c
– Remove retaining ring from piston pin eye. s s
ce
le
un
pt
– Drive out piston pin using drift - VW 222 A- .
an
d
itte
y li
erm
Installing ab
ility
ot p
Install in reverse order of removal, observing the following: wit

is n
h re
ole,
spec
Note
t to the co

rrectne
– Oil running surfaces of bearing shells.

s
– Install piston with commercially available piston ring clamp,

s o
noting installation position ⇒ page 106 .

cial p
f inform
– Install conrod bearing cap, noting installation position

mer
atio
⇒ Item 11 (page 105) .

om
n
c
– Install cylinder head

or
n thi
e
⇒ “1.3 Removing and installing cylinder head”, page 117 .

t
sd
iva
o
pr
– Install upper part of sump

um
r
fo
en
ng

t.
yi Co
page 196 . Cop py
ht. rig
rig ht
Specified torques py by
co Vo
by lksw
cted agen
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 104 Prote AG.

Golf 2013 ➤ , Golf 2017 ➤olk,sGolf Sportsvan 2015 ➤ , Golf Variant 2014 ➤ ...
wagen AG
agen AG. V (1.6
engine l engine,
does4 V, EA 211) - Edition 11.2018
lksw n
o ot g
yV ua
edb ra
♦ ⇒ “1.1 Assembly
ho
ris overview - cylinder head”, page 114 ntee
aut or
ac
ss overview - sump/oil pump”, page 187
ce
le
un
pt
4.3 Checking pistons and cylinder bores
an
d
itte
y li
erm
ab
ility
ot p
wit
♦ External micrometre 75 - 100 mm - VAS 6071-
is n
h re
ole,
Checking piston
spec
– Using an external micrometre, measure approx. 10 mm from
t to the co
lower edge, offset 90° from piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
rrectne
Piston diameter, mm
ss
Specification without solid film 76.455 + 0.009
o
cial p
f
lubricant - 0.009
inform
mer
Specification with solid film lu‐ 76.485 + 0.017
atio
bricant - 0.017
om
n
c
i
or
n thi
e
Measuring piston ring gap

t
sd
iva
o
pr
– Insert piston ring at right angles to cylinder wall into cylinder cum
r
fo
en
ng
bore at bottom.
t.
yi Co
Cop py
– Insert piston ring to a depth of approx. 15 mm from bottom end
t. rig
gh ht
yri
of cylinder.
p by
o Vo
by c lksw
cted agen
– Push in using a piston without piston rings.
Prote AG.
Piston ring New Wear limit

mm mm
1st compression ring 0.20 + 0.15 1.0
2nd compression ring 0.40 + 0.20 1.0
Oil scraper rings, 3 parts 0.20 + 0.50 No wear limit
details availa‐
ble
Measuring ring-to-groove clearance

– Clean annular groove of piston before check.
Piston ring New Wear limit
mm mm
1st compression ring 0.04 … 0.08 0.15
2nd compression ring 0.03 … 0.07 0.15
Oil scraper rings (3 parts) Cannot be measured

Measuring cylinder bore
Note
Do not machine cylinder bore (reboring, honing, grinding) with

workshop equipment.
– Using cylinder gauge - VAS 6078- take measurements at 3

positions diagonally in lateral direction -A- and longitudinal di‐
rection -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore diameter, mm
Specification 76.5 + 0.015
+ 0.005
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
4.4 Separating new conrod

On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:
– Mark cylinder to which conrod belongs
⇒ Item 11 (page 105) . n AG. Volkswagen AG do
lkswage es n
o ot g
– Lightly clamp conrod in vice using protective
d by V aluminium jaws, ua
ran
as shown in figure. ir se tee
tho
u or
a ac
ss
ce
e
Note
nl
pt
du
an
itte
y li
erm
ab
♦ Only clamp the conrod lightly in order to avoid damaging it.

ility
ot p
♦ Conrod is clamped below the dashed line.

wit
, is n
h re
hole
spec
– Unscrew both bolts -arrows- about 5 turns.

es, in part or in w
t to the co
rrectness of i
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
4.5 Checking radial clearance of conrods
co lksw
by
cted agen
Prote AG.

♦ Plastigage
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm (without turning
further angle).
– Do not rotate crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
• Radial clearance: 0.028 to 0.065 mm.
– Renew conrod bolts.
AG. Volkswagen
4.6 Removing
Volksw and installing oilespray
agen AG do
s no
t
jets
y gu
db ara
Special tools and
or
ise workshop equipment required nte
h eo
ut ra
♦ Insert tool
ss - T10545-
a c
ce
le
Removing
un
pt
an
d
itte
y li

rm
ab

pe
ility
ot
sulation .
wit
, is n
h re

hole
spec

es, in part or in w
page 196 .
t to the co
Note
rrectness of i
l purpos
♦ The crank web of the respective cylinder must be positioned

so that the socket - T10545- can be inserted vertically in the
pressure relief valve.
nform
ercia
♦ Furthermore, the corners of the socket - T10545- and of the

m
a
com
pressure relief valve must engage well.

ion in
r
te o
thi
– Turn crankshaft via vibration damper securing bolt in direction

s
iva
do
of engine rotation until the respective bolt is accessible.

r
rp
cum
fo
en
g
– Unscrew pressure relief valve -1-.

n
t.
yi Co
Cop py
– Remove oil spray jets -2-.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installing
1- Pressure relief valve - 27 Nm
2- Oil spray jet
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
Note
♦ Do not bend oil spray jets.

♦ Check clearance of oil jets after reinstallation of pistons.
♦ Bent oil spray jets must be renewed.

page 196 .
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
4.7 Setting piston to TDC position

♦ Locating bolt - T10340-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Procedure
hole
spec

es, in part or in w
t to the co

sulation .
– Place a cloth underneath to catch any engine oil which may
rrectness of i
drain out.
l purpos
– Unscrew plug -arrow- from back of cylinder block.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Screw locking pin - T10340- -A- into cylinder block as far as

stop and tighten to 30 Nm.
• Bolt head of locking pin - T10340- -A- must contact cylinder
block when doing this.
Note
If the locking pin - T10340- -A- cannot be screwed in as far as

stop, this indicates that the crankshaft is not in the correct posi‐
tion.
– Unscrew locking pin - T10340- -A-.

– Turn crankshaft 90° in direction of rotation of engine.
– Screw locking pin - T10340- -A- into cylinder block as far as
stop and tighten to 30 Nm.
– Rotate crankshaft in normal direction of rotation as far as stop. agen AG. Volkswagen AG d
The locking pin - T10340- -A- now rests against the crank web.
Vol
ksw
oes
not
g y ua
db ran
rise tee
tho or
Note ss
au ac
ce
le
un
pt
Locking pin - T10340- -A- locks crankshaft in direction of engine
an
d
itte
rotation only.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Unclip wiring harness -arrows- and place to one side.
t to the co
– Unscrew bolts -1- and -3-.
– Remove toothed belt cover -2-.
rrectne
– Cover coolant pump with a cloth.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
– Unscrew bolt -arrow-, and remove cap -1-.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

• Grooves -1- of inlet camshaft -3- are positioned above the

horizontal camshaft centre line -2-.
• Grooves -1- of exhaust camshaft are positioned above hori‐
zontal camshaft centre line -2-.
• The centre-line of the holes close to hub of the gear -3- is
slightly above the grooves.
– If the grooves of the camshafts are not in the specified position,
turn the crankshaft 360° further in the direction of engine ro‐
tation and check the positions again.
Specified torques
♦ ⇒ “1.2 Assembly overview - camshaft housing”, page 116
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 220 G. Volkswagen nA AG do
wage e
y Voverview - air filter housing”, page
olks s no
t gu 267
b ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 114
⇒ “1.2 Assembly overview - camshaft housing”, page 116
⇒ “1.4 Removing and installing camshaft housing”, page 120
⇒ “1.5 Checking compression”, page 123
1.1 Assembly overview - cylinder head
1 - Cylinder head gasket

❑ Observe installation po‐
sition: Part number to
cylinder head
❑ Renewing
stalling cylinder head”,
page 117
2 - Dowel sleeve
❑ Qty. 2
3 - Cylinder head
stalling cylinder head”,
page 117
❑ Check for distortion lkswage es n
Vo ot g
⇒ page 115ed. by ua
ra
is nte
or
4 - Dowel pins
au
th eo
ra
ss c
5 - Seal
ce
e
nl
pt
du
❑ With oil strainer

an
itte
y li
erm
❑ Inserted into cylinder

ab
ility
head
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
♦ The oil strainer is fitted only if the

t to the co
cylinder head has the appropri‐

ate recess.
rrectness of i
♦ Cylinder heads without recess

do not require an oil strainer.
l purpos
6 - Seal
nf
ercia

rm
m
atio
m
7 - Camshaft case
o
n in
or c
❑ Removing and installing ⇒ “1.4 Removing and installing camshaft housing”, page 120
thi
te
sd
iva
8 - Bolt
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
9 - Bolt
C py
t. rig
gh ht
yri
❑ Renew after removal p by
co Vo
by lksw
cted
❑ Sequence when loosening ⇒ page 119 .
agen
Prote AG.
114 Rep. gr.15 - Cylinder head, valve gear

Cylinder head - specified torque and sequence
Note

1 -1 … 10- 40 Nm
Checking cylinder head for distortion

AG. Volkswagen AG d
agen o
– Use straight edge 500Vomm
lksw - VAS 6075- and feeleres ngauge to
ot g
measure cylindersehead
db
y
for distortion at several points. uaran
i tee
or
• Max. permissible
au
th distortion: 0.05 mm or
ac
ss ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 115

1.2 Assembly overview - camshaft housing
1 - Bolt
tightening sequence
⇒ page 117
2 - Inlet camshaft control valve n AG. Volkswagen AG do
1 - N205- lkswage es n
o ot g
yV ua
❑ Removing and installing ir se
d b ran
tee
⇒ “3.6 Removing and in‐ utho
or
stalling camshaft control ss
a ac
valve 1 N205 ”,
ce
le
un
pt
page 176
an
d
itte
y li
3 - Bolt
erm
ab
ility
ot p
❑ 8 Nm
wit
is n
h re
4 - Camshaft case
ole,
spec
t to the co
stalling camshaft hous‐
ing”, page 120
rrectne
5 - Hall sender - G40-
ss
o
cial p
f
stalling Hall sender”,
inform
page 315
mer
atio
6 - Bolt
om
n
c
❑ 8 Nm
i
or
n thi
te
sd
a
7 - Seal
iv
o
pr
cum
r
❑ For exhaust camshaft,

fo
en
ng
gearbox end
t.
yi Co
Cop py
t. rig
gh ht
yri
⇒ “3.5 Removing and in‐ p by
co Vo
lksw
stalling camshaft oil
by
cted agen
Prote
seal”, page 169
AG.
8 - Crankshaft
❑ For coolant pump
⇒ “2.4 Removing and installing toothed belt pulley for coolant pump”, page 227
9 - Bolt
❑ Specified torque ⇒ Item 8 (page 221)
10 - Bolt
❑ 8 Nm
11 - Cap
12 - O-ring
13 - Seal
14 - Dowel pin
15 - Seal
❑ With oil strainer
❑ Inserted into cylinder head

Note
♦ The oil strainer is fitted only if the AG. Volkswagen AG d

agen oes
ksw
cylinder head has the appropri‐ by Vol not
gu
ate recess. d ara
rise nte
tho eo
♦ Cylinder heads without recess s au ra
c
do not require an oil strainer.
s
ce
le
un
pt
an
d
itte
16 - Seal
y li
erm
ab
❑ For inlet camshaft
ility
ot p
wit
❑ Removing and installing ⇒ “3.5 Removing and installing camshaft oil seal”, page 169
is n
h re
ole,
17 - Seal
spec
❑ For exhaust camshaft urposes, in part or in wh
t to the co
❑ Removing and installing ⇒ “3.5 Removing and installing camshaft oil seal”, page 169
18 - Cap
rrectness
Camshaft housing - specified torque and tightening sequence
o
cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
op
Stage Bolts Specified torque/turning further angle C py
t. rig
gh ht
yri by
1 -1 … 15- 10 Nm cop Vo
by lksw
cted agen
2 -1 … 15- Turn 180° further Prote AG.
1.3 Removing and installing cylinder head

Removing
Note
Attach all heat-shielding sleeves in the same places when instal‐

ling.
– Remove intake manifold

⇒ “4.2 Removing and installing intake manifold”, page 272 .
– Remove camshaft housing
⇒ “1.4 Removing and installing camshaft housing”,
page 120 .
– Remove gasket for camshaft housing
⇒ “1.2 Assembly overview - camshaft housing”, page 116 .

– Unscrew securing bolts -1- and -3-.

– Remove coolant pipe -2-, and place it to one side.
– Release and pull off connector -2- on oil pressure switch - F1-
-1-.
– If fitted, remove heat shield for right drive shaft ⇒ Running
gear, axles, steering; Rep. gr.G. V
40
olk;sDrive shaft; Removing and
wagen A
installing drive shaftlkheat
swa shield .
gen A G do
es n
o ot g
yV ua
edb ran
ris tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Unscrew nuts -1- for securing front exhaust pipe to cylinder

h re
hole
head.
spec
es, in part or in w
– Unscrew bolts -2- for exhaust pipe supports.

t to the co
– Remove exhaust pipe from cylinder head, and tie it up.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
– Release and pull off connector -2- for coolant temperature

at
do
riv
sender - G62- -1-.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
yV g
Golf 2013 ➤s,edGolf 2017 ➤ , Golf Sportsvan 2015 u➤
b ara, Golf Variant 2014 ➤ ...
nt
ri
4-cylinder
ut
ho injection engine (1.6 l engine, 4 V, EA e211) eo
ra
- Edition 11.2018
s a c
s
– Unscrew bolt -1- from engine support.
ce
e
nl
pt
du
an
itte
– Detach retaining clips for wiring harness from cylinder head.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Loosen cylinder head bolts in the sequence -1 … 10-, and un‐
nf
ercia
screw them.
orm
m
atio
– Remove cylinder head, and set it down on a soft surface (foam
om
plastic).
n in
or c
thi
e
Installing
t
sd
iva
o
r
rp
cu
– Carefully remove sealant residue from cylinder head and cyl‐
o
m
f
en
ng
inder block.
t.
yi Co
Cop py
ht. rig
rig ht
py by
Note
co Vo
by lksw
cted agen
Prote AG.
♦ Ensure that no long scores or scratches are made on the sur‐

faces.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
– Carefully remove remains of emery and abrasives.
Note
♦ Do not remove new cylinder head gasket from packaging until

it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Note

♦ Renew self-locking nuts as well as gaskets, seals and O-rings.
♦ When installing a replacement cylinder head, the contact sur‐
faces between hydraulic compensation elements, roller rocker
fingers and cams must be oiled before installing the camshaft
housing.
♦ Do not reuse coolant which has been drained off.

– Fit cylinder head gasket -1-.

AG. Volkswagen AG d
♦ Note centring pins in cylinder block -arrows-. ksw
agen oes
not
ol
yV gu
♦ Check installation position of cylinder head gasket. Charac‐
ise d b ara
nte
teristic: the part number should be legible from the inlet
ut
hor
side. eo
a ra
s c
– If crankshaft has been turned in the meantime: s
ce
e
nl
pt
du
♦ Set piston of no. 1 cylinder to TDC position.
an
itte
y li
erm
ab
♦ Turn crankshaft back slightly.
ility
ot p
wit
, is n
– Fit cylinder head.
h re
hole
spec
– Insert cylinder head bolts, and tighten them by hand. es, in part or in w
t to the co
– Tighten bolts for cylinder head ⇒ page 115 .
rrectness of i
Note
l purpos
After repair work it is not necessary to retighten the cylinder head

bolts.
nform
mercia
at
om
io
n
c
in t
or
his
e
– Install camshaft housing

at
do
riv

p
cum
or
page 120 .
f
en
ng
t.
yi Co
– Install intake manifold Cop py
t. rig
gh ht
pyri by
Vo
o
by c
– Change engine oil. ⇒ Maintenance ; Booklet
lksw
cted agen
Prote AG.
– Add coolant ⇒ “1.2 Draining and adding coolant”, page 212 .
Specified torques
♦ ⇒ Fig. ““Engine support - specified torque and installation se‐
quence”“ , page 41
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 114
♦ ⇒ “4.1 Assembly overview - intake manifold”, page 271
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Assembly overview - drive shaft
1.4 Removing and installing camshaft hous‐

ing
Note
♦ The camshafts must not be removed individually.

♦ In the event of repair, the camshaft housing must be renewed
completely.
Removing
– Remove coolant pump
⇒ “2.3 Removing and installing coolant pump”, page 224 .


– Remove coolant pipe -3-, and place it to one side.
– Remove ignition coils
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 312 .
– Remove toothed belt from camshafts
⇒ “2.8 Removing toothed belt from camshaft”, page 154 .
– Release and disconnect connectors -2- and -4-.

. Volkswagen AG
gen AG does
– Remove bolt -3-, move wiring harness clearoland
ksw place to left
a
not
side. byV gu
ara
ed nte
ris
– Pull out oil dipstick -1-. ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Loosen bolts for camshaft housing in the sequence -15 to 1-
and unscrew.
rrectness of i
– Carefully detach camshaft housing from adhesive bond and
remove it.
l purpos
– Mark allocation of roller rocker fingers and compensation ele‐

ments for reinstallation.
nform
ercia
– Remove roller rocker fingers together with compensation ele‐

m
at
ments and place them on a clean surface.
om
ion
c
in t
r
Installing
o
his
ate
do
riv
Install in reverse order of removal. When doing this, observe the

p
cum
or
following:
f
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.
♦ Renew gasket and seal with oil strainer.
– Check “TDC” position of camshaft and crankshaft:
• Camshaft clamp -T10477- installed to camshaft housing with

bolt -arrow-.

• Crankshaft is in “TDC” position

⇒ “2.6 Checking valve timing”, page 141 .
• Locking pin - T10340- screwed into cylinder block as far as
stop and tightened to 30 Nm.
Volkswa
– Check, if all roller rocker fingers are aseated
gen AG properlyn on
. ge AG
dvalve
oes
ksw
stem end and if their clipped binto
y Volthe respective compensation not
gu
ara
element. ris
ed
nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Fit gasket onto dowel pins -arrows- of cylinder head -1-.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Screw 2 studs -2- and -4- (e.g. -T10288/4- ) into cylinder head.
– Carefully fit camshaft housing -3- onto studs in cylinder head.
Note
Ensure that camshaft housing is not canted.
– Tighten bolts for camshaft housing ⇒ page 117 .

– Check valve timing, and adjust it if necessary.
⇒ “2.6 Checking valve timing”, page 141
– Install ignition coils
page 312 .
– Install coolant pump
– Install wires ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is operated.
Specified torques AG. Volkswagen AG d
agen oes
lksw not
♦ ⇒ “1.2 Assembly overview - camshaft housing”, page d116 by Vo gu
ara
rise nte
♦ ⇒ “3.1 Assembly overview - air filter housing”, pageutho 267 eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
page 220
rm
ab
pe
ility
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 127
ot
wit
, is n
h re
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 114
hole
spec
es, in part or in w
1.5 Checking compression
t to the co
rrectness of i
♦ Spark plug socket - 3122 B-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Compression tester - V.A.G 1763-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Procedure
es, in part or in w
t to the co
• Engine oil temperature at least 30 °C.
• Battery voltage at least 12.5 V.
rrectness of i
l purpos
– Release and pull off connector for injectors -1-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release and pull off connectors -1- for ignition coils with output
stages.
– Unscrew bolts -2-.
– Pull out ignition coils with output stages
page 312 .
– Unscrew spark plugs using spark plug socket , e.g. -3122 B- .

– Check compression pressure using compression tester -

V.A.G 1763- ; refer to ⇒ Operating instructions .
– Have a second mechanic press down accelerator completely
and simultaneously operate starter until pressure no longer
increases on tester display.
– Repeat procedure on each cylinder.
Compression pressures
New engine 1.0 … 1.5 MPa (
10.0 … 15.0 bar)
Wear limit 0.7 MPa
(7.0 bar)
Maximum difference between cylinders 0.3 MPa
(3.0 bar)
Installing
Assembly is carried out in reverse sequence; note the following:
AG. Volkswagen AG d
agen
– Install spark plugs. Volksw
oes
not
by gu
d ara
– Install ignition coils with output orisestages nte
eo
⇒ “1.2 Removing and installing auth ignition coils with output stage”, ra
page 312 . ss c
ce
le
un
pt
– Entries will have been made in the event memory of the engine
an
d
itte
control unit because connectors were separated and the en‐
y li
rm
ab
gine was started ⇒ Vehicle diagnostic tester.
pe
ility
ot
wit
Specified torques
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Variant . Volks2014
wage ➤ ...
4-cylinder injection engine (1.6 l engine, 4 V, EA 211) w- gen AG 11.2018 n AG doe
aEdition
olks s no
yV t gu
db ara
ir se nte
ho eo
2 Toothed belt drive ss
aut ra
c
ce
e
nl
⇒ “2.1 Assembly overview - toothed belt cover”, page 126
pt
du
an
itte
y li
⇒ “2.2 Assembly overview - toothed belt”, page 127
erm
ab
ility
ot p
⇒ “2.3 Removing and installing toothed belt guard”, page 128
wit
, is n
h re
⇒ “2.4 Removing and installing toothed belt”, page 129
hole
spec
⇒ “2.5 Preassembling and installing valve timing tool”,
es, in part or in w
t to the co
page 134
⇒ “2.6 Checking valve timing”, page 141
rrectness of i
⇒ “2.7 Adjusting valve timing”, page 144
l purpos
⇒ “2.8 Removing toothed belt from camshaft”, page 154
2.1 Assembly overview - toothed belt cover
nform
mercia
at
om
io
1 - Lower toothed belt guard
n
c
in t
or
his
ate
do
priv
c
installing lower toothed
um
for
en
g
belt guard”, page 128

n
t.
yi Co
op py
2 - Bolt
t. C rig
gh ht
yri by
❑ 8 Nm cop Vo
by lksw
cted agen
Prote
3 - Engine support
AG.

tightening sequence
view - assembly mount‐
ings”, page 39
4 - Bolt
tightening sequence
view - assembly mount‐
ings”, page 39
5 - Upper toothed belt guard
installing upper toothed
belt guard”, page 128
6 - Bolt
❑ 8 Nm

2.2 Assembly overview - toothed belt
1 - Toothed belt
chalk or felt-tipped
marker pen.
❑ Check for wear ⇒ Main‐
tenance ; Booklet 3.1
stalling toothed belt”,
page 129
2 - Bolt
❑ 25 Nm
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
page 82 .
4 - Bolt
❑ 50 Nm +90°
5 - Exhaust camshaft toothed
belt pulley
stalling toothed belt pul‐
ley”, page 165
6 - Inlet camshaft toothed belt n AG. Volkswagen AG do
pulley olkswage es n
ot g
yV
❑ With camshaft adjuster d b ua
ran
ir se tee
❑ Removing and installing autho
or
ac
camshaft adjuster ss
⇒ “3.2 Removing and installing camshaft adjuster”, page 160
ce
le
un
pt
an
d
itte
7 - Guide bush
y li
erm
ab
8 - Bolt
ility
ot p
wit
is n

h re
ole,
❑ 50 Nm +135°
spec
9 - O-ring
t to the co
❑ Check for damage, and renew if necessary; see ⇒ Electronic parts catalogue (ETKA)
10 - Plug
rrectne
❑ 20 Nm
ss
11 - O-ring
o
cial p
f i
❑ Captive, supplied with “item 13”.

nform
mer

atio
om
12 - Spacer sleeve
n
c
i
or
n thi
❑ Supplied with item “13”.

te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
127
co Vo
by lksw
cted 2. Toothed belt drive
agen
Prote AG.
4-cylinder injection engine (1.6 l engine,
wage
n A4
G.V,
VolEA
kswa211) - Edition
gen AG
doe 11.2018
ks s no
Vol t gu
by ara
13 - Idler roller ris
ed
nte
tho eo
14 - Bolt ss
au ra
c
❑ 40 Nm
ce
le
un
pt
an
d
itte
15 - Crankshaft pulley
y li
erm
ab
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
ility
ot p
wit
❑ Can only be fitted in one position
is n
h re
ole,
❑ Specified torque ⇒ “1.1 Assembly overview - poly V-belt drive”, page 67
spec
t to the co
Plug for “TDC” drilling in cylinder block - specified torque
rrectne
Note
ss o
♦ Plug with integrated seal -arrow-
cial p
f inform
♦ Renew if damaged
mer
atio
om
n
c
– Tighten bolt -arrow- to 30 Nm.
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
2.3 Removing and installing toothed belt
t. C rig
gh ht
yri by
guard
op Vo
by c lksw
cted agen
Prote AG.
⇒ “2.3.1 Removing and installing upper toothed belt guard”, page
128
⇒ “2.3.2 Removing and installing lower toothed belt guard”, page
128
2.3.1 Removing and installing upper toothed

belt guard
Removing
– Detach hoses from retainer -3-.
– Release clips -arrows-, and remove upper toothed belt guard
-1-.
Installing
Further assembly is carried out in the reverse order of removal.
Specified torques
2.3.2 Removing and installing lower toothed

belt guard
Removing:
– Remove poly V-belt pulley from crankshaft
⇒ “1.4 Removing and installing vibration damper”, page 80 .


– Remove lower part of toothed belt guard.
Installing:
Install in reverse order of removal. Observe the following:
– Install vibration damper
Specified torques:

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Torque wrench - VAS 6583-

♦ Counterhold - T10172- with adapter -T10172/1- and -
T10172/2-
2. Toothed belt drive 129

♦ Special wrench, 30 mm - T10499A-

♦ Insert tool - T10500- . Volkswagen AG
gen AG does
swa
♦ Assembly tool - T10487- yV
olk not
gu
d b ara
ise nte
or eo
♦ aut
h
ra
ss c
Removing
ce
e
nl
pt
du
an
– Set piston in cylinder no. 1 to TDC position.
itte
y li
erm
⇒ “4.7 Setting piston to TDC position”, page 111
ab
ility
ot p
– Remove lower toothed belt guard
wit
, is n
⇒ “2.3.2 Removing and installing lower toothed belt guard”,
h re
hole
page 128 .
spec
es, in part or in w
– Loosen plug and securing bolt for camshaft adjuster on inlet
t to the co
side
⇒ “3.2 Removing and installing camshaft adjuster”,
page 160 .
rrectness of i
l purpos
Note
nf
ercia
o
♦ If a used toothed belt runs in the opposite direction when it is
rm
m
refitted, it may break.
atio
om
n in
c
♦ Before removing, mark direction of rotation of toothed belt with

or
thi
te
sd
iva
o
r
rp
cu
o
– Loosen bolt -1- with tool insert - T10500- . m

f
en
ng
t.
yi Co
op
– Release tension on tensioning roller at eccentric -2- using C py
ht. rig
wrench - T10499A- . rig ht
py by
co Vo
by lksw
cted agen
NOTICE
Prote AG.
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.

Bend radius of toothed belt

• The bend radius -r- on the toothed belt -2- should therefore
never be below 25 mm (approx. half the diameter of gear -1-
on crankshaft).
Note
The contact points between the toothed belt and components -

such as camshaft pulleys, tensioning roller and idler pulley - must
AG. Volkswagen AG d
be kept free of oil. lksw
agen oes
no
o t gu
yV
edb ara
ris nte
– Remove ttoothed
ho belt. eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Remove crankshaft pulley -1- in -direction of arrow- from
es, in part or in w
crankshaft.
t to the co
Installing
rrectness of i
Note
l purpos

nform
ercia
♦ Renew the damaged O-ring of the plug at the toothed belt pul‐
m
ley of the inlet camshaft.

a
com
tion in
r
te o
thi
– Check “TDC” position of camshaft and crankshaft

s
iva

do
r
rp
cum
fo
en
ng
t.
yi Co
op
Note C py
ht. rig
rig ht
py by
Before installing the camshaft adjusters, ensure that the guide
co Vo
by lksw
cted agen
sleeves are inserted in the camshafts.
Prote AG.
– Renew bolts -1- and -2- for camshaft pulleys and screw them
in loosely.
• It should just be possible to turn the adjusters on the camshafts
but no rocking is permissible.

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan
n AG. Volk2015
swage➤ , Golf
n AG Variant 2014 ➤ ...
wage does
4-cylinder injection engine (1.6
y Vo l engine, 4 V, EA 211) - Edition
lk s not 11.2018
g
b ua
ed ran
ris tee
• The sheet-metal tab -arrow- thof the tensioning
o roller must en‐ or
au
gage in the cast notch inssthe cylinder head. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– Fit crankshaft sprocket onto crankshaft.
do
priv
cum
or
• The contact surface crankshaft pulley and crankshaft must be

f
en
ng
t.
free of oil and grease.
yi Co
Cop py
t. rig
• The contact surface -arrow- of the crankshaft pulley must be gh ht
yri by
positioned on the machined surface of the crankshaft journal. cop Vo
by lksw
cted agen
Prote AG.
Fit toothed belt in prescribed sequence:
Note the arrow for the correct direction of rotation when installing
the old toothed belt.
– Fit toothed belt -1- onto crankshaft pulley -2-.
– Pull toothed belt upwards, and fit it on idler pulley -1-, tension‐
ing roller -2- and camshaft pulleys -3- and -4-.

– Using special wrench, 30mm -T10499A- , rotate eccentric

-2- of tensioning roller in -direction of arrow- until adjustment
pointer -3- is located approx. 10 mm to the right from adjust‐
ment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ Use torque wrench only together with insert tool, 13 mm -
T10500- .
♦ When setting the specified torque on the torque wrench - VAS
6583- , note that the length indicated on insert tool - T10500-
must be entered in the torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm.

To do this, use insert tool - T10500- with torque wrench - VAS
6583- . Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
Note
rise nte
tho eo
au ra
c
Turning
ss the engine further or running the engine may lead to slight
ce
e
differences in the position of the adjustment indicator -3- in rela‐

nl
pt
du
tion to the adjustment window. This does not affect the toothed
an
itte
y li
belt tension.
erm
ab
ility
ot p
wit
– Tighten securing bolt for inlet camshaft adjuster to specified

, is n
h re
initial torque. ⇒ page 163

hole
spec
– Tighten securing bolt for toothed belt pulley to specified initial

es, in part or in w
t to the co
torque. ⇒ page 167

rrectness of i
Note
l purpos
The securing bolts must not be tightened to the final specified

torque (turning further angle) until the valve timings have been
nform
ercia
checked and are OK.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Install lower toothed belt guard -arrows-.

– Install vibration damper
– Adjust valve timing ⇒ “2.7 Adjusting valve timing”, page 144 .
Continue installation in reverse order of removal. During this pro‐
cedure, observe the following:
Specified torques agen
AG. Volkswagen AG d
oes
olksw not
• Bolt for crankshaft pulleys ed by
V gu
ara
⇒ “1.1 Assembly overview - poly V-belt drive”, page 67 horis nte
eo
aut ra
• Bolt for toothed belt guard ss c
ce
le
un
pt
an
d
• Rollers and toothed belt pulleys itte
y li
rm
ab
pe
ility
ot
• Bolt for ignition coil with output stage
wit
, is n
h re
⇒ “1.1 Assembly overview - ignition system”, page 311
hole
spec
• Plug for hole in cylinder block ⇒ page 128
es, in part or in w
t to the co
• Plug on camshaft housing
⇒ “1.2 Assembly overview - camshaft housing”, page 116
rrectness of i
• Bolts for cover of thermostat
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
l purpos
page 220
• Noise insulation ⇒ General body repairs, exterior; Rep. gr.
nform
ercia
66 ; Noise insulation; Assembly overview - noise insulation

m
a
com
tio
2.5 Preassembling and installing valve tim‐
n in
r
te o
thi
ing tool
s
iva
do
r
rp
cum
⇒ “2.5.1 Preassembling valve timing tool”, page 134
fo
en
ng
t.
yi Co
⇒ “2.5.2 Installing test tool VAS 611 007 ”, page 137 Cop py
t. rig
gh ht
yri
⇒ “2.5.3 Teaching in test tool VAS 611 007 electronically and p by
o Vo
by c lksw
performing basic setting”, page 139 Prote
cted AG.
agen
2.5.1 Preassembling valve timing tool

♦ Tester for checking elongation of chain links - VAS 611 007-
♦ Adapter set - VAS 611 007/18- (not shown)

Test tool - VAS 611 007- :

A - Angle sensor - VAS 611

007/1-
B - Lock ring - VAS 611 007/2-
C - Clamping ring - VAS 611
007/3-
D - Adapter for camshaft hous‐
ing - VAS 611 007/11- for 1.0
and 1.6 l MPI engines
E - Adapter for angle sensor -
VAS 611 007/12- and adapter
for angle sensor - VAS 611
007/13-
❑ Adapter for angle sen‐
sor - VAS 611 007/12-
blue, for inlet camshaft
❑ Adapter for angle sen‐
sor - VAS 611 007/13-
red, for exhaust cam‐
shaft
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Preassembling test tool - VAS 611 007- : h re

hole
spec
es, in part or in w
Note
t to the co
The shape of the adapter for angle sensor -E- may differ depend‐
rrectness of i
ing on the engine.

l purpos
– Before inserting adapter for angle sensor - VAS 611 007/12-

and adapter for angle sensor - VAS 611 007/13- -E- in angle
nform
ercia
sensors - VAS 611 007/1- -A-, verify correct allocation in ac‐

cordance with colour coding -a-.
m
a
com
tio
– Insert adapter for angle sensor - VAS 611 007/912- and adapt‐
n in
r
er for angle sensor - VAS 611 007/13- -E- in angle sensors -

te o
thi
VAS 611 007/1- -A-.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Note position of dowel pins -a- when installing.

– The adapters for angle sensor - VAS 611 007/12- and -VAS
611 007/13- -E- can only be fitted in one position.
– Make sure that brake -b- is released. Do not apply force.
– Insert adapters for angle sensor - VAS 611 007/12- and -VAS
611 007/13- -E- to stop into angle sensor - VAS 611 007/1-
-A-.
– Fit clamping ring - VAS 611 007/3- -C- in groove -a- of adapter
for angle sensor - VAS 611 007/12- and -VAS 611 007/13-
-E-, and clip it in until it can be heard to engage.
G. Volkswagen nA AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Insert angle sensor - VAS 611 007/1- -A- with the red colour
nform
ercia
coding on the side marked in red -arrows a- of adapter for

camshaft housing - VAS 611 007/11- -D-.
m
a
com
tio
– To do this, release locking pins -c- by pulling them upwards.

n in
r
te o
thi
– Insert angle sensor - VAS 611 007/1- -A-, and push it in until
s
iva
do
locking pin can be heard to engage.

r
rp
cum
fo
en
– Repeat the procedure with the angle sensor - VAS 611 007/1-
ng
t.
yi Co
-A- with blue colour coding -arrows b-. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Screw in securing rings - VAS 611 007/2- -B- approx. 2 turns.

– Note colour coding -arrows a- and -arrows b- when doing this.
– Make sure that the shafts are free to move. It must be possible
to turn adapter for angle sensor - VAS 611 007/12- and -VAS
611 007/13- -E-.

2.5.2 Installing test tool - VAS 611 007-

Procedure
– Preassemble test tool - VAS 611 007- ⇒ page 135 .
– Teach in test tool - VAS 611 007- electronically, and perform
basic setting ⇒ page 139 .
G. Volkswagen
– Turn the two adapter for angle wsensor
agen
A
- VAS 611 A007/12-
G do
es n and
olks
-VAS 611 007/13- in suchbyaVway that the display shows approx.
ot g
ua
d
»0°«. or
ise ran
te
h eo
ut ra
Polo 2014, LHD vehicles,
ss
a Polo Lim RUS 2016: c ce
e
nl
– Remove brake master cylinder ⇒ Brake system; Rep. gr. 47 ;

pt
du
an
Brake servo/brake master cylinder; Removing and installing
itte
y li
brake master cylinder .

erm
ab
ility
ot p

wit
, is n
h re
– Perform the preliminary work for checking the valve timing

hole
spec

es, in part or in w
t to the co
– Make sure that the piston in cylinder no. 1 is at “TDC” position

for repair work on toothed belt drive
rrectness of i
– Make sure that brakes on angle sensor - VAS 611 007/1- are
l purpos
released on both sides ⇒ page 136 .

nf
ercia
Note
rm
m
atio
om
Before positioning the test tool - VAS 611 007- against the cam‐
n in
or c
shaft housing, the grooves of the camshafts must be checked for

thi
te
sd
damage.
iva
o
r
rp
cu
o
m
f
en
ng
– Align adapter for angle sensor -E- by hand with grooves of

t.
yi Co
op
camshafts -arrows-. C py
ht. rig
rig ht
– Check proper alignment through recess, and adapt position by
py by
co Vo
by lksw
turning. Prote
cted AG.
agen

– Fit adapter for camshaft housing - VAS 611 007/11- -D- to

camshaft housing, and slide it on.
– Tighten knurled screws -arrows a- alternately by hand.
– Make sure that adapter for camshaft housing - VAS 611
007/11- -D- is properly seated.
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
by ara
d
rise nte
♦ If camshaft housing adapter - VASut611
ho 007/8- -D- touches the eo
ra
housing of the coolant pump, the
ss abasic setting of the coolant c
pump is incorrect.
ce
e
nl
pt
du
an
♦ In this case, correct adjustment or testing of the valve timing
itte
y li
is not possible.
erm
ab
ility
ot p
♦ The coolant pump must be removed and readjusted
wit
, is n
h re
hole
spec
es, in part or in w
• Test tool - VAS 611 007- must rest flush against camshaft
t to the co
housing.
– Make sure that brakes on angle sensor - VAS 611 007/1- are
rrectness of i
released on both sides ⇒ page 136 .
l purpos
– Tighten locking ring - VAS 611 007/2- -B- on both sides evenly
by hand. When doing this, ensure that camshaft housing
nf
ercia
adapter - VAS 611 007/11- -D- always lies flat against cam‐
or
shaft housing -1-.
m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
• Camshaft housing adapter - VAS 611 007/11- -D- should not

lift off of camshaft housing -1-.
Note
♦ The correct preload is achieved when the camshaft housing

adapter - VAS 611 007/11- lies flat against the camshaft hous‐
ing.
♦ If the locking ring - VAS 611 007/2- is tightened too much, the
camshaft housing adapter - VAS 611 007/11- will lift off of the
camshaft housing. This will falsify the result of the measure‐
ment.

Golf 2013 ➤a,gGolf
en AG2017
. Volksw➤
ag,enGolf
AG doSportsvan 2015 ➤ , Golf Variant 2014 ➤ ...
sw e
4-cylinder
y Volk injection engine (1.6s nloengine,
t gu 4 V, EA 211) - Edition 11.2018
b ara
ed nte
ris
– Make sure that brakes
au
th -a- are
o
released on both sides. e or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.5.3 Teaching in test tool - VAS 611 007-
l purpos
electronically and performing basic set‐
nform
ercia
ting
m
a
com
t
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– 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 the angle sensors are not connected, the message shown
in the illustration is displayed.
– Connect test tool - VAS 611 007- , and press CONNECT .

wa(1.6 l engine,
gen AG
. Volkswag4enV,
AGEA
doe211) - Edition 11.2018
ks s no
Vol t gu
by a
– If the test tool - VAS 611 ris 007- is
ed
connected, the display is as rante
shown in the illustration.
autho eo
ra
ss c
ANW - Exhaust camshaft, red
ce
le
un
pt
an
d
ENW - Inlet camshaft, blue

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Turn adapter for angle sensor - VAS 611 007/13- -E- of ex‐
haust camshaft.
l purpos
– If »OK« is displayed, the exhaust camshaft has been taught-
nform
ercia
in.
m
– Turn adapter for angle sensor - VAS 611 007/12- -E- of inlet
a
com
tio
camshaft.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– If the display is as shown in the illustration, the exhaust cam‐ cted agen
Prote AG.
shaft has been taught-in.
– Select function MEASURE .
– When the angle display appears, the valve timing can be

checked or adjusted

– Make sure that the brake indicator on the display is »green«.

– Display must not be »yellow« or »red«.
A - »Green«, brake is released
B - »Yellow«, brake is applied
C - »Red«, brake has been tightened to final torque
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
2.6 Checking valve timing
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr

cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Preliminary work for the procedure:
hole
spec
es, in part or in w
t to the co
– Release and pull off fuel supply line -1- and breather line
rrectness of i
-2-.⇒ Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-in
connectors .
l purpos
– Open line guide -3- and remove hoses.
nform
ercia
– Seal lines so that fuel system is not contaminated by dirt.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
– Detach clips -arrows-.
ht
pyri by
Vo
o
by c lksw
– Unscrew securing bolt -1-, and detach cover -2-.
cted agen
Prote AG.
– Remove vacuum line -1- from intake manifold -2-.

– Lay vacuum line to one side.

AG. Volkswagen AG d
agen4-cylinder injection
oesengine (1.6 l engine, 4 V, EA 211) - Edition 11.2018
olksw not
y V gu
d b ara
– Loosen clamp rise -4- and disconnect hose -3-. nte
tho eo
au ra
– Unscrew
s bolts -arrows-.
s c
ce
e
nl
pt
– Remove cover -2-.
du
an
itte
y li
– Set piston in cylinder no. 1 to “TDC” position for repair work on
erm
ab
ility
toothed belt drive
ot p
wit
, is n
h re
hole
– Preassemble test tool - VAS 611 007-
spec
⇒ “2.5.1 Preassembling valve timing tool”, page 134 .
es, in part or in w
t to the co
– Install test tool - VAS 611 007- ⇒ page 137 .
rrectness of i
Checking valve timing:
l purpos
– Make sure that brakes -a- on test tool - VAS 611 007- are re‐
leased on both sides.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Make sure that the brake indicator on the display is »green« Prote AG.
-A-.
– Unscrew locking pin - T10340- .

– Turn crankshaft 2 turns in direction of rotation of engine.
– Screw in locking pin - T10340- .
– Set piston in cylinder no. 1 to »TDC« position

– Read valve timing angles on display, and compare values with

specifications.
Specified angle in ° Inlet camshaft Exhaust camshaft

-0.2°±1.5° 0.7°±1.5°
Note
♦ Adjust valve timing as precisely as possible. The settings must

AG. Volkswagen A
be as close to the specifications as
olks
possible.
wage
n G do
es n
ot g
yV ua
♦ The valve timing must not rbe db
ise outside the tolerance limits. ran
tee
tho or
au ac
– If the valve timing is not
ss OK, adjust valve timing
ce
e
⇒ “2.7 Adjusting valve timing”, page 144 .

nl
pt
du
an
itte
Assemble in reverse order of dismantling. The following should

y li
erm
ab
be observed:
ility
ot p
wit

, is n
h re
hole

spec

es, in part or in w
t to the co
Note
rrectness of i

l purpos
– Renew O-rings, seals and gaskets after each removal.

nf
ercia
or
Specified torques
m
m
atio
om

n in
or c
thi
e
♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block - specified tor‐

t
sd
iva
que”“ , page 128

o
r
rp
cu
o
m
f
en
ng

t.
yi Co
op py
t. C rig
gh ht
yri
page 220 p by
o Vo
by c lksw
cted agen
♦ ⇒ Brake system; Rep. gr. 45 ; Control unit and hydraulic unit; Prote AG.
Assembly overview - control unit and hydraulic unit
♦ ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder, Assembly overview - brake servo/brake master cylinder
2.7 Adjusting valve timing


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Golf 2013 ➤ , Golf 2017 ➤ , Golf
e o Sportsvan 2015 ➤ , Golf Variant 2014 ➤ ...
ut
ss a 4-cylinder injection engine (1.6
ra
c l engine, 4 V, EA 211) - Edition 11.2018
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
t
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Engine bung set - VAS 6122-
Procedure
• Toothed belt installed.
– Check valve timing ⇒ “2.6 Checking valve timing”, page 141 .
– Do not relieve tension from toothed belt, and do not remove
toothed belt from camshafts when adjusting valve timing. Only
loosen camshaft adjuster.
– Loosen camshaft adjuster on inlet side ⇒ page 161 .
– Loosen toothed belt sprocket on exhaust side ⇒ page 166 .
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.

Note
♦ The contact points between the toothed belt and components

en AG. V
olkswagen AG
- such as camshaft pulleys, tensioning roller and ksidler
wag pulley - does
not
Vol
must be kept free of oil. ed
by gu
ara
ris nte
♦ Catch any engine oil which runs out immediately,
au
tho and remove eo
ra
it. ss c
ce
e
nl
♦ Remove any engine oil which ran out from camshaft adjusters
pt
du
an
after the engine has been cranked.
itte
y li
erm
ab
ility
ot p
– Place a cloth under the camshaft adjusters and over tension‐
wit
, is n
ing roller to catch the engine oil which runs out.
h re
hole
spec
– Make sure that the piston of cylinder no. 1 is at “TDC” position
es, in part or in w
t to the co
– Renew bolts -1- and -2- and screw in loosely
rrectness of i
page 160 .
l purpos
– It must still be possible to turn camshaft adjusters on cam‐

shafts.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Setting camshafts to »0°«: yri
p by
co Vo
by lksw
cted
– Make sure that bolts -a- for brakes on test tool - VAS 611 007-
agen
Prote AG.
are released on both sides.

– Make sure that the brake indicator on the display is »green«

-A-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Set both camshafts to »0.0°«.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– To do this, turn camshafts with adapter for angle sensor - VAS
nform
ercia
611 007/12- and -VAS 611 007/13- -E-.

m
at
– Hold camshafts in »0.0°« position using adapters for angle
om
io
sensor - VAS 611 007/12- and -VAS 611 007/13- -E- and a
n
c
in t
r
hexagon key.
o
his
ate
do
priv
cum
for
Note
en
ng
t.
yi Co
Cop py
. rig
♦ The camshafts tend to turn.
ht ht
rig by
copy Vo
♦ Use a hexagon key to hold the camshafts in »0.0°« position.
by lksw
cted agen
Prote AG.
♦ Always remove the hexagon key after the camshafts have
been tightened.
– Tighten brakes after adjustment has been completed.

– Tighten bolts -a- for brakes on test tool - VAS 611 007- to
11 Nm on both sides.

– Make sure that the brake indicator on the display is »red«

-C-.
– Display must not be »yellow« or »green«.

G. Volkswagen AG d
– Tighten camshaft adjuster on inlet camshaft to specified
lksw
ainitial
gen A oes
not
torque ⇒ page 163 . by
Vo gu
ara
d
ise nte
– Tighten toothed belt sprocket of exhaust camshaft
uthor
to specified eo
initial torque ⇒ page 163 . ss a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Make sure that brakes -a- on test tool - VAS 611 007- are re‐
leased on both sides.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


-A-.
AG. Volkswagen AG d
agen oes
o lksw not
byV gu
ara
ed
ris nte
ho eo
ut
– Seal camshaft adjusters -2-, as shown,
ss a using suitable plugs ra
c
-A- from engine bung set - VAS 6122- .
ce
le
un
pt
an
d
– Fit a piece of paper into plugs to catch the engine oil.

itte
y li
rm
ab
– Insert plugs into camshaft adjusters with the open side facing
pe
ility
towards front, as shown in illustration.
ot
wit
, is n
h re
– Turn crankshaft 2 turns in direction of rotation of engine.
hole
spec
es, in part or in w
Determining correction angle:
t to the co
– Screw in locking pin - T10340- .
rrectness of i
l purpos
– Read valve timing on display and write down values.
nform
ercia
1. Measurement example: value reading on display

m
a
com
tion in
Note
r
te o
thi
s
iva
do
♦ The correction angle is determined for each individual vehicle.

r
rp
cum
fo
en
g
♦ The value read after the engine has been cranked is used for
n
t.
yi Co
op
determining the correction angle. C py
ht. rig
rig ht
♦ Note the algebraic signs of the values.
py by
co Vo
by lksw
cted agen
♦ The correction angle results from the difference between the
Prote AG.
specification and the value which has been read after the
crankshaft has been cranked twice.
♦ The correction angle is used to adjust the valve timing.
♦ The difference between the actual value (read after 2 full rev‐
olutions of the engine) and the specification is calculated.
♦ The result is the correction angle to be set, with the corre‐
sponding algebraic sign/direction of rotation.

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)
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
Angle in ° Inlet camshaft Exhaust camshaft
erm
ab
ility
ot p
Specified value -0.2°±1.5° 0.7°±1.5°
wit
is n
h re
ole,
spec
– Set determined correction angle for camshafts.
t to the co
Setting valve timing with correction angle:
– Place a cloth underneath camshaft adjuster to catch any en‐
rrectne
gine oil which runs out.
s
– Remove plugs taken from engine bung set - VAS 6122- from
s o
camshaft adjuster.
cial p
f inform
– Remove paper from plugs and camshaft adjusters.
mer
atio
m
– Clean camshaft adjusters with a cleaning cloth, and remove

o
n
c
as much engine oil as possible.
i
or
n thi
te
sd
a
– Loosen camshaft adjuster on inlet side ⇒ page 161 .

iv
o
pr
cum
r
fo
– Loosen toothed belt sprocket on exhaust side ⇒ page 166 .

en
ng
t.
yi Co
Cop py
NOTICE
t. rig
gh ht
pyri by
Vo
o
Risk of damage to engine caused by incorrect valve timing.
c by lksw
cted agen
Prote AG.
– Do not turn crankshaft out of TDC position.
– Make sure that the piston in cylinder no. 1 is at “TDC” position

– Make sure that bolts -a- for brakes on test tool - VAS 611 007-
are released on both sides.

. Volkswagen AG
gen AG d
Golf 2013 olk➤
swa, Golf 2017 ➤ , Golf Sportsvan
oes
not 2015 ➤ , Golf Variant 2014 ➤ ...
yV gu
ised 4-cylinder
b injection engine (1.6 l engine,
ara 4 V, EA 211) - Edition 11.2018
n
r tee
ho
ut or
– Make sure that the
ss brake
a
indicator on the display is »green« ac
-A-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
– Set the two camshafts to the determined correction angle

p
cum
r
fo
⇒ page 149 .
en
ng
t.
yi Co
op
– To do this, turn camshafts with adapter for angle sensor - VAS
C py
t. rig
gh
611 007/12- and -VAS 611 007/13- -E-.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
If the valve timing has been set:

– Tighten bolts -a- for brakes on test tool - VAS 611 007- to
11 Nm on both sides.

– Make sure that the brake indicator on the display is »red«

-C-.
– Display must not be »yellow« or »green«.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Tighten camshaft adjuster on inlet camshaft to specified initial
s
torque ⇒ page 163 .
s o
cial p
– Tighten toothed belt sprocket of exhaust camshaft to specified f inform

initial torque ⇒ page 163 .
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
– Release brakes -a- on test tool - VAS 611 007- on both sides. co Vo
by lksw
cted agen
Prote AG.


-A-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Seal camshaft adjusters -2- again, as shown, using suitable

plugs -A- from engine bung set - VAS 6122- .
. Volkswagen AG
a gen AG does
– Fit a new piece of paper into plugs -A- to catch the
Vol engine oil.
ksw not
gu
by ara
d
– Turn crankshaft 2 turns in direction of rotation
oris of engine.
e nte
eo
h
ut ra
– Screw in locking pin - T10340- . ss a c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
– Check valve timing ⇒ “2.6 Checking valve timing”, page 141 .
ility
ot
wit
, is n
h re
NOTICE
hole
spec
Adjust valve timing as precisely as possible. The settings must
es, in part or in w
t to the co
be as close to the specifications as possible.
The valve timing must not be outside the tolerance limits.
rrectness of i
– Read valve timing, and compare it with specifications.
l purpos
Specified angle in °
nform
ercia
Inlet camshaft Exhaust camshaft

m
a
-0.2°±1.5° 0.7°±1.5°
com
tion in
r
te o
– If the valve timing is not OK, adjust valve timing again
thi
s
iva
⇒ “2.7 Adjusting valve timing”, page 144 .
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Unscrew locking pin - T10340- . C py
ht. rig
rig ht
– Make sure that brakes on test tool - VAS 611 007- are released
py by
co Vo
by lksw
on both sides. Prote
cted AG.
agen
– Tighten camshaft adjuster on inlet camshaft to specified final

torque ⇒ page 163 .
– Tighten toothed belt sprocket of exhaust camshaft to specified
final torque ⇒ page 163 .
Specified torques
♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block - specified tor‐
que”“ , page 128
♦ ⇒ “3.1 Assembly overview - valve gear”, page 159
♦ ⇒ “3.1 Assembly overview - crankcase breather system”, page
202
page 220
2.8 Removing toothed belt from camshaft


equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
♦ Torque hor wrench - VAS 6583- eo
aut ra
♦ Counterhold
ss
- T10172- with adapter -T10172/1- and - c
ce
le
T10172/2-
un
pt
an
d
itte

y li
erm
ab
ility

ot p
wit
is n
♦ Special wrench, 30 mm - T10499A-

h re
ole,
spec
♦ Insert tool - T10500-

t to the co

Procedure
rrectne
– Set piston in cylinder no. 1 to TDC position.

ss o
– Remove upper part of toothed belt guard

cial p
f in
⇒ “2.3.1 Removing and installing upper toothed belt guard”,

form
mer
page 128 .
atio
om
– Loosen securing bolt for camshaft adjuster on inlet side

n
c
i
or

thi
te
page 160 .
sd
iva
o
pr
cum
r
– Loosen securing bolt of toothed belt pulley on exhaust side

fo
en
ng
⇒ page 166 .
t.
yi Co
Cop py
ht. rig
rig ht
by
155
copy Vo
by lksw
cted agen 2. Toothed belt drive
Prote AG.
– Loosen bolt -1- with tool insert - T10500- .

n AG. Volkswagen A ge G do
swa es n
– Release tension on tensioning by
roller
Volk at eccentric -2- using ot g
ua
wrench - T10499- . ris
ed ran
tee
tho or
– Remove toothed beltssfrom
au camshaft pulleys. ac
ce
e
Installing
nl
pt
du
an
itte
y li
NOTICE
erm
ab
ility
ot p
Risk of damage to toothed belt by bending it excessively. The
wit
, is n
toothed belt is made of glass fibre fabric which will be damaged
h re
hole
if it is bent excessively.
spec
es, in part or in w
– Never bend toothed belt to a radius less than r = 25 mm.
t to the co
rrectness of i
l purpos
nf
ercia
or
Bend radius
m
m
atio
om
• The bend radius -r- on the toothed belt -2- should therefore
n in
or c
never be below 25 mm (approx. half the diameter of gear -1-
thi
te
sd
on crankshaft).
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
♦ Renew bolts that are tightened with turning further angle. cop Vo
by lksw
cted agen
Prote
♦ Renew the damaged O-ring of the plug at the toothed belt pul‐
AG.
ley of the inlet camshaft.
• Crankshaft is in “TDC” position

– Fit new bolts -1, 2- for camshaft pulleys, but do not tighten.
• It should just be possible to turn the adjusters on the camshafts
but no rocking is permissible.

• The sheet-metal tab -arrow- of the tensioning roller must en‐

gage in the cast notch in the cylinder head.
Fit toothed belt in prescribed sequence:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Pull toothed belt upwards, and fit it on idler pulley -1-, tension‐
ce
e
nl
pt
du
ing roller -2- and camshaft pulleys -3- and -4-.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Turn eccentric -2- of belt tensioner in -direction of arrow- using

special wrench, 30mm - T10499A- until adjustment pointer
-3- is located approx. 10 mm to the right from adjustment win‐
dow.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ Use torque wrench only together with insert tool, 13 mm -
T10500- .
♦ When setting the specified torque on the torque wrench - VAS
6583- , the length indicated on insert tool, 13 mm - T10500-
must be entered in the torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm.

To do this, use insert tool - T10500- with torque wrench - VAS
6583- .
– Hold eccentric in this position, and tighten bolt -1- to reduced
specified torque of 12 Nm. To do this, use insert tool - T10500-
with torque wrench - V.A.G 1410- .
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. This does not affect the toothed
belt tension.
Note AG. Volkswagen AG d

agen oes
olksw not
V gu
by
After completing work, make sureiseto remove the locking pin -
d ara
nte
T10340- . ut
hor eo
ra
s a c
s
ce
Continue installation in reverse order of removal.

e
nl
pt
du
an
itte
Specified torques
y li
erm
ab
ility
♦ Bolt for toothed belt guard

ot p
wit

, is n
h re
hole
♦ Rollers and toothed belt pulleys

spec

es, in part or in w
t to the co
♦ Plug for hole in cylinder block ⇒ page 128

♦ Thermostat
rrectness of i

page 220
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
158
op Vo
by c lksw
Rep. gr.15 - Cylinder head, valve gear Prote
cted AG.
agen
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 159
⇒ “3.2 Removing and installing camshaft adjuster”, page 160
⇒ “3.3 Removing and installing toothed belt pulley”, page 165
⇒ “3.4 Measuring axial play of camshaft”, page 168
⇒ “3.5 Removing and installing camshaft oil seal”, page 169
⇒ “3.6 Removing and installing camshaft control valve 1 N205 ”,
page 176
⇒ “3.7 Removing and installing valve stem seals”, page 176
3.1 Assembly overview - valve gear

⇒ “3.1.1 Assembly overview - valves”, page 159
3.1.1 Assembly overview - valves
1 - Inlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 186
AG. Volkswagen AG d
❑ Checking valve guides ksw
agen oes
not
l
⇒ “4.1 Checking valve by Vo gu
ara
guides”, page 185 rise
d
nte
tho eo
u
2 - Outlet valve ss a ra
c
❑ Do not rework. Only lap‐
ce
le
un
pt
ping in is permitted.
an
d
itte
y li
❑ Valve dimensions
rm
ab
pe
ility
⇒ “4.3 Valve dimen‐

ot
wit
sions”, page 186

, is n
h re
❑ Checking valve guides

hole
spec
⇒ “4.1 Checking valve

es, in part or in w
guides”, page 185

t to the co
3 - Cylinder head
rrectness of i
4 - Valve stem seal

❑ Renewing
l purpos

stalling valve stem
nform
ercia
seals”, page 176

m
5 - Valve springs
a
com
tion in
❑ Fitting position
r
te o
⇒ page 160
thi
s
iva
do
r
6 - Valve spring plate

rp
cum
fo
en
g
7 - Valve cotters
n
t.
yi Co
Cop py
t.
8 - Roller rocker fingers
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
⇒ “1.4 Removing and in‐ Prote AG.
stalling camshaft hous‐
ing”, page 120
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
3. Valve gear 159

olkswagen AG
en AG. V
Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan
ksw
ag 2015 ➤ , Golf
does Variant 2014 ➤ ...
not
Vol
4-cylinder injection engineed(1.6 l engine, 4 V, EA 211) - Editiongu11.2018
by ara
ris nte
tho eo
❑ Lubricate contact surfaces
au before installing. ra
c
ss
9 - Retaining clip
ce
e
nl
pt
du
an
❑ For hydraulic compensation element.
itte
y li
erm
ab
10 - Hydraulic compensation element
ility
ot p
wit
❑ Do not interchange
, is n
h re
❑ Oil contact surface
hole
spec
es, in part or in w
t to the co
Installation position of valve spring
rrectness of i
• The end with smaller diameter -a- must face towards valve
spring plate.
l purpos
• The end with larger diameter -b- must face towards cylinder
head.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
3.2 Removing and installing camshaft ad‐
t. rig
gh ht
pyri by
juster
co Vo
by lksw
cted agen
Prote AG.
Removing
♦ Counter-hold tool - T10554/1-
♦ Knurled screws - T10554/2- (not illustrated)

♦ Counter-hold tool - T10172A-
Preparing tools
– Bolt on counter-hold tool - T10172- and counter-hold tool -
T10554/1- using knurled screws - T10554/2- -arrows-.
Procedure
Removing
Note
♦ Place a cloth under the camshaft adjuster and tensioning roller

to catch the engine oil which runs out. olksw
agen
AG. V agen AG
does
olksw not
V gu
♦ The contact points between the toothed
edb
y
belt and components ara
nte
is
- such as camshaft pulleys, tensioning
thor roller and idler pulley - eo
must be kept free of oil. ss au ra
c
ce
e
nl
pt
du

an
itte
y li
erm
ab
ility
ot p
Fitting counter-hold tool - T10554- wit

, is n
h re
hole
• The contours of pins -1- and -2- of counter-hold tool -

spec
T10554/1- are not distributed evenly on the bolt circle.

es, in part or in w
t to the co
• They correspond to the contour of the bolt circle in the cam‐

shaft adjuster.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
– Fit counter-hold tool - T10554- with counter-hold tool -

or
his
e
T10172- to camshaft pulley -1- as shown in illustration.

at
do
priv
cum
– The pins must be inserted properly into holes -arrows-.

for
en
ng
t.
yi
– Fit counter-hold tool - T10554- so that it rests flat against cam‐
Co
Cop py
shaft adjuster -1-.
t. rig
gh ht
pyri by
Vo
o
– Hold inlet camshaft in position using counter-hold tool - by c lksw
cted agen
T10554- and counter-hold tool - T10172- .
Prote AG.
3. Valve gear 161

Golf 2013 ➤ , Golfag2017
en AG.➤
Vo,lkGolf
swageSportsvan
n AG d
oes
2015 ➤ , Golf Variant 2014 ➤ ...
sw
y Volk engine (1.6 l engine, 4 nV,
ot gEA 211) - Edition 11.2018
u
b ara
ed nte
ris
– Loosen plug
au
th -1-, and
o
unscrew it. e or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fit counter-hold tool - T10554- with counter-hold tool -
l purpos
T10172- again, to loosen securing bolt -1- of camshaft adjust‐

er.
nform
ercia
– Loosen bolt -1- of camshaft adjuster -2-.

m
at
om
io
– Loosen securing bolt of toothed belt pulley on exhaust side
n
c
in t
r
⇒ “3.3 Removing and installing toothed belt pulley”,

o
his
e
page 165 .
at
do
priv
cum
– Detach toothed belt from camshafts.
for
en
ng
t.
yi Co
– Unscrew securing bolt -1- of camshaft adjuster, and remove Cop py
camshaft adjuster -2-. ht. rig
rig ht
py by
o Vo
Installing by c lksw
cted agen
Prote AG.
• Camshafts are located in “TDC” position.
• Camshaft pulleys are properly aligned.
• Crankshaft is in “TDC position”.
Note
♦ Before installing the camshaft adjuster, ensure that the guide

sleeve is inserted in the camshaft.
♦ Check O-ring of plug for damage, and renew if necessary; see
⇒ Electronic parts catalogue (ETKA) .

lks side, and screw wage es n
– Renew bolt -1- for camshaft adjuster on Voinlet ot g
by ua
it in to stop by hand. ris
ed ran
tee
tho or
– Renew bolt -2- for toothed belt au pulley on exhaust side, and ac
ss
screw it in to stop by hand.
ce
e
nl
pt
du
• It should just be possible to turn camshaft pulleys on cam‐
an
itte
y li
shafts but no rocking is permissible.
erm
ab
ility
– Fit toothed belt onto camshafts ⇒ page 157 . ot p
wit
, is n
h re
Pre-tightening
hole
spec
es, in part or in w
t to the co
Note
♦ If the camshafts are turned when pre-tightening with the crank‐
rrectness of i
shaft fixed in place using the locking pin - T10340- , the valve
timing will be changed.
l purpos
♦ If the crankshaft is not locked in place, the deviations that oc‐
nform
ercia
cur when counter holding will be transferred to the crankshaft

via the toothed belt.
m
at
om
io
♦ The valve timing will not be affected in this case.
n
c
in t
or
his
ate
– Before pre-tightening, unscrew locking pin - T10340- .
do
priv
cum
or
– Hold inlet camshaft in position using counter-hold tool -

f
en
ng
t.
yi
T10554- and counter-hold tool - T10172- .
Co
Cop py
t. rig
gh ht
yri by
– Pre-tighten bolt -1- to specified pre-tightening torque in two cop Vo
by lksw
stages. cted agen
Prote AG.
Stage Securing bolt for camshaft Specified torque

adjuster
1 -1- 18 Nm
2 -1- 50 Nm
T10172- and adapter - T10172/1- .
– Pre-tighten bolt -1- to specified pre-tightening torque in two

stages.
Stage Securing bolt for toothed Specified torque
belt pulley
1 -1- 18 Nm
2 -1- 50 Nm
Tightening to final specified torque
– Screw locking pin - T10340- back in.
3. Valve gear 163

– Tighten bolt -1- for camshaft adjuster to final specified torque.

Stage Securing bolt for camshaft Angle to turn bolts
adjuster
1 -1- 135°
– Tighten securing bolt for toothed belt pulley on exhaust side

to final specified torque.
Stage Securing bolt for toothed Angle to turn bolts
belt pulley
1 -1- 90°
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Screw in plug -1-, and tighten it to specified torque.

T10172A- and counter-hold tool - T10554- .
Stage Plug for camshaft adjuster Specified torque
1 -1- 20 Nm
Installing
Note
Make sure to remove the camshaft locking pin before cranking

the engine.
Specified torques
202
Volkswa AG. gen AG
agen does
♦ ⇒ “2.6 Checking adjustment of assemblyy Vmountings
olks
w
(engine not
gu
and gearbox mountings)”, page 63 ised b ara
nte
r
ho eo
♦ ⇒ “1.1 Assembly overview - polyauV-belt
t
drive”, page 67 ra
c
ss
ce
e
nl
pt
du
- alternator
an
itte
y li
erm
ab
ility
ot p
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”, wit

, is n
page 220 h re
hole
spec
es, in part or in w

t to the co
pulley
rrectness of i

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Valve gear 165

♦ Counter-hold tool - T10554/1-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Knurled screws - T10554/2- (not illustrated)
es, in part or in w
t to the co
♦ Counter-hold tool - T10172A-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Preparing tools C py
t. rig
gh ht
yri by
– Bolt on counter-hold tool - T10172- and counter-hold tool - cop Vo
by lksw
T10554/1- using knurled screws - T10554/2- -arrows-. cted agen
Prote AG.
Procedure
Removing
Note
♦ Place a cloth under the camshaft adjuster and tensioning roller

to catch the engine oil which runs out.
♦ The contact points between the toothed belt and components
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.

⇒ “2.8 Removing toothed belt from camshaft”, page 154
– Loosen bolt for camshaft adjuster on inlet side
page 160 .
T10172- and adapter - T10172/1- .

– Loosen bolt -1-.

– Unscrew securing bolt -1- of toothed belt pulley, and remove
toothed belt pulley.
Installing
• Camshafts are located in “TDC” position.
• The camshaft pulleys are properly aligned with each other.
• Crankshaft is in “TDC position”.
Note
♦ Before installing the camshaft adjuster, ensure that the guide

sleeve is inserted in the camshaft.
♦ Check O-ring of plug for damage, and renew if necessary; see
⇒ Electronic parts catalogue (ETKA) .
– 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.
Pre-tightening
– Hold inlet camshaft in position using counter-hold tool - agen AG. Volkswagen AG do
T10554- and counter-hold tool - T10172- . yV
olks
w es n
ot g
b ua
ed ran
oris tee
– Pre-tighten bolt -1- to specified pre-tightening
au torque
th in two or
ac
stages. ss
ce
e
nl
pt
du
Stage Securing bolt for camshaft Specified torque

an
itte
y li
adjuster
erm
ab
ility
1 -1- 18 Nm
ot p
wit
, is n
2 -1- 50 Nm
h re
hole
spec

es, in part or in w
T10172- and adapter - T10172/1- .

t to the co
rrectness of i
l purpos
– Pre-tighten bolt -1- to specified pre-tightening torque in two

stages.
nform
ercia
Stage Securing bolt for toothed Specified torque

belt pulley
m
at
om
io
1 -1- 18 Nm
n
c
in t
or
his
e
2 -1- 50 Nm
at
do
priv
cum
Tightening to final specified torque

for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Valve gear 167

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ris, Golf Variant 2014 ➤ ...
ed
nte
o eo
4-cylinder injection engine (1.6 l engine, 4 V, EAau211)
th - Edition 11.2018 ra
ss c
ce
le
– Tighten bolt -1- for camshaft adjuster to final specified torque.
un
pt
an
d
itte
y li
Stage Securing bolt for camshaft Angle to turn bolts
rm
ab
pe
adjuster
ility
ot
wit
, is n
1 -1- 135°
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Tighten securing bolt for toothed belt pulley on exhaust side
nform
to final specified torque. mercia
a
com
ti
Stage Securing bolt for toothed Angle to turn bolts
on in
belt pulley
r
te o
thi
s
iva
1 -1- 90°
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Screw in plug -1-, and tighten it to specified torque.

T10172A- and counter-hold tool - T10554- .
Stage Plug for camshaft adjuster Specified torque
1 -1- 20 Nm
Installing
Further assembly is performed in the reverse order of removal.
Note
Make sure to remove the camshaft locking pin before cranking

the engine.
Specified torques:
• ⇒ “2.1 Assembly overview - toothed belt cover”, page 126
• ⇒ “2.2 Assembly overview - toothed belt”, page 127
• ⇒ “3.1 Assembly overview - crankcase breather system”, page
202
3.4 Measuring axial play of camshaft


♦ Universal dial gauge holder - VW 387-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
Procedure
ot p
wit
is n
Checking camshaft axial clearance

h re
ole,
spec


t to the co
page 120 .
– Secure dial gauge - VAS 6079- with universal dial gauge
rrectne
bracket - VW 387- to camshaft housing as shown in illustration.

– Press camshaft against dial gauge by hand.
ss o
– Set dial gauge to “0”.

cial p
f inform
mer
– Press camshaft away from dial gauge and read off value:
atio
m
Axial clearance:
o
n
c
i
or
n thi
• Wear limit: 0.25 mm

te
sd
iva
o
pr
cum
r
fo
3.5 Removing and installing camshaft oil

en
ng
t.
yi Co
seal Cop py
t. rig
gh ht
pyri by
⇒ “3.5.1 Removing and installing camshaft oil seal, inlet camshaft,
o Vo
by c lksw
cted
pulley end”, page 169
agen
Prote AG.
⇒ “3.5.2 Removing and installing camshaft oil seal, exhaust cam‐

shaft, pulley end”, page 171
⇒ “3.5.3 Removing and installing camshaft oil seal, exhaust cam‐
shaft, gearbox end”, page 173
3.5.1 Removing and installing camshaft oil

seal, inlet camshaft, pulley end
3. Valve gear 169

♦ Assembly tool - T10478 B-
Removing
– Unscrew bolt -1- and remove camshaft toothed belt pulley.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Remove seal -1- using extractor hook -T20143/1- .

spec
es, in part or in w
Installing
t to the co
rrectness of i
Note
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Fit seal -1- over fitting sleeve -T10478/3- onto guide sleeve -
T10478/2- .
– Separate fitting sleeve and guide sleeve.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Draw in seal to stop using thrust piece -T10478/1A- and bolt
c by lksw
cted agen
-1- for camshaft pulley. Prote AG.

seal, exhaust camshaft, pulley end
3. Valve gear 171

♦ Assembly tool - T10478 B-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Removing
wit
is n
h re
ole,
spec
t to the co
– Unscrew bolt -2- and remove camshaft toothed belt pulley.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
– Remove seal -1- using extractor hook -T20143/1- . t. Cop py
rig
gh ht
Installing pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note

– Fit seal -1- over fitting sleeve -T10478/3- onto guide sleeve -
T10478/2- .
– Fit guide sleeve -T10478/2- with oil seal -1- to camshaft.
– Pull in thrust piece -T10478/1A- with bolt -T10478/5- as far Aas

G. Volkswagen AG d
stop. swagen oes
olk no t gu
yV
– Install toothed belt ⇒ page 156 . db ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

seal, exhaust camshaft, gearbox end
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
173
AG.
3. Valve gear
♦ Assembly tool - T10479 A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
Removing
y li
erm
ab
ility
– Remove toothed belt pulley for coolant pump
ot p
wit
⇒ “2.4 Removing and installing toothed belt pulley for coolant
is n
h re
pump”, page 227 .
ole,
spec
t to the co
Note
Risk of chemical damage to the coolant pump gasket caused by
rrectne
oil entering between the coolant pump and the cylinder head.
ss
– Cover coolant pump with a cloth.
o
cial p
f inform
– Carefully fit extractor hook -T20143/1- between camshaft and
mer
seal -1-.
atio
om
– Lever out seal. n

c
i
or
n thi
te
Installing
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove any burrs in the outer area of the grooves in the ex‐
haust camshaft -arrows- using fine sandpaper (220 … 1000
grain).
Note

4-cylinder injection engines(1.6 n AG. Volkswagen AG o
wage l engine, 4 V, EAd211)
kes - Edition 11.2018 not
Vol gu
d by ara
– Fit seal -1- over fitting sleeve -T10479/3- ontoris guide
e sleeve - nte
T10479/2- . utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
– Fit guide sleeve -T10479/2- with oil seal -2- centrally to cam‐
thi
te
sd
a
shaft.
iv
o
pr
cum
r
fo
– Secure guide sleeve onto camshaft using bolt -1- for coolant
en
ng
t.
pump drive sprocket.
yi Co
Cop py
t. rig
– Push seal onto camshaft and unbolt guide sleeve. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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
pump”, page 227 .
3. Valve gear 175

3.6 Removing and installing camshaft con‐

trol valve 1 - N205-
Removing
– Unscrew bolt -2-, and remove camshaft control valve 1 -
N205- .
Installing
Install in the reverse order of removal. When doing this, note the
following:
Note
Renew O-ring.
Specified torque
3.7 Removing and installing valve stem

seals
⇒ “3.7.1 Removing and installing valve stem seals (cylinder head
installed)”, page 176
⇒ “3.7.2 Removing and installing valve stem seals (cylinder head
removed)”, page 180
AG. Volkswagen AG d
agen oes
3.7.1 Removing and installing valve stem byV
olksw not
gu
ara
seals (cylinder head installed) ed
ris nte
ho eo
aut ra
Special tools and workshop equipment required ss c
ce
e
nl
pt
♦ Spark plug socket - 3122 B-

du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Removal and installation device for valve cotters - VAS 5161A-

m
with guide plate - VAS 5161A/32-32- .

at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Hose adapter - VAS 5161A/35- (not shown)

♦ Valve stem seal fitting tool - 3365-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
♦ Valve stem pliers - VAS 6770- ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Procedure
Golf SV
nf
ercia
or
– Remove plenum chamber cover ⇒ General body repairs, ex‐
m
m
atio
terior; Rep. gr. 50 ; Bulkhead; Assembly overview - plenum
om
n in
chamber cover .
or c
thi
te
– Remove plenum chamber bulkhead ⇒ General body repairs,

sd
iva
o
r
exterior; Rep. gr. 50 ; Bulkhead; Assembly overview - bulk‐

rp
cu
o
head .
f
en
ng
t.
yi Co
op
– If fitted, remove heat shield for right drive shaft ⇒ Running C py
ht. rig
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and rig ht
py by
installing drive shaft heat shield .
co Vo
by lksw
cted agen
Prote AG.
page 120 .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.
– Remove roller rocker fingers together with compensation ele‐
ments and place them on a clean surface.
– Unscrew spark plugs with spark plug socket - 3122 B- .
3. Valve gear 177

4-cylinder injection engine (1.6 l engine, 4 V, EA 211) - Editione11.2018
n AG. Volkswagen AG ag does
ksw not
Vol gu
– Unscrew locking pin - T10340- . ed
by ara
nte
oris eo
– Set piston of respective cylinder to “bottom dead centre”.
au
th
ra
ss c
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ The pistons of cylinders no. 1 and no. 4 are at »TDC« position
ot
wit
after the camshaft housing has been removed.
, is n
h re
hole
♦ The pistons of cylinders no. 2 and no. 3 are at »bottom dead
spec
centre« position after the camshaft housing has been re‐
es, in part or in w
t to the co
moved.
♦ Crank engine via crankshaft half a turn in direction of engine
rotation. The pistons for cylinders no. 1 and no. 4 are at »bot‐
rrectness of i
tom dead centre« position.
l purpos
♦ When cranking the engine, hold and guide the toothed belt by
hand to prevent it from being damaged.
nform
mercia
a
– Fit guide plate -VAS 5161A/32-1- onto cylinder head and se‐
com
tion in
cure with knurled screws -VAS 5161/12- .
r
te o
thi
– Screw hose adapter - VAS 5161A/35- into respective spark
s
iva
do
r
plug thread hand-tight.

rp
cum
fo
en
ng
– Connect adapter to compressed air supply using a commer‐

t.
yi Co
op
cially available union and apply pressure continuously. C py
t. rig
gh ht
yri by
• Minimum pressure: 6 bar. op Vo
by c lksw
cted agen
Prote
– Insert punch -VAS 5161/3A- into guide plate.
AG.
– Use a plastic hammer to knock loose the firmly seated valve

cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and
insert cartridge into guide plate -VAS 5161A/32-3- .
– Attach pressure fork -VAS 5161/2- to toothed piece at a suit‐
able angle and press assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and move to side.
• The compressed air hose remains connected.
– Remove valve spring and valve spring plate.

– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Note
AG. Volkswagen AG d
agen oes
Risk of damage when installing valve stem seals.y Volksw not
gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Lightly oil sealing lip of valve stem seal -A-.
l purpos
– Carefully press valve stem oil seal -A- onto valve guide using
valve stem seal fitting tool - 3365- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
If valve cotters have been removed from assembly cartridge:
– First, insert valve cotters into insertion device - VAS 5161 A/
32-3- .
– Press down spring washer until three grooves are visible.
– Fit valve cotters into grooves.
• Larger diameter of valve cotters faces upwards.
– Release the spring washer. The spring force pushes the wash‐
er back upwards and holds the valve cotters in place.
– Press assembly cartridge - VAS 5161A/32-1- onto insertion
device from above and pick up valve cotters.
– To do this, move knurled screw back and forth to press apart
valve cotters and capture them in assembly cartridge.
3. Valve gear 179

– Bolt guide plate -VAS 5161A/32-1- onto cylinder head again.

– Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS
5161A/32-3- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Installing
Assemble in reverse order of dismantling. During this procedure,
observe the following:
Golf SV
– Install plenum chamber bulkhead. ⇒ General body repairs,
exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Assembly
overview - plenum chamber cover
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Plenum chamber bulkhead; Assembly
overview - plenum chamber cover
olkswagen AG
en AG. V
– Install spark plugs ⇒ Maintenance
olks
wag ; Booklet . does
not
V gu
by ara
– Install camshaft housing
ris
ed nte
⇒ “1.4 Removingauand
tho installing camshaft housing”, eo
ra
page 120 . ss c
ce
le
un
Specified torques
pt
an
d
itte
y li

erm
ab
ility
ot p

wit
is n
h re
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Plenum cham‐

ole,
spec
ber bulkhead; Assembly overview - plenum chamber cover

t to the co
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Plenum cham‐

ber bulkhead; Assembly overview - plenum chamber bulkhead
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
rrectne
Assembly overview - drive shaft

ss o
3.7.2 Removing and installing valve stem

cial p
f inform
seals (cylinder head removed)

mer
atio
m

o
n
c
i
or
n thi
♦ Removal and installation device for valve cotters - VAS 5161A-

te
sd
va
with guide plate - VAS 5161A/32-32- .

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Engine and gearbox support - VAS 6095-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
♦ Cylinder head tensioning device - VAS 6419-
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
♦ Valve stem pliers - VAS 6770-

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Valve stem seal fitting tool - 3365-
3. Valve gear 181

Procedure
– Removing cylinder head.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seals are to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
– Fit guide plate -VAS 5161A/32-1- onto cylinder head and se‐
cure with knurled screws -VAS 5161/12- .
– Insert punch -VAS 5161/3A- into guide plate.
– Use a plastic hammer to knock loose the firmly seated valve
cotters.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
– Screw toothed piece -VAS 5161/6- with hooking fork -auth eo
ra
VAS 5161/5- into guide plate. ss c
ce
e
nl
pt
– Slide sleeve -VAS 5161A/32-2- onto assembly cartridge and
du
an
itte
insert cartridge into guide plate -VAS 5161A/32-3- .
y li
erm
ab
ility
– Attach pressure fork -VAS 5161/2- to toothed piece and press
ot p
assembly cartridge down.
wit
, is n
h re
hole
– At the same time, turn knurled screw of assembly cartridge
spec
clockwise until tips engage in valve cotters.
es, in part or in w
t to the co
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
rrectness of i
– Release pressure fork.
l purpos
– Remove installation cartridge.

– Unbolt guide plate and move to side.
nform
ercia
– Remove valve spring and valve spring plate.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
Risk of damage when installing valve stem seals. rise
d b ara
nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Lightly oil sealing lip of valve stem seal -A-.
nform
ercia
– Carefully press valve stem oil seal -A- onto valve guide using
valve stem seal fitting tool - 3365- .
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
If valve cotters have been removed from assembly cartridge:

– First, insert valve cotters into insertion device - VAS 5161 A/
32-3- .
– Press down spring washer until three grooves are visible.
– Fit valve cotters into grooves.
• Larger diameter of valve cotters faces upwards.
– Release the spring washer. The spring force pushes the wash‐
er back upwards and holds the valve cotters in place.
– Press assembly cartridge - VAS 5161A/32-1- onto insertion
device from above, and pick up valve cotters.
– To do this, move knurled screw back and forth to press apart
valve cotters and capture them in assembly cartridge.
3. Valve gear 183

– Bolt guide plate -VAS 5161A/32-1- onto cylinder head again.

– Insert assembly cartridge -VAS 5161A/32-2- with sleeve -VAS
5161A/32-3- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
– Install cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 117 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Inlet and exhaust valves

⇒ “4.1 Checking valve guides”, page 185
⇒ “4.2 Checking valves”, page 185
⇒ “4.3 Valve dimensions”, page 186
4.1 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Test sequence
t to the co
– 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.
rrectness of i
– Determine rock.
l purpos
• Wear limit: 0.5 mm.

nform
ercia
– If the wear limit is exceeded, repeat the measurement with

m
new valves.
at
om
ion
c
– Renew cylinder head if wear limit is still exceeded.

in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op
Valve guides cannot be exchanged.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
4.2 Checking valves
AG.
– Check for scoring on valve stems and valve seat surfaces.

– Exchange valve if significant scoring can be seen.
4. Inlet and exhaust valves 185

4.3 Valve dimensions
Note
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
Dimension Inlet valve Outlet valve

∅a mm 29.5 27.0
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 187
⇒ “1.2 Removing and installing lower part of sump”, page 190
⇒ “1.3 Removing and installing oil pump”, page 194
⇒ “1.4 Removing and installing upper part of sump”, page 196
⇒ “1.5 Engine oil:”, page 199
1.1 Assembly overview - sump/oil pump
Note
♦ Metal shavings or a large quantity of small metal particles found during engine repair could indicate that the
crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following work
must be carried out following the. Vrepair: Carefully clean oil channels and renew oil spray jets, engine oil
olkswagen AG
cooler and oil filter. swagen AG does
olk not
yV g
♦ Oil spray jet and
ise
pressure
db relief valve ⇒ “4.6 Removing
ua
raand
n installing oil spray jets”, page 110 .
r tee
ho
aut or
ac
ss
ce
le
1 - Oil dipstick
un
pt
an
d
❑ Oil capacities ⇒ Mainte‐

itte
y li
rm
nance ; Booklet ; En‐

ab
pe
ility
gine oil: capacities and

ot
wit
specifications
, is n
h re
hole
2 - O-ring
spec
es, in part or in w

t to the co
❑ Lubricate before instal‐

ling.
rrectness of i
3 - Bleeder valve
l purpos

sition
nform
ercia
4 - Cap
m
5 - Oil separator
com
tion in

r
te o
thi

s
iva
do
stalling oil separator”,

r
rp
cum
page 203
fo
en
ng
t.
❑ Renew if damaged
yi Co
Cop py
t. rig
6 - Bolt
gh ht
pyri by
Vo
co
❑ Specified torques and
by lksw
cted agen
tightening sequence
Prote AG.

page 203
7 - Oil pressure switch - F1-
❑
1. Sump, oil pump 187

0.03 … 0.06 MPa (0.3 … 0.6 bar)

❑ Checking oil pressure switch ⇒ “4.3 Checking oil pressure”, page 206 .
❑ 20 Nm
❑ Renew O-ring after each removal
Note AG. Volkswagen AG d

agen oes
olksw not
♦ The oil pressure
ed byV switch is fitted gu
ara
withthao captive seal.
ris nte
eo
au ra
♦ The
ss seal is not designed for re‐ c
peated use.
ce
e
nl
pt
du
an
itte
y li
8 - Connector
erm
ab
ility
ot p
9 - Baffle plate
wit
, is n
h re
10 - Upper part of sump
hole
spec
❑ Removing and installing ⇒ “1.4 Removing and installing upper part of sump”, page 196
es, in part or in w
t to the co
11 - Oil filters
❑ Moisten seal with oil before installing
rrectness of i
❑ If outer circumference of oil filter is damaged, renew oil filter
l purpos
❑ 20 Nm
❑ If the connecting union for oil filter in sump became loose ⇒ page 209 nform
ercia
12 - Lower part of sump

m
at
❑ Removing and installing ⇒ “1.2 Removing and installing lower part of sump”, page 190
om
ion
c
in t
13 - Bolt
or
his
ate
❑ Specified torques and tightening sequence ⇒ page 189

do
priv
cum
or
14 - Seal
f
en
ng
t.
yi Co
❑ Renew after removal . Cop py
rig
ht ht
15 - Oil drain plug
rig by
copy Vo
by lksw
❑ 30 Nm cted agen
Prote AG.
16 - Bolt
❑ Specified torques and tightening sequence ⇒ page 189
17 - Intake manifold
18 - Bolt
❑ 8 Nm
19 - Bolt
❑ Specified torques ⇒ page 196
20 - Bolt
❑ For tensioning device.
❑ Specified torques ⇒ “1.1 Assembly overview - poly V-belt drive”, page 67
21 - Seal
❑ Renewing ⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”, page 84
❑ For oil pump drive.
22 - Bolt
❑ Specified torques ⇒ page 196
188 Rep. gr.17 - Lubrication

23 - Oil pump
❑ Removing and installing ⇒ “1.3 Removing and installing oil pump”, page 194
24 - Seal
❑ Note guide pins for proper positioning
Lower part of sump - specified torque and tightening sequence

Stage Bolts Specified torque
2 -1- to -19- 12 Nm
. Volkswag
Upper part of sump - specified
ksw
agentorque and tightening
AG en AG
does sequence
not
Vol gu
by ara
ed nte
oris
Note auth eo
ra
ss c
ce
e

nl
pt
du
an
itte
y li
erm
ab

ility
ot p
wit

, is n
h re
hole

spec
es, in part or in w
1 -1- to -19- 8 Nm
t to the co
2 -1- to -19- Turn 90° further

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.2 Removing and installing lower part of

sump
Special tools and work‐
shop equipment re‐
quired
♦ Hexagon bit, long
reach - T10058-
lkswage es n
o ot g
byV ua
d ran
♦ Drip tray - VAS 6208-orise tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Wedge - T10383/2-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Cutting tool - T10561-

♦ Applicator gun - VAS

6966-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
♦ Protective mat - VAS

nl
pt
du
an
531003-
itte
y li
erm
ab
♦ Scraper
ility
ot p
wit
, is n
♦ Hand drill with plastic
h re
brush attachment
hole
spec
♦ Sealant remover
es, in part or in w
t to the co
♦ Cleaner and de‐
greaser
rrectness of i
♦ Safety goggles and
protective gloves
l purpos
♦ Silicone sealant ⇒
Electronic Parts
nf
ercia
o
Catalogue “ETKA”
rm
m
atio
m
Cutting tool - T10561-

o
n in
or c
thi
1- Bolt
te
sd
iva
o
r
2- Washer
rp
cu
o
m
f
en
ng
t.
3- Bracket
yi Co
Cop py
t. rig
4- Knife gh ht
pyri by
Vo
o
by c lksw
5- Guide Prote
cted AG.
agen
6- Handle
7- Inserts for support
(rod) for conver‐
sion of handle
8- Bolt
9- Support bearing
Removing
– Drain engine oil.
– Remove front right
wheel housing liners
⇒ General body re‐
pairs, exterior; Rep.
gr. 66 ; Wheel hous‐
ing liner; Assembly
overview - front wheel
housing liner .

– After radiator cowl has been removed, fit protective mat - VAS
531003- to vehicle as shown in illustration.
– Loosen and unscrew bolts in the sequence -19 … 1-.

– Loosen 2 bolts on oil sump, but do not unscrew completely.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Cut through seal between oil sump -4- and engine -1-.
es, in part or in w
t to the co
– Use cutting tool - T10561- to do this.

rrectness of i
Note
l purpos
♦ The sump is sealed with liquid sealant -2- ⇒ Electronic parts

catalogue .
nform
ercia
♦ When hardened, the sealant has a high adhesive strength.

m
a
com
tion in
– Separation is made centrally between bolts -3-.

r
te o
thi
s
iva
– Position cutting tool - T10561- on seal -arrows- without it cant‐

do
r
rp
ing.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Drive in cutting tool - T10561- -3- using a hammer as far as it

will go -arrow-.
– Do not cant cutting tool - T10561- when doing this.
– Do not cutting tool - T10561- sideways.
– Do not lever with cutting tool - T10561- .
– Perform procedure at other points as described until sump is
detached.
– Use wedge - T10383/2- to further loosen detached positions.
– Using a plastic hammer carefully drive in wedge.
– Drive in wedge - T10383/2- only to same depth as sealing
surface.
AG. Volkswagen AG d
agen oes
– Carefully detach sump (bottom section) from adhesive
Vol bond.
ksw not
gu
by ara
ed
– Fit wedge - T10383/2- at another position and ho
risdetach the bon‐ nte
eo
ded joint in the same way. aut ra
c
ss
– Carefully detach lower part of sump from adhesive bond using
ce
le
un
pt
a commercially available scraper.
an
d
itte
y li
rm
ab
pe
– Carefully separate at position indicated by -arrow-.
ility
ot
wit
, is n
– To do this, carefully lever bottom section of sump off crank‐
h re
hole
case using a suitable screwdriver or assembly lever.
spec
es, in part or in w
Installing
t to the co
Note
rrectness of i
l purpos
♦ Danger of soiling lubrication system.

♦ Cover open parts of engine.
nform
mercia
– Spray sealing surface with sealant remover and leave to act.
a
com
tion in
– Remove sealant residues from sump upper part with a flat
r
te o
thi
scraper.
s
iva
do
r
rp
cum
CAUTION
fo
en
ng
t.
yi Co
Risk of eye injury caused by sealant residue. Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove sealant residue from sump (bottom section) using a

rotating plastic brush, for example.
– Remove any oil and grease from sealing surfaces.
Note
♦ Observe use-by date of sealant.

♦ The sump must be installed within 5 minutes after applying
sealant.
♦ The sump can be positioned more easily and with greater se‐
curity if two M6 studs are screwed into the upper part of sump.

– Cut off nozzle on tube at front marking (∅ of nozzle approx. olkswage es n
ot g
3 mm). db
yV ua
ran
e
ris tee
tho or
au ac
Note ss
ce
e
nl
pt
du
an
♦ Risk of blocking lubrication system with excess sealant.
itte
y li
erm
ab
♦ Do not apply sealant bead thicker than specified.
ility
ot p
wit
, is n
h re
– Apply sealant in a bead -arrow- to clean sealing surface of
hole
spec
bottom section of sump using applicator gun - VAS 6966- .
es, in part or in w
t to the co
Sealant bead must be:
♦ 2…3 mm thick.
rrectness of i
♦ Run bead along inner side of bolt holes -arrows-.
l purpos
– Fit bottom section of sump, and tighten bolts ⇒ page 189 .
nf
ercia
o
Note
rm
m
atio
om
n in
After installing bottom section of sump, wait about 30 minutes for
or c
thi
sealant to dry. Only then fill with engine oil.
te
sd
iva
o
r
rp
cu
o
– Replenish engine oil and check oil level.
m
f
en
ng
t.
yi Co
Specified torques Cop py
ht. rig
rig ht
♦ ⇒ Fig. ““Lower part of sump - specified torque and tightening py by
co Vo
by lksw
sequence”“ , page 189 Prote
cted AG.
agen
1.3 Removing and installing oil pump

Removing
– Remove toothed belt
⇒ “2.4 Removing and installing toothed belt”, page 129 .
page 190 .
– Remove suction pipe of oil pump ⇒ Item 17 (page 188) .
page 196 .
– Remove baffle plate ⇒ Item 8 (page 188) .
– Remove tensioner for poly V-belt
⇒ “1.3 Removing and installing tensioner for poly V-belt”, page
79 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove crankshaft oil seal on belt pulley end
page 84 .

– Unscrew oil pump securing bolts -1- and -2-.

– Pull oil pump in a straight line off dowel pins on cylinder block.
– Remove gasket -1- from dowel pins -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Installing
hole
spec
– Fit new gasket -1- onto dowel pins -arrows-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
– Rotate oil pump gear to a position where 2 opposing notches

a
do
riv
-arrows- are aligned as shown in illustration.

p
cum
for
en
ng
t.
– Fit oil pump onto dowel pins. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw not
Golf 2013 ➤ , Golf 2017 ➤ ,bGolf y V Sportsvan 2015 ➤ , Golf Variant
ol
gu
ara
2014 ➤ ...
d
4-cylinder injection engine rise(1.6 l engine, 4 V, EA 211) - Edition 11.2018 nte
tho eo
s au ra
c
Specified torques s
ce
e
nl
pt
du
– Tighten new securing bolts -1- and -2- in the specified se‐
an
itte
y li
quence:
erm
ab
ility
Stage Bolts ot p
Specified torque/turning further angle
wit
, is n
h re
1 -1- 5 Nm
hole
spec
2 -2- 10 Nm
es, in part or in w
t to the co
3 -1- 8 Nm
4. -2- 20 Nm
rrectness of i
5. -1- and -2- Turn 90° further
l purpos
– Install new crankshaft oil seal on belt pulley end

page 84 .
nform
ercia

m
at
om
i
on
c
page 196 .
in t
or
his
ate
do
priv
cum
or
Specified torques
f
en
ng
t.
yi Co
op
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 187
C py
t. rig
gh ht
yri by
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 127 cop Vo
by lksw
cted agen
Prote
AG.

- alternator
- battery
1.4 Removing and installing upper part of

sump
♦ Hexagon bit, long reach - T10058-
♦ Hand drill with plastic brush

♦ Safety glasses
♦ Sealant ⇒ Electronic Parts Catalogue


SV 2015, Golf 2017>”, page 76 .
– Separate connector -1- on air conditioning compressor regu‐
lating valve - N280- .
CAUTION
G. Volkswagen
Risk of freezing injury
ksw caused by refrigerant.
agen
A AG do
es n
Vol ot g
– Do not open
ed b refrigerant circuit of air conditioning
y ua
ra system.
ris nte
ho eo
aut ra
ss c
NOTICE
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
100 mm.
wit
is n
h re
ole,
spec
t to the co
nected and tie it up on the right side.
rrectne
ss
page 190 .
o
cial p
f inform
mer
– Unscrew securing bolts -arrows- for gearbox to upper section

atio
of sump -1-.
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Loosen and unscrew bolts in the sequence -19 to 1-.

– Carefully detach upper part of sump from adhesive bond.
– Remove baffle plate.
Installing
Note

♦ Renew gaskets, oil seals and self-locking nuts.
Note
♦ Risk of soiling lubrication system.

♦ Cover open parts of engine.
– Remove sealant residues from cylinder block with a flat scra‐

per.
CAUTION
Risk of eye injury from dust and plastic parts being flung into
the air.
Eye irritation and injury possible.
– Remove sealant residue from upper part of sump, e.g. with

rotating plastic brush.
– Check oil galleries in upper part of sump and cylinder block for
soiling. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Remove any oil and grease from sealing surfaces. d by ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Observe use-by date of sealant.

rrectness of i
l purpos
Note
nf
ercia

orm
m

atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
198
AG.
Rep. gr.17 - Lubrication
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

2 mm).
– Apply sealant in a bead -arrow- to clean sealing surface of
bottom section of sump using applicator gun - VAS 6966- .
• Thickness of sealant bead: 2 to 3 mm.
Note
Upper part of oil sump must be installed within 5 minutes after

sealant has been applied.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Check that dowel pin -2- is securely seated in cylinder block.
ce
e
nl
pt
du
an
itte
– Attach baffle plate -1- to cylinder block.
y li
erm
ab
ility
– Position top section of sump and tighten bolts ⇒ page 189 .
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Install bottom section of sump
t to the co
page 190 .
rrectness of i
l purpos
stalling air conditioner compressor from and to bracket .

– Replenish engine oil, and check oil level ⇒ Maintenance ;
nform
ercia
Booklet .
m
at
om
Specified torques
ion
c
in t
or
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 187 his

ate
do
riv

p
cum
or
torques for gearbox

f
en
ng
t.
yi Co
op
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐ C py
t. rig
pressor gh ht
pyri by
Vo
o
by c lksw
cted agen
1.5 Engine oil:
Prote AG.
Note
♦ Risk of damage to catalytic converter.

♦ Oil level must not be above “max.” mark.
Capacities and specifications ⇒ Maintenance ; Booklet ; Engine

oil: Capacities and specifications .
Check engine oil level ⇒ Maintenance ; Booklet ; Engine oil level:
Checking .

2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 200
⇒ “2.2 Removing and installing engine oil cooler”, page 200
2.1 Assembly overview - engine oil cooler
1 - Engine oil cooler

❑ Removing and installing Volkswagen AG
⇒ “2.2 Removing and in‐ swagen AG. does
stalling engine oil cool‐by Volk not
gu
ara
er”, page 200 ris
ed
nte
ho eo
❑ Renew coolantauafter re‐
t ra
c
placing. ss
ce
le
un
pt
2 - Bolt
an
d
itte
y li
erm
ab
ility
ot p
❑ Qty. 4
wit
is n
❑ 8 Nm +90°
h re
ole,
spec
3 - Oil seals
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.2 Removing and installing engine oil cool‐

er
Removing
– Drain coolant
– Remove intake manifold

– Unscrew bolts -arrows- and detach engine oil cooler -1-.

Installing
– Insert new O-rings.
– Install intake manifold
Specified torques
♦ ⇒ “2.1 Assembly overview - engine oil cooler”, page 200
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Engine oil cooler 201

3 Crankcase ventilation
⇒ “3.1 Assembly overview - crankcase breather system”,
page 202
⇒ “3.2 Removing and installing oil separator”, page 203
3.1 Assembly overview - crankcase breather system
1 - Bolt
AG. Volkswagen AG d
❑ 9 Nm agen oes
olksw not
y V gu
d b ara
2 - Oil separator orise nte
th eo
s au ra
c
⇒ “3.2 Removing and in‐ s
ce
e
nl
pt
du
an
page 203
itte
y li
erm
ab
ility
ot p
wit
3 - O-ring
, is n
h re
hole
spec
❑ Lubricate before instal‐
es, in part or in w
t to the co
ling.
4 - Union
rrectness of i
sition
l purpos
5 - Hose
❑ For crankcase ventila‐
nf
ercia
tion. orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Oil separator - specified torque and sequence

– Tighten bolts in the sequence -1- to -9- to 9 Nm.

3.2 Removing and installing oil separator

♦ Applicator gun - VAS 6966-
♦ Scraper
♦ Commercially available studs, M6x20 mm, qty. 2
♦ Sealant remover
♦ Cleaner and degreaser
♦ Safety goggles and protective gloves
♦ Silicone sealant ⇒ Electronic Parts Catalogue “ETKA”
Removing
AG. Volkswagen AG d
Rep. gr. 66 ; Noise insulation;
olkswagen Assembly overview oes - noise in‐
not
sulation . db
yV gu
ar
e an
ris te
– Remove intake tho manifold eo
s au
⇒ “4.2 Removing and installing intake manifold”, page 272
r
. ac
s
ce
le
– Loosen and unscrew bolts in the sequence -9- to -1-.

un
pt
an
d
itte
y li
– Carefully release oil separator from bonded joint.

erm
ab
ility
ot p
Installing
wit
is n
h re
ole,
spec
following:
t to the co
CAUTION
Risk of injury from sealant and grease removers. Sealant and
rrectne
grease removers are highly flammable and may cause eye and
skin irritation.
s

s o
cial p
f i

nform
mer
atio
m
– Remove sealant residue on cylinder block and sump using a

o
n
c
chemical sealant remover or a flat scraper.

i
or
n thi
te
sd
a
– Degrease sealing surfaces.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Crankcase ventilation 203

– Screw 2 M6x20 mm studs a few turns into holes -arrows-.
AG. Volkswagen AG d
Note agen oes
olksw not
byV gu
ara
ed
Observe use-by-date of sealant.
horis nte
eo
aut ra
ss c
ce
le
un
pt
an
Note
d
itte
y li
rm
ab
pe
ility
♦ Risk of soiling the lubrication system.
ot
wit
, is n
♦ Cover any opened engine components.
h re
hole
spec
es, in part or in w
t to the co
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
1.5 mm).
rrectness of i
Note
l purpos

nform
ercia

m
a
com
tion in
– Apply bead of sealant -arrow- onto clean sealing surface of oil

r
te o
thi
separator using applicator gun - VAS 6966- as illustrated.

s
iva
do
r
rp
• Width of sealant bead: 1.5 mm.

um
fo
en
ng
t.
yi Co
Cop py
. rig
Note
ht ht
rig by
copy Vo
by lksw
cted
The oil separator must be installed within 5 minutes after sealant
agen
Prote AG.
has been applied.
– Fit oil separator, and tighten bolts.

– Tighten bolts in the sequence -1- to -9-.
Perform further installation in reverse order, paying attention to
the following:
Specified torque
202

4 Oil filter, oil pressure switch

⇒ “4.1 Assembly overview - oil filter/oil pressure switch”,
page 205
⇒ “4.2 Removing and installing oil pressure switch F1 ”,
page 205
⇒ “4.3 Checking oil pressure”, page 206
⇒ “4.4 Removing and installing oil filter housing”, page 208
4.1 Assembly overview - oil filter/oil pressure switch

AG. Volkswagen AG d
1 - Oil filters agen oes
olksw not
yV gu
❑ Removing and installing ed b ara
nte
is
⇒ “4.4 Removing and in‐ hor eo
ut
stalling oil filter hous‐ ss a ra
c
ing”, page 208
ce
e
nl
pt
du
❑ Before installing, lightly
an
itte
y li
coat seal with clean en‐
erm
ab
gine oil.
ility
ot p
❑ Observe notes
wit
, is n
h re
⇒ page 187
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
❑ If the connecting union
for oil filter in sump be‐
came loose
⇒ page 209
rrectness of i
l purpos
❑ Switch pressure
0.03 … 0.06 MPa (0.3 …
nf
ercia
o
0.6 bar)
rm
m
atio
❑ Checking oil pressure
om
switch
n in
or c
⇒ “4.3 Checking oil
thi
te
sd
a
pressure”, page 206 .

iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
op
stalling oil pressure C py
ht. rig
switch F1 ”, page 205 rig ht
py by
o Vo
❑ 20 Nm
by c lksw
cted agen
Prote AG.
3 - Seal
4.2 Removing and installing oil pressure

switch - F1-
4. Oil filter, oil pressure switch 205

♦ Jointed wrench 24 mm - T40175-
Removing
• Depending on version
– Remove skid plate ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation; Assembly overview - noise insulation .
Note n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
ed ran
The alternator must be covered with a cloth in order to avoid
oris tee
damage due to spilled engine oil. auth or
ac
ss
ce
e
nl
– Unscrew oil pressure switch - F1- -1-.
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
wit
, is n
following:
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Renew seal.
rrectness of i
♦ Insert the new oil pressure switch - F1- immediately into the
l purpos
bore so that no larger amounts of oil can escape.
– Check oil level ⇒ Maintenance ; Booklet .

nf
ercia
orm
Specified torques
m
atio
om
n in
c
♦ ⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page

or
thi
205
te
sd
iva
o
r
rp
cu
o
4.3 Checking oil pressure

f
en
ng
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Oil pressure tester - V.A.G 1342-
♦ Adapter set - V.A.G 1594 C-
♦ Voltage tester - V.A.G 1527B-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
• Oil level OK. Checking ⇒ Maintenance ; Booklet . wit

is n
h re
ole,
• Engine oil temperature at least 80 °C (radiator fan must have

spec
run once)
t to the co
Checking oil pressure

– Remove oil pressure switch - F1-
rrectne
⇒ “4.2 Removing and installing oil pressure switch F1 ”, page

205 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Screw oil pressure tester - V.A.G 1342- into bore for oil pres‐
sure switch in cylinder head.
– Screw oil pressure switch - F1- into bore in oil pressure tester
- V.A.G 1342- .
– Start engine.
• Oil pressure at idling speed: at least 0.1 MPa (1 bar)
AG. Volkswagen AG d
• Minimum oil pressure at 3000 rpm: 0.25 MPa (2.5 bar) ksw
agen oes
not
Vol
y gu
• Minimum oil pressure at 4500 rpm: 0.3 MPa (3 bar) ise
d b ara
nte
or eo
th
au ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
♦ Mechanical damage, e.g. due to worn bearings or camshaft
erm
ab
adjusters, could be the cause for oil pressure being too low.
ility
ot p
wit
, is n
♦ The oil pressure must not exceed 0.5 MPa (5 bar). Otherwise
h re
the fault is in the pump control circuit.
hole
spec
es, in part or in w
t to the co
Checking oil pressure switch - F1-
– Switch off engine.
rrectness of i
– Connect brown wire of tester to earth (-).
l purpos
– Connect voltage tester - V.A.G 1527B- to battery positive (+)

and oil pressure switch - F1- using cables from auxiliary test
nf
ercia
set - V.A.G 1594C- .
orm
m
atio
• LED must not light up.
om
n in
or c
If the LED lights up:
thi
te
sd
iva
– Replace oil pressure switch - F1-
o
r
rp
cu
o
m
f
If LED does not light up:
en
ng
t.
yi Co
op py
– Start engine, and increase engine speed. t. C rig
gh ht
pyri by
• At an oil pressure of 0.03 … 0.06 MPa (0.3 … 0.6 bar) the LED
co Vo
by lksw
cted
must light up; otherwise renew oil pressure switch
agen
Prote AG.
205 .
– Install oil pressure switch - F1-
205 .
4.4 Removing and installing oil filter housing

♦ Oil filter tool - 3417-
Removing
sulation .
– Drain engine oil ⇒ Maintenance ; Booklet .

AG. Volkswagen AG d
agen oes
olksw not
yV g
Golf 2013 ➤ise, Golf 2017 ➤ , Golf Sportsvan 2015 u➤
d b ara , Golf Variant 2014 ➤ ...
nte
r
4-cylinder
ut
ho injection engine (1.6 l engine, 4 V, EA 211) eo
r a - Edition 11.2018
s a c
s
– Remove oil filter -arrow- using oil filter tool - 3417- .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
Tightening connecting union for oil filter
inform
mer
• If the connecting union -2- in the top section of sump -1- is
atio
loose, retighten it as described below.
om
n
c
i
or
n
Use only the two nuts -3 and 4- for this procedure.
thi
te
sd
va
• Hexagon nuts - 068 115 723- , qty. 2 ⇒ Electronic Parts Cata‐

i
o
pr
cum
r
logue
fo
en
ng
t.
yi Co
– Screw nuts -3- and -4- onto connecting union -2-, and coun‐ Cop py
terlock them.
t. rig
gh ht
pyri by
Vo
o
by c
– Tighten connecting union -2- using nut -3-.
lksw
cted agen
Prote AG.
– Loosen the two nuts and remove them, taking care not to
loosen the connecting union.
Specified torque
Connecting union Specified torque
-2- 50 Nm
Installing
following:
– Moisten seal of oil filter with engine oil.
– Tighten oil filter to specified torque of 20 Nm using oil filter tool
- 3417- .
– Fill engine oil.

19 – Cooling
1 Cooling system/coolant
yV
olks
wage es n
ot g
b ua
ed ran
⇒ “1.1 Connection diagram h-orcoolant
is hoses”, page 210 tee
t or
au ac
⇒ “1.2 Draining and adding
ss coolant”, page 212
ce
e
nl
⇒ “1.3 Checking cooling system for leaks”, page 216
pt
du
an
itte
y li
1.1 Connection diagram - coolant hoses
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
♦ Brown = coolant circuit for heater
♦ Green = coolant circuit for ATF (only for vehicles with auto‐
matic gearbox)
rrectness of i
♦ The arrows point in the direction of coolant flow.
l purpos
♦ The arrows on the coolant pipes and on the ends of the coolant
hoses must be aligned with each other.
nform
mercia
at
om
ion
c
1 - Radiator for engine coolant
in t
or
his
e
❑ Renew coolant after re‐

at
do
riv
placing
p
cum
for
❑ Assembly overview
en
ng
t.
yi Co
⇒ “4.1 Assembly over‐ Cop py
view - radiator/radiator
t. rig
gh ht
yri
fan”, page 237
p by
o Vo
by c lksw
cted
agen
Prote AG.
stalling radiator”,
page 240
2 - Cylinder head and cylinder
block
placing
3 - Coolant expansion tank
4 - Cap
❑ For coolant expansion
tank
❑ The coolant expansion
tank may have a differ‐
ent shape depending on
the model year.
❑ Check pressure relief
valve ⇒ page 218
5 - Radiator outlet coolant -
G62-
view - coolant tempera‐
ture sender”, page 222
stalling coolant temper‐
210 Rep. gr.19 - Cooling

ature sender G62 ”,

page 231
6 - Heat exchanger for heater
❑ Renew coolant after replacing
7 - Coolant pump
❑ With thermostat housing
❑ Assembly overview ⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 220
❑ Removing and installing ⇒ “2.3 Removing and installing coolant pump”, page 224
8 - ATF cooler
❑ Only models with automatic gearbox
9 - Engine oil cooler
❑ Assembly overview ⇒ “2.1 Assembly overview - engine oil cooler”, page 200
❑ Removing and installing ⇒ “2.2 Removing and installing engine oil cooler”, page 200
10 - Radiator outlet coolant temperature sender - G83-
❑ Not fitted in every equipment variant
❑ Assembly overview ⇒ “2.2 Assembly overview - coolant temperature sender”, page 222
⇒ “2.7 Removing and installing radiator outlet coolant temperature sender G83 ”, page 232
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cooling system/coolant 211

1.2 Draining and adding coolant

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-

. Volkswage
Golf 2013 ➤ , Golf 2017 wag➤ ,G
en A Golf Sportsvan
n AG d
o2015
es n ➤ , Golf Variant 2014 ➤ ...
olks ot g
4-cylinderd injection
by
V engine (1.6 l engine, 4 V, uEA
ar 211) - Edition 11.2018
e an
ris tee
ho
♦ Safety glasses au
t or
ac
ss
♦ Safety gloves
ce
le
un
pt
an
d
itte
♦ Cooling system tester - V.A.G 1274 B-
y li
rm
ab
pe
ility
Draining
ot
wit
, is n
h re
CAUTION hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
g
The coolant expansion tank and cap may have a different shape
n
t.
yi Co
op
depending on the model year. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
CAUTION
agen
Prote AG.


sulation .
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Disconnect connector -2- from radiator outlet coolant temper‐

ature sender - G83- -3-.
– Pull out retaining clip -1-, and remove lower left coolant hose
from radiator.
– Drain coolant.
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 motor.
♦ 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.
♦ ONLY refractometer - T10007A- may be used for determining
current anti-freeze value.
AG. Volkswagen AG d
agen
♦ Frost protection must be guaranteed down to -25°C
Volas a min‐
ksw
oes
not
imum and, in countries with arctic conditions, sdown d b to approx.
y gu
ara
i e
-36°C. Increasing the frost protection is permissible
tho
r only if cli‐ nte
eo
matic conditions require stronger frost protection.
s au It may, how‐ ra
c
ever, be increased only to a maximum of s
-48°C. Otherwise,
ce
e
the cooling effect will be impaired.

nl
pt
du
an
itte
y li
♦ Do not reduce the coolant concentration by adding water even
erm
ab
in warmer seasons and in warmer countries. Frost protection
ility
ot p
must be guaranteed down to at least -25°C.
wit
, is n
h re
♦ Read off anti-freeze figures for respective replenished coolant
hole
spec
additives.
es, in part or in w
♦ The temperature read off the refractometer - T10007A- corre‐ t to the co

sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
rrectness of i
♦ Never reuse old coolant.

l purpos
♦ Use only a water/coolant additive mixture as a slip agent for

coolant hoses.
nform
mercia
Coolant mixture ratio

at
om
ion
c
in t
Frost Coolant additive Coolant ad‐ Distilled wa‐

or
his
e
protection to concentration ditive 1) ter 1)

at
do
priv
cum
or
-25°C 40% 3.2 l 4.8 l

f
en
g
-36°C 50% 4.0 l 4.0 l

n
t.
yi Co
Cop py
t. rig
1)The quantity of coolant can vary depending on the vehicle pyri
gh by
ht
equipment.
o Vo
by c lksw
cted agen
Prote AG.
• Coolant: ⇒ Electronic Parts Catalogue .
Procedure
– Connect coolant hose with plug-in connector to radiator (bot‐
tom left) ⇒ page 238 .

– Fill reservoir of -VAS 6096- with at least 10 litres of pre-mixed

coolant in correct mixture ratio:
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Place cooling system charge unit - VAS 6096- on adapter -
V.A.G 1274/8- .
– Feed vent hose -1- into a small
wage container -2-.
es ks not
Vol gu
d by ara
e nte
ris
Note utho eo
ra
a c
ss
ce
e
Exhaust air takes a slight quantity of coolant along with it; this
nl
pt
du
should be collected.
an
itte
y li
erm
ab
ility
– Close valves -A- and -B- (turn lever transverse to direction of
ot p
wit
flow to do this).
, is n
h re
hole
– Connect hose -3- to compressed air.
spec
es, in part or in w
• Pressure: 6 to 10 bar.
t to the co
– Open valve -B-; turn lever in direction of flow to do this.
rrectness of i
• The suction-jet pump reduces pressure in the cooling system
l purpos
to below atmospheric pressure.

• The needle on the gauge should move into the green zone.
nform
ercia
– In addition, briefly open valve -A- (turn lever in direction of flow

m
to do this) so that hose on reservoir of -VAS 6096- fills with

at
om
coolant. ion
c
in t
or
his
e
– Close valve -A- again.

at
do
priv
– Leave valve -B- open for a further 2 minutes.

um
for
en
ng
t.
yi
• The suction-jet pump will continue generating a vacuum in the
Co
op py
cooling system.
t. C rig
gh ht
pyri by
Vo
• The needle on the gauge must remain in the green zone.
co lksw
by
cted agen
Prote AG.
– Close valve -B-.
• The needle on the gauge must stay in the green zone.
• The low pressure in the cooling system is then sufficient for
subsequent filling.
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.
– Pull off compressed air hose.

– Open valve -A-.
• The partial vacuum in cooling system causes coolant to be
extracted from -VAS 6096- reservoir and coolant system to be
filled.
– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank.

– Fill coolant up to max. mark.

tion .
– On vehicles with auxiliary heater, switch on auxiliary heater for
about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor.
• LED in the button must not light up.
– Tighten cap of coolant expansion tank until it engages.
agen
AG. Volkswagen AG d
o w es n
olks ot g
– Start engine and run alternately at approx.d b 1500 rpm to max‐
yV ua
ran
rise operating.
imum of 2800 rpm until radiator fan starts tee
ho t or
au ac
– Switch off engine and let it cool off.
ss
ce
le
un
pt
an
d
– Check coolant level.

itte
y li
rm
ab
– Screw adapter for cooling system tester - V.A.G 1274/8- again
pe
ility
onto expansion tank.
ot
wit
, is n
h re
– Use cooling system tester - V.A.G 1274 B- to apply a pressure
hole
spec
of 1 bar to the cooling system.
es, in part or in w
t to the co
– Use tester to relieve pressure and remove cooling system
tester - V.A.G 1274 B- .
– With the engine running, fill coolant up to approx. 5 mm above
rrectness of i
max. mark.
l purpos
• When the engine is cold, the coolant level must be between

the min. and the max. marks.
nform
ercia
• The coolant level can be at or above the max. mark when the
m
a
engine is at operating temperature.
com
tion in
r
te o
thi
1.3 Checking cooling system for leaks

s
iva
do
r
rp
cum

fo
en
ng
t.
yi Co
♦ Cooling system tester - V.A.G 1274 B- t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
Vol
ksw not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
To perform the leakage test correctly, first run a self-test on the

cooling system tester - V.A.G 1274 B- .
Self-test of cooling system tester - V.A.G 1274 B-

– Operate cooling system tester - V.A.G 1274 B- several times.
– Build up a pressure of 3.0 bar on cooling system tester .

– Observe pressure on pressure gauge of cooling system tester
for 30 seconds.
If no pressure builds up or if the pressure drops again:
The cooling system tester - V.A.G 1274 B- is leaking and should
not be used.
• Engine at operating temperature.
Procedure

Note
The coolant expansion tank and cap may have a different shape
depending on the model year.
• Engine at operating temperature.
CAUTION
AG. Volkswagen AG d
– Wear protective goggles. ksw
agen oes
not
Vol
– Reduce excess pressure by d covering
by cap of coolant expan‐ gu
ara
sion tank with cloths and rise
opening it carefully. nte
ho e t or
au ac
ss
ce
le
un
pt
– Fit cooling system tester - V.A.G 1274 B- with adapter -
an
d
itte
V.A.G 1274/8- to coolant expansion tank.
y li
erm
ab
ility
– Using hand pump of cooling system tester - V.A.G 1274 B- ,
ot p
build up a pressure of approx. 1.0 bar.
wit
is n
h re
ole,
• The pressure must not drop by more than 0.2 bar within 10 mi‐
spec
nutes.
t to the co
– If pressure drops by more than 0.2 bar, locate leaks and rectify
faults.
rrectne
Note
ss o
cial p
♦ A pressure drop of 0.2 bar within 10 minutes is caused by the

inform
coolant cooling down.

mer
atio
♦ The colder the engine, the lower the pressure loss.

om
n
c
i
or
♦ If necessary, repeat the check while the engine is cold.

thi
te
sd
iva
o
pr
cum
Check pressure relief valve in cap.

r
fo
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
The cap may have a different shape depending on the model Prote AG.
year.

– 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 Volkswagen AG
cooling system tester - V.A.G 1274 B- using connecting hose swagen AG. does
supplied. by
Volk not
gu
a d ran
se
– Build up pressure using hand pump of cooling system
tho tester.
ri tee
or
au ac
Blue cap ss
ce
le
un
pt
♦ The pressure relief valve must open at a pressure of 1.4 bar.
an
d
itte
y li
rm
ab
Black cap
pe
ility
ot
♦ The pressure relief valve must open at a pressure of 1.6 to
wit
, is n
h re
1.8 bar.
hole
spec
If the pressure relief valve opens prematurely: es, in part or in w
t to the co
– Renew cap.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Coolant pump, regulation of cooling

system
page 220
⇒ “2.2 Assembly overview - coolant temperature sender”,
page 222 AG. Volkswagen AG d
agen oes
olksw not
⇒ “2.3 Removing and installing coolant pump”, page 224 d by V gu
ara
rise nte
utho eo
ra
pump”, page 227 ss a c
ce
e
nl
⇒ “2.5 Removing and installing thermostat”, page 228
pt
du
an
itte
y li
⇒ “2.6 Removing and installing coolant temperature sender G62 erm
ab
”, page 231
ility
ot p
wit
, is n
⇒ “2.7 Removing and installing radiator outlet coolant tempera‐
h re
ture sender G83 ”, page 232
hole
spec
es, in part or in w
2.1 Assembly overview - coolant pump, thermostat
t to the co
1 - Thermostat housing
rrectness of i
l purpos

installing thermostat for
cylinder block coolant
nf
ercia
o
circuit”, page 230
rm
m
atio
❑ Observe tightening se‐
om
n in
quence when tightening
or c
thi
to coolant pump
te
sd
a

iv
o
r
rp
cu
stalling coolant pump”,
o
m
f
en
ng
page 224 . yi
t.
Co
op py
2 - Thermostat
t. C rig
gh ht
yri by
❑ For cylinder block cool‐ cop Vo
by lksw
ant circuit
cted agen
Prote AG.
❑ Starts to open at approx.
87 °C
❑ Different versions ⇒
Electronic Parts Cata‐
logue “ETKA”
installing thermostat for
cylinder block coolant
circuit”, page 230
3 - Seal
❑ Ensure proper seating
of seal
❑ Lightly coat with coolant
before installing.
4 - Coolant pump
stalling coolant pump”,
page 224
❑ Renew toothed belt after removing coolant pump

5 - Bolt
❑ 8 Nm
❑ Tightening sequence ⇒ page 222
6 - Seal
❑ Ensure proper seating of seal
AG. Volkswagen AG d
❑ Lightly coat with coolant before installing. lksw
agen oes
not
o
yV gu
7 - Toothed belt guard rised b ara
nte
o eo
❑ For toothed belt for coolant pump aut
h
ra
ss c
8 - Bolt
ce
e
nl
pt
du
an
❑ Renew after removal itte
y li
erm
ab
ility
ot p
9 - Toothed belt
wit
, is n
h re
❑ Renew toothed belt after removing coolant pump
hole
spec
❑ For coolant pump drive
es, in part or in w
t to the co
❑ Removing and installing ⇒ “2.3 Removing and installing coolant pump”, page 224
10 - Crankshaft
rrectness of i
❑ For coolant pump drive
l purpos

⇒ “2.4 Removing and installing toothed belt pulley for coolant pump”, page 227
nform
ercia
11 - Bolt
❑ 8 Nm
m
at
om
ion
12 - Bolt
c
in t
or
his
e

at
do
priv
c
13 - Cap
um
for
en
ng
t.
❑ For thermostat
yi Co
Cop py
ht. rig
14 - Seal rig ht
py by
o Vo
by c lksw
cted agen
Prote AG.
❑ Lightly coat with coolant before installing.
15 - Thermostat
❑ For cylinder head coolant circuit
❑ Starts to open at approx. 80 °C
⇒ “2.5.1 Removing and installing thermostat for main coolant circuit (radiator)”, page 228
❑ Fitting position ⇒ page 222
16 - Bolt
2. Coolant pump, regulation of cooling system 221

Installation position of thermostat for cylinder block coolant circuit

• Must be positioned with centring pin in guide -arrow- in ther‐
mostat housing.
Thermostat housing to coolant pump - specified torque and se‐

quence
– Tighten bolts in the sequence -A … F- to 8 Nm.
Cover for thermostat to thermostat housing - specified torque
Note
Start thread cutting screws by hand

agen
so
AG.that
Volksthey
wageare
n AGscrewed
does into
the existing thread. Then, tighten
Volksw bolt to specified torque. not
g by ua
ed ran
ris tee
– Tighten bolts foruthcover -1-
o
in sequence -A- to -D- to 8 Nm. or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
2.2 Assembly overview - coolant temperature sender

wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1 - Bolt
❑ 8 Nm
2 - Support ring
3 - O-ring
G62-
page 231
5 - O-ring
6 - Radiator outlet coolant tem‐
perature sender - G83-
❑ Not fitted in every equip‐
ment variant
❑ Removing and installing lkswage es n
o ot g
⇒ “2.7 Removing and in‐ byV ua
d ran
stalling radiator outlet ir se tee
ho
coolant temperature aut or
ac
sender G83 ”, ss
ce
le
page 232
un
pt
an
d
itte
y li
7 - Retaining clip
erm
ab
ility
❑ Check for firm seating
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.3 Removing and installing coolant pump

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Coolant system charge unit - VAS 6096-

♦ Release tool - T10527-

♦ Release tool - T10527/1-
Removing
sulation .
– Drain coolant
– Lay wiring harness to one side -arrows-.
– Unscrew bolts -1, 3-, and remove toothed belt guard -2- for
toothed belt for coolant pump.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
– Release hose clips -arrows-, and remove coolant hoses.

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Loosen and unscrew bolts in the sequence -5- to -1-.

– Detach coolant pump with toothed belt.
Installing
Note olkswage es n
ot g
byV ua
d ran
ir se
♦ Renew gaskets
tho -arrows-. tee
or
au ac
♦ Renew toothed belt after removing coolant pump.
ss
ce
le
un
pt
an
d
itte
original equipment ⇒ Electronic Parts Catalogue “ETKA” .
y li
erm
ab
ility
ot p
wit
is n
– Ensure proper seating of gaskets -arrows-.
h re
ole,
spec
– Lubricate seal for coolant pump lightly with coolant.
t to the co
• Always adhere to the sequence of work steps given below
when installing the coolant pump.
• This ensures that the toothed belt is correctly tensioned.
rrectne
• The following work steps must be carried out with the aid of a
s
2nd mechanic.
s o
cial p
f i
• Always renew toothed belts in conjunction with removal of
coolant pump. nform
mer
atio
m
– Set No. 1 cylinder to TDC

o
n
c

or
n thi
te
sd
a
– Fit toothed belt centrally onto camshaft pulley and coolant

iv
o
pr
pump toothed belt pulley.

um
r
fo
en
ng
t.
yi
– Mount coolant pump on cylinder head with securing bolts.
Co
Cop py
t. rig
gh ht
yri by
– Pre-tighten bolts in the specified sequence: cop Vo
by lksw
cted agen
Prote AG.
2 -1- to -5- 10 Nm
– Loosen all bolts again by one turn.

– Fit torque wrench, e.g. -VAS 6583- , with 10 mm hexagon key

socket -item 6- to hex socket on coolant pump.
– Using torque wrench, e. g. -VAS 6583- , preload coolant pump
clockwise to 30 Nm.
Note
♦ Do not support torque wrench with your other hand.

♦ To ensure the poly V-belt is not over-tensioned, do not »push
the torque wrench again« after the specified torque has been
achieved.
– Pre-load coolant pump.

– While doing so, have a second mechanic tighten coolant pump
securing bolts in clockwise direction from right to left.
olkswagen AG
en AG. V
– Starting with bolts -2-, -1- and -5- (»stage 3«), pretighten
ksw to
ag does
not
Vol
10 Nm. ed
by gu
ara
ris nte
– Then tighten securing bolts (»stage 4«). autho eo
ra
ss c
ce
e
nl
pt
du
an
3 -2, 1, 5- 10 Nm
itte
y li
erm
ab
4 -3, 4, 5, 1, 2- 12 Nm
ility
ot p
wit
, is n
Perform further installation in reverse order, paying attention to
h re
the following:
hole
spec
es, in part or in w
t to the co
Specified torques
rrectness of i
Component Specified torque
Thermostat housing to coolant 7 Nm
l purpos
pump
Coolant pump 12 Nm
nf
ercia
or
Toothed belt guard 8 Nm
m
m
atio
m
Bolts for coolant pipe ⇒ “3.1 Assembly overview -

o
n in
or c
coolant pipes”, page 234

thi
te
sd
iva
Specified torques
o
r
rp
cu
o
m
f
en
ng
♦ Tightening sequence for coolant pump ⇒ page 226

t.
yi Co
Cop py
t. rig
gh ht
yri
page 220 p by
o Vo
by c lksw
cted agen
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview Prote AG.
- battery

pulley for coolant pump

♦ Counterhold - T10172- with adapter -T10172/2-
Removing
– Loosen bolt -1- using counterhold - T10172A- with adapters -
T10172/2- .
– Unscrew bolt, and remove toothed belt pulley of coolant pump
drive -2-.
Installing
following:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Fit toothed belt pulley of the coolant pump drive onto camshaft. ce
le
un
pt
an
d
itte
– The asymmetrical grooves -1- and -2- in the camshaft must be y li

erm
ab
exactly centred in the recesses -arrows- in the toothed belt ility
ot p
pulley.
wit
is n
h re
• The grooves -1- and -2- in the camshaft are arranged asym‐
ole,
spec
metrically.
t to the co
• The recesses -arrows- in the toothed belt pulley of the coolant

pump drive are also arranged asymmetrically.
rrectne

Specified torque
ss o
cial p

inform
page 220
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
2.5 Removing and installing thermostat

en
ng
t.
yi Co
Cop py
t.
⇒ “2.5.1 Removing and installing thermostat for main coolant cir‐
rig
gh ht
yri by
cuit (radiator)”, page 228 op Vo
by c lksw
cted agen
Prote
⇒ “2.5.2 Removing and installing thermostat for cylinder block
AG.
coolant circuit”, page 230
2.5.1 Removing and installing thermostat for

main coolant circuit (radiator)

♦ Special wrench - T10508-
Removing
AG. Volkswagen AG d
– Drain coolant lksw
agen oes
not
⇒ “1.2 Draining and adding coolant”, page 212 . d by
Vo gu
ara
ise nte
r
– Release hose clip -4- and detach coolant hose -3-.
ut
ho eo
ra
s a c
– Remove bolts -arrows- and detach cover -2- from thermostat s
ce
le
housing.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove thermostat using special wrench - T10508- .

l purpos
– Slightly push down special wrench - T10508- and turn it in

-direction of arrow- while doing so.
nform
ercia
Installing
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Insert thermostat ensuring that the centring pin of thermostat

is seated in guide -arrow-.
AG. Volkswagen AG d
agen oes
– Install thermostat using special wrench - T10508- V. olksw not
gu
y
db ara
– Slightly push down special wrench - T10508-orandise turn it to stop nte
eo
in -direction of arrow- while doing so. th
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
Renew seals.
h re
ole,
spec
– Moisten gasket with coolant.
t to the co
Specified torques
rrectne
♦ ⇒ Fig. ““Cover for thermostat to thermostat housing - specified
s
torque”“ , page 222
s o
cial p
f inform
2.5.2 Removing and installing thermostat for
mer
atio
cylinder block coolant circuit
om
n
c
i
or
n thi
Removing
te
sd
iva
o
pr

cum
r
fo

en
ng
t.
yi Co
op
– Unscrew bolts in the sequence -F to A-.
C py
t. rig
gh ht
yri by
– Detach coolant pump from thermostat housing. cop Vo
by lksw
cted agen
Prote AG.

– Detach thermostat -2- from coolant pump -1-.

Installing
Note
Renew seals.
– Moisten gasket with coolant.
– Fit thermostat housing onto coolant pump.

• Centring pins on thermostat must be fitted in guides -arrows-
on coolant pump.
– Tighten bolts for thermostat housing ⇒ page 222 .
Specified torques
♦ ⇒ Fig. ““Thermostat housing to coolant pump - specified torque
and sequence”“ , page 222
2.6 Removing and installing coolant temper‐ AG. Volkswagen AG d

ature sender - G62- V olksw
agen oes
not
g y ua
db ran
Removing rise tee
tho or
au ac
• Engine cold. ss
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
The coolant expansion tank may vary in design depending on the
wit
, is n
type and version of the vehicle.
h re
hole
spec
es, in part or in w
– Briefly open cap -arrow- of coolant expansion tank to reduce
t to the co
residual pressure in cooling system, and then tighten cap
again until it engages.
rrectness of i
– Separate electrical connector:
l purpos
Note
nform
ercia
Place a cloth underneath to catch escaping coolant.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Unscrew bolt -1- and pull off coolant temperature sender -

G62- -item 2-.
Note
♦ If O-ring -3- with support ring -4- remains lodged in cylinder

head, lift out O-ring with support ring using a piece of wire.
♦ Insert new coolant temperature sender - G62- immediately in‐
to cylinder head in order to avoid loss of coolant.
Installing
Note
Renew O-ring.
– Check coolant level ⇒ page 216 .

Specified torques
♦ ⇒ “2.2 Assembly overview - coolant temperature sender”,
page 222 olks
wage es n
o
yV t gu
db ara
ise nte
2.7 Removing and installing radiator outlet
r
tho eo
au ra
coolant temperature sender - G83-
ss c
ce
le
un
pt
an
Removing
d
itte
y li
rm
ab
• Engine cold.
pe
ility
ot
wit
– Briefly open cap -arrow- of coolant expansion tank to reduce

, is n
h re
residual pressure in cooling system, and then tighten cap

hole
spec
again until it engages.

es, in part or in w
t to the co

sulation .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Disconnect connector -2-.
Note
Place a cloth underneath to catch escaping coolant.

AG. Volkswagen AG d
agen oes
olksw not
V
– Pull off retaining clip -1- and pull radiator outlet coolantedtem‐
by gu
ara
perature sender - G83- out of connection -3-. thoris nte
eo
au ra
Installing ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ Renew O-ring.
spec
es, in part or in w
♦ Insert new coolant temperature sender - G62- immediately in‐
t to the co
to connection in order to avoid loss of coolant.
rrectness of i
– Install front noise insulation ⇒ General body repairs, exterior;
l purpos
sulation .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 234
⇒ “3.2 Removing and installing coolant pipes”, page 234
3.1 Assembly overview - coolant pipes
1 - Coolant hose
2 - Bolt
❑ 8 Nm
3 - Coolant pipe
4 - Coolant hose
5 - Bolt
❑ 8 Nm
6 - Coolant hose
7 - Coolant pipe
❑ Carefully lever it out of
catches using a screw‐
driver when removing.
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 8 Nm
10 - Coolant hose
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
The arrow markings on the coolant pipes and on the ends of the
nform
ercia
coolant hoses must align.

m
a
com
tion in
3.2 Removing and installing coolant pipes

r
te o
thi
s
iva
do

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Hose clamps to 25 mm - 3094-
♦ Spring-type clip pliers - VAS 6362- AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Removing
rrectne
CAUTION
s
s o
cial p
f inform
mer
atio
om
n
c
– Wear protective goggles. i

or
n thi
e

t
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi Co
– Open filler cap -arrow- for coolant expansion tank. Cop py
ht. rig
rig ht
– Clamp off coolant hoses using hose clamps, up to 25 mm - py by
co Vo
3094- .
by lksw
cted agen
Prote AG.
3. Coolant pipes 235

– Release hose clips -arrows-, and remove coolant hoses.

– Remove coolant pipe -2-.

– Remove coolant pipe -3-.
Installing AG. Volkswagen AG d
agen oes
lksw not
Install in the reverse d byorder of removal. When doing this,
Vo gu note the
ara
following: orise nte
eo
h
aut ra
ss c
ce
e
Note
nl
pt
du
an
itte
y li
Secure all hose connections with hose clips corresponding to

erm
ab
ility

ot p
wit
, is n
h re

hole
spec
es, in part or in w
Specified torques
t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
4 Radiator, radiator fan by ara
d
rise nte
tho eo
u ra
⇒ “4.1 Assembly overview - radiator/radiator fan”, spage
sa 237 c
ce
le
⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page
un
pt
an
d
239
itte
y li
erm
ab
⇒ “4.3 Removing and installing radiator”, page 240
ility
ot p
wit
is n
⇒ “4.4 Removing and installing radiator cowl”, page 248
h re
ole,
spec
⇒ “4.5 Removing and installing radiator fan V7 ”, page 249
t to the co
4.1 Assembly overview - radiator/radiator
fan
rrectne
Note
ss o
cial p
f in
The arrows on the coolant pipes and on the ends of the coolant
form
mer
hoses must align with each other.
atio
om
n
c
i
or
n thi
e
1 - Bolt
t
sd
iva
o
pr
c
❑ 5 Nm
um
r
fo
en
ng
❑ Qty. 2
t.
yi Co
Cop py
2 - Upper radiator mounting
t. rig
gh ht
pyri by
❑ For radiator
co Vo
by lksw
cted agen
Prote
❑ If the securing tabs
AG.
break off, it is not nec‐

essary to renew the up‐
per radiator mounting.
The securing tabs can
be replaced by a specif‐
ic bolt ⇒ Electronic
Parts Catalogue “ET‐
KA” .
3 - Radiator/cooler
stalling radiator”,
page 240
placing
4 - Coolant hose
❑ Connect ⇒ page 238
5 - Radiator cowl with radiator
fan - V7-
view - radiator cowl and
radiator fan”, page 239
stalling radiator cowl”,
page 248
❑ With radiator fan control
unit - J293-
6 - Lower radiator mounting
❑ For radiator
4. Radiator, radiator fan 237

7 - Coolant hose
❑ Connect ⇒ page 238
Versions with plug-in connector:
❑ Pull out retaining clip to remove
Versions with spring-type clip:
❑ Locking bonded spring-type clips ⇒ page 238
8 - Plug
❑ 10 Nm
Locking bonded spring-type clips

– Engage clip -1- in direction of -arrow- using release tool - VAS
531 001- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
Connecting coolant hose with plug-in connector

nl
pt
du
an
itte
y li
– Check old O-ring -2- in coolant hose -3- for damage, and re‐
erm
ab
new if necessary; see ⇒ Electronic parts catalogue (ETKA) .
ility
ot p
wit
– Push coolant hose into connection -1- until it audibly engages.
, is n
h re
hole
– Press again on coolant hose and check plug-in connector is

engaged correctly by pulling hose back. spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4.2 Assembly overview - radiator cowl and radiator fan
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
stalling radiator cowl”,
page 248
3 - Radiator fan - V7-
stalling radiator fan V7 ”,
page 249
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
239
Prote AG.
4. Radiator, radiator fan
4.3 Removing and installing radiator

⇒ “4.3.1 Removing and installing radiator, Polo 2014>, Polo Sa‐
loon RUS 2016>”, page 240
⇒ “4.3.2 Removing and installing radiator, Golf 2013>, Golf Estate
2014>, Golf SV 2015>, Golf 2017>, Polo 2018>”, page 243
4.3.1 Removing and installing radiator, Polo 2014>, Polo Saloon RUS 2016>
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise ne
Golf 2013 ➤ , Golf 2017 ➤ , Golf thor Sportsvan 2015 ➤ , Golf Variant 2014 ➤ t...
eo
u
a (1.6 l engine, 4 V, EA 211) - Edition 11.2018 r ac
ss
ce
le
un
pt
an
d
itte
y li
equipment required
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Guide pins - 3411-
♦ Torque wrench (5 … 13 Nm) - VAS 6854-
♦ Ratchet insert 1/4" - VAS 6234- AG. Volkswagen
n AG do
wage es n
Removing Volks ot g
y u b ara
ed n
– Remove noise insulation
tho
ris ⇒ General body repairs, exterior; tee o
Rep. gr. 66 ; sNoise insulation; Assembly overview - noise in‐ r ac
au
sulation . s
ce
e
nl
pt
du
– Drain coolant from radiator
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Vehicles with air conditioner:
es, in part or in w
t to the co
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
rrectness of i
l purpos

– Pull upper coolant hose -1- off radiator -2-. nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew securing bolts -arrows-.

– Lift radiator out of lower mountings and press it slightly towards
rear.
Vehicles with air conditioning system
NOTICE
Risk of damage to coolant pipes caused by deformation.
– Never attempt to reshape the coolant pipe.
CAUTION


– Place condenser in lock carrier at front and secure it in place
to prevent it from falling down.
– Removing radiator.
Installing
the following:
Note
If there are minor dents in the fins, refer to

⇒ “3.7 Fitting radiator and condensers”, page 6 .
– Tighten securing bolts -arrows- using torque wrench

(5 ... 13 Nm) - VAS 6854- and ratchet insert 1/4 inch - VAS
6234- .
– Install front bumper cover ⇒ General body repairs, exterior;
cover .
– Add coolant ⇒ “1.2 Draining and adding
wage
ncoolant”,
AG. Volkswpage
agen A212
G do .
e ks s no
Vol t gu
d by ara
e nte
ris
Note utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
Specified torques
erm
ab
ility
ot p

wit
, is n
h re
hole
spec
4.3.2 Removing and installing radiator, Golf

es, in part or in w
t to the co
2013>, Golf Estate 2014>, Golf SV

2015>, Golf 2017>, Polo 2018>
rrectness of i

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Ratchet 1/4” x 9-11 - VAS 6234-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
♦ Torque wrench 2-10 Nm - VAG 1783- ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Lever - 3409-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Drain coolant

– Remove assembly frame -1- ⇒ General body repairs, exterior;

Rep. gr. 50 ; Lock carrier; Removing and installing lock carri‐
er .
⇒ “4.4 Removing and installing radiator cowl”, page 248

– Pull off coolant hoses -1- from top left of radiator -2-.
AG. Volkswagen AG d
agen oes
o lksw not
byV gu
ara
ed
ris nte
– Separate electrical
ut
ho
connector -4- and remove from its retainer eo
ra
-arrow-.ss a c
ce
e
nl
– Press in locking tab on both sides using removal wedge -

pt
du
an
3409- -1-.
itte
y li
erm
ab
– Move cowling -2- slightly in direction of -arrow- to gain access

ility
ot p
to radiator mounting -3-.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Vehicles with original radiator mounting carrier

l purpos
– Release catches -arrows- of radiator mounting -1- on left and

right, or cut through using side cutters.
nf
ercia
orm
m
atio
om
n in
Note
or c
thi
te
sd
a
The radiator mounting carrier will be reused during installation. It

iv
o
r
rp
cu
will then be bolted to the lock carrier. Bolts ⇒ ETKA (Electronic

o
m
f
en
ng
parts catalogue) .
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Vehicles with radiator mounting carrier, bolted

– Unscrew bolts -2- of radiator mounting carrier -1- on left and
right.
Vehicles with air conditioning system

– Push upper edge of radiator slightly in direction of engine.
– Raise radiator, disengage from lower mounting points and
push backwards.
– Press catches -1- on both sides in -direction of arrow A- to
release them.
– Pull condenser -3- upwards in direction of -arrow B- and de‐
tach from radiator.
– Tie up condenser on lock carrier.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Continued for all vehicles ised b ara
nte
or eo
h
– Lift radiator -1- at bottom out of radiator mountings
aut -arrows-. ra
ss c
ce
– Remove radiator -1- upwards.
le
un
pt
an
d
itte
Installing
y li
erm
ab
ility

ot p
wit
is n
h re
ole,
spec
Note
t to the co
If there are minor dents in the fins, refer to

⇒ “3.7 Fitting radiator and condensers”, page 6 .
rrectne
– Insert radiator -1- at bottom into radiator mountings -arrows-.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Bring condenser -3- into installation position.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Installation position of radiator mounting
ce
e
nl
pt
du
an
– Fit radiator mountings -1- on left and right onto radiator. When
itte
y li
erm
doing so, note the installation position -arrow-.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
– Insert radiator into lock carrier. Ensure proper seating of radi‐

f
en
ng
t.
yi
ator mountings -1- in lock carrier.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Vehicles with radiator mounting carrier, bolted

– If fastener was cut off, bolt radiator mountings to lock carrier.
Bolts -2- ⇒ Electronic parts catalogue (ETKA) .
• Specified torque: 5 Nm
– Install assembly frame ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Removing and installing lock carrier .
– Install front bumper cover ⇒ General body repairs, exterior;
cover .
⇒ “4.4 Removing and installing radiator cowl”,
lksw
agepage 248 . es n
o ot g
yV ua
– Add coolant ⇒ page 213 . ir se
db ran
tee
ho
Specified torques aut or
ac
ss
ce
le

un
pt
an
d
itte
y li
rm
4.4 Removing and installing radiator cowl
ab
pe
ility
ot
wit
, is n
h re
CAUTION
hole
spec
Danger of injury; the radiator fans can run at any time.
es, in part or in w
t to the co
– Separate electrical connectors.
Removing
rrectness of i
l purpos

sulation .
nform
ercia
– Release and pull off connector -1- on radiator fan.

m
a
com
ti
– To do this, push securing mechanism towards rear -arrow A-,

on in
and press down release mechanism.

r
te o
thi
s
iva
– Press locking tabs on left and right of radiator cowl -arrow B-.
do
r
rp
cum
fo
– Pull radiator cowl upwards, and remove it from mountings on

en
ng
t.
yi
radiator.
Co
Cop py
t. rig
gh
– Turn radiator cowl slightly, and remove it towards bottom.
ht
pyri by
Vo
co lksw
by
Installing
cted agen
Prote AG.

the following:
– Install wires ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
Specified torques

4.5 Removing and installing radiator fan -

V7-
Torque wrench - V.A.G 1410-
Removing
Note
Reinstall all cable ties in the same locations when installing.

olkswagen AG
– Separate electricalswconnector:
agen
AG. V does
k not
Vol g
– Unscrew bolts d by-arrows- and remove radiator fanu-arV7-
an .
ise tee
or
Installing auth or
ac
ss
ce
le
un
pt
an
d
itte

y li
erm
⇒ “4.4 Removing and installing radiator cowl”, page 248 . ab

ility
ot p
Specified torques
wit
is n
h re
ole,
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,

spec
page 239
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen
Golf 2013 ➤ , Golf 2017ksw ➤ , Golf Sportsvan 2015
agen AG do
es n ➤ , Golf Variant 2014 ➤ ...
Vol o g
db
y engine (1.6 l engine, 4 V, EA t211)
ua - Edition 11.2018
ra
e nte
ris
tho eo
au ra
24 – Mixture preparation - injection

ss c
ce
e
nl
pt
du
an
itte
y li
erm
1 Injection system
ab
ility
ot p
wit
, is n
⇒ “1.1 Overview of fitting locations - injection system”,
h re
page 250
hole
spec
es, in part or in w
⇒ “1.2 Assembly overview - fuel system”, page 256
t to the co
1.1 Overview of fitting locations - injection system
rrectness of i
Overview of fitting locations - engine from above, Golf, Golf Es‐
tate, Golf SV, Polo 2018
l purpos
1 - Inlet camshaft control valve
nform
ercia
1 - N205-
m
at
om
ion
c
in t
or
view - camshaft hous‐
his
ate
ing”, page 116
do
priv
cum
or

f
en
g

n
t.
yi Co
op
stalling camshaft control C py
t. rig
valve 1 N205 ”,
gh ht
pyri by
page 176
o Vo
by c lksw
cted agen
Prote AG.
2 - Ignition coils with output
stages
♦ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stage - N292-
view - ignition system”,
page 311
stalling ignition coils
with output stage”, page
312
3 - Lambda probe 1 before cat‐
alytic converter - GX10-
❑ Lambda probe - G39-
and Lambda probe
heater - Z19-
❑ Assembly overview ⇒ “7.1 Assembly overview - Lambda probe”, page 287
❑ Removing and installing ⇒ “7.2 Removing and installing Lambda probe”, page 288
4 - Lambda probe 1 after catalytic converter - GX7-
❑ Lambda probe after catalytic converter - G130- and Lambda probe heater 1 after catalytic converter -
Z29-
250 Rep. gr.24 - Mixture preparation - injection


❑ Camshaft position sensor
❑ Assembly overview ⇒ “1.1 Assembly overview - ignition system”, page 311
❑ Removing and installing ⇒ “1.4 Removing and installing Hall sender”, page 315
6 - Engine control unit - J623-
❑ Removing and installing ⇒ “6 Engine control unit”, page 278
8 - Intake manifold sender - GX9-
❑ Consists of intake air temperature sender - G299- and intake manifold pressure sender - G71-
❑ Assembly overview ⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 277
❑ ⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 277
9 - Throttle valve module - GX3-
❑ with throttle valve drive - G186- , angle sensor 1 for throttle valve drive - G187- and angle sensor 2 for
throttle valve drive - G188-
❑ Assembly overview ⇒ “4.1 Assembly overview - intake manifold”, page 271
❑ Removing and installing ⇒ “4.3 Removing and installing throttle valve module GX3 ”, page 274
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module GX3. V”,olpage
kswage275 AG n AG d
agen oes
10 - Injectors olksw not
yV gu
db ara
♦ Injector, cylinder 1 - N30- rise nte
tho eo
au ra
♦ Injector, cylinder 2 - N31- ss c
ce
e
nl
pt
♦ Injector, cylinder 3 - N32-
du
an
itte
y li
erm
ab
ility
ot p
❑ Assembly overview ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 258
wit
, is n
❑ Removing and installing ⇒ “2.3 Removing and installing injectors”, page 261
h re
hole
spec
❑ Checking injectors ⇒ “2.4 Checking injectors”, page 261 .
es, in part or in w
❑ Cleaning injectors ⇒ “2.5 Cleaning injectors”, page 265 t to the co

11 - Activated charcoal filter solenoid valve 1 - N80-
❑ ⇒ Rep. gr. 20 ; Activated charcoal filter system; Checking fuel tank breather
rrectness of i
l purpos
Overview of fitting locations - engine from above, Polo 2014, Polo

nform
ercia
Saloon RUS 2016

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Injection system 251

1 - Inlet camshaft control valve

1 - N205-
view - camshaft hous‐
ing”, page 116
stalling camshaft control
valve 1 N205 ”,
page 176
stages
stage - N70-
AG. Volkswagen AG d
stage - N127- ksw
agen oes
n ol ot g
yV ua
♦ Ignition coil 3 with
ed output
b ran
ris
stage - N291-
ut
ho tee
or
sa ac
♦ Ignition coil
s 4 with output ce
le
stage - N292-
un
pt
an
d
itte
y li
erm
ab
ility
ot p

wit
is n
page 311
h re
ole,

spec

t to the co

with output stage”, page
312
rrectne

ss
❑ Lambda probe - G39-

o
cial p
and Lambda probe

inform
heater - Z19-
mer
atio

om
n
c
i
or
n thi
te
sd
a
4 - Lambda probe 1 after catalytic converter - GX7-

iv
o
pr
cum
r
❑ Lambda probe after catalytic converter - G130- and Lambda probe heater 1 after catalytic converter -
fo
en
ng
Z29-
t.
yi Co
op py
t. C rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote
AG.
❑ Camshaft position sensor

6 - Engine control unit - J623-
❑ Removing and installing ⇒ “6 Engine control unit”, page 278
❑ Consists of intake air temperature sender - G299- and intake manifold pressure sender - G71-

❑ Assembly overview ⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 277
❑ ⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 277
❑ with throttle valve drive - G186- , angle sensor 1 for throttle valve drive - G187- and angle sensor 2 for
throttle valve drive - G188- n AG. Volkswagen AG do
wage es n
❑ Assembly overview ⇒ “4.1 Assembly overview - intakeymanifold”, Volks page 271 ot g
ua
d b
❑ Removing and installing ⇒ “4.3 Removing and installing
o
ir se throttle valve module GX3 ”, page 274
ran
tee
th or
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module s auGX3 ”, page 275 ac
s
ce
e
10 - Injectors
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ Removing and installing ⇒ “2.3 Removing and installing injectors”, page 261
rrectness of i
❑ Cleaning injectors ⇒ “2.5 Cleaning injectors”, page 265
l purpos
11 - Activated charcoal filter solenoid valve 1 - N80-
nform
mercia
at
Overview of fitting locations - intake side
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Knock sensor 1 - G61-

page 311
stalling knock sensor 1
G61 ”, page 314
view - oil filter/oil pres‐
sure switch”, page 205
stalling oil pressure
switch F1 ”, page 205
3 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ ⇒ Rep. gr. 20 ; Activa‐
ted charcoal filter sys‐
tem; Checking fuel tank
breather
4 - Injectors
AG. Volkswagen AG d
❑ Assembly overviewlkswagen oes
not
⇒ “2.1 Assembly d b over‐
yV
o gu
ara
view - fuel rail
oris with injec‐
e nte
tors”, pageaut 258
h eo
ra
s c
❑ Removing s
and installing
ce
e
nl
⇒ “2.3 Removing and installing injectors”, page 261

pt
du
an
itte

y li
erm
ab

ility
ot p
wit
, is n

h re
hole

spec
es, in part or in w
t to the co

❑ Consists of intake manifold pressure sender - G71- and intake air temperature sender - G42-
rrectness of i

l purpos
❑ Removing and installing ⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 277
7 - Engine speed sender - G28-
nform
ercia

m
at
om
❑ Removing and installing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 316
on
c
in t
or
his
ate
do
priv
Overview of fitting locations - exhaust side

um
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1 - Lambda probe 1 after cata‐

lytic converter - GX7-
❑ Consists of Lambda
probe after catalytic
converter - G130- and
Lambda probe heater 1
after catalytic converter
- Z29-
stalling Lambda probe”,
page 288
G62-
❑ Assembly overview -
ture sender”, page 222 .
page 231
stages
stage - N70-
stage - N127-
stage - N291-
stage - N292-
AG. Volkswagen AG d
❑ Assembly overview agen oes
olksw not
V
⇒ “1.1 Assembly over‐ d by gu
ara
view - ignition system”, page 311 rise nte
tho eo
u r
❑ Removing and installing ⇒ “1.2 Removing sand
s a installing ignition coils with output stage”, pageac312 ce
e
nl
4 - Lambda probe 1 before catalytic converter - GX10-

pt
du
an
itte
y li
erm
ab
❑ Consists of Lambda probe - G39- and Lambda probe heater - Z19-

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
255
Prote AG.
1. Injection system
1.2 Assembly overview - fuel system
1 - Air filter
view - air filter housing”,
page 267
stalling air filter hous‐
ing”, page 268
G62-
❑ Assembly overview -
ture sender”, page 222 .
page 231
❑ Consists of Lambda
probe after catalytic
converter - G130- and
Lambda probe heater 1
after catalytic converter
- Z29-
page 288 agen
AG. Volkswagen AG d
oes
olksw not
4 - Engine control unit - J623- ed byV gu
ara
is nte
❑ Removing and installing uth or eo
⇒ “6.1 Removing and in‐ ss a ra
c
stalling engine (motor)
ce
e
nl
control unit J623 ”, page 278

pt
du
an
itte
y li
5 - Intake manifold
erm
ab
ility
ot p

wit
, is n
❑ Removing and installing ⇒ “4.2 Removing and installing intake manifold”, page 272
h re
hole
spec

es, in part or in w
t to the co
❑ Consists of intake manifold pressure sender - G71- and intake air temperature sender - G42-
rrectness of i

l purpos

❑ Removing and installing ⇒ “4.3 Removing and installing throttle valve module GX3 ”, page 274
nf
ercia
orm
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module GX3 ”, page 275

m
atio
om

n in
or c
thi
e

t
sd
iva
o
r
❑ Removing and installing ⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page 314
rp
cu
o
m
f
en
ng
9 - Fuel rail with injectors

t.
yi Co
Cop py
.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
256
Prote AG.
Rep. gr.24 - Mixture preparation - injection

❑ Removing and installing fuel rail ⇒ “2.2 Removing and installing fuel rail”, page 259 .
❑ Removing and installing injectors ⇒ “2.3 Removing and installing injectors”, page 261 .
❑ Assembly overview ⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page 205
❑ Removing and installing ⇒ “4.2 Removing and installing oil pressure switch F1 ”, page 205
11 - Lambda probe 1 before catalytic converter - GX10-
❑ Consists of Lambda probe - G39- and Lambda probe heater - Z19-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2 Injectors
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 258
⇒ “2.2 Removing and installing fuel rail”, page 259
⇒ “2.3 Removing and installing injectors”, page 261
⇒ “2.4 Checking injectors”, page 261
⇒ “2.5 Cleaning injectors”, page 265
2.1 Assembly overview - fuel rail with injectors
1 - Supply line
❑ From fuel delivery unit
❑ Black with white marks.
❑ Secure with spring-type
clips
❑ Ensure firm seating
stalling fuel rail”,
page 259 wage
es n
lks
❑ Checking injectors for d byV
o ot g
ua
leaks and quantity injec‐ o
ir se
ran
tee
ted auth or
ac
⇒ “2.4 Checking injec‐
ss
tors”, page 261
ce
le
un
pt
an
d
itte
3 - Bolt
y li
erm
ab
❑ 7 Nm
ility
ot p
wit
is n
4 - Injection valve
h re
ole,
❑ Injector, cylinder 1 -
spec
N30-
t to the co
N31-
rrectne
N32-
ss
N33-
o
cial p
f in

form
mer

atio
stalling injectors”,
om
page 261
c
i
or
n thi
e
❑ Checking injectors for

t
sd
va
leaks and quantity injec‐

i
o
pr
cum
r
ted
fo
en
ng
⇒ “2.4 Checking injectors”, page 261

t.
yi Co
Cop py
. rig
5 - O-ring
t
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
❑ Before installing, moisten lightly with clean engine oil.
6 - Retaining clip
❑ Ensure correct seating on injector and fuel rail

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b Golf 2013 ➤ , Golf 2017 a➤
ran , Golf Sportsvan 2015 ➤ , Golf Variant 2014 ➤ ...
ris tee
utho 4-cylinder injection engine or (1.6 l engine, 4 V, EA 211) - Edition 11.2018
a ac
ss
2.2 Removing and installing fuel rail
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
♦ Socket Torx T 30 - T10405-
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
2. Injectors 259
– Release fuel supply line -1- nand

AG. Vpull itaoff.
olksw gen ADisconnect
G do plug-in
connectors ⇒ Rep. Vgr. wage
olks20 ; Plug-in connectors; Disconnecting
es n
ot g
plug-in connectors
ed .
by ua
ra
ris nte
ho eo
ut
CAUTION
ss
a ra
c
ce
le
The fuel system is pressurised.

un
pt
an
d
itte
Danger of injury caused by fuel spray.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– To release pressure, wrap a clean cloth around the connec‐
hole
spec
tion and carefully loosen the connection.
es, in part or in w
t to the co
– Open clamp for fuel supply line on coolant expansion tank
rrectness of i
-2-, and remove fuel supply line.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Open clamp for fuel supply line -3- on upper toothed belt guard rig ht
py by
Vo
-1-, and remove fuel supply line.
co lksw
by
cted agen
Prote AG.
– Seal line so that fuel system is not contaminated by dirt.
– Unscrew bolts -arrows- from intake manifold.

– Pull fuel rail -1- together with injectors out of the intake mani‐
fold.
Installing
following:
– Renew oil seals.
– Before installing, lightly coat seals with clean engine oil.
– Ensure proper seating of seals.
– Firmly press down fuel rail in area of fastener, and screw in
bolts by two full turns.
– Tighten bolts evenly and diagonally.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 258

2.3 Removing and installing injectors

Removing
– Removing fuel rail
⇒ “2.2 Removing and installing fuel rail”, page 259 .
– Carefully remove retaining clip -4- of injector to be removed in
-direction of arrow A-.
. Volkswagen AG
wa gen AG d
– Pull off injector onVfuel
olks rail -1- in -direction of arrow
oes
not B-.
g
y ua
db ran
Installing orise tee
h
ut or
Install in reverse
ss
a
order of removal. During this procedure, observe ac
the following:
ce
e
nl
pt
du
an
– Renew seals -3-.
itte
y li
erm
ab
– Before installing, lightly coat seals with clean engine oil.
ility
ot p
wit
, is n
h re
hole
spec
– Ensure proper seating of injectors -2- in fuel rail -1-.
es, in part or in w
t to the co
– Ensure proper seating and installation position of retaining
clips -4-.
– Installing fuel rail
rrectness of i
l purpos
Specified torques
nf
ercia
orm
m
atio
m
2.4 Checking injectors

o
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
♦ Remote control for V.A.G 1348 - V.A.G 1348/3A-

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Adapter line - V.A.G 1348/3-2-
2. Injectors 261
Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 n A➤
G.,VGolf
olkswaVariant
gen AG 2014 ➤ ...
wage does
4-cylinder injection engine (1.6 l engine,y V4oV, EA 211) - Edition 11.2018
lks not
g
b ua
ed ran
ris tee
♦ Auxiliary measuring set , e.g. -V.A.G 1594tho C- or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Injection rate tester - V.A.G 1602-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Adapter - VAS 5565-
Test conditions
• Do not disconnect fuel hoses.
• Injectors are not being removed from fuel rail.
• Fuel pressure OK ⇒ Rep. gr. 20 ; Fuel pump; Checking fuel
system pressurisation pump G6 .
• Engine and fuel temperature: approx. 20°C.
• Battery voltage must be at least 11.5 V. If necessary, connect
battery charger ⇒ Electrical system; Rep. gr. 27 ; Battery;
Charging battery .
Test sequence

– Remove fuel rail together with injectors

– Remove three measuring glasses from injection rate tester -
V.A.G 1602- .
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
Golf SV:
– Remove right rear seat ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seats; Removing and installing bench seat/indi‐
vidual seats .
– Partially detach cover -1- in floor covering at parting line
-arrow-. Volkswa AG. gen AG
agen do
– Do not detach coverolks completely from floor covering
w es n
ot g in order to
yV
ensure it issereinstalled
db in the correct installation position.
ua
ran
ri tee
ho
– Detachauitt just enough that the cover can be folded upwards.
or
ac
ss
– Fold up cover in -direction of arrow-.
ce
e
nl
pt
du
an
itte
Golf and Golf Estate:
y li
erm
ab
– Remove rear bench seat ⇒ General body repairs, interior;
ility
ot p
Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
wit
, is n
h re
individual seats .
hole
spec
es, in part or in w

t to the co
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Unclip sealing grommet -1- downwards from cover -2-.

t.
yi Co
op py
– Push cover -2- back along wiring harness -3-.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Injectors 263
– Release and pull off connector -2- on flange of fuel delivery lkswage es n
unit. d byV
o ot g
ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Connect adapter - VAS 5565- to fuel delivery unit -1-.
rrectne
– Connect remote control - V.A.G 1348/3A- to adapter -
VAS 5565- and to battery positive terminal in engine compart‐
s
ment.
s o
cial p
f
– Using auxiliary cable -3- from auxiliary measuring set , e.g. -
inform
V.A.G 1594 C- , connect connection -5- (yellow) of adapter -
mer
VAS 5565- to battery negative terminal clamp.
atio
om
n
c
i
or
n thi
te
sd
Note
iva
o
pr
cum
r
fo
This step serves only to have the fuel pump running when the
en
ng
t.
yi Co
engine is stopped. t. Cop py
rig
gh ht
pyri by
Checking quantity injected
co Vo
by lksw
cted agen
Prote AG.

– Connect a contact of injector to be checked to engine earth

using auxiliary cables from auxiliary measuring set - V.A.G
1594C- .
– Connect second injector contact with adapter cablege-nV.A.G
AG. Volkswagen AG d
1348/3-2- to remote control for V.A.G 1348 - VV.A.Gwa
olks 1348/3A- .
oes
not
g y ua
db ran
– Connect crocodile clip to positive battery
ris pole in engine com‐
e
tee
ho
partment. au
t or
ac
ss
– Place a measuring glass of injection rate tester - V.A.G 1602-
ce
le
un
pt
under injector to be checked.
an
d
itte
y li
– Activate fuel delivery unit. erm
ab
ility
ot p
– Operate remote control for V.A.G. 1348 - V.A.G 1348/3A- for
wit
is n
30 seconds to activate the injector to be checked.
h re
ole,
spec
– Switch off fuel pump.
t to the co
– Repeat check on other injectors.
– After all injectors have been activated, place measuring
rrectne
glasses on a level surface and compare the fuel quantity in‐
jected.
ss
The specification is 84…99 ml per injector.
o
cial p
f in
If the measured values of one or more injectors are above or be‐
form
mer
low the prescribed specifications:
atio
m
– Renew defective injector

o
n
c
i
or
n
⇒ “2.3 Removing and installing injectors”, page 261 .
thi
te
sd
va
Leakage test
i
o
pr
cum
r
fo
en
ng
– Place measuring glasses of injection rate tester - V.A.G 1602- yi

t.
Co
under injectors. ht. Cop py
rig
rig ht
– Activate fuel delivery unit. py by
co Vo
by lksw
cted agen
No more than 2 drops/min. must escape from each injector. Prote AG.
– Switch off fuel pump.

If the fuel loss is greater:
– Renew defective injector
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Renew O-rings on all injectors, and slightly moisten them with
clean engine oil.
– Fit fuel rail with secured injectors onto intake manifold and
tighten evenly
⇒ “2.1 Assembly overview - fuel rail with injectors”,
page 258 .
2.5 Cleaning injectors

♦ Ultrasonic cleaning device - VAS 6418-
♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid ⇒ Electronic Parts Catalogue
2. Injectors 265
Note
♦ The ultrasonic unit must be filled with cleaning agent to upper

edge of holes (see detail).
♦ Observe ultrasonic unit safety regulations and operating in‐
structions.
Cleaning
– Remove injectors
– Insert injectors -1- all the way into mounting plate for injection
modules - VAS 6418/1- -item 2-.
– Immerse injectors together with mounting plate for injection
modules - 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-.
– Switch on ultrasonic unit with button -3-.
Note
lkswage es n
Vo ot g
The time set starts to elapse as soon as a cleaning temperature ed by ua
ran
of 50°C has been attained. tho
ir s tee
u or
a ac
ss
– After cleaning, renew combustion chamber ring seal for each
ce
e
nl
pt
injector ⇒ “2.3 Removing and installing injectors”, page 261 .
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Air filter
⇒ “3.1 Assembly overview - air filter housing”, page 267
⇒ “3.2 Removing and installing air filter housing”, page 268
3.1 Assembly overview - air filter housing
1 - Air duct (bottom section)

❑ On lock carrier.
2 - Bolt
❑ 2 Nm
3 - Rubber mounting
❑ Ensure it is properly
seated.
AG . Volkswagen AG
4 - Air filter lower part ksw
agen does
not
Vol
❑ Remove any mechani‐ ed
by gu
ara
cal soiling ho
ris nte
eo
ut ra
❑ Depending on ss avehicle, c
with additional vacuum
ce
le
un
pt
connection
an
d
itte
y li
5 - Air filter element
rm
ab
pe
ility
❑ Use only genuine air fil‐
ot
wit
, is n
ter elements ⇒ Elec‐
h re
hole
spec
❑ For change intervals re‐
es, in part or in w
t to the co
fer to ⇒ Maintenance ta‐
bles
rrectness of i
⇒ Maintenance ; Book‐
let 819
l purpos
6 - Air filter upper part

nform
ercia
7 - Bolt
m
❑ 2 Nm
a
com
tion in
8 - Hose
r
te o
thi
s
❑ For crankcase ventila‐

iva
do
r
tion.
rp
cum
fo
en
ng
9 - Air intake hose

t.
yi Co
Cop py
❑ Golf 2013>, Golf Estate
t. rig
gh ht
yri
2014>, Golf SV 2015>, Golf 2017> p by
o Vo
by c lksw
cted agen
10 - Hose clamp Prote AG.
❑ Golf 2013>, Golf Estate 2014>, Golf SV 2015>, Golf 2017>

11 - Bolt
❑ Polo 2018>
❑ 2 Nm
12 - Intake connecting pipe
❑ Polo 2018>
13 - Seal
❑ Ensure it is properly seated.
14 - Bolt
❑ Qty. 2 (Golf 2013>, Golf Estate 2014>, Golf SV 2015, Golf 2017>)
3. Air filter 267

❑ Qty. 4 (Polo 2018>)
❑ 2 Nm
15 - Cover
❑ For air duct
16 - Air duct (top section)
❑ On lock carrier.
17 - O-ring
18 - Water drain hose
❑ Cleaning
3.2 Removing and installing air filter hous‐

ing
Removing air filter housing
– Pull off hose -2-.
Golf 2013>, Golf Estate 2014>, Golf SV 2015, Golf 2017>
– Release hose clip -3-, and remove air hose.
Polo 2018> AG. Volkswagen AG d
agen oes
olksw not
– Unscrew bolt for intake manifold ⇒ Item 11 (page 267) . d by V gu
ara
ise nte
r
Continued for all vehicles ut
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
– If fitted, pull vacuum line -1- off air filter -2-.
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sequence of work steps when removing the air filter housing
Note
AG. Volkswagen AG d
agen oes
ksw
When removing the air filter housing,by
Vol
make sure to perform thenot gua
necessary work steps in the risequence
se
d specified below. Other‐ ran
tee
wise, the ball heads on theuthointake manifold -arrow A- may break or
off. ss
a ac
ce
e
nl
pt
du
an
– First, pull air filter housing -1- off ball heads -arrows B-.
itte
y li
erm
ab
– Then, pull air filter housing -1- off ball heads -arrows A-.
ility
ot p
wit
– While doing this, guide out air duct -arrow C- of throttle valve
, is n
h re
module connection -2-.
hole
spec
Installing
es, in part or in w
t to the co
the following:
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Air filter 269

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Golf 2013 ➤ , Golf 2017 ➤is,e Golf Sportsvan 2015 ➤ , Golf Variant
d b ara2014 ➤
nte ...
r
ut (1.6 l engine, 4 V, EA 211) - Edition 11.2018or a
ho e
s a c
s
Sequence of work steps when installing the air filter housing
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
h re
When installing the air filter housing, make sure to perform the
hole
necessary work steps in the sequence specified below. Other‐
spec
wise, the ball heads on the intake manifold -arrow A- may break
es, in part or in w
t to the co
off.
– First, fit air filter housing -1- onto ball heads -arrows A-.
rrectness of i
– While doing this, guide air duct -arrow C- onto connection of
l purpos
throttle valve module -2-.

– Then, fit air filter housing -1- onto ball heads -arrows B-.
nform
ercia
• Make sure that the air filter housing is seated properly and
m
a
com
t
evenly on all ball heads.
ion in
r
te o
– Press air filter housing -1- as far as stop onto ball heads
thi
s
iva
-arrows A-.
do
r
rp
cum
fo
– Then, press air filter housing -1- as far as stop onto ball heads
en
ng
t.
-arrows B-.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Note
lksw
cted agen
Prote AG.
♦ If the air filter element is very dirty or wet, particles of dirt or

water may reach the components and falsify the measured air
mass value. This would lead to loss of power, since a smaller
injection quantity is calculated.
♦ A clean air filter housing is essential.
♦ Hose unions and air intake pipes/hoses must be free of oil and
grease when installing.
♦ Use a silicone-free lubricant to install the air hoses.
♦ When using compressed air to blow out the air filter housing,
cover the critical air-carrying components, such as air pipes,
with a clean cloth. This is to avoid any functional impairments.
♦ Observe disposal regulations.
– Extract mechanical soiling from upper and lower part of air fil‐
ter housing.
– Blow out water drain with compressed air.
Specified torques

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
h
aut Golf 2013 ➤ , Golf 2017 ➤ , Golf oSportsvan
ra
c
2015 ➤ , Golf Variant 2014 ➤ ...
s
s 4-cylinder injection engine (1.6 l engine, 4 V, EA 211) - Edition 11.2018
ce
e
nl
pt
du
an
itte
y li
4 Intake manifold
erm
ab
ility
ot p
wit
⇒ “4.1 Assembly overview - intake manifold”, page 271
, is n
h re
hole
⇒ “4.2 Removing and installing intake manifold”, page 272
spec
es, in part or in w
⇒ “4.3 Removing and installing throttle valve module GX3 ”, page
t to the co
274
⇒ “4.4 Cleaning throttle valve module GX3 ”, page 275
rrectness of i
4.1 Assembly overview - intake manifold
l purpos
nf
ercia
1 - Throttle valve module -
or
GX3-
m
m
atio
m
❑ Throttle valve module -

o
n in
c
GX3- consists of
or
thi
te
sd
iva
♦ Throttle valve drive for elec‐
o
r
rp
cu
tronic power control -
o
m
f
en
ng
G186-
t.
yi Co
Cop py
♦ Throttle valve drive angle
t. rig
gh ht
yri
sender 1 for electronic pow‐ p by
o Vo
by c lksw
er control - G187- Prote
cted AG.
agen
♦ Throttle valve drive angle

sender 2 for electronic pow‐
er control - G188-
❑ Cleaning
⇒ “4.4 Cleaning throttle
valve module GX3 ”,
page 275
stalling throttle valve
module GX3 ”,
page 274
❑ If renewed, clear pro‐
grammed values and
adapt engine control
unit - J623- ⇒ Vehicle di‐
agnostic tester
2 - Bolt
❑ 7 Nm
❑ Qty. 4
3 - Bolt
❑ 7 Nm
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 258
❑ Removing and installing ⇒ “2.2 Removing and installing fuel rail”, page 259
5 - Seal
6 - Intake manifold
❑ Removing and installing ⇒ “4.2 Removing and installing intake manifold”, page 272
7 - Seal
4. Intake manifold 271

8 - Seal
❑ Intake manifold sender - GX9- consists of:
♦ Intake manifold pressure sender - G71-
♦ Intake air temperature sender - G42-
❑ Repair solution for missing locking tab
⇒ “5.1 Removing and installing intake manifold sender GX9 ”, page 277
10 - Bolt
♦ Starting in centre, screw in bolt alternately towards outside as far as stop
♦ Starting in centre, tighten bolt alternately towards outside to specified torque
❑ 10 Nm
11 - Seal
4.2 Removing and installing intake manifold

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Socket Torx T 30 - T10405-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
Removing
p
cum
for

en
ng
t.
yi Co
⇒ “1 Safety information”, page 1 . t. Cop py
rig
gh ht
– Observe rules for cleanliness pyri by
Vo
co
by lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan tee 2015 ➤ , Golf Variant 2014 ➤ ...
tho
or
au 4-cylinder injection engine (1.6 l engine,
ac 4 V, EA 211) - Edition 11.2018
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
sulation .
ility
ot p
– Detach wiring harness from bottom of intake manifold
wit
, is n
h re
-arrow-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
– Release securing mechanism of plug-in connector -arrow-,

or
thi
e
and pull vacuum line -2- off intake manifold -1-.

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Release and pull off connector -2- for throttle valve module -
J338- .
– Release and pull off connector -3- for intake manifold sender
- GX9- .
– Release and pull off connector -4- of activated charcoal filter
solenoid valve 1 - N80- .
– Unclip breather line from retainer -arrow-.
– Unclip activated charcoal filter solenoid valve 1 - N80- from
intake manifold.
– Carefully pull breather line to intake manifold off activated
charcoal filter solenoid valve 1 - N80- .
– Remove fuel rail together with injectors and lay to side
Note
♦ The fuel line does not need to be disconnected.

♦ Do not remove injectors from fuel rail.

– Pull wiring harness -1- off intake manifold -arrows-.

– Remove intake manifold -1-.
If intake manifold is to be renewed, remove throttle valve module
- J338-
⇒ “4.3 Removing and installing throttle valve module GX3 ”, page
274 .
Installing
the following:
Note
Renew seals and O-rings. agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
d
orise nte
eo
aut
h
ra
tion . ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Specified torques
ot p
wit
, is n
♦ ⇒ “4.1 Assembly overview - intake manifold”, page 271 .
h re
hole
spec
es, in part or in w
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 267 t to the co

rrectness of i

l purpos
4.3 Removing and installing throttle valve

module - GX3-
nf
ercia
orm
m
atio
Removing
om
n in
c

or
thi
e

t
sd
iva
o
r
rp
cu

o
m
f
en
ng

t.
yi Co
op py
. C rig
ht ht
rig by
opy Vo
– Remove air filter housing by c lksw
cted agen
⇒ “3.2 Removing and installing air filter housing”, page 268 . Prote AG.


– Unscrew bolts -arrows-, and remove throttle valve module -
GX3- -1-.
Installing
the following:
– After throttle valve module - GX3- has been renewed, it must
be readapted to engine control unit - J623- ⇒ Vehicle diag‐
nostic tester.
♦ Guided Engine Functions
♦ Adaption of throttle valve module - J338
Specified torques
♦ ⇒ “3.1 Assembly overview - air filter housing”,
agen
AG.page
Volksw267
agen AG
d oes
ksw not
Vol gu
by ara
4.4 Cleaning throttle valve module - GX3- ed
ris nte
utho eo
ra
a c
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ If a new engine control unit - J623- is installed the throttle valve
ility
ot p
module must be adjusted.
wit
, is n
h re
♦ Contamination and coking in end stop can result in incorrect
hole
adaptation values.
spec
es, in part or in w
t to the co
♦ When cleaning the throttle valve housing, take care not to
scratch it.
rrectness of i
l purpos
♦ Acetone (commercially available)

♦ Brush
nform
ercia
Procedure
m
at
om
io

n
c
in t
r

o
his
ate
do
riv

p
cum
or

f
en
ng
t.
yi Co
– Note repair instructions ⇒ “3 Repair instructions”, page 5 . t. Cop py
rig
gh ht
– Remove throttle valve module - GX3- pyri by
Vo
co
⇒ “4.3 Removing and installing throttle valve module GX3 ”,
by lksw
cted agen
Prote
page 274 .
AG.

– Open throttle valve by hand and lock it in open position with a

wedge (plastic or wood) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.
Note
Do not use compressed air to clean throttle valve.
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush. G. Volkswage nA n AG d
wage oes
– Wipe the inside of the throttle valve housing with Vol a lint-free
ks not
gu
by
cloth. ise
d ara
nte
r
tho eo
– Allow acetone to dry off completely. s au ra
c
s
ce
– Install throttle valve module - GX3-
le
un
pt
⇒ “4.3 Removing and installing throttle valve module GX3 ”,
an
d
itte
y li
page 274 .
rm
ab
pe
ility
– Delete learnt values, and adapt engine control unit - J623- to
ot
wit
, is n
throttle valve module - GX3- ⇒ Vehicle diagnostic tester.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5 Senders and sensors

⇒ “5.1 Removing and installing intake manifold sender GX9 ”,
page 277
5.1 Removing and installing intake manifold

sender - GX9-
Intake manifold sender - GX9- consists of:
♦ Intake air temperature sender
♦ Intake manifold pressure sender - G71-
Removing
– Release and pull off connector on eintake manifold
n AG. Volkswagen Asender
G do
-
GX9- -2-. olks
wag es n
o V t gu
by a
– Remove intake manifold ris sender - GX9- -2-. To do this, release ntee
ed ra
retaining tab -arrow-.
au
tho
or
a
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
The intake manifold sender - GX9- -2- may then also be bolted to
ility
ot p
the intake manifold -1-. In this case unscrew the bolts from holes
wit
, is n
-3-.
h re
hole
spec
es, in part or in w
Installing
Install in reverse order of removal. During this procedure, observe t to the co
the following: rrectness of i
l purpos
Note
nf
ercia
♦ Renew O-ring.
orm
m
atio
♦ If the retaining tabs broke off during removal, the sender can
om
be secured using two securing bolts as per ⇒ Electronic Parts

n in
or c
Catalogue ⇒ page 277 .

thi
te
sd
iva
o
r
rp
cu
Torque
o
m
f
en
ng
t.
yi Co
Component Specified torque
Cop py
t. rig
gh ht
Intake manifold sender - GX9- 3 Nm
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Senders and sensors 277

6 Engine control unit

⇒ “6.1 Removing and installing engine (motor) control unit J623
”, page 278
6.1 Removing and installing engine (motor)

control unit - J623-
⇒ “6.1.1 Removing and installing engine control unit J623 , engine
control unit with metal locking plate, Golf 2013>, Golf Estate
2014>, Golf SV 2015>, Golf 2017>; Polo 2018>”, page 278
control unit with protective housing, Golf 2013>, Golf Estate
2014>, Golf SV 2015>, Golf >2017, Polo 2018>”, page 281
control unit with protective housing, Polo 2014>, Polo Saloon
RUS 2016>”, page 283
⇒ “6.1.4 Removing and installing engine control unit J623 , without
protective housing, Polo 2014> Polo Saloon RUS 2016>”,
page 285
6.1.1 Removing and installing engine control AG. Volkswagen AG d

agen
unit - J623- , engine control unit with by Volksw oes
not
gu
metal locking plate, Golf 2013>, Golf iEs‐
d ara
se nte
or eo
h
tate 2014>, Golf SV 2015>, Golfss2017>;
aut ra
c
Polo 2018>
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Hot air blower - VAS 1978/14A- -1- with nozzle attachment
wit
-2- from wiring harness repair set - VAS 1978 B-
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
♦ Wiring harness repair set - VAS 1978 B-

i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Small grinder (commercially available)

♦ Vehicle diagnostic tester

Removing
– If engine control unit is renewed, select test sequence/function
Replace engine control unit on “vehicle diagnostic tester” in
“Guided functions” mode.
– Switch off ignition and remove key from ignition lock.
Note
♦ If the engine control unit comes into contact with the positive
battery terminal, permanent damage to the engine control unit
will be the consequence. agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ Therefore, make sure to disconnect
d b the battery before remov‐
yV ua
ran
ing the engine control unit. ris
e
tee
tho or
au ac
ss
ce
e
nl
Disconnecting and connecting battery .
pt
du
an
itte
y li
– Release retaining clip -arrow- and take out engine control unit
erm
ab
- J623- .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Make groove (for a screwdriver) in head of shear bolt -1- using

atio
m
a small grinder -2-.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Engine control unit 279

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.
♦ Set hot air blower as shown in illustration.
– In other words, set potentiometer for temperature regulation

-2- to maximum heating output and 2-stage switch for air vol‐
ume -3- to position 3.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
– Hold hot air blower - VAS 1978/14A- with nozzle attachment

-arrow- to thread of shear bolt.
– Heat shear bolts for approx. 20 to 30 seconds.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Unscrew shear bolt -1- with screwdriver -2-.

hole
spec
– Detach metal locking plate from connectors for engine control

es, in part or in w
t to the co
unit - J623- .
– Release and pull off connectors.
rrectness of i
Installing
l purpos

the following:
nform
ercia
– The metal locking plate must always be re-fitted on the engine

control unit - J623- .
m
a
com
tion in
– Clean the threaded holes for the shear-head bolts of locking

r
te o
thi
compound residues. A thread chaser is suitable for cleaning.

s
iva
do
r
– Use new shear-head bolts.

rp
cum
fo
en
ng
After a new engine (motor) control unit has been installed, the
t.
yi Co
op
following work procedure must be carried out:
C py
ht. rig
rig ht
py by
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; co Vo
by lksw
cted agen
Prote AG.
– Connect vehicle diagnostic tester .

– Switch on ignition and select the following menu options on
vehicle diagnostic tester :
♦ Renewing engine control unit

6.1.2 Removing and installing engine control

AG. Volkswagen AG d
unit - J623- , engine control unit with olksw
agen oes
not
protective housing, Golf 2013>, Golf
yV
Es‐
b gu
d ara
ise nte
r
tate 2014>, Golf SV 2015>, ut Golf >2017,
ho eo
a ra
s c
Polo 2018> s
ce
le
un
pt
an
d
itte
y li
rm
ab
♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle -2- from
pe
ility
ot
wiring harness repair set - VAS 1978 B-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
♦ Wiring harness repair set - VAS 1978 B-
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Small grinder (commercially available)

♦ Vehicle diagnostic tester
Removing
– If engine control unit is renewed, select test sequence/function
Replace engine control unit on “vehicle diagnostic tester” in
“Guided functions” mode.
– Switch off ignition and remove key from ignition lock.
Note
will be the consequence.
♦ Therefore, make sure to disconnect the battery before remov‐
ing the engine control unit.


To remove protective housing -1-, unscrew shear bolts -arrows-

as follows:
– Make groove (for a screwdriver) in head of shear bolt -1- using

a small grinder -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ The threads of the shear bolts are secured with locking fluid.
To unscrew these bolts, the threads must therefore be heated
rrectne
with the hot air blower.
s
♦ Set hot air blower as shown in illustration.
s o
cial p
f inform
– In other words, set potentiometer for temperature regulation
mer
-2- to maximum heating output and 2-stage switch for air vol‐
atio
m
ume -3- to position 3.

o
n
c
i
or
n thi
te
NOTICE
sd
iva
o
pr
cum
r
Risk of damage to adjacent components caused by hot air

fo
en
ng
blower. Risk of overheating.

t.
yi Co
op py
– If necessary, cover adjacent components. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.

– Unscrew shear bolt -1- with screwdriver -2-.
– Release fastener -arrow- and detach engine control unit -1-.

– Release and pull off connectors for engine (motor) control unit
- J623- .
Installing
– It is essential that the engine (motor) control unit - J623- be
provided with the protective housing again.
– Use new shear-head bolts.
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out: wage
e
olks s no
t gu
– Connect battery ⇒ Electrical system; Rep. gr. 27ed;byBattery;
V
ara
Disconnecting and connecting battery . ho
ris nte
eo
t
au ra
– Connect vehicle diagnostic tester . ss c
ce
e
nl
pt
– Switch on ignition and select the following menu options on
du
an
itte
vehicle diagnostic tester :
y li
erm
ab
ility
ot p
wit
, is n
♦ Renewing engine control unit
h re
hole
spec
es, in part or in w

t to the co
unit - J623- , engine control unit with
protective housing, Polo 2014>, Polo
rrectness of i
Saloon RUS 2016>

l purpos
If engine control unit is to be renewed:

nf
ercia

orm
m
atio
– Select operating mode Guided functions .

om
n in
or c
– Carry out guided function Renew control unit .

thi
te
sd
iva
o
r
Removing
rp
cu
o
m
f
en
ng
– Switch off ignition.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note
will be the consequence.
– Open line guide -1- and raise catch -2-.

– Remove engine control unit from its bracket.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Unscrew shear-head bolts -1- using a pair of pliers.
s c
ce
le
un
pt
– Turn engine control unit -2- around and also unscrew second
an
d
itte
shear-head bolt using a pair of pliers.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– Pull bracket -1- and protective housing -2- off engine control
s o
cial p
unit -3- in -direction of arrow-.

inform
mer
– Release connector from engine control unit and pull off.

atio
m
Installing
o
n
c
i
or
n thi
e
Install in reverse order of removal. When doing this, observe the

t
sd
va
following:
i
o
pr
cum
r
fo
en
– Attach and lock connectors.

ng
t.
yi Co
op py
– Push protective housing over engine control unit. t. C rig
gh ht
pyri by
– Install protective housing bracket with new shear bolts.
o Vo
by c lksw
cted agen
Prote AG.
– Tighten shear-head bolts evenly until bolt head breaks off.

– Insert engine control unit into mounting bracket on plenum

chamber bulkhead until it audibly engages in catch -1-.
– Press line into line guide -1- and close.
– Read event memory and rectify any faults.
– Clear event memory.
– Carry out road test.
– Read event memory again.
If engine control has been renewed:
Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
– Carry out guided function Renew engine control unit .

unit - J623- , without protective housing, AG. Volkswagen AG d
agen
Polo 2014> Polo Saloon RUSby2016>
oes
olksw not
V gu
ara
ed nte
If engine control unit is to be renewed: oris e
th or
au ac
– Connect vehicle diagnostic tester . ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
Removing
is n
h re
ole,
– Switch off ignition.
spec
t to the co
Note
rrectne
will be the consequence. ss o
cial p

inform

mer
atio
om
– Release -arrow- connectors from engine control unit and pull

c
i
or
off.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw
Golf 2013 ➤ , Golf by
V2017 ➤ , Golf Sportsvan 2015ot➤
ol n
gu , Golf Variant 2014 ➤ ...
d ara
orise engine (1.6 l engine, 4 V, EA 211) -nEdition
tee 11.2018
h
aut or
ac
– Press clips -arrows A- outwards and pull engine control unit
ss
ce
e
out to side -B-.
nl
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
– Insert new engine control unit and press it to left.
wit
, is n
h re
– Connect connectors and lock.
hole
spec
es, in part or in w
t to the co
– Read event memory and rectify any faults.
– Clear event memory.
rrectness of i
– Carry out road test.
l purpos
– Read event memory again.

If engine control has been renewed:
nf
ercia
orm
m
Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
atio
m
connecting and connecting battery .

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
lksw not
7 Lambda probe Vo gu
by ara
d
rise nte
ho eo
⇒ “7.1 Assembly overview - Lambda probe”,
s a page 287
ut ra
c
s
⇒ “7.2 Removing and installing Lambda probe”, page 288
ce
e
nl
pt
du
an
itte
7.1 Assembly overview - Lambda probe
y li
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
♦ New lambda probes are coated with an assembly paste. This paste must not get into the slots on the Lambda
t to the co
probe body.
♦ In the case of a used Lambda probe, grease only the thread with high-temperature paste. This paste must
rrectness of i
not get into the slots on the Lambda probe body. High-temperature paste ⇒ Electronic parts catalogue .
l purpos
♦ During installation, the electrical connecting cable of the Lambda probe must be secured at the same points.
The wire must be prevented from touching the exhaust pipe.
nf
ercia
orm
m
atio
om
n in
or c
thi
e
❑ Not fitted on Polo 2018>

t
sd
iva
with emissions class
o
r
rp
cu
EU3
o
m
f
en
ng
t.
yi
❑ Lambda probe 1 after
Co
op py
catalytic converter - t. C rig
gh ht
GX7- consists of yri
p by
co Vo
by lksw
cted
♦ Lambda probe after catalyt‐
agen
Prote AG.
ic converter - G130-
♦ Lambda probe 1 heater af‐
ter catalytic converter -
Z29-
page 288
❑ 55 Nm
2 - Connector
❑ For Lambda probe 1 be‐
fore catalytic converter -
GX10- .
3 - Connector
❑ For Lambda probe 1 af‐
ter catalytic converter -
GX7- .
❑ Lambda probe 1 before
catalytic converter -
GX10- consists of
♦ Lambda probe - G39-
♦ Lambda probe heater -
Z19-
❑ 55 Nm
7. Lambda probe 287

7.2 Removing and installing Lambda probe

AG. Volkswagen n AG do
ks wage es
⇒ “7.2.1 Removing and yinstalling
Vol lambda probe 1 before not catalytic
g
converter GX10 / lambdad b probe 1 after catalytic converteruGX7
nte ”,
ara
ise
r
page 288 utho eo
r
a ac
ss
7.2.1 Removing and installing lambda probe 1
ce
le
un
pt
before catalytic converter - GX10- /
an
d
itte
y li
rm
lambda probe 1 after catalytic converter
ab
pe
ility
- GX7-
ot
wit
, is n
h re
hole
spec
es, in part or in w
♦ Lambda probe open ring spanner set - 3337-
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
♦ Lambda probe 1 after catalytic converter - GX7- -1-
cted agen
Prote AG.
♦ Not fitted on Polo 2018> with emissions class EU3.
Removing
– Unplug corresponding electrical connector:
1- For Lambda probe 1 after catalytic converter - GX7- .
2- For Lambda probe 1 before catalytic converter - GX10- .

– Unscrew corresponding Lambda probe using a spanner from

Lambda probe open ring spanner set - 3337- .
1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39-
Installing
following:
Note
♦ New lambda probes are coated with an assembly paste. This

paste must not get into the slots on the Lambda probe body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic Parts Catalogue “ETKA”
♦ During installation, the electrical connecting cable of the
Lambda probe must be secured at the same points. The wire
must be prevented from touching the exhaust pipe.
– If a lambda probe has been renewed, erase learnt values and

adapt lambda probe to engine control unit.
– Switch on ignition, connect ⇒ Vehicle diagnostic tester and
select the following on after the other:
♦ Erase learnt values agen
AG. Volkswagen AG d
oes
olksw not
♦ Lambda probe adaption ed by V gu
ara
ris nte
o eo
Specified torques aut
h
ra
ss c
♦ ⇒ “7.1 Assembly overview - Lambda probe”, page 287
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Lambda probe 289

26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 290
⇒ “1.2 Separating exhaust pipes from silencers”, page 297
⇒ “1.3 Removing and installing silencer”, page 299
⇒ “1.4 Aligning exhaust system free of stress”, page 303
⇒ “1.5 Check exhaust system for leaks”, page 303
1.1 Assembly overview - silencers

⇒ “1.1.1 Assembly overview - silencers, Golf 2013>, Golf SV
2015>, Golf 2017>”, page 290
⇒ “1.1.2 Assembly overview - silencers, Golf Estate 2014>”, page
292
⇒ “1.1.3 Assembly overview - silencers, Polo 2014>, Polo Saloon
RUS 2016>, Polo 2018>”, page 295
1.1.1 Assembly overview - silencers,

Volkswa
Golf 2013>, Golf SV 2015>, Golf 2017>
AG. gen AG
agen does
olksw not
yV gu
1 - Retainer rise
db ara
nte
❑ Renew if damagedtho eo
s au ra
c
s
2 - Bolt
ce
e
nl
pt
du
an
❑ 20 Nm
itte
y li
erm
ab
3 - Mounting »A«
ility
ot p
wit
, is n
h re
❑ Only for rear silencer

hole
spec
❑ Aligning ⇒ page 291

es, in part or in w
t to the co
4 - Rear silencer
❑ Combined in one unit
rrectness of i
with front silencer as

original equipment. Can
l purpos
be renewed individually
for repair purposes.
nform
ercia

m
at
stalling silencer”,
om
io
page 299
n
c
in t
or
his
e
❑ Separating exhaust
at
do
riv
pipes from silencers

p
cum
⇒ “1.2 Separating ex‐

for
en
g
haust pipes from silenc‐

n
t.
yi Co
op
ers”, page 297 C py
t. rig
gh ht
❑ Aligning exhaust sys‐ yri
p by
o Vo
tem free of tension
c by lksw
cted agen
⇒ “1.4 Aligning exhaust
Prote AG.
system free of stress”,

page 303 .
5 - Rear clamp
❑ Align exhaust system
free of tension before
tightening
290 Rep. gr.26 - Exhaust system

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Golf 2013 ➤ , Golf 2017 orise ➤ , Golf Sportsvan 2015 ➤ , Golf Variant nte 2014 ➤ ...
eo
h
s aut
engine (1.6 l engine, 4 V, EA 211) - Edition r a11.2018
c
s
ce
le
un
page 303 .
pt
an
d
itte
y li
erm
ab
❑ Tighten threaded connections evenly.
ility
ot p
wit
is n
6 - Nut
h re
ole,
❑ 30 Nm
spec
t to the co
7 - Retainer
rrectne
8 - Bolt
❑ 20 Nm +90°
ss
9 - Mounting »B«
o
cial p
f in
form
mer
❑ Only for front silencer
atio
om
n
c
i
or
n thi
e
10 - Front silencer
t
sd
iva
o
pr
c
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
um
r
fo
purposes.
en
ng
t.
yi Co
op
❑ Removing and installing ⇒ “1.3 Removing and installing silencer”, page 299 C py
t. rig
gh ht
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 297 yri
p by
co Vo
by lksw
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 303 . cted agen
Prote AG.
Aligning mounting »A«

– Pre-tighten bolt.
– Align mounting at elongated hole as necessary.
– Using blunt side of commercially available 8 mm drill bit, align
holes of mounting -A- centrally and perpendicular to longitu‐
dinal member.
– Then tighten to specified torque.
1. Exhaust pipes and silencers 291

Aligning mounting »B«

– Using blunt end of commercially available 8 mm drill bit, align
holes -arrows- of mounting -B- centrally and parallel to longi‐
tudinal member.
Installation position of rear clamp

– Fit clamp in position shown.
AG. Volkswagen AG d
agen oes
• Permissible installation angle -α- = approx. 20°. y Volksw not
gu
b ara
ed
• Bolt connections face to rear. ho
ris nte
eo
t
au ra
• Nuts upwards. ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
1.1.2 Assembly overview - silencers, Golf Estate 2014>
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw not
Golf 2013 ➤ , Golf by V 2017 ➤ , Golf Sportsvan 2015
ol
gu➤ , Golf Variant 2014 ➤ ...
ara
d
4-cylinder
orise injection engine (1.6 l engine, 4 V, EA nte 211) - Edition 11.2018
eo
th
au ra
s c
1 - Front silencer s
ce
e
nl
pt
du
an
itte
with rear silencer as
y li
erm
ab
ility
ot p
wit
, is n
h re
❑ Removing and installing hole
spec
es, in part or in w
t to the co
page 299
rrectness of i
l purpos

ers”, page 297
nform
ercia
❑ Aligning exhaust sys‐

tem free of tension
m
at
om
ion
c
in t
or
page 303 .
his
ate
do
priv
c
2 - Retainer
um
for
en
g
n
t.
yi Co
Cop py
3 - Mounting »A«
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
AG.
4 - Bolt
❑ M8 x 25
❑ 20 Nm
5 - Nut
❑ 30 Nm
6 - Rear clamp
tightening ⇒ “1.4 Aligning exhaust system free of stress”, page 303 .
7 - Mounting »B«
8 - Bolt
❑ M8 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 299
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 297
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 303 .
10 - Mounting »C«
11 - Retainer

12 - Bolt
❑ M8 x 25
❑ 20 Nm
Aligning mounting »A«

– Using blunt end of commercially available 8 mm drill bit, align wage
es n
holes -arrows- of mounting -A- centrally and parallel to longi‐ y V olks ot g
ua
tudinal member. ised b ran
r tee
ho
– Then tighten to specified torque. aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Aligning mounting »B«
rrectness of i
l purpos
nform
ercia
– Align holes -arrows- of mounting -B- centrally using blunt side

m
of commercially available 8 mm drill bit.
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Mounting »C«
– Align holes -arrows- of mounting -C- centrally using blunt end
of commercially available 8 mm drill bit.
swage es n
Installation position of rear clamp byV
olk ot g
ua
d ran
ir se
– Fit clamp in position shown. th o tee
or
au ac
• ss
Permissible installation angle -α- = approx. 20°.
ce
le
un
pt
• Bolt connections face to rear.
an
d
itte
y li
rm
ab
• Nuts upwards.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.1.3 Assembly overview - silencers, Polo 2014>, Polo Saloon RUS 2016>, Polo
2018> rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Mounting
2 - Bolt
❑ 20 Nm
❑ Qty. 2
3 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
page 299
ers”, page 297
tem free of tension
AG. Volkswagen AG d
ksw
agen oes
not
l
page 303 . by Vo gu
a d ran
ise
4 - Mounting uthor tee
or
a ac
❑ Renew ss if damaged
ce
le
un
pt
5 - Centre silencer
an
d
itte
y li

rm
ab
with rear silencer as

pe
ility
ot

wit
, is n
h re
hole

spec
es, in part or in w

t to the co

stalling silencer”, page 299
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 297
rrectness of i
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 303 .
l purpos
6 - Clamping sleeve
❑ Align exhaust system free of tension before tightening
nform
ercia
⇒ “1.4 Aligning exhaust system free of stress”, page 303 .

m

com
tion in

r
te o
thi
s
iva
❑ 23 Nm
do
r
rp
cum
fo
7 - Mounting
en
ng
t.
yi Co
❑ Renew if damaged t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installation position of rear clamp

• Angle -α- = approx. 20°.
• Bolt connections face to rear.
• Nuts upwards.
1.2 Separating exhaust pipes from silencers

⇒ “1.2.1 Separating exhaust pipes from silencers, Polo 2014>,
Polo Saloon RUS 2016>, Golf 2013>, Golf SV 2015>, Golf 2017”,
page 297
⇒ “1.2.2 Separating exhaust pipes from silencers, Golf Estate
2014, Polo 2018>”, page 298
1.2.1 Separating exhaust pipes from silenc‐

ers, Polo 2014>, Polo Saloon RUS
2016>, Golf 2013>, Golf SV 2015>, Golf
2017
♦ Chain-type pipe cutter - VAS 6254-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Procedure
es, in part or in w
t to the co
♦ The connecting pipe can be cut through at the cutting location

in order to renew the centre and rear silencers separately.
rrectness of i
♦ Cutting location is marked by an indentation on the circumfer‐

ence of exhaust pipe.
l purpos
– Cut through exhaust pipe at right angles at separating point

-arrow- using chain pipe cutter - VAS 6254- .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ar
Golf 2013 oris ➤ , Golf 2017 ➤ , Golf Sportsvan 2015an➤
e
tee, Golf Variant 2014 ➤ ...
h
4-cylinder
aut injection engine (1.6 l engine, 4 V, EA 211)or-acEdition 11.2018
ss
ce
e
– Position clamp centrally at side marks -arrows- when instal‐ nl
pt
du
an
ling.
itte
y li
erm
ab
– Fit rear clamp ⇒ page 295 .
ility
ot p
wit
, is n
– Align exhaust system free of stress
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
1.2.2 Separating exhaust pipes from silenc‐
ercia
orm
ers, Golf Estate 2014, Polo 2018>
m
atio
om
n in
c

or
thi
te
sd
a
♦ Chain-type pipe cutter - VAS 6254-

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Procedure
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.
– Cut through exhaust pipe at right angles at separating point
-arrow- using chain pipe cutter - VAS 6254- .
– When installing, position clamp centrally (-dimension a-) be‐

tween side marks -arrows-.
– Fit rear clamp ⇒ page 295 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
hGolf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015
o eo ➤ , Golf Variant 2014 ➤ ...
aut ra
ss 4-cylinder injection engine (1.6 l engine, 4 cV, EA 211) - Edition 11.2018
ce
le
un
pt
1.3 Removing and installing silencer
an
d
itte
y li
erm
ab
⇒ “1.3.1 Removing and installing front silencer, Golf 2013>, Golf
ility
Estate 2014>, Golf SV 2015>, Golf 2017>”, page 299 ot p
wit
is n
h re
ole,
⇒ “1.3.2 Removing and installing rear silencer, Golf 2013>, Golf
spec
2017>, Golf SV 2015>”, page 300
t to the co
⇒ “1.3.3 Removing and installing rear silencer, Golf Estate 2014”,
page 300
rrectne
⇒ “1.3.4 Removing and installing silencers, Polo 2014>, Polo Sa‐
loon 2016>, Polo 2018>”, page 301
ss
1.3.1 Removing and installing front silencer,
o
cial p
f in
Golf 2013>, Golf Estate 2014>, Golf SV
form
mer
2015>, Golf 2017>
atio
om
n
c
i
or
n
Removing
thi
te
sd
va
– Remove rear tunnel cross member ⇒ General body repairs,

i
o
pr
cum
exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
r
fo
en
ng
view - underbody cladding .

t.
yi Co
Cop py
ht. rig
rig ht
py by
Note
co Vo
by lksw
cted agen
Prote AG.
♦ The illustration is provided for better clarity.

♦ Installation locations may vary depending on version.
Separating point without clamp

– Separate silencers
⇒ “1.2 Separating exhaust pipes from silencers”, page 297
Separating point with clamp
– Loosen clamp -arrow-, and push it towards rear.
– Detach rubber mounting of front silencer
⇒ Item 7 (page 291) .
– Loosen clamp -arrow-, and push it forwards.

– Remove front silencer.
Installing
the following:
Specified torques
• ⇒ “1.1 Assembly overview - silencers”, page 290
• ⇒ “2.1 Assembly overview - emission control”, page 305
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding; Assembly overview - underbody cladding

1.3.2 Removing and installing rear silencer,

Golf 2013>, Golf 2017>, Golf SV 2015>
Removing
– If fitted, remove rear left underbody trim ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Assembly over‐
view - underbody panels .
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
n AG. Volkswagen A
Separating point without clamp olkswage G do
es n
ot g
y V ua
b
– Separate silencers rised ran
tee
⇒ “1.2 Separating exhaust
ut
ho
pipes from silencers”, page 297 or
a ac
ss
Separating point with clamp
ce
le
un
pt
an
– Loosen clamp -arrow-, and push it forwards.
d
itte
y li
erm
ab
– Remove bolt -2- on both sides.
ility
ot p
wit
– Remove rear silencer -1-.
is n
h re
ole,
Installing
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
Make sure to obtain the same distance -dimension a- to the marks
yi Co
op
-arrows-.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Align exhaust system free of stress Prote
cted AG.
agen
Specified torques
1.3.3 Removing and installing rear silencer,

Golf Estate 2014
Removing
– If fitted, remove rear left underbody trim ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Assembly over‐
view - underbody panels .

CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.
Separating point without clamp

– Separate silencers n AG. Volkswagen AG do
wage
⇒ “1.2 Separating exhaust
yV
olkspipes from silencers”, page
es n
ot 297
g b ua
ed ran
Separating point with
ho
risclamp tee
t or
au ac
– Loosen clamp
ss -arrows-, and push it forwards.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolts -1- and -2-.
nform
ercia
– Unscrew bolt -3-, and remove rear silencer -4-.

m
Installing
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Make sure to obtain the same distance -dimension a- to the marks

-arrows-.

Specified torques
1.3.4 Removing and installing silencers, Polo

2014>, Polo Saloon 2016>, Polo 2018>
Removing
– Separate exhaust system
⇒ “1.2 Separating exhaust pipes from silencers”, page 297 .

4-cylinder injection engine (1.6 l engine,
wag4e V, EA 211) - Edition
n AG. Volkswagen AG do 11.2018
e ks s no
Vol t gu
by ara
Centre silencer ris
ed
nte
utho eo
– Loosen clamp -arrow-, and push
ss it to rear.
a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolts -2- to remove bracket -4-.

– Remove middle silencer -5-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Rear silencer
– Remove brackets -1- and -2-.
– To do this, unscrew bolts -2-.
– Guide out rear silencer -3- between rear axle and body.
Installing
the following:
Specified torques
♦ ⇒ “1.1 Assembly overview - silencers”, page 290

1.4 Aligning exhaust system free of stress

⇒ “1.4.1 Aligning exhaust system free of stress”, page 303
⇒ “1.4.2 Align end exhaust pipes”, page 303
1.4.1 Aligning exhaust system free of stress

Procedure
• The exhaust system must be aligned when cold.
gen AG
. Volkswagen AG
d wa oes
olks not
– Loosen bolt connections for front clamp
d b -arrow-.
yV gu
ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Push exhaust system towards front of vehicle until preloading
at mounting for exhaust pipe -a- = 5 mm.
s
– Fit front clamp ⇒ page 306 .
s o
cial p
f in
Specified torques
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
1.4.2 Align end exhaust pipes
c by lksw
cted agen
Prote AG.
Procedure
– Unfasten rear silencer mounting to align tailpipes.
– Align rear silencer maintaining distance -a- and -b- between
bumper cut-out and exhaust pipe.
Adjustment dimension
Dimension a: 35 mm
Dimension b: 25 mm
Specified torques
♦ Securing bolts for mountings
⇒ “1.1 Assembly overview - silencers”, page 290
1.5 Check exhaust system for leaks

Procedure
– Start engine and run it at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.

– Check (by listening) points of connection between exhaust

manifold and cylinder head as well as cutting points to make
sure there are no leaks.
– Repair any leaks found.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Exhaust gas cleaning

agen
AG. Volkswagen AG d
o w es n
olks ot g
⇒ “2.1 Assembly overview -demission
by
V control”, page 305 ua
ran
e
ris tee
⇒ “2.2 Removing and installing
ut
ho catalytic converter”, page 308 or
a ac
ss
2.1 Assembly overview - emission control
ce
e
nl
pt
du
an
itte
⇒ “2.1.1 Assembly overview - emission control, Golf 2013>, Golf
y li
erm
ab
2017>, Golf SV 2015>, Golf Estate 2014”, page 305
ility
ot p
wit
⇒ “2.1.2 Assembly overview - emission control, Polo 2014>, Polo
, is n
h re
Saloon RUS 2016>, Polo 2018>”, page 307
hole
spec
2.1.1 Assembly overview - emission control, Golf 2013>, Golf 2017>, Golf SV
es, in part or in w
t to the co
2015>, Golf Estate 2014
rrectness of i
1 - Clamping sleeve
l purpos

tightening
nf
ercia
o
rm
m
atio
m
page 303 .
o
n in
or c
thi
❑ Installation position and
te
sd
a
specified torque
iv
o
r
rp
cu
⇒ page 306
o
m
f
en
ng
❑ Tighten bolted connec‐

t.
yi Co
op
tions evenly.
C py
ht. rig
rig ht
py by
2 - Front exhaust pipe with cat‐ co Vo
by lksw
alytic converter
cted agen
Prote AG.
❑ Do not bend flexible joint
more than 10°. Other‐
wise, it can be dam‐
aged.
❑ Install flexible joint so
that it is not under ten‐
sion
❑ Take care not to dam‐
age wire mesh on de‐
coupling element.
❑ Protect catalytic con‐
verter from damage by
knocks and impact
stalling catalytic con‐
verter”, page 308
❑ Do not remove protec‐
tive packaging from re‐
placement part until you
are ready to fit the flexi‐
ble joint
tem free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 303 .
3 - Nuts
4 - Seal
2. Exhaust gas cleaning 305

5 - Nuts
6 - Bolt
7 - Bracket
8 - Bracket
❑ Renew if damaged AG. Volkswagen AG d
agen oes
olksw not
y V gu
9 - Bracket d b ara
rise nte
❑ Renew if damaged autho eo
ra
ss c
10 - Bolt
ce
e
nl
pt
du
❑ 20 Nm
an
itte
y li
erm
ab
ility
ot p
wit
Installation position of front clamp
, is n
h re
hole
spec
es, in part or in w
• Angle -α- = approx. 20°.
t to the co
• Bolted connection facing towards right.
rrectness of i
• Nuts upwards.
l purpos
nform
mercia
at
om
ion
c
in t
or
Installing front exhaust pipe - specified torque and tightening se‐ his
ate
quence
do
priv
cum
for
1) Fit front exhaust

– pipe onto
en
ng
t.
yi
studs on cylinder head and at
Co
Cop py
the same time into brackets
t. rig
gh ht
pyri by
2) Screw in nuts– -1-, nuts -3- and • It should still be
co Vo
by lksw
cted
bolts -2- loosely by hand possible to move
agen
Prote AG.
front exhaust pipe
and bracket
3) Tighten
– nuts -1- 20 Nm
4) Tighten
– nuts -3- 20 Nm
5) Tighten bolts
– -2- for securing 20 Nm
brackets to cylinder head.

2.1.2 Assembly overview - emission control, Polo 2014>, Polo Saloon RUS
2016>, Polo 2018>
1 - Clamping sleeve
tightening
page 303 .
❑ Installation position and
specified torque
⇒ page 308
❑ Tighten bolted connec‐
tions evenly.
2 - Front exhaust pipe with cat‐
alytic converter
❑ Do not bend flexible joint
more than 10°. Other‐
wise, it can be dam‐
aged.
❑ Install flexible joint so
that it is not under ten‐
sion
❑ Take care not to dam‐
age wire mesh on de‐
coupling element.
❑ Protect catalytic con‐
verter from damage by
knocks and impact
stalling catalytic con‐
verter”, page 308
AG. Volkswagen AG d
❑ Do not remove protec‐ ksw
agen oes
not
l
tive packaging from re‐ byV
o gu
ara
placement part until you ris ed
nte
are ready to fit the flexi‐
aut
ho eo
ra
ble joint ss c
ce
e

nl
pt
du
an
tem free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 303 .
itte
y li
erm
ab
3 - Nuts
ility
ot p
wit

, is n
h re
hole
4 - Seal
spec
es, in part or in w

t to the co
5 - Bolt
❑ Not fitted on Polo 2018> with emissions class EU3
rrectness of i

l purpos
6 - Bracket
nform
ercia
m
at
om
7 - Nuts
on
c
in t
or

his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
307
copy Vo
by lksw
cted agen 2. Exhaust gas cleaning
Prote AG.
8 - Retaining rubbers
Installation position of front clamp

AG. Volkswagen AG d
agen oes
– Fit clamp in position shown. Volksw not
gu
d by ara
e
• Angle -α- = approx. 20°. horis nte
eo
aut ra
• Bolted connection facing towards right. ss c
ce
e
nl
• Nuts upwards.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Installing front exhaust pipe - specified torque and tightening se‐
quence
rrectness of i
1) Fit front exhaust
– pipe onto
studs on cylinder head and at
l purpos
the same time into brackets

2) Screw in nuts– -1-, nuts -3- and • It should still be
nf
ercia
o
bolts -2- loosely by hand possible to move
rm
m
front exhaust pipe
atio
m
and bracket
o
n in
or c
thi
te
sd
3) Tighten
– nuts -1- 20 Nm
iva
o
r
rp
cu
4) Tighten
– nuts -3- 20 Nm
o
m
f
en
ng
t.
yi
5) Tighten bolts
– -2- for securing 20 Nm
Co
op py
brackets to cylinder head. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted
2.2 Removing and installing catalytic con‐
agen
Prote AG.
verter
Note
The catalytic converter is removed together with the front exhaust

pipe.

♦ High-temperature paste ⇒ Electronic parts catalogue .
Removing
– Release and pull off connectors -1- and -2-.
– Remove connectors from retainers.
– Unclip wires from retainers, and lay them to one side.
sulation .
– Remove tunnel cross-piece ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Assembly overview - underbody
trim panels .

– Unscrew nuts -1- for securing front exhaust pipe to cylinder

head.
Note
The items -2- and -3- should be disregarded for the Polo 2018>.
– Unscrew nuts -3- for securing front exhaust pipe to brackets.

– Unscrew bolts -2- for securing brackets to cylinder head.
– Pull front exhaust pipe
ageoff
n AGstuds
. Volkson
wagcylinder
en AG
do head. w es n
olks ot g
Continuation for
ed
bGolf,
y V Golf SV and Golf Estate: ua
ran
ris tee
ho
ut or
– Unscrew
ss
a bolts -arrows-. ac
ce
e
Continuation for Polo:

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Detach exhaust hangers -3- in -direction of arrow- from sub‐

frame -2-.
nf
ercia
– Lower exhaust system -1- until it rests on subframe -2-.

rm
m
atio
m
Continued for all:

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Exhaust gas cleaning 309

– Loosen clamp -arrow-, and push it to rear.
Note
♦ Do not bend the flexible joint in the front exhaust pipe by more
than 10° because it might otherwise be damaged.
♦ Do not bend flexible joint by pulling.
♦ Do not damage wire mesh of flexible joint.
– Remove front exhaust pipe towards rear.

Installing
the following:
Note
♦ Renew seals/gaskets and self-locking nuts.

♦ Coat studs and bolts of front exhaust pipe with high-tempera‐
ture paste ⇒ Electronic Parts Catalogue “ETKA” .

Specified torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
olkswagen AG
en AG. V
♦ ⇒ General body repairs, exterior; Rep. gr. 66o;lksNoise
wag insula‐ does
not
ed
by V gu
ara
ris nte
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

28 – Ignition system agen

AG. Volkswagen AG d
oes
olksw not
y V gu
1 Ignition system d b ara
rise nte
tho eo
au ra
⇒ “1.1 Assembly overview - ignition
ss system”, page 311 c
ce
le
un
pt
an
d
itte
page 312
y li
rm
ab
pe
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
ility
ot
page 314
wit
, is n
h re
hole
⇒ “1.4 Removing and installing Hall sender”, page 315
spec
es, in part or in w
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
t to the co
316
1.1 Assembly overview - ignition system
rrectness of i
l purpos
1 - Bolt
❑ Specified torque influ‐
nform
ercia
ences the function of the

m
knock sensor.
a
com
tio
❑ 20 Nm
n in
r
te o
thi
s
iva
do
r
rp
c
um
fo
en
ng
t.
yi Co
stalling knock sensor 1 Cop py
G61 ”, page 314
t. rig
gh ht
pyri by
Vo
o
3 - Spark plug
c by lksw
cted agen
Prote AG.
❑ Remove and install us‐
ing spark plug socket ,
e.g. -3122 B-
❑ Change interval ⇒ Main‐
tenance ; Booklet
❑ Note part numbers ⇒
Electronic Parts Cata‐
logue “ETKA”
❑ 22 Nm
4 - Ignition coil with output
stage
stage - N70-
stage - N127-
stage - N291-
stage - N292-
with output stage”, page 312
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
1. Ignition system 311


8 - O-ring
9 - Bolt
❑ 5 Nm
10 - Engine speed sender - G28- agen
AG. Volkswagen AG d
oes
lksw not
❑ Removing and installing ⇒ “1.5 Removingdand
by V installing engine speed sender
o guG28 ”, page 316
a
e ran
ris t
11 - Sealing flange on gearbox end ut
ho
ee
or
a ac
❑ Removing and installing ⇒ “2.4 Removing
ss and installing sealing flange on gearbox side”, page 93
ce
le
un
pt
12 - Sender wheel
an
d
itte
y li
❑ For engine speed sender - G28-
erm
ab
ility
ot p
❑ Cannot be removed separately, only together with sealing flange -item 11-
wit
is n
h re
13 - Bolt
ole,
spec
t to the co
14 - Bolt
rrectne
ss o
cial p
1.2 Removing and installing ignition coils
f inform
with output stage
mer
atio
om
n
c
i
or
n thi
e
♦ Puller - T10530-
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ The ignition coils are easier to remove when the engine is

warm.
♦ The grease used upon assembly in the factory makes it easier
to remove ignition coils or the spark plug connectors when the
engine is warm.
♦ When installing used ignition coils with output stage, the igni‐
tion coils must be lubricated with silicone paste ⇒ Electronic
parts catalogue (ETKA) .
♦ Ignition coils with output stage and spark plug connectors are
available individually for repairs ⇒ Electronic parts catalogue
(ETKA)
312 Rep. gr.28 - Ignition system

Removing
– Disconnect connector -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Push puller -T10530- into hole in ignition coil -1- to stop.
ss
ce
le
un
pt
– Tighten nut -2- in -direction of arrow- so that puller -T10530-
an
d
itte
y li
is securely seated in hole of ignition coil.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Using puller -T10530- , pull ignition coil in -direction of arrow-
o
cial p
f
out of camshaft housing.
inform
mer
– Loosen nut of puller -T10530- , and remove puller from hole

atio
m
in ignition coil.
o
n
c
i
or
– Using puller -T10530- , pull remaining ignition coils one after

thi
te
sd
a
the other out of camshaft housing.

iv
o
pr
cum
r
fo
Installing
en
ng
t.
yi Co
op
Install in the reverse order of removal. When doing this, note the C py
t. rig
following: gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Apply a thin coat of silicone paste around sealing hose of ig‐

nition coil ⇒ Electronic parts catalogue (ETKA) .
– Insert ignition coils loosely into spark plug recess.
– Align ignition coils so that securing bolt can be screwed in.
– Press ignition coils evenly onto spark plugs by hand (do not
use tools). AG. Volkswagen AG d
agen oes
olksw not
y V gu
Specified torques d b ara
rise nte
ho eo
♦ ⇒ “1.1 Assembly overview - ignition system”, page 311 aut ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.3 Removing and installing knock sensor 1
rrectness of i
- G61-
l purpos
nform
ercia
♦ Ring ratchet spanner, 13 mm AF - T10384-

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
sulation .


SV 2015, Golf 2017>”, page 76 .
– Release and pull off connector -1- on air conditioner compres‐
sor regulating valve - N280- .
CAUTION
NOTICE
100 mm.

nected, and tie it up towards outside.
AG. Volkswagen AG d
agen oes
Vol
ksw not
gu
y
db ara
rise nte
– Release connector
tho -2- and pull off. eo
s au ra
c
s
– Unscrew bolt -arrow- and remove knock sensor 1 - G61- -1-
ce
le
un
from engine.
pt
an
d
itte
y li
Installing
rm
ab
pe
ility

ot
wit
, is n
the following:
h re
hole
spec
Specified torques
es, in part or in w
t to the co

♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing and installing air conditioner compressor
rrectness of i

l purpos
1.4 Removing and installing Hall sender

nform
mercia
Hall sender - G40-

a
com
tion in
Removing
r
te o
thi
s
iva

do
r
rp

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

. Volkswagen AG
gen AG does
swa
Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan y V 2015 ➤ , Golf Variant 2014 ➤t g...
olk no
ua
b
4-cylinder injection engine (1.6 l engine, ris 4 V, EA 211) - Edition 11.2018
ed ran
tee
tho
u or
a ac
– Release connector -2- and pull off. ss
ce
e
nl
pt
– Unscrew bolt -arrow-.
du
an
itte
y li
erm
– Remove Hall sender - G40- -1-.
ab
ility
ot p
Installing
wit
, is n
h re
– Install in reverse order of removal.
hole
spec
Specified torques es, in part or in w
t to the co
rrectness of i
l purpos
1.5 Removing and installing engine speed
nform
ercia
sender - G28-
m
at
om
ion
c
in t
r

o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Socket, 4 mm - T10370-
Removing
– Release connector -1- and pull off. To do this, use spring-type
clip pliers - T10118- .

– Unscrew bolt -arrow- using socket - T10370- .

– Pull out engine speed sender - G28- -1-.
Installing
Note
♦ Carefully insert the engine speed sender - G28- into the hole.
♦ This will prevent the engine speed sender - G28- from falling
between engine and gearbox.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Install in reverse order horisof removal, observing the following: nte
eo
aut ra
– Bring engine speed
ss sender - G28- in installation position mak‐ c
ing sure that guide -3- engages in sealing flange -4-.
ce
e
nl
pt
du
an
itte
– Tighten bolt -2-, and connect connector -1-.
y li
erm
ab
ility
Specified torques
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Manual VW Polo 2018+ PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Manual VW Polo 2018+ PDF

Încărcat de

Drepturi de autor:

Formate disponibile

AG.

Golf 2013 ➤ , Golf 2017 ➤ ,

Golf Sportsvan 2015 ➤ ,

Golf Variant 2014 ➤ , Polo 2014 ➤ ,

Polo 2018 ➤ , Polo Lim RUS 2016 ➤

4-cylinder injection engine (1.6 l engine, 4 V, EA 211)

Service Department. Technical Information

24 - Mixture preparation - injection

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg D4B8042C9AB

3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.6 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 63

2.7 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

2.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.3 Removing and installing toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3.4 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.6 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.2 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

1.2 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

2.4 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

1.3 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1.1 Safety regulations for working on fuel supply

and carefully loosen the connection.

Danger of fire caused by escaping fuel

1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start

If the vehicle's start/stop system is activated, the engine could

ning. Touching the ignition system may result in an electric shock.

Risk of damage to components

gine while it is running may damage components.

– Switch off the ignition before connecting or disconnecting elec‐

– Switch off the ignition before washing the engine.

Risk of poisoning due to chemical substances

2 Rep. gr.00 - Technical data