Workshop Manual Transporter 2016 4-29

Service

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Edition 03.2019
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, valve gear
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17 - Lubrication
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19 - Cooling
21 - Turbocharging/supercharging
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23 - Mixture preparation - injection
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26 - Exhaust system
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28 - Glow plug system

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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 © 2019 Volkswagen AG, Wolfsburg D4B8055F189

4-cylinder common rail engine (2.0 l, 4V, turbocharger) - Edition 03.2019
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 the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . .A.G.. V. o.lk.s.w.ag. e.n.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.2 Separating engine and gearbox wage
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1.3 Securing engine on engine ed and gearbox support . . . . . . . . . . r.an. . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.5 Removing and installing damper weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.6 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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1.8 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.5 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.6 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.7 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.5 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.6 Removing and installing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.7 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.9 Removing and installing cover for camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 Toothed belt drive . . . . . . .w.a.ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G
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2.1 Assembly overview - toothed Volks belt cover . . . . . . . . . s. n.o.t g. . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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2.2 Assembly overview oris- toothed belt . . . . . . . . . . . . . . . . . . . .n.te.e . . . . . . . . . . . . . . . . . . . . . . 94
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au toothed belt guard . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . 95
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2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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2.5 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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3.4 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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3.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 138
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2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.1 Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 143
3.4 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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3.5 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

3.6 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 146
4 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.1 Assembly overview - oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.2 Removing and installing oil supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.3 Removing and installing oil return line for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.4 Removing and installing coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.4 Removing and installing charge air cooling pump V188 . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.5 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 192
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2.6 Removing and installing auxiliary pump for heating V488 . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.8 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.9 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.10 Removing and installing coolant agen valve for cylinder
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2.11 Removing and installing by V coolant temperature sendert G62
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2.12 Removing and oinstalling
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............ 201
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2.13 Removing and aut installing coolant temperature sender 3 G812or a . . . . . . . . . . . . . . . . . . . . . .
c 203
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2.14 Removing and installing 3/2-way valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

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3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

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4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

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4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

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4.4 Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
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1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
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1.2 Assembly overview - solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

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1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

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1.4 Removing and installing solenoid valves N75 / N274 / N529 . . . . . . . . . . . . . . . . . . . . . . 235
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1.5 Renewing vacuum unit for turbocharger, bi-turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

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1.6 Removing and installing upper connecting pipe, bi-turbo . . . . . . . . . . . . . . . . . . . . . . . . . . 243

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1.7 Renewing upper connecting pipe, bi-turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

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1.8 Removing and installing lower connecting pipe, bi-turbo . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.9 Removing and installing compressor housing and turbine housing, bi-turbo . . . . . . . . . . . . 248
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2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
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2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.4 Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . . 254
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.6 Detaching and securing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Contents iii
2.7 Removing and installing bracket for charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.8 Checking charge air cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.1 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.2 Checking fuel system for leaks . . w. a.g.e.n A .G. ..V.o.lk.sw
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2.1 Connection diagram - vacuum tho system . . . . . . . . . . . . . . . . . . . . . .te.e .o . . . . . . . . . . . . . . . . 265
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3 Injectors/high-pressure ss accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . . . . . . . . 268
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3.2 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

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3.3 Adapting correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
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3.4 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
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3.5 Testing jammed-open injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
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3.6 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 273
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3.7 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
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3.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.9 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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3.10 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
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4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
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4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
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5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

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5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
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5.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

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5.4 Removing and installing intake manifold flap valve N316 . . . . . . . . . . . . . . . . . . . . . . . . . . 296
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5.5 Removing and installing vacuum unit for intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 296
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6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
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6.1 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 298
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6.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
6.4 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
6.5 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 305
6.6 Removing and installing charge air temperature sender ahead of charge air cooler G810
........................................................................ 307
6.7 Removing and installing charge air temperature sender after charge air cooler G811 . . . . 307
6.8 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
6.9 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
7.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 310
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8.3 Checking high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
9.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
9.2 Removing and installing Lambda probe 1 before catalytic converter GX10 . . . . . . . . . . . . 319
9.3 Removing and installing control unit for sensor electronics J849 / particulate sensor G784
........................................................................ 321
9.4 Removing and installing control unit for NOx sender 2 J881 / NOx sender 2 G687 . . . . . . 323
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
iv Contents
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
1.3 Removing and installing front silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
1.4 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
1.7 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3 SCR system (selective catalytic reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3.1 Assembly overview - tank for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3.2 Assembly overview - delivery module for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3.3 Removing and installing reducing agent tank VX85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3.4 Removing and installing reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3.5 Removing and installing delivery unit for reducing agent metering system GX19 . . . . . . 346
3.6 Removing and installing injector for reduction agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 349
3.7 Removing and installing control unit for reducing-agent heater J891 . . . . . . . . . . . . . . . . 352
satelettronica
3.8 Draining reducing agent tank VX85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
4 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 356
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
5.1 Assembly overview - Aexhaust
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G. Volkswa recirculation
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5.2 Removingbyand V installing exhaust gas recirculation
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5.3 Removing rise and installing pipes for exhaust gas arecirculation
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tee system . . . . . . . . . . . . . . . . . . 369
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5.4 Removing
aut and installing temperature sensor 2 for exhaust
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gas recirculation G690 . . . . . . 371
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5.5 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
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5.6 Removing and installing temperature sensor 3 for exhaust gas recirculation G949 . . . . . . 375
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5.7 Removing and installing bracket for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . 377
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5.8 Flushing exhaust gas recirculation cooler and exhaust gas recirculation valve 1 GX5 . . . . 377
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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

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1.1 Assembly overview - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1.3 Checking glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
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1.4 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 387
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1.5 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

1.6 Removing and installing knock sensor 2 G66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
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1.7 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

1.8 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
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1.9 Cleaning glow plug bore for cylinder 3 combustion chamber pressure sender G679 . . . . 391
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Contents v
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Transporter 2016 yV ➤
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vi Contents
AG. Volkswagen AG d
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1 Safety information
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⇒ “1.1 Safety regulations for working on fuel supply”, page 1
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⇒ “1.2 Safety measures when working on vehicles with a start/
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⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
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⇒ “1.4 Safety precautions when working on the cooling system”,
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⇒ “1.5 Safety precautions when working on the SCR system”,
page 2
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⇒ “1.6 Safety precautions when working on ignition system”, page
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⇒ “1.7 Safety precautions when working on exhaust system”,
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1.1 Safety regulations for working on fuel supply

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Risk of injury from highly pressurised fuel.

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The fuel system is pressurised. Injury from fuel spray possible.
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Before opening the fuel system:
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– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connection
and carefully loosen the connection.
Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected engine start
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
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.
1.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
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On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
1.5 Safety precautions when working on the SCR system

Risk of injury due to reducing agent agen
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The reducing agent may cause eye dand by skin irritations as well as
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– Always wear protective clothes.

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– Make sure that a sufficient amount of fresh air is supplied. In

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closed areas, switch on the exhaust gas extractor system.

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Risk of damage caused by reducing agent

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If reducing agent gets onto trim panels and body components, the
reducing agent may solidify after a while and thus damage the
ss
surface.
o
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– Make sure that no reducing agent gets onto the trim panels or
form
mer
body components.
atio
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– If any reducing agent does get onto surfaces, remove it im‐

n
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or
mediately using water and a cloth.

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Rep. gr.00 - Technical data
Automatic return of reducing agent

• After the ignition has been switched off, the reducing agent is
returned from the metering line leading to the reducing agent
injector - N474- back to the reducing agent tank - VX85- .
• Before any work is done in this area, it is necessary to wait
until all the reducing agent has been returned to the tank; this
can take up to 10 minutes after the ignition is switched off.
• Similarly, it is not permissible to disconnect the battery until all
the reducing agent has been returned to the tank, i.e. 10 mi‐
nutes after the ignition has been switched off.
1.6 Safety precautions when working on ignition system

Risk of injury due to electric shock
The ignition system is under high voltage when the engine is run‐
ning. Touching the ignition system may result in an electric shock.
– Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
satelettronica
Risk of damage to components
Connecting or disconnecting electric cables or washing the en‐
gine while it is running may damage components.
– Switch off the ignition before connecting or disconnecting elec‐
tric cables.
– Switch off the ignition before washing the engine.
AG. Volkswagen AG d
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1.7 Safety precautions when working on exhaust system ise nte
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– Never open an exhaust gas temperature sender by cutting,

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Risk of injury due to hot condensate and particles in the exhaust

es, in part or in w
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system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
rrectness of i
system, as well as poisoning.

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– Always wear protective gloves and eye protection when cut‐

ting the exhaust system.
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– When cutting, use an extraction system or otherwise ensure

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1. Safety information 3
2 Identification
⇒ “2.1 Engine number/engine data”, page 4
2.1 Engine number/engine data

The engine number (engine code and serial number) is located
at the front on the joint -arrow- between engine and gearbox.
In addition, a sticker is attached to the top of the toothed belt guard
-arrow- showing the engine code.
The engine codes have four characters.
The first 3 characters stand for the engine's cubic capacity and
mechanical structure. They are stamped into the cylinder block
together with the serial number.
The fourth character denotes the engine's performance and tor‐
que rating and depends on the engine control unit.
Note
satelettronica
The locations of the vehicle data labels can be gleaned from
⇒ Maintenance ; Booklet 20.1 .
Codes CXEB CXEC CXFA CXHA

Exhaust emission standard EU 6 plus EU 6 plus EU 6 plus EU 6 plus
Displacement l 2.0 AG. Vo2.0
lkswagen AG d 2.0 2.0
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Power kW at rpm 150/
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db
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Torque Nm at rpm auth 450/ 450/ 340/ ra
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340/
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1400-2400 1400-2400 1500-3000 1500-3000
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Displacement cm3 1968 1968 1968 1968

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Bore Diameter, mm 81.0 81.0 81.0 81.0

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Stroke mm 95.5 95.5 95.5 95.5

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Valves per cyl‐ 4 4 4 4

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Compression ratio 15.5 15.5 15.5 15.5

es, in part or in w
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RON Diesel EN 590 Diesel EN 590 Diesel EN 590 Diesel EN 590

Turbocharger Bi-turbo Bi-turbo Mono-turbo Mono-turbo
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Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

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Codes CXGC CXHB CXGA CXGB

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Exhaust emission standard EU 6 plus EU 6 ZD/E/F EU 6 plus EU 6 plus

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Displacement l 2.0 2.0 2.0 2.0

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Power kW at rpm 84/ 84/ 62/ 75/

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3250-3750 3250-3750 2750-3750 3000-3750

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Torque Nm at rpm 250/ 250/ 220/ 250/

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Stroke mm 95.5 95.5 95.5 95.5
Valves per cyl‐ 4 4 4 4
inder
4 Rep. gr.00 - Technical data

AG. Volkswagen AG d
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not 2016 ➤
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4-cylinder common rail ris engine (2.0 l, 4V, turbocharger) - Edition
ed
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Codes CXGC
s CXHB CXGA CXGB
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Compression ratio 15.5 15.5 15.5 15.5
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RON Diesel EN 590 Diesel EN 590 Diesel EN 590 Diesel EN 590
erm
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2. Identification 5
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 General information”, page 6
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⇒ “3.5 Contact corrosion”,
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page 7 c
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⇒ “3.6 Routing and attachment of lines”, page 8
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⇒ “3.7 Fitting radiator and condensers”, page 8
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3.1 Rules for cleanliness
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Even slight soiling can cause faults. You must therefore comply
t to the co
with the following cleanliness rules when working on the fuel sup‐
ply system, injectors or the turbocharger:
rrectness of i
♦ Carefully clean connection points and the surrounding area,
satelettronica
and dry thoroughly before opening.
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♦ Seal open pipes and connections immediately with clean

plugs for example from the engine bung set - VAS 6122- .
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♦ Place removed parts on a clean surface and cover them over.
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Use lint-free cloths only.

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♦ If repair work cannot be performed immediately, carefully cov‐

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er or seal components.
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♦ Install only clean parts; do not remove new parts from pack‐
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♦ If system is open, do not work with compressed air. Try not to
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move the vehicle.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
♦ The components must be clean and dry.
3.2 General information

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and for fault finding, read event memory.
Also the vacuum hoses and connections must be checked
(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. It reduces
the danger of a fire in a crash as the fuel pump is switched off
via the fuel pump relay.
♦ 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 ⇒ page 1 .

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3.3 General repair instructions tho
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♦ Clean tools and workbench etc. before
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system.
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♦ The injectors and locations are to be checked before installa‐
erm
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tion by means of a visual inspection for damage and dirt. It
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clean the injector shaft using a clean cloth. Take care not to
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cause any damage (do not use any sharp tools!).
spec
♦ If high-pressure lines are not renewed, they must be labelled es, in part or in w
t to the co
on removal. High-pressure fuel lines must always be re-instal‐
led in their original positions (i.e. on the same cylinder).
rrectness of i
♦ Take care not to damage the injectors when removing the old
copper seals.
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♦ Check all new O-rings for damage before installing. Lubricate

O-rings with engine oil or assembly oil before installing.
nform
ercia
♦ Align high-pressure lines so that they are not subjected to

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stress . First tighten all unions hand-tight and then tighten to
ion
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satelettronica
do
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tools may only be used for loosening and tightening pipe un‐
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ions. All other components must always be removed and
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♦ Press the fuel return lines onto the injectors by hand from
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above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then, press the
release pin downwards. Pull fuel return lines upwards by hand
to check that they are firmly attached and are not leaking.
♦ Disassembling individual common rail components is not per‐
mitted. The components should be replaced as complete units
if faulty.
♦ Do not carry out any installation work on common rail system
whilst engine is running.
♦ Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine.
♦ All cable ties which were opened or cut during removal must
be renewed at the same locations.
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
not permissible.
3.4 Foreign objects in engine

♦ To prevent the ingress of foreign bodies during work on the
engine, seal all openings.
♦ Seal openings with suitable bungs from engine bung set - VAS
6122- .
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.
3. Repair instructions 7
If there is any doubt about the suitability of parts, a general rule

is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .
3.6 Routing and attachment of lines

Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Make sure there is sufficient clearance between the lines and
moving or hot components.
3.7 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the olkswagen AG
charge air cooler may have small dents in their fins. This does agnot
en AG. V does
ksw
mean that these components have been damaged. ItbyisV not per‐
ol not
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missible to renew radiators, charge air coolers or condensers
rised only ara
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because of such minor dents. ut
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3.8 Checking vacuum system
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Special tools and workshop equipment required
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ility
♦ Hand operated vacuum pump - VAS 6213-
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Procedure
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– Check all vacuum lines throughout entire vacuum system for:

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♦ Porous areas and other leaks
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– Check vacuum line to solenoid valve and from solenoid valve

to relevant component.
– If a fault has been entered in the event memory, make sure to
check not only all vacuum lines leading to the specified com‐
ponent, but also those 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.

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 9
⇒ “1.2 Separating engine and gearbox”, page 17
⇒ “1.3 Securing engine on engine and gearbox support”,
page 18
⇒ “1.4 Installing engine”, page 20
1.1 Removing engine

♦ Engine and gearbox jack - VAS 6931-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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♦ Engine bung set - VAS 6122-
an
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♦ Hose clamps up to 25 mm - 3094- or hose clamps up to 40 mm

m
- 3093-
a
com
tion in
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1. Removing and installing engine 9

AG. Volkswagen AG d
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olksw not
V gu
d by ara
e nte
Transporter 2016 ➤ horis
eo
ut
4-cylinder common rail engine (2.0
ss a l, 4V, turbocharger) - Edition 03.2019 ra
c
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pt
♦ Hose clamp pliers - VAS 6340-
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♦ Engine support - T50066-

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Removing
– If fitted, remove engine cover panel ⇒ page 33 .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Unscrew nut -2-.
– Remove wiring harness -1-.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
10 Rep. gr.10 - Removing and installing engine

– Disconnect electrical connector -1-.

– Move clear wiring harness -4-.
– Unscrew bolts -3-.
– Lay coolant expansion tank -2- to one side.
– Detach coolant hose from retainer -5-.
satelettronica
– Pull off vacuum hoses -7- and place to one side.
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Wear protective goggles. n AG. Volkswagen AG do
swage es n
– Wear protective gloves. yV
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– To release pressure, wrap oar clean cloth around the connec‐
is tee
tion and carefully loosenauthe connection.
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– Release fuel hoses -1-.

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– Remove fuel filter bracket -2- with fuel filter.

hole
spec
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t to the co
Note
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Seal open lines and unions with clean plugs from engine bung set
- VAS 6122- .
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– Remove left headlight ⇒ Electrical system; Rep. gr. 94 ;

nf
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Headlights; Removing and installing headlights .

orm
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– Remove upper part of electronics box ⇒ Electrical system;

atio
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Rep. gr. 97 ; Relay carrier, fuse carrier, electronics boxes;

o
n in
or c
Removing and installing electronics boxes .

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– Unscrew nuts -1- and -4-.

– Remove wiring harness -2- and -3-.
AG. Volkswagen AG d
agen oes
olksw not
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satelettronica
– Open clip -1-.
rrectness of i
– Unplug electrical connectors -2, 3, 5, 6-.
l purpos
– Remove wiring harness with seal -7- from electronics box and
place to one side.
nform
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– Unplug electrical connectors -2-.


4-cylinder
en Acommon
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en engine
AG (2.0 l, 4V, turbocharger) - Edition 03.2019
ag does
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– Remove wiring harness d b with seal -1- from electronics box gand
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place to one side.thor tee
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at
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– Move wiring harness -3- aside.

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– Remove nut -1-.
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– Place bracket -4- on engine. t. C rig
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– Remove air filter housing ⇒ page 289 .
cop Vo
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– Remove intake hose ⇒ Item 19 (page 289) .
– Drain coolant ⇒ page 179 .
– If present, remove propshaft ⇒ Rep. gr. 39 ; Propshaft; Re‐
moving and installing propshaft .
– Remove particulate filter ⇒ page 338 .
– Remove subframe without steering rack ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐
ling subframe without steering rack .


– Unclip bracket -3- and detach wiring harness -2-.
– If fitted, remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Re‐
moving and installing bevel box .
– Remove rear engine support ⇒ page 41 .
– Remove front engine support ⇒ page 40 .
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
Vehicles with air conditioning system
– Remove air conditioner compressor from bracket with lines
still attached, and secure it on vehicle ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Air conditioner compressor; Removing
air conditioner compressor from and installing on bracket .
Continued for all vehicles
– Remove vane pump (lines remain connected) from bracket
and secure it to body ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Hydraulic power steering, Removing and installing
vane pump .
satelettronica
Vehicles with dual clutch gearbox
– Remove selector lever cable from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector lever
cable .
Vehicles with manual gearbox
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐ AG. Volkswagen AG d
anism . agen oes
olksw not
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– Remove breather from gearbox ⇒ Rep. gr. 30 ; Clutch mech‐ rised
nte
anism; Removing and installing breather . aut
ho eo
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nl
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– Loosen clamp -2-.
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– Pull off coolant hose -3-.
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es, in part or in w
t to the co
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– Release clips -2-.

– Pull off coolant hoses -1-.
– Release catch -4-.
– Move brake servo vacuum pipe -3- to one side.
AG. Volkswagen AG d
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– Attach threaded pin - T50066/1- -2- with recess -arrow- to en‐

gine in such a way that bolt -1- can be unscrewed.

– Attach engine support - T50066- with threaded pins -

T50066/1- , threaded pins - T50066/3- and threaded pins -
T50066/2- to engine -1-.
– Secure threaded pin - T50066/2- -4- to engine -1- with bolt
-2- and tighten by hand.
AG. Volkswagen AG d
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– Start bolt -1- on front of engine -2- and tighten by hand.
itte
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– Tighten all bolts of engine support - T50066- .
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– Secure engine and gearbox jack - VAS 6931- to engine sup‐
h re
port - T50066- .
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es, in part or in w
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– Unscrew bolts -2- connecting engine support -1- and engine C py
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– Unscrew bolts -1- from left gearbox mounting -3-.
Note
Depending on equipment, it can be necessary to detach or dis‐

connect other connection, coolant, vacuum and intake hoses.
– Carefully lower engine with gearbox. When doing this, have a

second mechanic guide all connecting, coolant, vacuum and
intake hoses to prevent damage.
1.2 Separating engine and gearbox
satelettronica
♦ Lifting tackle - 3033-
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– Remove engine ⇒ page 9 .

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and the lifting tackle - 3033- .
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– Secure workshop hoist - VAS 6100- with lifting tackle - 3033-
to engine.
– Place engine and gearbox jack in front of workbench.

– Lower engine and gearbox until gearbox comes to rest on

workbench.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Remove bolts -1 … 8-.
– Disconnect gearbox with aid of second mechanic.
Vehicles with 6-speed manual gearbox

satelettronica
– Disconnect gearbox withenaid
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Vehicles with 5-speed manual gearbox

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– Disconnect gearbox with aid of second mechanic.

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1.3 Securing engine on engine and gearbox

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Special tools and workshop equipment required t. C rig
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♦ Lifting tackle - 3033-
♦ Engine and gearbox support - VAS 6095A-
satelettronica
♦ Workshop hoist - VAS 6100-
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Procedure
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to carry out repairs.

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– Separate engine and gearbox ⇒ page 17 .
rrectness of i
– If necessary, remove flywheel ⇒ page 48 .

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Connect lifting tackle - 3033- as shown:

• Flywheel end: position 11
nform
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• Vibration damper end: position 4.

a
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– Attach workshop hoist - VAS 6100- to lifting tackle - 3033- .

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– If necessary, adjust position via spindles -arrows-.

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– Secure engine on engine and gearbox support - VAS 6095A-

-1-.
1.4 Installing engine

satelettronica
♦ Torque wrench - V.A.G 1332-
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♦ Engine support - T50066-
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♦ Vehicle diagnostic tester

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Installing
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Install in reverse order of removal, observing the following:

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– Install engine using engine and gearbox jack - VAS 6931- and
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for
engine support - T50066- .

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Note
♦ Renew all bolts that are tightened with a turning further angle
after each removal.
♦ Renew self-locking nuts and bolts as well as gaskets, seals
and O-rings after each removal.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Attach cable ties in all the same places when installing.
♦ Fit heat shield sleeves in the same place when installing.
♦ Route lines of any kind and cables so that original routing is
restored.
♦ Ensure that there is sufficient clearance to all moving or hot
components.
♦ When installing a new short engine, it is compulsory to fix and
satelettronica
tighten the clamping jaws of the injectors to the specified tor‐
que after installing the high-pressure lines. The clamping
pieces are only secured hand-tight for setting the injectors
while installing the high-pressure lines. Non-observance of
these notes may lead to damage to engine.
♦ After components have been renewed (engine/short engine,
cylinder head, camshaft housing or turbocharger), the oil pres‐
sure control must be set to max. pressure for approx. 1000 km
if the function is available in the engine control unit. This will
compensate for the increased friction during run-in of new
components, and a better transport of wear-related particles
is guaranteed. AG. Volkswagen A
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– Connect ⇒ Vehicle diagnostic
ed
by
tester. ua
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– Switch on ignition.auth or
ac
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– Activate oil pressure control ⇒ Vehicle diagnostic tester, 01 -
ce
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un
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Engine electronics functions , Adaption , Oil pres-

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sure for engine operation .

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– Follow further instructions displayed on ⇒ Vehicle diagnostic

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Specified torques
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 24

♦ ⇒ “2.1 Assembly overview - emission control”, page 332
rrectne
♦ ⇒ “4.1 Assembly overview - air filter housing”, page 288

♦ Assembly overview - vane pump ⇒ Running gear, axles,
ss
steering; Rep. gr. 48 ; Hydraulic power-assisted steering; As‐

o
cial p
sembly overview - vane pump

inform
mer
♦ Assembly overview - air conditioner compressor ⇒ Heating,

atio
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air conditioning; Rep. gr. 87 ; Air conditioner compressor; As‐

o
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c
sembly overview - drive unit of air conditioner compressor

i
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♦ Assembly overview - battery ⇒ Electrical system; Rep. gr. 27 ;

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Battery; Assembly overview - battery .

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♦ Assembly overview - bumper cover ⇒ General body repairs,
Co
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♦ Assembly overview - noise insulation ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation Volkswa n AG. gen AG
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M12 65
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2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 24
⇒ “2.2 Removing and installing engine mounting”, page 26
⇒ “2.3 Removing and installing engine mounting”, page 28
⇒ “2.4 Removing and installing gearbox mounting”, page 29
⇒ “2.5 Removing and installing damper weight”, page 29
⇒ “2.6 Supporting engine in installation position”, page 30
2.1 Assembly overview - assembly mountings
1 - engine mounts
❑ Right
❑ Removing and installing
⇒ page 28
2 - Bolt
satelettronica
❑ Renew after removal
❑ 90 Nm +90°
3 - Bolt
❑ 50 Nm +90°
4 - Bolts
❑ Qty. 2
❑ 50 Nm +90°
5 - Bolts
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❑ Right
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7 - Bolts
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❑ 50 Nm +90°
❑ Specified torque for up‐
per right bolt only on sin‐
rrectness of i
gle turbo: 20 Nm +120°

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8 - Bolt
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❑ 50 Nm +90°
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9 - Bolt
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❑ 50 Nm +90°
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10 - Engine support
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Rep. gr.10 - Removing and installing engine
❑ Removing and installing ⇒ page 40
11 - Engine mounting
❑ Rear
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❑ Qty. 4 aut ra
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❑ 20 Nm +180°
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13 - Bolts
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❑ Qty. 3
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❑ 50 Nm +90°
hole
spec
14 - Gearbox mounting
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15 - Bolts
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satelettronica
❑ Qty. 2
❑ 50 Nm +90°
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❑ Front
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❑ 50 Nm +90°
19 - Bolt
❑ 90 Nm +120°
20 - Bolt
❑ 50 Nm +90°
21 - Engine support
❑ Front
22 - Bolt
❑ 50 Nm +90°
23 - Vibration damper
24 - Bolt
❑ 20 Nm
2. Assembly mountings 25
25 - Cap
26 - Bolts
❑ Qty. 3
❑ 50 Nm +90°
❑ Right
2.2 Removing and installing engine mount‐

ing
⇒ “2.2.1 Removing and installing right engine mounting”,
page 26
⇒ “2.2.2 Removing and installing rear engine mountings”,
page 26
⇒ “2.2.3 Removing and installing front engine mountings”,
satelettronica
page 27
2.2.1 Removing and installing right engine

mounting
AG. Volkswagen AG d
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Special tools and workshop equipment required Volksw not
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♦ Torque wrench - V.A.G 1332- horis nte
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Removing
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– Remove engine mounting ⇒ page 28 .

nform
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– If fitted, unscrew earth wire.

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– Remove motor mounting -2-.

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Installing
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Specified torques
t. C rig
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 24 by c lksw
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2.2.2 Removing and installing rear engine

mountings

AG. Volkswagen AG d
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♦ Socket AF 16 - T10261/1-
ce
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Removing
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ab
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– If fitted, remove noise insulation ⇒ General body repairs, ex‐
ility
ot
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
wit
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noise insulation .
h re
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spec
– Loosen clamp ⇒ Item 7 (page 332) .
es, in part or in w
satelettronica
t to the co
– Unscrew bolt -1-.
rrectness of i
– Unscrew bolts -4- while counterholding on nuts -5-.
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– Push engine upwards slightly at rear.

– Remove engine mounting -2- with aid of second mechanic.
nform
ercia
Installing
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Note
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Bolt ⇒ Item 9 (page 24) is the last to be tightened for all operations
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as this is used to achieve horizontal tolerance compensation.
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Specified torques
2.2.3 Removing and installing front engine

mountings
Removing wage
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– If fitted, remove noise ed insulation ⇒ General body repairs, ex‐
by ua
ran
terior; Rep. gr. 66 hor; Noise insulation; Removing and installing
is tee
noise insulation au.
t or
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nl
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– Remove motor mounting -1-.
ot p
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Installing
h re
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spec
es, in part or in w
t to the co
Note
rrectness of i
Bolt ⇒ Item 19 (page 25) is the last to be tightened for all opera‐
l purpos
tions as this is used to achieve vertical tolerance compensation.
nf
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Specified torques
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satelettronica
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2.3 Removing and installing engine mount‐
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Removing
– Support engine in its installation position ⇒ page 30 .
– If fitted, unscrew earth wire.
– Unscrew bolts -1- and -2-.
– Remove engine carrier -4-.
Installing
Specified torques

2.4 Removing and installing gearbox

mounting
Removing
– Support engine in its installation position ⇒ page 30 .
satelettronica
noise insulation .
– Remove subframe without steering rack ⇒ Running gear,
Volkswagen AG
axles, steering; Rep.swgr.
age40
n AG; .Subframe; Removing
does and instal‐
ling subframe without
b y Vol
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steering rack . not
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Continued forthoall
ri vehicles e or
au ac
– Unscrew
ss bolts -1-.
ce
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Lower engine slightly if necessary.

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– Remove gearbox mounting -3-.

Installing
rrectness of i

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Specified torques
nform
mercia
at
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2.5 Removing and installing damper weight

at
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or

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Removing
– Remove cap -2-.
– Unscrew bolt -3-. n AG. Volkswagen AG do
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– Remove damper weight -1-. d b ua
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Installing aut or
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Specified torques
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2.6 Supporting engine in installation posi‐
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spec
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♦ Support - 10 - 222 A-
rrectness of i
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♦ Adapter - 10-222A/23-
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♦ Adapter - 10-222A/23-1-
♦ Adapter - 10-222A/16-
♦ Hook - 10-222A/10-
♦ Hook - 10-222A/2-
♦ Adapter - 10-222A/3-
Procedure
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing and
installing plenum chamber cover .

– Remove left and right cover for plenum chamber bulkhead ⇒

General body repairs, exterior; Rep. gr. 50 ; Bulkhead; Re‐
moving and installing plenum chamber bulkhead .
– Remove protective cap for left and right suspension strut.
– Move coolant expansion tank -2- aside slightly with coolant
hoses still attached.
AG. Volkswagen AG d
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Assemble engine support bracket - 10-222 A- as follows:
♦ Position adapter - 10-222A/23- with adapter - 10-222A/23-1-
rrectne
on suspension strut/lock carrier.
s
♦ Place adapter - 10-222A/16- and adapter - 10-222A/3- on
s o
support bracket - 10-222 A- .
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♦ Place hook - 10-222A/10- on adapter - 10-222A/3- .
mer
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♦ Attach hook - 10-222A/2- to adapter - 10-222A/16- .

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♦ Tighten support bracket - 10-222 A- to adapter - 10-222A/23- .
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Attach lifting tackle - 10-222 A- to engine as follows: AG. Volkswagen AG d

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• Attach hook - 10-222A/10- to right of engine. d byV
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– Attach hook - 10-222A/2- to left of engine.
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If they are in the way, unclip, detach or push aside any coolant
f
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t.
hoses or vacuum hoses in the area of the support bracket - 10 -
yi Co
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222 A- or adapter .
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– Take up weight of engine and gearbox with support bracket - cted agen
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10 - 222 A- on spindles .
Specified torques
Component Specified torque
Bolts for coolant expansion 3.5 Nm
tank

3 Engine cover panel

⇒ “3.1 Removing and installing engine cover”, page 33
3.1 Removing and installing engine cover

Removing
– Release spreader rivet -3-.
– Pull engine cover panel -1- out of brackets -2- and remove.
Installing
Specified torques
Bolt for engine cover panel 2 Nm
satelettronica
AG. Volkswagen AG d
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3. Engine cover panel 33

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block (pulley end)”,
page 34
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
36
⇒ “1.3 Removing and installing poly-V belt”, page 36
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 37
⇒ “1.5 Removing and installing vibration damper”, page 38
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 39
⇒ “1.7 Removing and installing engine support”, page 40
⇒ “1.8 Removing and installing sealing flange on pulley end”,
page 44
satelettronica
olkswagen AG
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1.1 Assemblyy Vooverview
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1 - Ancillary bracket
au ac
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⇒ page 39
an
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2 - High-pressure pump
ab
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❑ Assembly overview
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⇒ page 311
h re
hole

spec
⇒ page 312
es, in part or in w
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3 - Bolts
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❑ Qty. 5
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❑ Assembly overview ⇒
Electrical system; Rep.
gr. 27 ; Alternator; As‐
sembly overview - alter‐
nator
⇒ Electrical system;
Rep. gr. 27 ; Alternator;
Removing and installing
alternator
34 Rep. gr.13 - Crankshaft group

7 - Vane pump
❑ Assembly overview ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted steering;
Assembly overview - vane pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-assisted steer‐
ing; Removing and installing vane pump
8 - Dowel sleeve
❑ Ensure correct seating in air conditioner compressor bracket
9 - Air conditioner compressor AG. Volkswagen AG d
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not
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10 - Bolt
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11 - Poly V-belt
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❑ Check for wear
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❑ Before removing, mark direction of rotation with chalk or felt-tipped pen
satelettronica
t to the co
❑ Do not kink
❑ When installing, make sure it is properly seated on pulleys.
rrectness of i
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12 - Idler roller
13 - Bolt
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❑ 20 Nm
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14 - Cover
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❑ Qty. 4 Prote AG.

❑ 10 Nm +90°
❑ Bi-turbo CXEB: 20 Nm +180°
17 - Vibration damper
❑ Installation position: hole in vibration damper must align over protrusion on crankshaft pulley.
18 - Bolt
❑ Specified torque ⇒ page 311
19 - Bolt
20 - Bolt
1. Cylinder block (pulley end) 35

1.2 Assembly overview - sealing flange, belt pulley end
1 - Sealing flange at belt pulley

end
❑ With oil seal for crank‐
shaft
⇒ page 44
2 - Bolts
❑ Qty. 6
❑ Specified torque and
tightening sequence:
⇒ page 36
3 - Crankshaft pulley
❑ Contact surface be‐
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⇒ page 94
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Sealing flange at belt pulley end - Prescribed torque and tighten‐

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3 -7 … 10-Prote 13 Nm
AG.
1.3 Removing and installing poly-V belt


♦ Locking pin - T10060 A-
Removing
noise insulation .
– Before removing the poly V-belt, use a piece of chalk or a felt
pen to mark the running direction.
satelettronica
– To loosen poly V-belt, swing tensioning device -1- in anti-
clockwise direction -arrow- using a ring spanner.
– Use the locking pin - T10060 A- to lock the tensioner.
– Remove poly V-belt -2-.
Installing
Note
Observe correct direction when a used poly V-belt is reinstalled.

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1.4 Removing and installing tensioner for

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poly V-belt
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Cop py
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Removing AG. Volkswagen AG d

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– Remove poly V-belt d by⇒
V page 36 .
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– Remove idler roller ⇒ Item 12 (page 35) .
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Specified torques
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♦ ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page
34
ss o
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mer
1.5 Removing and installing vibration damp‐
atio
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Prote AG.
♦ Ejector - T50071- (if required)

Removing
– Remove poly V-belt ⇒ page 36 .
– If fitted, remove plug.
– Unscrew bolts -1-, counterholding on bolt of crankshaft
sprocket to do so.
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– Remove vibration ldamper
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♦ On vehicles with bi-turbo there is a risk of corrosion between

un
pt
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the vibration damper and the gear wheel of the crankshaft.

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ole,
spec
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the crankshaft from the vibration damper.
t to the co
satelettronica
Installing
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ss
• Installation position: hole -arrow- in vibration damper must
o
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align over protrusion on crankshaft pulley.
inform
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Specified torques
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c
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34
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♦ ⇒ “2.2 Assembly overview - toothed belt”, page 94

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1.6 Removing and installing bracket for an‐

cillaries

Removing
– Remove high-pressure pump ⇒ page 312 .
– Remove tensioner for poly V-belt ⇒ page 37 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove vane pump from bracket with hoses still attached ⇒
Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power-
assisted steering; Removing and installing vane pump .
– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning system; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing air conditioner compressor from and in‐
stalling on bracket .
– Unscrew bolt -1-. AG. Volkswagen AG d
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– Remove bolts -1 … 5-. ss c
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– Remove ancillary bracket -6-.
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– Check that a dowel sleeve is fitted between bracket for ancil‐
hole
spec
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es, in part or in w
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Specified torques
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34
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1.7 Removing and installing engine support

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⇒ “1.7.1 Removing and installing right engine support”, C py
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page 40
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⇒ “1.7.2 Removing and installing rear engine support”, Prote
cted AG.
agen
page 41
⇒ “1.7.3 Removing and installing front engine support”,
page 43
1.7.1 Removing and installing right engine

support

Transporter
AG. Volkswagen AG d 2016 ➤
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V olksl,w4V, turbocharger) - Edition
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♦ Torque wrench - V.A.G 1332- tho
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c
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hole
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t to the co
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Removing l purpos
– Remove upper part of toothed belt guard ⇒ page 95 .
nform
ercia
– Remove engine mounting ⇒ page 28 .

m
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i
– Remove engine mounting (right-side) ⇒ page 26 .
on
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– Remove engine support -2-.
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Install in reverse order of removal, observing the following: gh ht
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Specified torques Prote
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1.7.2 Removing and installing rear engine

support

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♦ Torque wrench - VAS 6854- au
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♦ Flared ring attachment AF 16 - VAS 6854/1- l purpos
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c
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ate
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um
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Cop py
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Prote AG.
♦ Adapter - VAS 6948-
Removing
– Remove rear engine mounting ⇒ page 26 .

Note
Bolt -3- is only fitted on front-wheel drive vehicles.
– If fitted, unscrew bolt -3-.

Installing
– To tighten bolt ⇒ Item 4 (page 332) , use adapter - VAS 6948-
and flared ring attachment AF 16 - VAS 6854/1- .AG. Volkswagen
n AG do
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Specified torques Volks ot g
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♦ ⇒ “2.1 Assembly overview - assemblyoris mountings”, page 24 tee
th or
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1.7.3 Removing and installing front engine
ce
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satelettronica
nl
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Removing
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– Remove front engine mounting ⇒ page 26 .

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– Move to service position ⇒ General body repairs, exterior; C py
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Rep. gr. 50 ; Lock carrier; Moving to and back from service rig ht
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position .
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– Remove bracket -3-.

– Unclip wiring harness -1-.

– Separate electrical connector from radiator outlet coolant tem‐
perature sender - G83- .
Installing
Specified torques
Volkswa
♦ ⇒ “2.1 Assembly overview
swa
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assembly
AG. mountings”,
gen AG
does page 24
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1.8 Removing and installing sealing flange
h re
satelettronica
hole
on pulley end
spec
es, in part or in w
t to the co
♦ Counter-hold tool - 3415-
rrectness of i
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♦ Assembly tool - T10053- py by
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Removing
– Remove toothed belt ⇒ page 99 .
– Using counterhold tool - 3415- , loosen bolt -1- for crankshaft
pulley -2-.
– Remove crankshaft pulley -2-.
– Remove sump ⇒ page 134 .
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– Unscrewss bolts
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– Carefully detach sealing flange -2- from adhesive bond, and

nl
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remove it.
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Cop py
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Prote AG.

Installing
– Clean sealing surfaces.
– Position guide sleeve - T10053/1- -1- on crankshaft journal
-2-.
– Push sealing flange over guide sleeve - T10053/1- -1-.
• Dowel pins must locate in holes of cylinder block
– Remove guide sleeve - T10053/1- -1-.
– Screw in sealing flange bolts as far as stop by hand.
– Tighten sealing flange bolts diagonally and alternately
⇒ page 36 .
– Apply sealant bead to clean sealing surface of sump
⇒ page 134 .
• The sump must be installed within 5 minutes after applying the
sealant.
Specified torques
satelettronica
AG . Volkswage
♦ ⇒ “1.2 Assembly overview - sealing flange,ksw
belt
agenpulley end”, AG does
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page 36 by
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2 Cylinder block, gearbox end

Volkswa
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⇒ “2.2 Removing andthinstalling
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flywheel”, page 48 tee
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2.1 Assembly overview - cylinder block, gearbox end
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1 - Bolts
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t to the co
❑ Check whether ⇒ TPI
2038587 applies, follow
TPI instructions as nec‐
essary.
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❑ Qty. 6
s
❑ 60 Nm +90°
s o
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satelettronica
in
2 - Flywheel
form
mer
❑ Can only be fitted in one
atio
m
position
o
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⇒ page 48
sd
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3 - Sender wheel
fo
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❑ For engine speed send‐
Co
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⇒ page 50
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4 - Engine speed sender -

G28-
⇒ page 390
5 - Bolt
❑ 5 Nm
6 - Dowel pin
❑ Qty. 2
7 - Intermediate plate
❑ Do not damage or bend
when assembling.
❑ Take account of differ‐
ent dowel sleeves ⇒
Electronic parts cata‐
logue (ETKA)
❑ Removing ⇒ page 48
8 - Sealing flange, gearbox side
❑ With shaft seal
❑ Renew after removal ⇒ page 50
9 - Bolts
❑ Specified torque and tightening sequence ⇒ page 48
2. Cylinder block, gearbox end 47

Removing intermediate plate

• Gearbox is removed.
– Detach intermediate plate -1- from sealing flange -2-
-arrow B-.
– Detach intermediate plate from dowel sleeves -arrows A-.
Removing intermediate plate

• Gearbox is removed.
– Unscrew bolts -arrows-.
– Detach intermediate plate -1-.
satelettronica
Bolts -arrows- 25 Nm
AG. Volkswagen AG d
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Sealing flange on gearbox side - specified torque and tighteningd by Vo gu
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– Tighten bolts in stages in the sequence shown. ss a c
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2 -1 … 6- 13 Nm
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2.2 Removing and installing flywheel
rrectness of i
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♦ Counter-hold tool - 3067-
nf
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AG. Volkswagen AG d
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➤ aut Transporteror a2016
c
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4-cylinder common rail engine (2.0 l, 4V, turbocharger) - Edition 03.2019s
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Removing
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Note
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♦ Check whether ⇒ TPI 2038587 applies, follow TPI instructions
en
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Co
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♦ The flywheel is equipped with centrifugal weights. The centri‐
gh ht
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o Vo
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cted
cranked by hand. The clicking sound is inherent of the design
agen
Prote AG.
and no cause for complaint. When the cranking speed is at‐
tained, the noise will disappear.


– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
clutch .
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox .
Note
♦ The illustration shows the flywheel of the bi-turbo engine. Only

6 bolts secure the flywheel of the single turbocharger engine.
♦ Item A: tighten bolts.
♦ Item B: loosen bolts.
– Insert counterhold - 3067- in hole on cylinder block.

• Do not unscrew bolts with an power impact wrench. Unscrew
satelettronica
them by hand (risk of damage to flywheel).
Installing
Note
Fitting is only possible in one position.
Specified torques
AG. Volkswagen AG d
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♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
olks page
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2.3 Removing and installing sealing flange
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on gearbox side
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♦ Insert tool, 24 mm - V.A.G 1332/11-

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♦ Assembly tool - T10134- (mono-turbo)
♦ Assembly tool - T50010- (bi-turbo)
satelettronica
♦ Depth gauge - VAS 6082-
AG. Volkswagen AG d
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♦ Bolt M6×35 (qty. 3)
erm
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Note
hole
spec
es, in part or in w
♦ The procedure described here is based on using the assembly

t to the co
tool - T10134- .
♦ Depending on the equipment, it may be necessary to use the
rrectness of i
assembly tool - T50010- . The procedure follows the same

pattern in this case.
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2. Cylinder block, gearbox end
Removing
AG. Volkswagen AG d
– Remove flywheel ⇒ page 48 . ksw
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– Remove intermediate plate -1- from dowel sleeves ised ara
nte
-arrows A-. ut
hor eo
a ra
s c
– Guide intermediate plate -1- upwards. s
ce
le
un
pt
– While doing so, pull retaining lug -arrow B- of intermediate
an
d
itte
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plate -1- out of recess behind sealing flange.
rm
ab
pe
ility
– Turn crankshaft on bolt for toothed belt pulley until crankshaft
ot
wit
, is n
is at “TDC” position ⇒ page 104 .
h re
hole
spec
es, in part or in w
t to the co
– Remove engine speed sender - G28- ⇒ page 390 .
– Unscrew bolts -arrows- for sealing flange -1-.
rrectness of i
l purpos
nform
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satelettronica
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tion in
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– To press off, screw 3 bolts M6 x 35 into sealing flange -1- pyri by
Vo
o
by c
-arrows-.
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cted agen
Prote AG.
Note
The sealing flange -1- is pressed off crankshaft -3- together with
the sender wheel -2-.
– Screw bolts alternately into sealing flange not more than 1/2
turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
Pressing in sealing flange with sender wheel
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring -2-. This support ring serves as a fitting sleeve
and must not be removed prior to installation.
♦ Sealing flange and sender wheel -1- must not be separated or
turned after removal from packaging.
♦ The sender wheel -1- is held in its installation position on the
locating pin of the assembly tool - T10134- ⇒ page 53 .
♦ 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 53 .

. Volkswagen AG
4-cylinder wagen AG rail engine
common d(2.0
oes l, 4V, turbocharger) - Edition 03.2019
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Components of assembly htool rise - T10134- : nte
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A - Clamping surface ss c
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le
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pt
B - Nut
an
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C - Assembly housing erm
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ility
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D-
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Locating pin
h re
ole,
spec
E - Hexagon socket head bolt (qty. 2)
t to the co
F - Guide pin for petrol engines (red knob)
G-
rrectne
Guide pin for diesel engines (black knob)
H - Knurled screws (qty. 3)
ss o
I - Inner part
cial p
f inform
mer
Mounting sealing flange with sender wheel on assembly tool -
atio
m
T10134-
o
n
c
i
or
n
– Screw on nut -B- until just before it touches clamping surface
thi
te
sd
a
-A- of threaded spindle.
satelettronica
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o
pr
cum
r
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
– Clamp assembly device - T10134- at clamping surface -A- of

threaded spindle in a vice -1-.
– Push assembly housing -C- downwards until it rests against
nut -B-.
• Inner part of assembly tool and assembly housing must be at
same height.
– If fitted, remove securing clip -arrow- from new sealing flange

-1-.
Note
Do not take the sender wheel out of the sealing flange or rotate it
out of position.

– Place sealing flange with front side facing down on a clean

level surface.
– Push sealing lip support ring -1- downwards in
-direction of arrow- until it rests against flat surface.
AG. Volkswagen AG d
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pt
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erm
ab
• Upper edge of sealing lip support ring -1- and front edge of
ility
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sealing flange -2- must align -arrows-.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
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nf
ercia
orm
m
atio
m
– Place sealing flange -1- with front side facing downwards onto
o
n in
c
assembly tool - T10134- so that locating pin -D- is seated in

or
thi
e
hole -3- in sender wheel hole -2-.

t
sd
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• The sealing flange must rest flat against the assembly tool.
o
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f
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Cop py
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pyri by
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cted agen
Prote AG.
– Screw knurled screws -H- into sealing flange -1-.

• Only 2 of the 3 knurled screws -H- can be screwed in.
– 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 ⇒ page 104 .
– 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‐
ing -C-.
– Align flat side of assembly housing to sealing surface of cyl‐
inder block on sump side.
– Attach assembly tool - T10134- together with sealing flange

-1- to crankshaft flange -2-. To do this, screw hexagon socket
head bolts -E- into crankshaft flange (approx. 5 full turns) using
a hexagon key.
– Push guide pin for diesel engines (black knob) -G- into crank‐
shaft flange.
satelettronica
– To guide sealing flange -1-, screw two M6×35 mm bolts -2-
into cylinder block.
AG. Volkswagen AG d
agen oes
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ara
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ris nte
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pt
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Bolt assembly tool - T10134- onto crankshaft flange

erm
ab
ility
ot p
– Push assembly housing -C- by hand in -direction of arrow- until

wit
, is n
sealing lip support ring -1- rests against crankshaft flange

h re
hole
-2-.
spec
es, in part or in w
– Make sure that guide pin for diesel engines (black knob) -G-
t to the co
is properly seated in hole in crankshaft. This ensures that the

sender wheel reaches its final installation position.
rrectness of i
l purpos
Note
Do not insert the guide pin for petrol engines (red knob) in the
nf
ercia
threaded hole of the crankshaft.

rm
m
atio
om
n in
– Tighten the two hexagon socket head bolts of assembly tool

or c
hand-tight.
thi
te
sd
iva
– Screw nut -B- by hand onto threaded spindle until it rests

r
rp
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o
against assembly housing -C-.

f
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

Pressing sender wheel onto crankshaft flange using assembly

tool - T10134-
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.
• After the nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block and sealing
lkswageflange -1-. es n
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ris tee
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pt
du
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erm
ab
ility
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wit
Checking sender wheel installation position on crankshaft
, is n
h re
hole
– Screw on nut -B- until it reaches end of threaded spindle.
spec
es, in part or in w
– Unscrew the two bolts -2- from cylinder block.
t to the co
– Pull guide pin for diesel engines (black knob) -G- out of crank‐
shaft flange.
rrectness of i
– Unscrew knurled screws -H- from sealing flange -1-.
l purpos
satelettronica
– Unbolt assembly tool - T10134- from crankshaft flange, un‐
screwing hexagon socket head bolts -E- from crankshaft
nform
ercia
flange.
m
at
– Remove sealing lip support ring.
om
ion
c
in t
or
his
e
– Position depth gauge - VAS 6082- on crankshaft flange -2-.

at
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.
– 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 57 .
– If specification is achieved, proceed with subsequent work
steps ⇒ page 57 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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horis Transporter
eo 2016 ➤
ut
4-cylinderss common rail engine (2.0 l, 4V, turbocharger) - Edition
a ra
c 03.2019
ce
e
nl
pt
Re-pressing sender wheel
du
an
itte
y li
erm
– Secure assembly tool - T10134- on crankshaft flange.
ab
ility
ot p
– Make sure that locating pin of assembly tool - T10134- is prop‐
wit
, is n
erly seated in sender wheel hole.
h re
hole
spec
– Tighten hexagon socket head bolts -E- by hand.
es, in part or in w
t to the co
– Push assembly tool - T10134- by hand against sealing flange
-1-.
rrectness of i
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly tool - T10134- .
l purpos
– Push guide pin for diesel engines (black knob) -G- into crank‐
shaft flange.
nform
ercia
– Screw knurled screws -H- into sealing flange -1-.

m
at
om
io
– To guide sealing flange, screw two M6×35 mm bolts -2- into
n
c
in t
r
cylinder block.
o
his
ate
do
priv
c
– Tighten nut -B- of assembly tool - T10134- to 40 Nm.
um
for
en
ng
t.
yi
– Check sender wheel installation position on the crankshaft
Co
op
satelettronica
py
again ⇒ page 56 .
t. C rig
gh ht
pyri by
Vo
– If the specification is not achieved, tighten nut of assembly tool
o
by c lksw
cted agen
- T10134- to 45 Nm. Prote AG.
– Check sender wheel installation position on the crankshaft

again ⇒ page 56 .
Assembling
Assembly is carried out in reverse sequence; note the following:
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
47

3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 58
⇒ “3.2 Crankshaft dimensions”, page 59
⇒ “3.3 Renewing needle bearing in crankshaft”, page 59
⇒ “3.4 Measuring axial clearance of crankshaft”, page 61
⇒ “3.5 Measuring radial clearance of crankshaft”, page 61
3.1 Assembly overview - crankshaft

swage es n
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o
The assembly overview refers exclusively to engines
auth without balance shafts. or
ac
ss
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nl
pt
du
an
itte
1 - Cylinder block
y li
erm
ab
ility
2 - Crankshaft bearing shell
ot p
satelettronica
wit
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❑ For cylinder block with
h re
oil groove
hole
spec
❑ Renew worn bearing
es, in part or in w
t to the co
shells
3 - Crankshaft
rrectness of i
❑ For oil pump drive.
❑ Not available as sepa‐
l purpos
rate part
4 - Crankshaft bearing shell
nf
ercia
or
❑ For bearing cap without
m
m
atio
oil groove.
om
n in
c

or
thi
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shells
t
sd
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5 - Bolts
o
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❑ Qty. 10
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❑ To measure radial clear‐
cop Vo
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ance, tighten to 65 Nm
agen
Prote AG.
but not further.
❑ 65 Nm +90°
6 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ Installation position:
bearing shell retaining
lugs in cylinder block
and bearing caps must
align vertically.
7 - Thrust washer
❑ For bearing 3
❑ Various versions for cylinder block and bearing cap.
❑ Note fixing arrangement

8 - Crankshaft
❑ On vehicles with dual clutch gearbox a needle bearing must be fitted on crankshaft. If necessary, install
needle bearing ⇒ page 59 .
❑ Crankshaft dimensions ⇒ page 59 .
❑ Measuring axial clearance ⇒ page 61 .
❑ Measuring radial clearance ⇒ page 61
3.2 Crankshaft dimensions

Honing Crankshaft Conrod bearing journal diameter
dimen‐ bearing journal in mm
sion diameter in mm
Basic di‐ 54.00 -0.022 50.90 -0.022
mension -0.042 -0.042
3.3 Renewing needle bearing in crankshaft

♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621- wage es n
satelettronica
olks ot g
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d ran
ir se tee
tho
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Internal puller, e. g. KUKKO 21-2 - VAS 251 605-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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♦ Drift - VW 207 C-
co Vo
by lksw
cted agen
Prote AG.
3. Crankshaft 59
Removing n AG. Volkswagen AG do

lkswage es n
– Remove gearbox ⇒ Rep. gr. 34 ; Removing by V and installing
o ot g
ua
gearbox; Removing gearbox . ir se
d ran
tee
tho
u or
• The front edges of the inner puller
ss
a must be free of chips. ac
ce
e
– Pull out needle bearing -1- with internal puller, e.g. KUKKO
nl
pt
du
an
21-2 - VAS 251 605- -A- and counter support, e.g. KUKKO
itte
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22-1 - VAS 251 621- -B- in direction of -arrow- from crankshaft erm
ab
-2-.
ility
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wit
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• The internal puller must be positioned behind the needle-and-
h re
hole
cage assembly -arrow-.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Installing
orm
m
atio
– Clean bearing seat in crankshaft and apply a thin coat of com‐
satelettronica
om
mercially available grease.
n in
or c
thi
e
– Drive needle bearing into crankshaft to installation depth using

t
sd
iva
drift - VW 207 C- .
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

renewed because it will be damaged when it is pulled out again.

3.4 Measuring axial clearance of crankshaft

♦ Universal dial gauge holder - VW 387-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
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un
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itte
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erm
ab
ility
ot p
♦ Dial gauge - VAS 6079-
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
Procedure
thi
te
sd
iva
– Attach dial gauge - VAS 6079- with universal dial gauge holder
pr
cum
r
fo
- VW 387- to cylinder block as shown in illustration and set

en
ng
t.
against crankshaft.
yi Co
Cop py
t. rig
– Press crankshaft against dial gauge by hand.
gh ht
pyri by
Vo
o
by c lksw
– Set dial gauge to 0. cted agen
Prote AG.
– Push crankshaft away from dial gauge and read off measured
value.
Axial clearance:
• New: 0.07 … 0.17 mm
• Wear limit: 0.37 mm
3.5 Measuring radial clearance of crank‐

shaft
♦ Plastigage
3. Crankshaft 61
Procedure
Note
♦ Mark used bearings for re-installation but not on bearing sur‐

face.
♦ If the bearing shells have worn down to the nickel layer, they
must be renewed.
– Remove bearing cap and clean crankshaft journal.

– Place a Plastigage corresponding to the width of theobearing
lksw
age es n
ot g
on the journal or into the bearing shells. db
y V ua
ran
e
ris tee
• The Plastigage must be in the middle of theuthbearing
o shell. or
a ac
ss
– Fit bearing cap and tighten. Do not rotate crankshaft.
ce
e
nl
pt
du
an
– Remove bearing cap again.
itte
y li
erm
ab
– Compare width of Plastigage with the measurement scale.
ility
ot p
wit
Radial clearance:
, is n
h re
satelettronica
hole
• New: 0.03 to 0.08 mm
spec
es, in part or in w
• Wear limit: 0.17 mm.
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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 63
⇒ “4.2 Removing and installing pistons”, page 65
⇒ “4.3 Measuring piston projection at TDC”, page 66
⇒ “4.4 Checking pistons and cylinder bores”, page 68
⇒ “4.5 Separating new conrod”, page 69
⇒ “4.6 Checking radial clearance of conrods”, page 69
⇒ “4.7 Removing and installing oil spray jets”, page 70
4.1 Assembly overview - pistons and conrods
1 - Bolts
❑ Oil threads and contact
surface
satelettronica
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ The conrod bearing cap
only fits in one position
and only on the appro‐
priate conrod due to the
breaking procedure
(cracking) separating
the cap from the conrod.
❑ Mark conrod and cylin‐
der allocation in colour
-B- lkswage es n
Vo ot g
❑ Installation position:ed by ua
ran
markings -A- face thor to‐
is tee
or
wards belt pulley
s au end. ac
s
ce
le
3 - Bearing bushes
un
pt
an
d
❑ Fitting position
itte
y li
rm
⇒ page 65
ab
pe
ility

ot
wit
, is n
shells
h re
hole
❑ Note version: upper

spec
bearing shell (towards

es, in part or in w
t to the co
piston) made of a more

wear-resistant material.
Identification on new
rrectness of i
bearing shells: black

line on bearing surface
l purpos
in area of joint
❑ Ensure firm seating
nform
ercia
4 - Connecting rod
m
❑ With industrially cracked conrod bearing cap

com
tion in
❑ Renew as set only.

r
te o
thi
s
iva
❑ Mark conrod bearing cap and cylinder allocation in colour -B-

do
r
rp
cum
❑ Axial clearance, wear limit: 0.37 mm

fo
en
ng
t.
yi
❑ Measuring radial clearance ⇒ page 69
Co
Cop py
.
❑ Separate new conrod ⇒ page 69 .
t rig
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pyri by
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co lksw
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Prote AG.
4. Pistons and conrods 63

❑ Installation position: markings -A- towards belt pulley end
5 - Retaining ring
❑ Qty. 2
6 - Piston pin
7 - Piston
❑ With combustion chamber. AG. Volkswagen AG d
agen oes
olksw not
❑ Renew piston if cracks are visible on piston crown or piston
ed by skirt
V gu
ara
is nte
❑ Mark installation position and cylinder number ⇒ page
ut
hor
64 . eo
a ra
❑ Checking piston and cylinder bore ⇒ page 68 s s c
ce
e
nl
❑ Measuring piston projection at TDC ⇒ page 66
pt
du
an
itte
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8 - Compression rings
erm
ab
ility
❑ Measuring ring gap ⇒ page 69
ot p
wit
, is n
❑ Measuring ring-to-groove clearance ⇒ page 69
h re
hole
❑ Use commercially available piston ring pliers to remove and install.
spec
es, in part or in w
❑ Note installation position, and mark top and bottom as necessary after removing
satelettronica
t to the co
❑ Offset gaps by 120°
9 - Oil scraper ring
rrectness of i
❑ Measuring ring gap ⇒ page 69
l purpos
❑ Measuring ring-to-groove clearance ⇒ page 69

❑ Use piston ring pliers to remove and install.
nform
ercia
❑ Note installation position, and mark top and bottom as necessary after removing
m
at
❑ Offset gap 120° relative to lower compression ring
om
ion
c
in t
or
his
ate
do
riv
Installation position and allocation of piston to cylinder

p
cum
for
en
g
• If worn pistons are to be reinstalled, mark their allocation to

n
t.
yi Co
op
the cylinder on the piston crown. Only use paint for this. C py
t. rig
gh ht
yri by
• Arrow on piston crown points to pulley end -arrow-. op Vo
by c lksw
cted agen
Prote AG.

Installation position of bearing shells in conrods

– Centre bearing shells on conrod and on conrod bearing cap.
• Dimension -a- = 2.5 mm. agen
AG. Volkswagen AG d
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ility
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wit
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h re
ole,
4.2 Removing and installing pistons
spec
t to the co
♦ Drift - VW 222 A-
rrectness o
satelettronica
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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ng
t.
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Cop py
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♦ Piston ring clamp, commercially available p by
co Vo
by lksw
cted agen
Removing Prote AG.
– Remove cylinder head ⇒ page 76 .

– Remove oil pump ⇒ page 137 .
– Mark installation position and allocation of conrod bearing
caps to cylinder and conrods as an aid for reinstalling
⇒ Item 2 (page 63) .
– Unscrew conrod bearing cap.
– Withdraw piston upwards together with conrod.
Note
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installing
Note
Renew bolts that are tightened with turning further angle.
– Oil running surfaces of bearing shells.

– Install piston with piston ring clamp.

Installation position:
• Piston ⇒ page 64
• Bearing shells in conrods ⇒ page 65 .
– Install conrod bearing cap in accordance with marking.
Specified torques
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 63
4.3 Measuring piston projection at TDC

♦ Measuring tool - VW 382-
satelettronica
♦ Measuring plate - VW 385/17-
AG. Volkswagen AG d
agen oes
olksw not
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pt
du
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itte
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ab

ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
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Cop py
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Prote AG.
Rep. gr.13 - Crankshaft group
Procedure
Note
♦ The piston projection at TDC must be measured

Volkswa
when instal‐
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– Secure dial gauge - VAS 6079- with measuring bridge -
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VW 382/7- and measuring plate - VW 385/17- to cylinder block
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as shown in illustration.
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– Measure the projection of each piston at the two points marked
, is n
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with -arrows- (at the rear side and front side of the piston seen
hole
spec
in the longitudinal direction of the engine).
es, in part or in w
t to the co
– Install the appropriate cylinder head gasket depending upon
piston projection, according to following table:
rrectness of i
Piston projection over upper Identification
satelettronica
edge of cylinder block (No. of holes)
l purpos
mm
0.91 … 1.00 1
nf
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1.01 … 1.10 2
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1.11 … 1.20 3
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Cylinder head gasket identification sd

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1- Part number
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Prote AG.
Note
If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct cylinder
head gasket size.

4.4 Checking pistons and cylinder bores

♦ External micrometer 75 - 100 mm - VAS 6071-
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♦ Feeler gauge , commercially available
Checking piston
rrectne
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
satelettronica
ton pin axis with a 75 to 100 mm external micrometer.
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• Maximum deviation from nominal dimension: 0.04 mm.
cial p
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Note
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♦ Check piston skirt coating for wear. Also check pistons and
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cylinder bores for carbon deposits in general.

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♦ Piston must be changed if piston shaft reveals cracking.
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Cop py
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Piston diameter, mm
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• 1) Dimensions include coating (thickness 0.02 mm). The coat‐

ing will wear down.
Measuring cylinder bore
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Measure at three points -c-, in direction -a- and direction -b-.

Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore diameter, mm
Specification 81.03
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095A- , as measurements
may be incorrect.

Measuring piston ring gap

– Push piston ring at right angles to cylinder wall from above
down into cylinder bore to approx. 15 mm from bottom end of
cylinder.
– Push in using a piston without piston rings.
Piston ring New Wear limit
mm mm
1st compression ring 0.30 … 0.40 0.55
2nd compression ring 0.20 … 0.45 0.95
Oil scraper ring 0.25 … 0.50 0.75
Measuring ring-to-groove clearance

– Clean annular groove of piston before check.
Volkswagen AG
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Piston ring New lkswagWear does
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1st compression ring 0.06 … uth 0.09
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2nd compression ring 0.05 … 0.08
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Oil scraper ring 0.03 … 0.06 0.08
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4.5 Separating new conrod
spec
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Procedure
rrectness of i
Note
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♦ To avoid damage, only clamp the conrod lightly in a vice and

use protective jaw covers. nform
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♦ On new conrods it is possible that the breaking point is not fully

m
separated. Proceed as follows if the conrod bearing cap can‐

com
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not be removed by hand:

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– Clamp conrod -1- below dashed line.

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– Unscrew bolts -2- approx. 5 turns.

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Cop py
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– Using a plastic hammer, carefully knock against conrod bear‐
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ing cap -1- in direction of -arrow- until it is loose.
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4.6 Checking radial clearance of conrods

♦ 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 while doing so.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
– Renew conrod bolts.
4.7 Removing and installing oil spray jets

satelettronica
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♦ Hexagon key - T10545-
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Cop py
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– Remove sump ⇒ page 134 . ss
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– Turn crankshaft in direction of engine rotation until respective
an
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pressure relief valve and oil spray jets are accessible.
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NOTICE
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Risk of damage to oil spray jets caused by deformation.
spec
– Do not bend oil spray jets.
t to the co
– Unscrew pressure relief valve -1- using Torx bit T40 -
T10545- .
rrectne
– Remove oil spray jets -2-.
ss
Installing
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– Align guiding edge of oil spray jet with machined surface of
om
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cylinder block.
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Specified torques
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15 – Cylinder head, valve gear

1 Cylinder head
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⇒ “1.5 Removing and installing cylinder head cover”, page 83
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⇒ “1.6 Removing and installing injector seals”, page 85
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⇒ “1.7 Removing and installing camshaft housing”, page 86
hole
spec
⇒ “1.8 Checking compression”, page 90
es, in part or in w
t to the co
⇒ “1.9 Removing and installing cover for camshaft housing”, page
91
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1.1 Assembly overview - cylinder head
satelettronica
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1 - Camshaft case
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⇒ page 74
at
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⇒ page 86
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2 - Bolts
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❑ Qty. 10
C py
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❑ Specified torque and p by
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tightening sequence Prote
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⇒ page 73
AG.
3 - Washers
❑ Qty. 10
4 - Cap
5 - Studs
❑ Qty. 8
❑ 15 Nm
6 - Bolt
❑ With seal
❑ 40 Nm
7 - Cylinder head gasket
❑ Renew coolant and en‐
gine oil after replacing.
❑ Cylinder head gasket
identification
⇒ page 73
8 - Cylinder head
❑ Must not be reworked.
❑ Check for distortion
⇒ page 73 .
❑ Renew coolant and engine oil after replacing.
72 Rep. gr.15 - Cylinder head, valve gear

4-cylinder common rail engine (2.0. Vl,o4V, turbocharger)
lkswage - Edition 03.2019
AG n AG d
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❑ Before installing, check that the two dowelbsleeves
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❑ Removing and installing ⇒ page 76 horis tee
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9 - Cap ss
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10 - Dowel pin
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❑ For camshaft housing
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Cylinder head - specified torque and sequence
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– Tighten bolts in stages in the sequence shown. urposes, in part or in wh
t to the co
Stage Bolts Specified torque/turning further angle
1 -1 … 10- 30 Nm
rrectne
2 -1 … 10- 70 Nm
s
3 -1 … 10- Turn 90° further
s o
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inform
mer
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Cop py
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Cylinder head gasket identification
1- Part number
2- Ignore
3- Holes
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection ⇒ page 66 .
♦ If the cylinder head gasket or cylinder head has been replaced,
select a new cylinder head gasket according to the number of
holes on the old cylinder head gasket.
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be determined by measuring
the piston projection at “TDC” ⇒ page 66 .
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm
1. Cylinder head 73
AG. Volkswagen AG d
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Assembly overview - camshaft housing
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spec
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⇒ page 117
t to the co
2 - Camshaft case
❑ With integrated cam‐
rrectness of i
shafts
l purpos

⇒ page 86
nform
ercia
3 - Bolts
m
❑ Qty. 15
at
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io
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c
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or
tightening sequence
his
ate
⇒ page 74
do
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4 - Seal
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Cop py
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5 - Cover yri
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❑ Removing and installing cted agen
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⇒ page 91
6 - Bolts
❑ Qty. 4
❑ 8 Nm
7 - Cap
Specified torque and tightening sequence for camshaft housing

– Tighten bolts for camshaft housing -16- in stages in the se‐
quence shown:
• Camshaft housing -16- must make
contact with cylinder head over en‐
tire contact surface
2 -1 … 15- 10 Nm

1.3 Assembly overview - cylinder head cover
1 - Bolts
❑ Qty. 2
❑ Specified torque:
⇒ page 268
2 - Clamping pieces
❑ Qty. 2
⇒ page 269
3 - Grommets
❑ Qty. 2
❑ In cylinder head cover
4 - Bolt
⇒ page 383
5 - Hall sender - G40-
satelettronica
⇒ page 389
6 - Seal
❑ For injectors
⇒ page 85 AG. Volkswagen AG d
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7 - Heat shield d by
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8 - Bolts ut
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❑ Qty. 2 ss c
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❑ 2 Nm
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9 - Cylinder head cover

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⇒ page 83
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10 - Seal
spec
es, in part or in w
❑ Renew if damaged or leaking

t to the co
11 - Bolts
❑ Renew gasket if damaged
rrectness of i
❑ Qty. 7
l purpos
❑ Specified torque and tightening sequence: ⇒ page 76

12 - Seal
nform
ercia
13 - Cap
m
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Cop py
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Prote AG.
1. Cylinder head 75
Specified torque and tightening sequence for cylinder head cover

– Tighten cylinder head cover bolts -8- in sequence -1 … 7-.
Bolts 9 Nm
1.4 Removing and installing cylinder head
satelettronica
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Cop py
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Prote AG.

♦ Drip tray for workshop hoist - VAS 6208-

lkswage es n
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♦ Contour blade set - VAS 852 005- or commercially available
ceramic glass scraper
rrectness of i
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nf
ercia
orm
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atio
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or c
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♦ Vehicle diagnostic tester t. Cop py
rig
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by
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Prote AG.
1. Cylinder head 77
Condition
• Do not use sandpaper, grinding wheels, abrasive or scour
pads or any other sanding or abrasive media.
• Sealing surface (see photo) must not project.
• Discolouration (dark spots, see photo) need not be removed.
• When removing the sealant residue, make sure no loose par‐
ticles get into the open channels of the engine.
• Ensure that all adjacent workspaces are clean, and that none
of the above mentioned sanding or abrasive media are used.
• Using unauthorised sanding or abrasive media may lead to
secondary damage such as, for example, damage to the tur‐
bocharger or the conrod bearings.
CAUTION
Risk of eye injury causedolbykswsealant residue.
age es n
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ed
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• Only remove sealant residue from cylinder head -1- and cyl‐
ce
le
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inder block -3- using contour blade set - VAS 852 005- -2- or pt
an
d
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a commercially available ceramic glass scraper. y li

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Removing wit
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
ole,
Disconnecting and connecting battery .

spec
Vehicles with bi-turbo and all-wheel drive

t to the co

rrectne

– Remove charge air cooler ⇒ page 250 .
ss o
– Remove camshaft housing ⇒ page 86 .

cial p
f inform
– Remove side toothed belt guard ⇒ page 96 .

mer
atio
m
– Remove rear toothed belt guard ⇒ page 98 .

o
n
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All vehicles apart from bi-turbo with all-wheel drive

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– Move to service position ⇒ General body repairs, exterior;

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Rep. gr. 50 ; Lock carrier; Moving to and back from service

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Cop py
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– Remove washer fluid reservoir filler pipe ⇒ Electrical system;
ht
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Rep. gr. 92 ; Windscreen washer system; Removing and in‐ by c lksw
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stalling washer fluid reservoir filler pipe . Prote AG.

– Remove turbocharger ⇒ page 227 .
– Remove exhaust gas recirculation cooler ⇒ page 365 .


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– Unscrew bolts -4-. ksw
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– Loosen bracket -1- on cylinder head -2-. ise d b ara
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satelettronica
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at
– Loosen bracket -1- on cylinder head -3-.
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Vehicles with single turbocharger

1. Cylinder head 79

– Pull off fuel hoses -4-.
– Pull off vacuum hose -3-.
– Unclip retainer -2-.
– Place fuel lines -1- to one side.
– Separate wiring harness in engine compartment and lay aside. AG. Volkswagen AG d
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– Unclip retainers for vacuum pipe -3- and -4-.
es, in part or in w
t to the co
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– Release and pull off vacuum pipe -3-.

– Detach vacuum hoses -4-.
– Move coolant pipes -7- to one side.

– Loosen bolts in the sequence -1 … 10-.

– Unscrew bolts in the sequence -1 … 10-.
– Assisted by a second mechanic, remove cylinder head and
AG. Volkswagen AG d
also tensioning roller at the same time. agen oes
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• Place cylinder head down in such a wayorthat
ise cylinder head or nte
parts installed on cylinder head are not
authdamaged. eo
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• If contact was made between pistons and valves, also renew
ce
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un
pt
the roller rocker fingers of the corresponding cylinder.
an
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Installing
ss
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mer
atio
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• Sealing surface (see photo) must not project.
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• Discolouration (dark spots, see photo) need not be removed.
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of the above mentioned sanding or abrasive media are used. Prote
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agen

CAUTION
Risk of eye injury caused by sealant residue.
1. Cylinder head 81
• Only remove sealant residue from cylinder head -1- and cyl‐
inder block -3- using contour blade set - VAS 852 005- -2- or
a commercially available ceramic glass scraper.
• The sealing surfaces must not be damaged.
• There must be no oil or coolant in the bolt pockets.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• If a new cylinder head is installed, contact surfaces between
roller rocker fingers and running surface of cam must be oiled.
• Handle the cylinder head gasket wage very carefully to dprevent
n AG. Volkswagen AG o
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damage to the silicone ycoating
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• Turn the crankshaft
au carefully at least 2 rotations to ensure that ac
ss
none of the valves make contact when the starter is operated.
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• When the cylinder head or cylinder head gasket is renewed,
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the entire coolant and the engine oil must be changed.
rm
ab
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ility
– Remove any loose remains using a lint-free cloth.
ot
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– Before fitting cylinder head, remove crankshaft stop - T10490-
satelettronica
hole
spec
and turn crankshaft opposite direction of rotation until all pis‐
es, in part or in w
tons are nearly uniformly below “TDC”.
t to the co
– If no dowel sleeves for centring cylinder block and cylinder
head are fitted, install dowel sleeves.
rrectness of i
– Observe identification of cylinder head gasket ⇒ page 73 .
l purpos
nform
mercia
a
com
tion in
r
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Prote AG.

– Fit cylinder head gasket on dowel sleeves -arrows- in cylinder

block.
• Cylinder head gasket installation position: marking “top” or
part number towards cylinder head
– Fit cylinder head with the aid of a second mechanic.
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– Fit and tighten cylinder head
Vol
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– Add coolant ⇒ page oris 179 .
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– Change engine
s oil, and renew oil filter element ⇒ Mainte‐
s a c
nance ; Booklet 20.1 .
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nl
pt
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– Fill/bleed fuel system ⇒ page 263 .
itte
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spec
After components have been renewed (engine/short engine, cyl‐
es, in part or in w
inder head, camshaft housing or turbocharger), the oil pressure
t to the co
control must be set to max. pressure for approx. 1000 km if the
function is available in the engine control unit. This will compen‐
sate for the increased friction during run-in of new components,
rrectness of i
satelettronica
and a better transport of wear-related particles is guaranteed.
l purpos
– Connect ⇒ Vehicle diagnostic tester.
nf
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– Switch on ignition.
orm
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Specified torques
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♦ ⇒ “1.1 Assembly overview - cylinder head”, page 72
co Vo
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Prote AG.
♦ ⇒ “1.2 Assembly overview - camshaft housing”, page 74
♦ ⇒ “1.3 Assembly overview - cylinder head cover”, page 75
♦ ⇒ “3.1 Assembly overview - injectors”, page 268
♦ ⇒ “3.2 Assembly overview - fuel rail”, page 270
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 93
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 220
♦ ⇒ “5.1 Assembly overview - exhaust gas recirculation”,
page 363
♦ ⇒ “2.1 Assembly overview - charge air system”, page 249
Bolts of bracket for high-pres‐ 30 Nm
sure pump of mono-turbo
1.5 Removing and installing cylinder head

cover
1. Cylinder head 83
AG. Volkswagen AG d
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Removing rise
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– If fitted, remove engine cover panel ⇒ page 33 . s au ra
c
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– Remove injectors ⇒ page 277 .
rm
ab
pe
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– Remove fuel rail ⇒ page 285 .
ot
wit
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satelettronica
– Separate electrical connector from Hall sender - G40-
h re
hole
⇒ Item 2 (page 384) .
spec
es, in part or in w
– Lay wiring harness for injectors and Hall sender - G40- aside.
t to the co
rrectness of i
– Release crankcase breather pipe -2-.
l purpos
nform
mercia
a
com
tion in
r
– Remove noise insulation -1-.

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– Loosen bolts in the sequence -7 … 1-.

– Remove cylinder head cover -8-.
Installing
• Observe tightening sequence for cylinder head cover
⇒ page 76 .
Specified torques
AG. Volkswagen AG d
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1.6 Removing and installing injector seals h eo
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satelettronica
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♦ Yoke - 3390-
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♦ Tool set - T10133C-

atio
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1. Cylinder head 85
♦ Seal puller - T40195-
Removing
– Remove injectors ⇒ page 277 .
– Twist oil seal extractor - T40195- into oil seal -1-.
– Fit impact hammer - T10133/3- with adapter - T10133/2- on oil
seal extractor - T40195- .
– Pull out seal -1- upwards by tapping it gently.
satelettronica
Installing
. Volkswagen AG
– Press in new seal -2- using carrier - 3390- and short extension kswagen AG does
-1- in direction of -arrow- onto stop. by
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1.7 Removing and installing camshaft hous‐

nform
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ing
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AG. Volkswagen AG d
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♦ Hub cap puller - 2041-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
at
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ion
c
in t
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ate
♦ Contour blade set - VAS 852 005- or commercially available
do
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ceramic glass scraper

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Condition
CAUTION
1. Cylinder head 87
• Only remove sealant residue from cylinder head -1- using

contour blade set - VAS 852 005- -2- or a commercially avail‐
able ceramic glass scraper
Removing
satelettronica
– Remove toothed belt from camshaft ⇒ page 111 .
. Volkswagen AG
gen AG does
– Remove cylinder head cover ⇒ page 83Vo.lkswa not
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db ara
– Loosen bolts in the sequence -15ori…
se 1-. nte
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– Unscrew bolts in the sequence
ss -15 … 1-.
a c
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– Carefully detach camshaft housing -16- from adhesive and

un
pt
an
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remove.
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AG. Volkswagen AG d
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eo
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a
4-cylinder
s common rail engine (2.0 l, 4V, turbocharger) - Edition
s c 03.2019
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– If necessary, use hub grease cap puller - 2041- to lever off. To
itte
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erm
ab
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ility
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– Carefully lever off camshaft housing -1-.
hole
spec
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– Cover open parts of engine.
t to the co
Installing
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CAUTION
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Risk of eye injury caused by sealant residue. cted agen
Prote AG.
• Only remove sealant residue from cylinder head -1- using

contour blade set - VAS 852 005- -2- or a commercially avail‐
able ceramic glass scraper
– Then, clean sealing surfaces.
1. Cylinder head 89
AG. Volkswagen AG d
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Use sealant as per ⇒ Electronic partsVcatalogue
olks
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(ETKA) . not
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Observe use-by date of sealant.
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– Cut off nozzle on tube at front marking (∅ of nozzle approx.
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2 mm).
wit
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es, in part or in w
t to the co
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nform
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a
com
ti
– Apply sealant bead -arrow- to clean sealing surfaces of cam‐
on in
satelettronica
shaft housing.
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• Thickness of sealant beads: 2 mm.
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• Do not apply sealant bead thicker than specified.
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• Install camshaft housing within 5 minutes of applying sealant.
C py
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rig ht
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– Tighten bolts for camshaft housing, adhere to tightening se‐
co Vo
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quence ⇒ page 74 .
agen
Prote AG.
• After installing the camshaft housing, wait about 30 minutes

for the sealant to dry. Do not start the engine before.
Note



tester.
Specified torques
1.8 Checking compression


♦ Compression tester - V.A.G 1763-

Procedure
• Engine oil temperature approx. 80°C.
• Battery voltage at least 12.5 V.
– Remove glow plugs ⇒ page 385 .
satelettronica
– Screw in adapter - V.A.G 1763/8- in place of the respective
glow plug.
– Connect compression tester - V.A.G 1763- .
Note
G. Volkswagen
♦ If necessary, secure quick-release coupling
lksw
ag- eV.A.G
nA 1763/3- AG does n
between compression tester - V.A.G db
y1763-
Vo
and adapter - ot g
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V.A.G 1763/8- . rise
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♦ s au ⇒ operating instructions .
Information on how to use tester ac
s
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un
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– Have a 2nd mechanic operate starter until compression tester

an
d
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- V.A.G 1763- shows no further pressure increase.

erm
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– Repeat procedure on each cylinder.

wit
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Compression pressures bar

ole,
spec
New 25.0 … 31.0

t to the co
Wear limit 19.0

Maximum difference between cylinders 5.0
rrectne
Assembling
s

s o
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f in

form
mer
atio
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c
– Delete engine control unit event memory.

i
or
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Specified torques
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♦ ⇒ “1.1 Assembly overview - glow plug system”, page 383

en
ng
t.
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1.9 Removing and installing cover for cam‐
gh ht
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shaft housing
c by lksw
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1. Cylinder head 91
Removing
– Remove bracket for exhaust gas recirculation cooler
⇒ page 377 .
– Unscrew bolts ⇒ Item 6 (page 74) . lkswage es n
o ot g
byV ua
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– Remove cover ⇒ Item 5 (page 74) . o
ir se
ran
tee
th or
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Installing a ac
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ss
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un
pt
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Specified torques
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ab
pe
ility
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wit
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hole
spec
page 363
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
r
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2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt cover”, page 93
⇒ “2.2 Assembly overview - toothed belt”, page 94
⇒ “2.3 Removing and installing toothed belt guard”, page 95
⇒ “2.4 Removing and installing toothed belt”, page 99
⇒ “2.5 Removing toothed belt from camshaft”,
wage
n page
AG. Vol111
kswagen AG
doe
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2.1 Assembly overview - toothed belt cover ris
ed by ara
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1 - Toothed belt guard
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❑ Bottom
an
itte
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⇒ page 96
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2 - Bolts
h re
hole
spec
❑ Qty. 4
es, in part or in w
❑ 12 Nm
t to the co
satelettronica
3 - Bolt
❑ 12 Nm
rrectness of i
l purpos
❑ On side
nform
ercia

⇒ page 96
m
at
om
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❑ Top
his
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do
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⇒ page 95
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6 - Bolt t. Cop py
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❑ 12 Nm
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❑ Rear
⇒ page 98
2. Toothed belt drive 93

Transporter 2016 ➤ gen AG
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does
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2.2 Assembly overview - toothed belt th e or
s au ac
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1 - Bolt
itte
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❑ Loosen and tighten with
wit
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counterhold - 3415-
h re
hole
spec
❑ Do not additionally oil
es, in part or in w
the thread and shoulder
t to the co
❑ 180 Nm +135°
2 - Crankshaft pulley
rrectness of i
❑ Contact surface be‐
l purpos
tween toothed belt pul‐

ley and crankshaft must
be free from oil
nform
ercia
❑ Can only be fitted in one

m
position
a
com
tion in
3 - Nut
r
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❑ 20 Nm
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4 - Idler roller
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5 - Nut Cop py
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❑ 20 Nm +45° Prote
cted AG.
agen
6 - Tensioning pulley
❑ Stud for tensioning roll‐
er: 15 Nm
7 - Toothed belt
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
❑ Check for wear
⇒ page 99
❑ Detaching from cam‐
shaft ⇒ page 111
8 - Bolt
❑ Use counter-hold tool - T10172- to loosen and tighten
❑ Do not additionally oil the thread and shoulder
❑ 100 Nm
9 - Bolt
❑ 9 Nm
10 - Camshaft toothed belt pulley
❑ Contact surface between sprocket and camshaft must be free of oil
11 - Follower for camshaft
12 - Bolt
❑ 20 Nm
13 - Idler roller
❑ Assembly overview ⇒ page 311

15 - Hub for high-pressure pump
❑ Contact surface between hub and toothed belt sprocket must be free of oil
16 - High-pressure pump toothed belt pulley
❑ Contact surface between hub and toothed belt sprocket must be free of oil
17 - Nut
❑ Do not additionally oil the thread and shoulder
18 - O-ring
❑ Moisten with coolant
19 - Coolant pump
❑ Assembly overview ⇒ page 187 n AG. Volkswagen AG do
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20 - Bolt ris nte
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2.3 Removing and installing toothed belt
rm
ab
pe
ility
guard
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wit
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hole
⇒ “2.3.1 Removing and installing upper toothed belt guard”, page
spec
95
es, in part or in w
t to the co
⇒ “2.3.2 Removing and installing side toothed belt guard”,
page 96
rrectness of i
⇒ “2.3.3 Removing and installing lower toothed belt guard”, page
96
l purpos
⇒ “2.3.4 Removing and installing rear toothed belt cover”,

page 98
nform
ercia
2.3.1 Removing and installing upper toothed

m
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belt guard
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Removing
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– Release locking lugs -1-. Cop py
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– Detach upper toothed belt guard -2- and remove in direction p by
co Vo
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of -arrow-.
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cted agen
Prote AG.
Installing
Install in reverse order of removal.

2.3.2 Removing and installing side toothed

belt guard
AG. Volkswagen AG d
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d by ara
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aut ra
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nl
pt
du
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ab
ility
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spec
es, in part or in w
t to the co
Removing
satelettronica
rrectness of i
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– Remove side toothed belt guard -2-.

Installing
nform
ercia

m
at
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ion
Specified torques
c
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priv
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
2.3.3 Removing and installing lower toothed

belt guard

Removing
Note
♦ To simplify the manufacturing process in the production facili‐

ties the lower toothed belt guard is provided with a guide at
bottom which engages in the sealing flange.
♦ When removing the toothed belt guard with engine support
installed, the guide in the toothed belt guard must be de‐
stroyed.
♦ Bear in mind that there are different versions!
– Remove side toothed belt guard ⇒ page 96 .

– Remove vibration damper ⇒ page 38 .
– If a toothed belt guard version which is about to be discontin‐
ued is fitted, drill a hole according to the following dimensions:
lkswage es n
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Note byV ua
satelettronica
d ran
ir se tee
tho
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To prevent damage, exercise extreme caution
au when performing ac
ss
the following work step!
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♦ Dimension -a- = 10 mm
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ility
♦ Diameter: 8 mm
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– Insert a screwdriver through drilled hole and break off guide
h re
hole
lug of toothed belt guard towards rear.
spec
es, in part or in w
t to the co
– If a more recent toothed belt guard version is fitted, insert
screwdriver into slot in guide lug.
rrectness of i
– Then, break off guide lug by turning screwdriver in
-direction of arrow-.
l purpos
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orm
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Cop py
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by
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Prote AG.


• Locking lug -3- broken off.
– Remove lower toothed belt guard -2-.
AG. Volkswagen AG d
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olksw not
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Installing ise
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– If a new toothed belt guard is installed, the guide lug -arrow-

nl
pt
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must be cut off prior to installing.
itte
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ility
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es, in part or in w
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– Fit toothed belt guard. Note dowel pin -arrow- while doing so.
l purpos
Specified torques
nform
mercia
at
om
ion
c
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ate
do
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for
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Cop py
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by
2.3.4 Removing and installing rear toothed
cted agen
Prote AG.
belt cover

Removing
– If fitted, remove coolant valve for cylinder head - N489-
⇒ page 199 .
– Pull out rear toothed belt cover -2- in direction of -arrow-.
Installing
satelettronica
Specified torques
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
ss c
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un
pt
2.4 Removing and installing toothed belt

an
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ility
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♦ Counter-hold tool - T10051-

is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
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or
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te
sd
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t.
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Cop py
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by c lksw
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Prote AG.


AG. Volkswagen AG d
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♦ Angled screwdriver - T10264-
t to the co
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cial p
f inform
satelettronica
mer
atio
om
n
c
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t.
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♦ Locking tool - T10265-
Co
Cop py
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by
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Prote AG.
♦ Pin - T10492-

♦ Crankshaft stop - T10490-
AG. Volkswagen AG d
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Removing rised ara
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– Removes upper
au part of toothed belt guard ⇒ page 95 . ra
c
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e
– If necessary, remove engine support on right ⇒ page 40 .

nl
pt
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itte
– Remove lower toothed belt guard ⇒ page 96 .
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ab
ility
• Only turn crankshaft in engine direction of rotation.
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satelettronica
– Turn crankshaft by bolt for crankshaft pulley until camshaft
h re
hole
pulley is at “TDC”.
spec
es, in part or in w
– Lock camshaft hub with locking pin - T10492- . To do this,
t to the co
insert locking pin into fork on follower -1- and into hole -2- be‐
hind it in cylinder head.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Loosen bolt -1- in camshaft sprocket by half a turn; do not un‐

thi
te
screw.
sd
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

– Lock crankshaft pulley -1- in position with crankshaft stop -

T10490- .
• Pins of crankshaft stop - T10490- must engage in threaded
holes of toothed belt pulley.
• Locking pin of crankshaft stop - T10490- must engage in hole
in sealing flange.
• It is essential that the torque for loosening and tightening
en AG. V the agen AG doe
olksw
central bolts on camshaft and high-pressureVpump lkswagis not trans‐ s no
o t gu
ferred to the respective locking pin. ed by ara
is nte
or
• Therefore, pull out locking pin for loosening
au
th and tightening the eo
ra
central bolt, and reinsert the locking
ss pin afterwards if neces‐ c
sary.
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Pull out locking pin, and slightly loosen bolt for camshaft. Be‐
satelettronica
fore loosening completely, insert locking pin back in.
rrectness of i
– Loosen bolt -1- for camshaft pulley. Use counterhold - T10172-
with adapter - T10172/11- to do this.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Lock high-pressure pump hub with diesel injection pump lock‐

ing pin - T10492- . To do this, insert locking pin into fork -2- on
hub and into hole -1- behind it in bracket for ancillaries.
– Pull out locking pin, and slightly loosen nut for high-pressure
pulley. Before loosening completely, insert locking pin back in.

– Loosen nut -1- for high-pressure pump pulley by approx. 90°.

Use counterhold - T10051- to do this.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
Note
rrectness of i
Different tensioning rollers -A or B- may be installed depending
l purpos
on the equipment. The adjustment jig -1- is the distinguishing fea‐

ture. The tensioning roller -A- is not locked in position using nform
ercia
locking tool - T10265- . Instead, the angle driver 8mm - T10409-

must be used for tensioning. Apart from that the procedure is
m
identical.
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 nut -1- for belt tensioner.

– Turn eccentric of tensioning roller anti-clockwise in direction
of -arrow- using angle driver - T10264- until tensioning roller
can be locked with locking tool - T10265- .

– Turn tensioning roller eccentric clockwise

AG. Volkin
swadirection
gen of
-arrow- onto stop using angle sw agen - T10264- . AG does
driver
olk no t gu V
ara by
– Tighten nut -1- hand-tight.
ris
ed nte
tho eo
– If the toothed belt
ss ais to be reinstalled, mark direction of rotation
u ra
c
with chalk or felt tipped pen.
ce
e
nl
pt
du
an
– Remove toothed belt first from coolant pump and then from
itte
y li
remaining toothed belt pulleys.
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
Installing (adjusting valve timing)

m
at
satelettronica
om
io
Prerequisites:
n
c
in t
or
his
e
• For adjusting work on the toothed belt, the engine must be

at
do
riv
cold.
p
cum
for
en
g
• When turning camshaft, crankshaft must be positioned so that

n
t.
yi Co
no piston is positioned at “TDC”. Cop py
t. rig
gh ht
yri
• Tensioning roller locked with locking tool - T10265- and se‐ p by
co Vo
lksw
cured to right stop with nut -1-.
by
cted agen
Prote AG.
• Metal lug -arrow- of tensioning roller must engage in cast re‐

cess on cylinder head.

• Camshaft hub locked with locking pin - T10492- .

• Bolt fitted but not tightened.
• It should just be possible to turn camshaft pulley easily without
axial movement.
• Bolt -1- of follower loosened by half a turn and positioned in
satelettronica
centre of elongated hole.
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
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rm
ab
• Crankshaft locked in position with crankshaft stop - T10490- .

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.

• Hub on high-pressure pump locked in place with locking pin -

T10492- .
• Nut fitted but not tightened.
• It should just be possible to turn high-pressure pump pulley
easily without axial movement.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– Turn toothed belt sprocket of camshaft and ris toothed belt
e nte
satelettronica
o eo
sprocket of high-pressure pump in theirauelongated
th
holes clock‐ ra
wise as far as the stop. ss c
ce
le
un
pt
– Fit toothed belt in sequence described:
an
d
itte
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rm
1- Crankshaft pulley
ab
pe
ility
ot
2- Tensioning pulley
wit
, is n
h re
3- Camshaft toothed belt pulley
hole
spec
es, in part or in w
4- High-pressure pump toothed belt pulley
t to the co
5- Coolant pump toothed belt pulley
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Loosen nut -1- for belt tensioner and remove locking tool -
s
iva
T10265- .
do
r
rp
cum
fo
• Metal lug of tensioning roller must remain engaged in cast re‐

en
ng
t.
yi
cess on cylinder head.
Co
Cop py
t. rig
gh
• The locking bolt must not lie against upper stop of elongated
ht
pyri by
Vo
hole after toothed belt has been tensioned.
o
by c lksw
cted agen
Prote AG.

– Check that bolt -1- is still located between centre of elongated

hole and lower stop. Otherwise, move position of camshaft
toothed belt pulley one tooth in clockwise direction and fit
toothed belt again.
– Using angle driver - T10264- or angle driver 8mm - T10409- ,
satelettronica
carefully turn tensioning roller eccentric clockwise in direction
of -arrow- until indicator -2- is in middle of gap in base plate.
• Make sure that the nut -1- does not turn at the same time.
– Hold tensioning roller in this position, and tighten nut -1-.
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
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erm
ab
– Position counterhold - T10172- with adapter - T10172/11- on

ility
ot p
camshaft sprocket as shown in illustration.

wit
, is n
h re
– Push counterhold - T10172- anti-clockwise in direction of

hole
spec
-arrow- and maintain tension.

es, in part or in w
t to the co
– Tighten bolt -1- and nut -2- to 10 Nm in this position.

rrectness of i
Note
l purpos
The high-pressure pump pulley can only be turned to a limited

extent. It is therefore essential to ensure that the toothed belt pul‐
nf
ercia
ley has not been turned to the limit after tensioning.

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.

– Ensure that marking on high-pressure pump toothed belt pul‐

ley is not in alignment with locking pin. If necessary, move
position of toothed belt pulley one tooth in clockwise direction
and fit toothed belt again.
wage es n
– Remove locking pin - T10492- and crankshaft stop - T10490-
yV
olks ot g
ua
and check valve timing ⇒ page 108 . ise
d b ran
r tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
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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
Checking valve timing:
satelettronica
nform
ercia
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐

m
a
com
t
gine's direction of rotation until crankshaft is at a position
ion in
shortly before “TDC”.
r
te o
thi
s
iva
– Place crankshaft stop - T10490- back on crankshaft toothed
do
r
rp
c
belt sprocket -1-.
um
fo
en
ng
t.
yi
– Turn crankshaft in direction of engine rotation until pin of
Co
op py
crankshaft stop engages in sealing flange whilst turning. t. C rig
gh ht
pyri by
Adjustment fault through inaccurate TDC setting
co Vo
by lksw
cted agen
Prote AG.
– If crankshaft has been turned beyond TDC, turn crankshaft
another 2 turns until it is just before TDC position again. Then,
while turning in this direction, lock crankshaft with crankshaft
stop - T10490- .
• It must be possible to lock the camshaft hub with locking pin -

T10492- .

• It is very difficult to find the locking point of the high-pressure

pump hub again. A minor deviation -arrow-, though, does not
influence engine operation.
• The belt tensioner indicator -2- must be in the middle between
satelettronica
tabs -1- and -3- of the base plate.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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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.

• The indicator -2- must not be offset relative to tab -1- bynmore
wage
AG. Volkswagen AG d
oes
than 6 mm -a- in direction of engine rotation. y Vo lks not
gu b ara
ed
If the conditions are fulfilled, continue with theris valve timing cor‐ nte
tho e
rectly adjusted ⇒ page 110 . sa
u or
ac
s
If the conditions are not fulfilled, correct the valve timing
ce
e
nl
pt
du
⇒ page 110 .
an
itte
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erm
ab
Correcting the valve timing:
ility
ot p
wit
– If the hub of the camshaft can not be locked in position, pull
, is n
h re
camshaft stop - T10490- back until the lug exposes the hole.
hole
spec
– Turn crankshaft back to slightly before TDC by turning it in
es, in part or in w
t to the co
opposite direction of engine rotation.
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be locked in position.
rrectness of i
– After locking, loosen bolts for toothed belt sprocket of cam‐
l purpos
shaft.
A - the lug of the crankshaft stop - T10490- must be to the left of
nform
ercia
the hole.
m
at
om
– Turn crankshaft in direction of engine rotation until pin of
satelettronica
on
c
crankshaft stop engages in sealing flange whilst turning.
in t
or
his
ate
– Tighten bolts for toothed belt sprocket of camshaft to 20 Nm.
do
priv
cum
or
B - Lug of the crankshaft stop - T10490- must be to the right of

f
en
ng
t.
the hole.
yi Co
Cop py
t. rig
– First, turn crankshaft a little in direction opposite to engine's
gh ht
yri by
direction of rotation. cop Vo
by lksw
cted agen
Prote AG.
– Turn crankshaft in engine's direction of rotation again until
crankshaft stop pin engages in sealing flange whilst turning.
– Tighten bolts for toothed belt sprocket of camshaft to 20 Nm.
Procedure after adjusting valve timing correctly:
– Remove locking pin - T10492- and crankshaft stop - T10490- .
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐
gine's direction of rotation until crankshaft is at a position
shortly before “TDC”.
– Check valve timing again ⇒ page 108 .
• It is essential that the torque for loosening and tightening the
central bolts on camshaft and high-pressure pump is not trans‐
ferred to the respective locking pin.
• Therefore, pull out locking pin for loosening and tightening the
central bolt, and reinsert the locking pin afterwards if neces‐
sary.

– If camshaft hub can now be locked, tighten bolt -1- for cam‐
shaft pulley to final torque using counterhold - T10172- with
adapter - T10172/11- .
– Tighten nut -2- for high-pressure pump pulley to final torque
using counterhold - T10051- .
– Check valve timing again ⇒ page 108 .
Assembling
Further installation is carried out in the reverse order of removal;
note the following:
Note
♦ Renew seals.
♦ Secure all hose connections with the correct type of hose clips
Specified torques
satelettronica
2.5 Removing toothed belt from camshaft

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.

♦ Angled screwdriver - T10264-
♦ Locking tool - T10265-
satelettronica
♦ Pin - T10492-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
♦ Crankshaft stop - T10490-

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
by
112
copy Vo
by lksw
Rep. gr.15 - Cylinder head, valve gear cted agen
Prote AG.
Removing
– Remove vibration damper ⇒ page 38 .
– Turn crankshaft by bolt for toothed belt sprocket until toothed
belt for camshaft is at “TDC”.
– Lock camshaft hub with locking pin - T10492- . To do this,
insert locking pin into fork on follower -1- and into hole -2- be‐
hind it in cylinder head.
– Loosen bolt -1- in camshaft sprocket by half a turn; do not un‐
satelettronica
screw.
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
– Lock crankshaft pulley in position with crankshaft stop -

T10490- .
nform
ercia
• Pins of crankshaft stop - T10490- must engage in threaded

holes of toothed belt pulley.
m
at
om
io
• Locking pin -arrow- of crankshaft stop - T10490- must engage

n
c
in t
or
in hole in sealing flange.

his
ate
do
riv
• It is essential that the torque for loosening and tightening the

p
cum
or
central bolts on camshaft and high-pressure pump is not trans‐

f
en
ng
ferred to the respective locking pin.

t.
yi Co
Cop py
t. rig
• Therefore, pull out locking pin for loosening and tightening the yri
gh by
ht
central bolt, and reinsert the locking pin afterwards if neces‐ cop Vo
by lksw
sary.
cted agen
Prote AG.

– Pull out locking pin, and slightly loosen bolt for camshaft. Be‐
fore loosening completely, insert locking pin back in.
– Loosen bolt -1- for camshaft pulley. Use counterhold - T10172-
with adapters -T10172/11- to do this.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
is e nte
– Lock high-pressure hor pump hub with diesel injection pump lock‐eo
satelettronica
ut
ing pin - T10492-
ss a . To do this, insert locking pin into fork -2- on ra
c
hub and into hole -1- behind it in bracket for ancillaries. 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
e
– Loosen nut -1- for high-pressure pump pulley by approx. 90°.

at
do
riv
Use counterhold - T10051- to do this.

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

Note
The installed tensioning rollers -A and B- differ from each other.

The adjustment jig -1- is the distinguishing feature. The tensioning
roller -A- is not locked in position using locking tool - T10265- .
Instead, the angle driver 8mm - T10409- must be used for ten‐
sioning. Apart from that the procedure is identical.
– Loosen nut -1- for belt tensioner.
satelettronica
– Turn eccentric of tensioning roller anti-clockwise in direction
of -arrow- using angle driver - T10264- until tensioning roller
can be locked with locking tool - T10265- .
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Turn tensioning roller eccentric clockwise in direction of

-arrow- onto stop using angle driver - T10264- .
– Tighten nut -1- hand-tight.
rrectne
– Take toothed belt off camshaft sprocket.

ss
Installing (adjusting valve timing) ⇒ page 104

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.

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 116
⇒ “3.2 Measuring axial play of camshaft”, page 117
⇒ “3.3 Removing and installing camshaft oil seal”, page 117
⇒ “3.4 Checking hydraulic compensation elements”, page 119
⇒ “3.5 Removing and installing valve stem seals”, page 120
3.1 Assembly overview - valve gear
1 - Dowel pins
❑ Qty. 2
❑ For camshaft housing
2 - Roller rocker fingers
❑ Qty. 16
❑ Mark installation posi‐
tion for re-installation.
satelettronica
❑ Check roller bearing for
ease of movement.
❑ Lubricate contact surfa‐
ces before installing.
⇒ page 86
3 - Valve cotters
❑ Qty. 32
4 - Valve spring plate
❑ Qty. 16
AG. Volkswagen AG d
agen oes
5 - Valve springs Volksw not
gu
by ara
❑ Qty. 16 rised
nte
ho eo
ut
6 - Valve stem seals ss a ra
c
❑ Qty. 16
ce
e
nl
pt
du
an

itte
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⇒ page 120
erm
ab
ility
ot p
7 - Hydraulic compensation el‐

wit
, is n
ements
h re
hole
spec
❑ Qty. 16
es, in part or in w
❑ Mark installation posi‐

t to the co
tion for re-installation.

❑ Lubricate contact surfa‐
rrectness of i
ces before installing.

❑ Checking ⇒ page 119
l purpos
8 - Cylinder head
nf
ercia

orm
m
atio
9 - Inlet valves
om
n in
c
❑ Qty. 8
or
thi
e
❑ Do not rework; only grinding-in is permissible

t
sd
iva
o
r
rp
cu
❑ Mark installation position for re-installation.

o
m
f
en
ng

t.
yi Co
op py
❑ Valve dimensions ⇒ page 132
t. C rig
gh ht
yri by
❑ Checking valve guides ⇒ page 131
op Vo
by c lksw
cted agen
Prote AG.

10 - Exhaust valves
❑ Qty. 8
❑ Do not rework; only grinding-in is permissible
❑ Mark installation position for re-installation.
❑ Valve dimensions ⇒ page 132
❑ Checking valve guides ⇒ page 131
3.2 Measuring axial play of camshaft

satelettronica
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
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erm
ab
ility
ot p
wit
, is n
Procedure
h re
hole
spec

es, in part or in w
t to the co
– Secure dial gauge - VAS 6079- with universal dial gauge

bracket - VW 387- on camshaft housing.
rrectness of i
– Press camshaft against dial gauge by hand.

l purpos
– Set dial gauge to 0.

– Press camshaft away from dial gauge and read off value:
nf
ercia
• Axial clearance: 0.05 to 0.15 mm

rm
m
atio
om
n in
or c
thi
e
3.3 Removing and installing camshaft oil

t
sd
iva
o
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rp
cu
seal
o
m
f
en
ng
t.
yi Co
Special tools and workshop equipment required ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Valve gear 117

♦ Puller - T10443-
AG. Volkswagen AG d
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olksw not
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
♦ Assembly tool - T10493-
rrectness of i
l purpos
nf
ercia
satelettronica
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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m
f
en
ng
t.
yi
Removing
Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted
– Unscrew bolts ⇒ Item 8 (page 94) and ⇒ Item 9 (page 94) .
agen
Prote AG.
– Remove toothed belt pulley ⇒ Item 10 (page 94) .
Note
If unscrewed too far, the internal thrust plate of the puller -T10443-
detaches from the thrust screw. In this case, the pressure plate
must be pressed back on to the thrust bolt.
– Carefully turn back bolt -arrow- of puller -T10443- until a slight

resistance is felt.
– Fit puller - T10443- in a straight line, and lock it in place by

screwing in bolt -A-.
– Screw in bolt -B- until camshaft seal has been pulled out.

AG. Volkswagen AG d
Installing agen oes
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Install in reverse order of removal, observing the following: orise nte
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– Clean contact surface and sealing surface. ss a c
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oil seal is being pressed in.
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– Fit guide sleeve - T10493/1- onto camshaft.
hole
spec
es, in part or in w
– Carefully slide seal -1- over guide sleeve onto camshaft.
t to the co
– Press in seal to stop using thrust piece - T10493/2- and bolt -
rrectness of i
T10493/3- . l purpos
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3.4 Checking hydraulic compensation ele‐
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♦ Feeler gauge
Note
♦ The hydraulic compensation elements cannot be repaired.

♦ Irregular valve noise during starting is normal.
Procedure
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to approx. 2500 rpm for 2 minutes. If
necessary, road test vehicle.
– If the hydraulic compensation elements are still noisy, find out
which is the defective compensation element as follows:
– Remove cylinder head cover ⇒ page 83 .
3. Valve gear 119

– Turn crankshaft by the bolt for the toothed belt wheel until cam
of supporting element to be tested is facing upwards.
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– Press roller rocker finger downwards -arrow- to check clear‐kswagen AG does
not
ance between cam and roller rocker finger. Vol gu
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– If a 0.20 mm feeler gauge can be inserted between ut
ho cam and
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roller rocker finger, replace hydraulic compensation
ss
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⇒ page 86 .
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3.5 Removing and installing valve stem
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seals
⇒ “3.5.1 Removing and installing valve stem seals (cylinder head
rrectne
installed)”, page 120
s
⇒ “3.5.2 Removing and installing valve stem seals (cylinder head
s o
removed)”, page 126
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3.5.1 Removing and installing valve stem
mer
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seals (cylinder head installed)

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♦ Valve stem seal puller - 3364-
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♦ Valve stem seal fitting tool - 3365-

♦ Valve spring tool - 3362-
♦ Dismantling and assembling device for valve cotters - VAS

5161 A-
AG. Volkswagen AG d
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♦ Guide plate for 2.0 l TDI engine - VAS 5161A/31-
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Procedure
h re
hole
spec
– Remove glow plugs ⇒ page 385 .
es, in part or in w
t to the co
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
rrectness of i
– Remove roller rocker fingers together with hydraulic compen‐
l purpos
sation elements and place down on a clean surface.

– Set piston of respective cylinder to top dead centre.
nform
mercia
at
om
io
Note
n
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ate
♦ Depending on the respective design, it might be necessary to

do
priv
use the valve spring tool - 3362- or the removal and installation
um
for
device for valve cotters - VAS 5161 A- .

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♦ Remove valve stem oil seals using removal and installation
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device for valve cotters - VAS 5161 A- ⇒ page 122 . py by
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♦ Remove valve stem oil seals using valve spring tool - 3362-
agen
Prote AG.
⇒ page 125 .
3. Valve gear 121

Procedure when using the removal and installation device for

valve cotters - VAS 5161 A-
Cylinders 1, 3, 4
– Place guide plate -VAS 5161/31- onto cylinder head.
• The lettering -A- faces towards turbocharger side
• The lettering -E- faces towards intake manifold side
– Secure guide plate with knurled screws -VAS 5161/12- by
hand.
• Position of knurled screws, as shown in illustration
Cylinder 2
hand.
satelettronica
AG. Volkswagen AG d
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Continuation for all cylinders aut
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– Screw sealing pins -VAS 5161/29-2- into guide plate.
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– Screw adapter -VAS 5161/11- hand-tight into relevant glow

itte
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plug thread.
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– Insert drift -VAS 5161/3A- into guide plate and use a plastic
ss
hammer to knock loose the firmly seated valve cotters.

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

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161/8A- onto assembly cartridge and in‐
sert cartridge into guide plate -VAS 5161/31-1- .
– Connect adapter to compressed air supply using a commer‐
cially available union and apply pressure continuously.
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• Minimum pressure:
Vol
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– Attach pressure
orise fork -VAS 5161/2- to toothed piecenteand press
assembly
aut
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– At the same time, turn knurled screw of assembly cartridge
ce
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un
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clockwise until tips engage in valve cotters.
an
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– Move knurled screw back and forth to press apart valve cotters
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and capture them in assembly cartridge.
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– Release pressure fork.
h re
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spec
– Remove assembly cartridge together with sleeve.
t to the co
– Remove valve spring and valve spring plate.
satelettronica
– Pull off valve stem seal using valve stem seal puller - 3364- .
rrectne
– Mark allocation of roller rocker fingers and hydraulic compen‐
s
s o
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– Remove roller rocker fingers together with hydraulic compen‐ f inform

mer
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– Fit plastic sleeve -A-, enclosed with new valve stem seals
-B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Pull off plastic sleeve -A- again.
If the valve cotters have been removed from the assembly car‐
tridge, the insert tool -VAS 5161/18- must be inserted first.
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto valve cotter insertion device
from above and pick up valve cotters.
3. Valve gear 123

– Insert assembly cartridge into guide plate -VAS 5161/31-

again. wage
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– Press pressure fork downwards ed
by and pull knurled screw up‐ guara
wards, turning it clockwise
ho
ris and anticlockwise. This inserts the nte
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valve cotters. s aut ra
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– Reduce pressure on pressure fork whilst pulling on knurled
ce
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pt
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screw.
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– Repeat procedure on each valve.
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– Ensure that all roller rocker fingers contact valve stem ends
t to the co
correctly and are clipped into relevant hydraulic compensation
elements.
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Procedure when using the valve spring tool - 3362-

Cylinders 1, 2, 3
– Place valve spring tool - 3362- -1- on cylinder head, and tight‐
en it. Use bolts from camshaft housing to do this.
• To secure, use M6 bolts with a thread length of 20 mm.
• Position threaded connections in such a way that valve spring
tool - 3362- -1- is located above respective valve.
Cylinder 4
wage es n
– Place valve spring tool - 3362- yV
o-1- on cylinder head, and tight‐
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en it. Use bolts from camshaft
ir se
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• Distance between valve
s au spring tool - 3362- -1- and cylinder
t or
ac
head must be larger due to restricted space.
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– To ensure this, insert spacer sleeves at threaded connection
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points of valve spring tool - 3362- -1- on cylinder head.
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• Spacer sleeves must be at least 30 mm in length.
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• To secure, use M6 bolts with a thread length of at least 50 mm.
hole
spec
satelettronica
• Position threaded connections in such a way that valve spring
es, in part or in w
t to the co
tool - 3362- -1- is located above respective valve.
Continuation for all cylinders
rrectness of i
– Align shaft for spindle of valve spring tool - 3362- -1- with valve
head of respective valve.
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– Engage shaft in side retainers in upper position, as shown in

illustration.
nform
ercia
• Valve spring tool - 3362- -1- must be positioned vertically

m
at
om
above valve spring. ion

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• Thrust piece - 3362/1- -2- from valve spring tool - 3362- -1-
his
ate
must be flush with valve head.

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• Side retainers of valve spring tool - 3362- -1- must rest against
f
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cylinder head.
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– Compress valve spring with thrust piece - 3362/1- -2-.
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– Screw spindle down until valve cotters can be removed with a Prote
cted AG.
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magnet.
• Make sure that thrust piece - 3362/1- -2- does not cant at cyl‐
inder head.
– If necessary, use a plastic hammer and punch - VAS 5161/3A-
to knock loose sticking valve cotters. Remove spring valve tool
- 3362- to do this.
– After removing valve cotters, measure and note thread length
of spindle for re-installation.
3. Valve gear 125

Installing
– Fit plastic sleeve -3- on valve stem -4-.
– Lightly oil sealing lip of valve stem oil seal -2-.
– Push valve stem seal -2- onto plastic sleeve -3-.
– Carefully press valve stem oil seal -2- onto valve guide using
valve stem seal fitting tool - 3365- -1-.
– Remove plastic sleeve -3-.
– Insert valve spring and valve spring plates.
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gen AG does
– Align valve spring tool - 3362-
Vol
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– Screw down thrustorpiece
ise - 3362/1- with spindle according torante
previously determined
au
th dimension. eo
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– Insert valve cotters and screw spindle up.
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ab
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3.5.2 Removing and installing valve stem
hole
spec
seals (cylinder head removed)
es, in part or in w
t to the co
♦ Valve stem seal puller - 3364- rrectness of i
l purpos
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tion in
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♦ Valve stem seal fitting tool - 3365- Prote
cted AG.
agen

♦ Engine and gearbox support

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lkswag6095A-
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es, in part or in w
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♦ Cylinder head tensioning device - VAS 6419-
rrectness of i
l purpos
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at
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♦ Valve spring tool - 3362-
gh ht
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co lksw
by
cted agen
Prote AG.
♦ Dismantling and assembling device for valve cotters - VAS

5161 A-
♦ Guide plate for 2.0 l TDI engine - VAS 5161A/31-

Procedure
– Remove intake manifold ⇒ page 292 .
– Remove cylinder head ⇒ page 76 .
3. Valve gear 127

4-cylinder common rail engine (2.0 l, 4V,olturbocharger)
ksw
- Edition 03.2019
AG. V agen AG
agen does
lksw not
– Mark allocation of roller rocker db
fingers
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and hydraulic compen‐ gu
ara
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– Remove roller rocker sfingers
s a together with hydraulic compen‐ c
ce
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un
pt
an
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– Insert cylinder head tensioning device - VAS 6419- into engine
itte
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and gearbox support - VAS 6095A- .
rm
ab
pe
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– Tension cylinder head on cylinder head tensioning device as
wit
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shown in illustration.
h re
hole
spec
– Connect cylinder head tensioning device to compressed air.
es, in part or in w
t to the co
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
rrectness of i
– Allow compressed air to flow into air cushion until it lies against
valve disc.
l purpos
Note
nform
mercia
a
♦ Depending on the respective design, it might be necessary to
com
tio
use the valve spring tool - 3362- or the removal and installation
n in
r
satelettronica
te o
device for valve cotters - VAS 5161 A- .
thi
s
iva
do
♦ Remove valve stem oil seals using removal and installation
r
rp
cum
fo
device for valve cotters - VAS 5161 A- ⇒ page 128 .
en
ng
t.
yi Co
op
♦ Remove valve stem oil seals using valve spring tool - 3362- C py
t. rig
⇒ page 125 . gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Procedure when using the removal and installation device for
valve cotters - VAS 5161 A-
Cylinders 1, 3, 4
hand.
Cylinder 2
hand.

Continuation for all cylinders

– Insert drift -VAS 5161/3A- into guide plate and 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. AG. Volkswagen AG d
swagen oes
k n ol ot g
yV
– Slide sleeve -VAS 5161/8A-iseonto
db assembly cartridge and in‐ ua
ran
sert cartridge into guide plate
thor
-VAS 5161/31-1- . tee
or
u ac
sa
– Attach pressure fork -VAS
s 5161/2- to toothed piece and press
ce
le
assembly cartridge down.

un
pt
an
d
itte
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– At the same time, turn knurled screw of assembly cartridge
satelettronica
rm
ab
clockwise until tips engage in valve cotters.
pe
ility
ot
wit
, is n
– Move knurled screw back and forth to press apart valve cotters
h re
and capture them in assembly cartridge.
hole
spec
– Release pressure fork.
es, in part or in w
t to the co
– Remove assembly cartridge together with sleeve.
– Remove valve spring and valve spring plate.
rrectness of i
l purpos
– Fit plastic sleeve -A-, enclosed with new valve stem seals nform
ercia
-B-, onto valve stem.

m
– Lightly oil sealing lip of valve stem seal.

com
tion in
r
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thi
s
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– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Pull off plastic sleeve -A- again.
3. Valve gear 129

If the valve cotters have been removed from the assembly car‐
tridge, the insert tool -VAS 5161/18- must be inserted first. AG. Volkswagen AG d
agen oes
lksw not
• Larger diameter of valve cotters faces upwards. d by Vo gu
ara
rise nte
– Press assembly cartridge onto valve cotter insertion udevice
tho eo
ra
from above and pick up valve cotters. ss a c
ce
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nl
– Insert valve spring and valve spring plate.
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Insert assembly cartridge into guide plate -VAS 5161/31-
again.
– Press pressure fork downwards and pull knurled screw up‐
rrectness of i
wards, turning it clockwise and anticlockwise. This inserts the
l purpos
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
nform
ercia
screw.
satelettronica
m
– Repeat procedure on each valve.
at
om
ion
c
Installing
in t
or
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ate
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or
f
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AG. Volkswagen AG d
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4V, turbocharger) - Edition 03.2019
ris
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4 Inlet and exhaust valves
s
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nl
pt
du
an
itte
⇒ “4.1 Checking valve guides”, page 131
y li
erm
ab
ility
⇒ “4.2 Checking valves”, page 132
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⇒ “4.3 Valve dimensions”, page 132
h re
hole
spec
4.1 Checking valve guides
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
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sd
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satelettronica
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f
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t.
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rig ht
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by lksw
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Prote AG.
Procedure
Note
♦ If the valve is to be renewed as part of a repair, use a new

valve for the measurement.
♦ Due to differing stem diameters, only use an inlet valve in inlet
valve guide and an exhaust valve in exhaust valve guide.
4. Inlet and exhaust valves 131

– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
– Insert valve into valve guide.
• The end of the valve stem must be flush with the guide.
– Determine rock.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be exchanged.
4.2 Checking valves olksw

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AG. Volkswagen AG d
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– Check for scoring on valve stems and valve ed seat surfaces. nte
satelettronica
ris
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– Exchange valve if significant scoring
ss a can be seen. ra
c
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le
4.3 Valve dimensions

un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
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hole
Never rework the inlet and exhaust valves. Only lapping-in is per‐
spec
mitted.
es, in part or in w
t to the co
Dimension Inlet valve Outlet valve
rrectness of i
∅a mm 28.10 25.00
b mm 99.30 99.30
l purpos
Diameter mm 4.975 4.965

c
nform
ercia
d ∠° 45 45
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tion in
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Prote AG.

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 133
⇒ “1.2 Engine oil:”, page 134
⇒ “1.3 Removing and installing sump”, page 134 agen
AG. Volkswagen AG d
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⇒ “1.4 Removing and installing oil pump”, page 137 ed by gu
ara
ris nte
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⇒ “1.5 Removing and installing oil level and oil temperature
aut
h send‐ eo
ra
er G266 ”, page 138 ss c
ce
e
nl
pt
1.1 Assembly overview - sump/oil pump
du
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itte
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ility
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1 - Cylinder block
wit
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2 - Dipstick guide tube
hole
spec
es, in part or in w
3 - Bolt
t to the co
satelettronica
❑ 8 Nm
4 - Bolt
rrectness of i
❑ 8 Nm
l purpos
5 - Valve for oil pressure con‐

trol - N428-
nf
ercia
orm
⇒ page 146
m
atio
om
n in
6 - O-ring
or c
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7 - Baffle plate
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8 - Seal
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9 - Bolt Prote
cted AG.
agen

❑ 8 Nm +60°
10 - Suction line
11 - Bolt
❑ 8 Nm
12 - O-ring
13 - Sump
⇒ page 134
14 - Seal
❑ No replacement part
❑ Renew with oil drain plug ⇒ Item 15 (page 133)
15 - Oil drain plug
❑ With seal
❑ 30 Nm
1. Sump, oil pump 133

16 - Bolts
❑ 9 Nm
17 - Oil level and oil temperature sender - G266-
18 - Bolts
❑ Qty. 20
❑ Specified torque and tightening sequence: ⇒ page 134
19 - Bolt
❑ 10 Nm +180°
20 - Dowel sleeve
21 - Oil pump
AG. Volkswagen AG d
❑ With integrated vacuum pump lksw
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❑ Removing and installing ⇒ page 137 byV gu
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22 - Seal aut
h
ra
ss c
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satelettronica
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pt
an
23 - Dowel sleeve
d
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ab
24 - Toothed belt
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ility
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wit
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hole
spec
es, in part or in w
Sump - specified torque and tightening sequence
t to the co
– Tighten bolts in stages as follows:
rrectness of i
l purpos
1) -2 … 21- In diagonal sequence to 5 Nm

2) -Arrows- 40 Nm
nform
ercia
3) -2 … 21- Diagonally in stages; final torque

13 Nm
m
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Prote AG.
1.2 Engine oil:

Capacities, oil specifications and viscosity grades ⇒ Mainte‐
nance ; Booklet 20.1
1.3 Removing and installing sump

134 Rep. gr.17 - Lubrication

♦ T-bar and socket, 10 mm - 3185-
satelettronica
♦ Hexagon key - T10058-
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Removing
– Drain engine oil ⇒ Maintenance ; Booklet 20.1 .
rrectne

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– If present, release clips -2-.

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– If present, remove noise insulation -3-.

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• Sealing surfaces must be free of grease and oil.
Use sealant as per ⇒ Electronic parts catalogue (ETKA) .
Note
Observe use-by date of sealant.
– Cut off nozzle on tube at front marking (diameter of nozzle:

approx. 2 to 3 mm).

– Apply sealant bead -arrow- to clean sealing surface of sump

bottom section with a thickness of 2 to 3 mm.
– Fit sump and tighten bolts; observe specified torque and tight‐
ening sequence ⇒ page 134 .
• Take particular care when applying sealant bead in area of the
sealing flange.
• Lower part of sump must be installed within 5 minutes after
applying sealant.
• Allow sealant to cure for approx. 30 minutes after installing
lower part of sump. Only then fill with engine oil.
– Replenish engine oil and check oil level ⇒ Maintenance ;
Booklet 20.1 .
Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 133
1.4 Removing and installing oil pump
satelettronica
AG. Volkswagen AG d
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Removing
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Note
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Oil pump with integrated vacuum pump

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– Insert dowel sleeves if oil pump has no dowel
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Specified torque thoris e or
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♦ ⇒ “1.1 Assembly overview -sssump/oil pump”, page 133
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1.5 Removing and installing oil level and oil
spec
es, in part or in w
temperature sender - G266-
t to the co
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Removing Prote AG.
– Drain engine oil ⇒ Maintenance ; Booklet 20.1 .

Vehicles with noise insulation
– Remove noise insulation -3-.


– Remove oil level and oil temperature sender - G266- -2-.
Installing
Specified torques
AG. Volkswagen AG d
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2 Engine oil cooler
Note
The engine oil cooler must not be separated from the oil filter
housing. In the event of defects, the engine oil cooler must be
renewed together with the oil filter housing ⇒ page 144 .
satelettronica
AG. Volkswagen AG d
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3 Oil filter, oil pressure switch

⇒ “3.1 Assembly overview - oil filter housing, oil pressure switch”,
page 141
⇒ “3.2 Removing and installing oil pressure switch F1 ”,
page 142
⇒ “3.3 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 143
⇒ “3.4 Checking oil pressure”, page 144
⇒ “3.5 Removing and installing oil filter housing”, page 144
⇒ “3.6 Removing and installing oil pressure regulating valve N428
”, page 146
3.1 Assembly overview - oil filter housing, oil pressure switch
1 - Oil drain plug

❑ 5 Nm
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2 - O-ring
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❑ Moisten with engine oil.

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⇒ Maintenance ; Book‐
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let 20.1
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6 - Oil pressure switch - F1-
❑ Switch pressure 2.3 to rrectne
3.0 bar
❑ Brown insulation
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❑ Checking ⇒ Vehicle di‐

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agnostic tester
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❑ Specified torque and tightening sequence ⇒ page 142
9 - Oil filter housing with engine oil cooler
❑ Do not separate oil filter housing and engine oil cooler.
3. Oil filter, oil pressure switch 141

10 - Seal
11 - Seal
Oil filter housing - specified torque and sequence

– Tighten bolts in stages in the sequence shown.
Stage Bolts Specified torque/turning further angle
1) -5 … 1- 20 Nm
2) -5 … 1- Turn 90° further wage
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3.2 Removing and installing oil pressure
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switch - F1-
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hole
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Installing
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– Renew oil pressure switch after each removal.

– Check oil level ⇒ Maintenance ; Booklet 20.1 .
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Specified torques
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♦ ⇒ “3.1 Assembly overview - oil filter housing, oil pressure
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3.3 Removing and installing oil pressure

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♦ Jointed wrench 24 mm - T40175-

Removing
• Engine is cold.
– Loosen charge air cooler ⇒ page 257 .
– On vehicles with bi-turbo, remove catalytic converter
⇒ page 335 .
– Detach rear coolant pipe and swing to side slightly.
Note
The oil pressure switch for reduced oil pressure - F378- is located
at the rear of the cylinder head above the turbocharger. Use a
small hand mirror if necessary as it is difficult to reach.
– Open thermal sleeve.

– Unscrew oil pressure switch for reduced oil pressure - F378-
satelettronica
-2-.
cation system.
Installing
– Renew oil pressure switch after each removal.
Specified torques
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The speed limiter for protecting the clutch does not allow for test‐
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ing all stages of oil pressure control while the vehicle is stationary.
es, in part or in w
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For this reason, oil pressure must be checked using the vehicle
diagnostic tester.
rrectness of i

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– Check oil pressure ⇒ Vehicle diagnostic tester, 01 - Systems
nform
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capable of self-diagnosis , 17 - Lubrication , Part

systems, framework conditions , Checking oil pres-
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Removing
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• The engine oil cooler must not be separated from the oil filter
housing.
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• In the event of a defect, the engine oil cooler must be renewed

n
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– Pull off hose -3-.

– Put used oil collection and extraction unit - VAS 6622A- un‐
derneath.
– Remove oil filter housing -6-.
cation system.
Installing
Note
Note tightening sequence ⇒ page 142 .
– Add coolant ⇒ page 179 .

Specified torques AG. Volkswagen AG d
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3.6 Removing and installing oil pressure s
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– Renew O-ring after each removal.

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4 Oil circuit
⇒ “4.1 Assembly overview - oil circuit”, page 147
⇒ “4.2 Removing and installing oil supply line”, page 149
⇒ “4.3 Removing and installing oil return line for turbocharger”,
page 151
4.1 Assembly overview - oil circuit

⇒ “4.1.1 Assembly overview - oil circuit, bi-turbo”, page 147
⇒ “4.1.2 Assembly overview - oil circuit, single turbocharger”,
page 148
4.1.1 Assembly overview - oil circuit, bi-turbo
1 - Banjo bolt
❑ Oil bolt before inserting
❑ 16 Nm
satelettronica
2 - Bolt
❑ 8 Nm
3 - Seal
4 - Bolts
❑ Qty. 2
❑ 14 Nm
5 - Bolt
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⇒ page 151
10 - Seal
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11 - Banjo bolt
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4. Oil circuit 147

14 - Oil seals
❑ Qty. 2
15 - Oil supply line
16 - Seal
4.1.2 Assembly overview - oil circuit, single turbocharger
1 - Banjo bolt
❑ 16 Nm
2 - Oil seals
satelettronica
❑ Qty. 2
3 - Oil supply line
❑ Oil supply line may have
a different shape de‐
pending on equipment.
❑ Bracket for bolt
⇒ Item 5 (page 148)
may be installed at top
depending on equip‐
ment.
❑ Removing and installing AG. Volkswagen AG d
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⇒ page 153
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11 - Oil seals
❑ Qty. 2
4.2 Removing and installing oil supply line

⇒ “4.2.1 Removing and installing oil supply line, bi-turbo”,
page 149
⇒ “4.2.2 Removing and installing oil supply line, single turbo”,
page 150
4.2.1 Removing and installing oil supply line,

bi-turbo
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4. Oil circuit 149


– Detach oil supply line -3-.
cation system.
Installing
– Oil securing bolts for oil supply line on turbocharger before
inserting them.
– Install oil supply line free of tension. To do this, screw in all
bolts by hand first and then tighten to specifiedagtorque.
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♦ ⇒ “4.1.1 Assembly overview - oil circuit, bi-turbo”, page 147
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4.2.2 Removing and installing oil supply line,
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– Pull off charge air pipe -2- and push aside slightly. by c lksw
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– Unscrew banjo bolt -3-.


noise insulation .
– Push coolant pipe -3- aside slightly.
– Unscrew banjo bolt -1-.
satelettronica
Note
♦ Oil supply line -3- may have a different shape depending on

equipment.
♦ Bracket for bolt -2- may be installed at top depending on
equipment.

– Remove oil supply line -3-.
AG. Volkswagen AG d
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♦ ⇒ “4.1.2 Assembly overview - oil circuit, single turbocharger”,

t to the co
page 148
rrectness of i
4.3 Removing and installing oil return line

for turbocharger
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⇒ “4.3.1 Removing and installing oil return line for turbocharger,

nform
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bi-turbo”, page 151

m
⇒ “4.3.2 Removing and installing oil return line for turbocharger,

com
tion in
single turbocharger”, page 153

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4.3.1 Removing and installing oil return line

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4. Oil circuit 151

♦ Open-end spanner - 3312-
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Removing
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• Align heat shield above oil retention valve if necessary to pre‐ Prote AG.
vent it coming into contact with turbocharger housing.
• Distance between heat shield of vacuum unit with position
sender 2 for charge pressure positioner - G580- and oil return
line must be 5 mm.
– Install oil return line free of tension. To do this, screw in all bolts
by hand first and then tighten to specified torque.
Specified torques
♦ ⇒ “4.1.1 Assembly overview - oil circuit, bi-turbo”, page 147

4.3.2 Removing and installing oil return line

for turbocharger, single turbocharger
AG. Volkswagen AG d
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⇒ page 363
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conditioning unit; Re‐ Prote AG.
8 - Y-piece
❑ Thermostat
10 - 2/2 way valve
13 - 3/2 way valve

15 - 3/2 way valve

AG. Volkswagen AG d
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18 - Radiator for engine coolant olksw
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19 - Pump for exhaust gas recirculation cooler - V400- d
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20 - Shut-off flap
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❑ Removing and installing ⇒ page 197 rig ht
py by
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25 - Coolant pump
cted agen
Prote AG.

1.1.11 Coolant hose schematic diagram, vehicles with dual clutch gearbox, 2nd
heat exchanger and supplementary heater

N474-
⇒ page 341
⇒ page 349
V488-
⇒ page 189
⇒ page 194
3 - Cylinder block
4 - Cylinder head AG. Volkswagen AG d
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❑ Assembly overview ksw
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⇒ page 72 ed by ara
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⇒ page 250
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⇒ page 365
rrectness of i
7 - Heat exchanger
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11 - 2/2 way valve
14 - 3/2 way valve


16 - 3/2 way valve
21 - Shut-off flap
satelettronica
AG. Volkswagen AG d
❑ Assembly overview ⇒ page 190 agen oes
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❑ Removing and installing ⇒ page 201 rised b ara
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24 - Engine oil cooler aut ra
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26 - Coolant pump
t to the co
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Cop py
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Prote AG.

1.1.12 Coolant hose schematic diagram, vehicles with dual clutch gearbox, 2nd
heat exchanger and auxiliary coolant heater

N474-
⇒ page 341
⇒ page 349
V488-
❑ Assembly overview AG. Volkswagen AG d
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❑ Removing and installing d b ara
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⇒ page 194 thor eo
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3 - 3/2 way valve ss
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5 - Heat exchanger
satelettronica
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moving and installing
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6 - Cylinder block
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7 - Cylinder head
nf
ercia
⇒ page 72
orm
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⇒ page 249
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⇒ page 250
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9 - Exhaust gas recirculation C py
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cooler
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Prote AG.
13 - 2/2 way valve

16 - 3/2 way valve

18 - 3/2 way valve
satelettronica
23 - Shut-off flap
AG. Volkswagen AG d
❑ For high-temperature circuit lksw
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28 - Coolant pump
nform
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1.2 Draining and adding coolant
Special tools and workshop

equipment required
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♦ Refractometer - T10007 A-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-

Transporter 2016 ➤wagen AG. Volkswagen AG doe
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Vol rail engine (2.0 l, 4V, turbocharger)
t gu - Edition 03.2019
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Draining au
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CAUTION
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Skin and other parts of the body may be scalded.
wit
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t to the co
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– Open cap -1- on coolant expansion tank.
ss o
cial p
f inform
mer
atio
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n
c
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satelettronica
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noise insulation . en
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t.
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op py
– Place drip tray for workshop hoist - VAS 6208- underneath. t. C rig
gh ht
pyri by
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by c lksw
cted agen
Prote AG.
– Pull coolant hose -2- off radiator.
– Drain coolant.
Filling

Note
♦ Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Since water quality differs from country
to country and even region to region, it is necessary to set a
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, always use only 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 engine.
♦ 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.
satelettronica
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- must be used to determine the
current anti-freeze value.
Volkswa
♦ Frost protection must be guaranteed downswtoag-25°C
en AG. as a min‐
gen AG
does
imum and, in countries with arctic conditions,
yV
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down to approx. not
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-36°C. Increasing the frost protection db
ise is permissible only if cli‐
ara
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matic conditions require stronger thofrost protection. It may, how‐ eo
au ra
ever, be increased only to a smaximum of -48°C. Otherwise,
s c
the cooling effect will be impaired.
ce
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♦ Do not reduce the coolant concentration by adding water even

itte
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in warmer seasons and in warmer countries. Frost protection

ab
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must be guaranteed down to at least -25°C.

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♦ Read off anti-freeze figures for respective replenished coolant

h re
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additives.
spec
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
ercia
Coolant mixture ratio

m
at
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• Coolant additive (40 %) and distilled water (60 %) for frost

n
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protection to -25 °C
o
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• Coolant additive (50%) and distilled water (50%) for frost pro‐
p
cum
or
tection to -36 °C
f
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t.
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• Coolant additive ⇒ Electronic parts catalogue (ETKA) ht. Cop py
rig
rig ht
– Reconnect coolant hoses, and secure them with clamps. py by
co Vo
by lksw
cted agen
Prote AG.

– Fill tank of cooling system charge unit - VAS 6096- with at least
8 litres of pre-mixed coolant in correct mixture ratio.
Note agen
AG. Volkswagen AG d
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The quantity may vary depending on the equipment level. rised b ara
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– Screw adapter for cooling system tester - V.A.G 1274/8-
ss onto c
ce
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coolant expansion tank -1-.
nl
pt
du
an
itte
– Mount cooling system charge unit - VAS 6096- on adapter -
y li
erm
ab
V.A.G 1274/8- .
ility
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wit
– Feed vent hose -2- into a small container -3-.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
rrectness of i
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– Close valves -A- and -B- (turn lever transverse to direction of
satelettronica
flow to do this).
nf
ercia
– Connect hose -4- to compressed air.
orm
m
atio
• Pressure: 6 to 10 bar.
om
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or c
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– Open valve -B-; turn lever in direction of flow to do this.

t
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• In cooling system, vacuum is generated by suction jet pump;
o
m
f
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ng
needle of gauge must move into green area.

t.
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op py
– In addition, open valve -A- briefly by turning lever in direction
. C rig
ht ht
rig
of flow until expansion tank hose of cooling system charge unit py by
co Vo
- VAS 6096- fills with coolant.
by lksw
cted agen
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– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• Vacuum continues to be generated in the cooling system by
the suction jet pump; the needle of gauge must remain in green
range.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
• If the needle does not reach the green zone, repeat the proc‐
ess.
• If vacuum drops, cooling system must be checked for leaks.
– Pull off compressed air hose.
– Open valve -A-.
• The vacuum in the cooling system causes coolant to be ex‐
tracted from coolant expansion tank of cooling system charge
unit - VAS 6096- and the cooling system to be filled.
– Then, remove cooling system charge unit - VAS 6096- from
coolant expansion tank again.
– If present, install noise insulation ⇒ General body repairs, ex‐
noise insulation .

– Fill approx. 300 ml of coolant over max. mark -arrow-.

– If fitted, switch off air conditioning system.
• LED in button should not light up.
– Fill coolant circuit ⇒ Vehicle diagnostic tester, 01 - Diesel
AG. Volkswagen AG d
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direct injection and preglow agensystem EDC 17 es n -
lksw
Engine electronics functions y Vo , 01 - Fill coolant ot g
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ise
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– Follow further instructions
ss
a
displayed on ⇒ Vehicle diagnostic ac
tester.
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– Allow engine to cool down to ambient temperature.

itte
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– Check coolant level.
ility
ot
wit
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– Adjust coolant level to max. mark.
h re
hole
spec
– Then add more coolant until 300 ml above MAX marking.
es, in part or in w
t to the co
satelettronica
1.3 Checking cooling system for leaks
rrectness of i
l purpos
♦ Cooling system tester - V.A.G 1274 B-
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
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
♦ Adapter for cooling system tester - V.A.G 1274/8-

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gen AG does
♦ Adapter for cooling system tester
Vol
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Prerequisites for check
rrectness of i
• Engine at operating temperature.
l purpos
CAUTION
nf
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o
rm
m
atio
om
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satelettronica
c

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t
sd
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t.
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op
sion tank with cloths and opening it carefully. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Open cap -1- of coolant expansion tank -2-. Prote
cted AG.
agen
– Place adapter for cooling system tester - V.A.G 1274/8- on

coolant expansion tank.
– Connect cooling system tester - V.A.G 1274 B- .
– Build up pressure of approx. 1.5 bar using hand pump of cool‐
ing system tester.
• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops by more than 0.2 bar, locate and rectify
leaks.
Note
The pressure drop of 0.2 bar within 10 minutes depends on the

how far the coolant can cool down. The colder the engine, the
lower the pressure drop. If necessary, repeat the check while the
engine is cold.
If the pressure does not drop
CAUTION
– Release pressure by pressing pressure relief valve on cool‐
ing system tester until the gauge shows a pressure of 0.

Check pressure relief valve in cap.

– Fit cooling system tester - V.A.G 1274 B- with adapter for
cooling system tester - V.A.G 1274/9- on cap -1-.
– Build up pressure using hand pump of cooling system tester.
• The pressure relief valve must open at a pressure of 1.4 to
1.6 bar.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.
1.4 Removing and installing

agen
AG. Volkcoolant
swagen AG expan‐
does
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sion tank d by Vol not
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satelettronica
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
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thi
s
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do
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rp
cum
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
♦ Hose clamps to 25 mm - 3094-

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
aut ra
ss c
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nl
pt
du
Removing
an
itte
y li
erm
ab
ility
ot p
wit
– Place drip tray for workshop hoist - VAS 6208- underneath.
, is n
h re
hole
spec
CAUTION
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos

nf
ercia
sion tank with cloths and opening it carefully. orm

m
atio
om
n in

or c
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te
– Clamp off coolant hoses -3- using hose clamps up to 25 mm

sd
iva
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- 3094- -4-.
rp
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f
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t.
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Cop py
t.
rig
gh ht
pyri by
Vo
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by c
lksw
cted agen
Prote AG.
– Turn coolant expansion tank -1- to one side.
– Remove coolant expansion tank -1-.
Installing
Specified torques
tank

4-cylinder common
en A
rail
G . Voengine
lkswagen(2.0
AG l, 4V, turbocharger) - Edition 03.2019
ag does
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2 Coolant pump, regulation of cooling thoris nte
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system ss c
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nl
pt
du
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
an
itte
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page 187
erm
ab
ility
ot p
⇒ “2.2 Assembly overview - electric coolant pump”, page 189
wit
, is n
h re
⇒ “2.3 Assembly overview - coolant temperature sender”,
hole
page 190
spec
es, in part or in w
t to the co
⇒ “2.4 Removing and installing charge air cooling pump V188 ”,
page 190
⇒ “2.5 Removing and installing pump for exhaust gas recirculation
rrectness of i
cooler V400 ”, page 192
l purpos
⇒ “2.6 Removing and installing auxiliary pump for heating V488

”, page 194
nform
ercia
⇒ “2.7 Removing and installing coolant pump”, page 196

m
at
om
⇒ “2.8 Removing and installing thermostat”, page 197
ion
c
in t
or
⇒ “2.9 Checking thermostat”, page 199
satelettronica
his
ate
do
riv
⇒ “2.10 Removing and installing coolant valve for cylinder head

p
cum
or
N489 ”, page 199

f
en
ng
t.
yi Co
op
⇒ “2.11 Removing and installing coolant temperature sender G62 C py
t. rig
”, page 200
gh ht
pyri by
Vo
o
by c lksw
⇒ “2.12 Removing and installing radiator outlet coolant tempera‐ Prote
cted AG.
agen
ture sender G83 ”, page 201
⇒ “2.13 Removing and installing coolant temperature sender 3
G812 ”, page 203
⇒ “2.14 Removing and installing 3/2-way valve”, page 206
2.1 Assembly overview - coolant pump, thermostat
2. Coolant pump, regulation of cooling system 187

1 - Bolt
❑ 8 Nm
2 - Coolant valve for cylinder
head - N489-
❑ Not actuated
⇒ page 199
3 - O-ring
❑ Not available as individ‐
ual replacement part;
renew together with
4 - Coolant pump
⇒ page 196
5 - O-ring
satelettronica
6 - O-ring
❑ Renew after removal olkswage es n
ot g
yV
❑ Not available das individ‐
b ua
ran
ir se
ual replacement
tho part; tee
or
renewsstogether
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itte
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7 - Bolts
pe
ility

ot
wit
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❑ Qty. 3
hole
spec
❑ 20 Nm +45°
es, in part or in w
t to the co
8 - O-ring
rrectness of i
9 - Coolant pipe
l purpos
❑ On front of engine
10 - Retaining clip
nform
ercia
❑ Ensure firm seating

m
11 - O-ring
com
tion in

r
te o
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12 - O-ring
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ng
t.
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❑ Moisten with coolant t. Cop py
rig
gh ht
13 - Bolts yri
p by
co Vo
by lksw
❑ Qty. 3 cted agen
Prote AG.
❑ 20 Nm
15 - Thermostat

16 - Union
AG. Volkswagen AG d
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17 - Bolt Volksw
oes
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❑ 20 Nm rise
d
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18 - Coolant hose ss au ra
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19 - Clip
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ility
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2.2 Assembly overview - electric coolant pump
wit
is n
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ole,
spec
1 - Bolts
t to the co
❑ 1.5 Nm
2 - Sleeve
rrectne
3 - Rubber mounting
❑ Ensure proper seating
ss
in bracket
o
cial p
f inform
4 - Bracket
mer
satelettronica
atio
5 - Bolts
om
n
c
i
❑ 8 Nm
or
n thi
te
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va

i
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pr
c
V488-
um
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ng
t.
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op
⇒ page 194
C py
t. rig
gh ht
yri by
7 - Clamps cop Vo
by lksw
cted agen
Prote AG.
8 - Bracket
9 - Nut
❑ 40 Nm
10 - Bolt
❑ 40 Nm
11 - Bolts
❑ 8 Nm
12 - Retaining bracket
13 - Bolt
❑ 8 Nm
14 - Charge air cooling pump -
V188-
❑ On front left of subframe
⇒ page 190
15 - Bracket

2.3 Assembly overview - coolant temperature sender
1 - Bolt
❑ 8 Nm
2 - Radiator outlet coolant -
G62-
⇒ page 200
3 - O-ring
❑ Qty. 4
4 - Coolant temperature send‐
er 3 - G812-
❑ In coolant pipe on front
left or bottom front de‐
pending on equipment
⇒ page 203
satelettronica
5 - Clips
❑ Qty. 3 . Volkswagen AG
gen AG does
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6 - Coolant temperaturey Vsend‐olk not
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er 3 - G812- risedb ara
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❑ In coolantautpipe on front
h
ra
left or bottom
ss front de‐ c
ce
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pending on equipment
un
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itte
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⇒ page 205
ab
pe
ility
ot
7 - Radiator outlet coolant tem‐

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perature sender - G83-

h re
hole
spec

es, in part or in w
⇒ page 201
t to the co
rrectness of i
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2.4 Removing and installing charge air cool‐

nform
ercia
ing pump - V188-

m
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ion in
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te o

thi
s
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rp
cum
fo
en
ng
t.
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Cop py
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Vo
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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3094- .
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♦ ⇒ “2.2 Assembly overview - electric coolant pump”,

page 189
rrectness of i
2.5 Removing and installing pump for ex‐

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haust gas recirculation cooler - V400-

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c
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– Remove pump for exhaust gas recirculation cooler - V400-
o
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-4-.
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mer
Installing
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page 189 gh ht
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2.6 Removing and installing auxiliary pump
Prote AG.
for heating - V488-


satelettronica
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noise insulation . agen
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Prote
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AG.
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– Remove auxiliary pump for heating - V488- -1- with bracket.
C py
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gh ht
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Installing
op Vo
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Prote AG.
Specified torques
♦ ⇒ “2.2 Assembly overview - electric coolant pump”,
page 189
2.7 Removing and installing coolant pump


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♦ Checking function by pulling the regulator valve of the coolant
h re
pump with your hand is not permitted. This can cause damage
hole
spec
to the coolant pump and lead to insufficient supply of coolant
es, in part or in w
to the engine.
t to the co
– Remove toothed belt ⇒ page 99 .
rrectness of i
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– If fitted, pull off coolant valve for cylinder head - N489- -2-.
nform
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– Add coolant ⇒ page 179 . Prote AG.
Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 187
2.8 Removing and installing thermostat



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position .
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wit
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spec
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Specified torques
ss
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
o
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page 187
inform
mer
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agen
Prote AG.
Starts to open Fully open Opening travel

92 ±2°C approx. 104 °C 1) 8.4 mm
• 1) Not testable
2.10 Removing and installing coolant valve

for cylinder head - N489-

Removing
Note
Coolant valve for cylinder head - N489- is not actuated.

agen
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nform
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page 187
ht ht
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2.11 Removing and installing coolant temper‐
Prote AG.
ature sender - G62-


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CAUTION
satelettronica

position .
– Unscrew bolt -2-. AG. Volkswagen AG d
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V- G62- -3-.
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ss
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♦ Insert new coolant temperature sender - G62- immediately in‐

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to cylinder head in order to avoid loss of coolant.

ole,
spec
♦ If an O-ring or spacer ring remains lodged in the cylinder head,

t to the co
pull it out with a piece of wire.
– Renew O-rings after removal.

rrectne

ss
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o
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♦ ⇒ “2.3 Assembly overview - coolant temperature sender”,

form
mer
page 190
atio
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2.12 Removing and installing radiator outlet

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coolant temperature sender - G83-

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2. Coolant pump, regulation of cooling system
AG.

- 3093-

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c
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do
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t.
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Cop py
t. rig
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Prote AG.

Removing
• Engine cold.
noise insulation .
CAUTION
satelettronica
3094- .
– Pull out retaining spring -3-.
– Pull out radiator outlet coolant temperature sender - G83-
-2-.
Installing
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Vol
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not
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Insert new coolant temperature sender at radiator outlet - G83-

du
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immediately in order to avoid loss of coolant.

y li
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2.13 Removing and installing coolant temper‐

ature sender 3 - G812-
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⇒ “2.13.1 Removing and installing coolant temperature sender 3

l purpos
G812 , front left coolant pipe”, page 203

⇒ “2.13.2 Removing and installing coolant temperature sender 3
nf
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G812 , bottom front coolant pipe”, page 205

orm
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2.13.1 Removing and installing coolant temper‐

atio
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c
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rig ht
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Prote AG.

satelettronica
AG. Volkswagen AG d
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tion in
r
te o
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cum
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t.
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Cop py
t. rig
gh ht
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Vo
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Prote AG.

Removing
CAUTION

– Clamp off coolant hoses using hose clamps, up ton25
AG.mm
Volks-wagen AG
3094- . olks
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satelettronica
– Pull out coolant temperature sender
ss
3 - G812- -3-. au ra
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Installing
nl
pt
du
an
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y li
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ab
ility
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Note
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hole
spec
To prevent any coolant loss, install the new coolant temperature
es, in part or in w
t to the co
sender 3 - G812- straightaway.
rrectness of i
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2.13.2 Removing and installing coolant temper‐ nf

ercia
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ature sender 3 - G812- , bottom front
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Prote AG.

Removing
CAUTION
satelettronica
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ran
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noise insulation . thor tee
or
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3094- .
wit
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– Pull out retaining spring -3-.

ole,
spec
– Pull out coolant temperature sender 3 - G812- -2-.

t to the co
Installing
rrectne
Note
ss o
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f in
To prevent any coolant loss, install the new coolant temperature

form
mer
sender 3 - G812- straightaway.

atio
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pr
cum
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2.14 Removing and installing 3/2-way valve
yi Co
Cop py
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Special tools and workshop equipment required p by
co Vo
by lksw
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Prote AG.

AG. Volkswagen AG d
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♦ Drip tray for workshop hoist
ss a - VAS 6208- c
ce
e
nl
pt
du
an
itte
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ab
ility
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satelettronica
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Removing
nf
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CAUTION
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Cop py
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gh ht
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p by
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by c lksw
cted agen
Prote AG.

noise insulation .
– Clamp off coolant hoses -2- using hose clamps, up to 25 mm
- 3094- .
– Pull out 3/2-way valve -1- from retainer.
Installing

AG. Volkswagen AG d
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nl
pt
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⇒ “3.1 Assembly overview - coolant pipes”, page 208
wit
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3.1 Assembly overview - coolant pipes hole
spec
es, in part or in w
t to the co
⇒ “3.1.1 Assembly overview - coolant pipes, vehicles with manual
gearbox”, page 208
⇒ “3.1.2 Assembly overview - coolant pipes, vehicles with dual
rrectness of i
clutch gearbox”, page 209
l purpos
3.1.1 Assembly overview - coolant pipes, vehicles with manual gearbox
nf
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1 - Bolts
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❑ Qty. 2
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C py
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3 - Coolant pipe cop Vo
by lksw
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❑ Upper left
Prote AG.

4 - Bolts
❑ Qty. 6
❑ 9 Nm
5 - Bolts
❑ Qty. 2
❑ 40 Nm
6 - Coolant pipe
❑ Rear
❑ For auxiliary pump for
heating - V488-
7 - Coolant pipe
❑ On rear of engine
❑ To injector for reducing
agent - N474-
8 - Bolts
❑ Qty. 3
❑ 9 Nm
9 - Coolant pipe
❑ On left of cylinder head
10 - Bolt
❑ 40 Nm
11 - Coolant pipe
❑ Front left
12 - Bolts
❑ Qty. 2
❑ 9 Nm


❑ In coolant pipe ⇒ Item 11 (page 208) or ⇒ Item 15 (page 209) depending on equipment
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14 - Coolant temperature sender 3 - G812- Vol
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oes
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❑ In coolant pipe ⇒ Item 11 (page 208) or ⇒ Item 15 rise(page 209) depending on equipment ante
d
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❑ Removing and installing ⇒ page 205 au
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15 - Coolant pipe
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❑ Front, lower
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16 - Coolant pipe
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❑ Front
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❑ On intake manifold
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17 - Bolts
❑ Qty. 2
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❑ 9 Nm
ss
satelettronica
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f i
3.1.2 Assembly overview - coolant pipes, vehicles with dual clutch gearbox
nform
mer
atio
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1 - Bolts
c
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❑ Qty. 2
t
sd
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❑ 5 Nm
p
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2 - Coolant pipe
t.
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Cop py
❑ Upper right
t. rig
gh ht
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❑ On charge oil cooler cop Vo
by lksw
cted agen
Prote AG.
3 - Coolant pipe
❑ Upper left
4 - Bolts
❑ Qty. 6
❑ 9 Nm
5 - Bolts
❑ Qty. 2
❑ 40 Nm
6 - Coolant pipe
❑ Rear
❑ For auxiliary pump for
heating - V488-
7 - Bolts
❑ Qty. 3
❑ 9 Nm
8 - Coolant pipe
❑ On rear of engine
❑ To injector for reducing
agent - N474-
9 - Coolant pipe
❑ On left of cylinder head
3. Coolant pipes 209

10 - Coolant pipe
❑ To gear oil cooler
11 - Bolt
❑ 40 Nm
12 - Bolt
❑ 9 Nm
14 - Coolant pipe
❑ Front left
16 - Coolant pipe
❑ Front, lower
satelettronica
17 - Coolant pipe
❑ Front
❑ On intake manifold
18 - Bolts
❑ Qty. 2
❑ 9 Nm
AG. Volkswagen AG d
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Cop py
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210
c by lksw
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Rep. gr.19 - Cooling Prote AG.
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AG. Volkswagen AG d
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Radiator, radiator fan c
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⇒ “4.1 Assembly overview - radiator/radiator fan”, page 211
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⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page
ility
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212
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⇒ “4.3 Removing and installing radiator”, page 212
hole
spec
⇒ “4.4 Removing and installing radiator cowl with radiator fan”,
es, in part or in w
page 218
t to the co
⇒ “4.5 Removing and installing radiator fan V7 ”, page 219
rrectness of i
4.1 Assembly overview - radiator/radiator fan
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❑ Qty. 2
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3 - Line ht. Cop py
rig
rig ht
4 - Bolt py by
co Vo
by lksw
❑ 5 Nm
cted agen
Prote AG.
5 - Mountings
❑ Qty. 2
❑ For bottom of radiator
6 - Bolts
❑ 5 Nm
7 - Coolant hoses
8 - Oil seals
❑ Qty. 2
❑ Not an individual part
9 - Bolts
❑ 5 Nm
10 - Radiator/cooler
❑ For low temperature
⇒ page 212
11 - Condenser
❑ Assembly overview ⇒
Heating, air conditioning
system; Rep. gr. 87 ;
Refrigerant circuit; As‐
sembly overview - condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser
12 - Radiator/cooler
❑ For high-temperature
4. Radiator, radiator fan 211

4.2 Assembly overview - radiator cowl and radiator fan
1 - Radiator cowl
⇒ page 218
2 - Radiator fan - V7-
⇒ page 219
3 - Bolts
❑ 5 Nm
4 - Bolts
❑ 5 Nm
satelettronica
AG. Volkswagen AG d
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4.3 Removing and installing radiator

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⇒ “4.3.1 Removing and installing low-temperature radiator”, page

spec
212
es, in part or in w
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⇒ “4.3.2 Removing and installing high-temperature radiator”,

page 214
rrectness of i
4.3.1 Removing and installing low-tempera‐

l purpos
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Removing
noise insulation .
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
3094- .
CAUTION
AG. Volkswagen AG d
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On a warm engine, the by cooling system is under high pressure.
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– Release clips -1-. spec

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– Remove front support element ⇒ General body repairs, exte‐

rrectness of i
rior; Rep. gr. 63 ; Front bumper; Removing and installing

impact bar .
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– Release retainer -3-.

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– If the radiator has been renewed, the entire coolant must be

changed.
Specified torques
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 211
4.3.2 Removing and installing high-tempera‐

ture radiator

AG. Volkswagen AG d
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Removing
position .
– Remove low-temperature radiator ⇒ page 212 .
3094- .
CAUTION
satelettronica

AG. Volkswagen AG d
– Unscrew bolts -1-. agen oes
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– Remove baffle plate -1-.
AG. Volkswagen AG d
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– Unscrew bolts -1-. hor eo
satelettronica
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– Unclip lines -2- from guides -3-. ss
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– Push down radiator mounting -4-.
an
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– If fitted, remove adaptive cruise control unit - J428- ⇒ Electri‐
ility
ot p
cal system; Rep. gr. 27 ; Adaptive cruise control; Removing
wit
and installing adaptive cruise control unit .
, is n
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spec
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– Pull out condenser -2- in direction of -arrow- from guides -3-.

– Hold condenser -1- to one side with aid of second mechanic.

– Remove high-temperature radiator -2- in direction of -arrow-.
Installing
Note
If there are minor dents in the fins, refer to ⇒ page 8 .
satelettronica
– If the radiator has been renewed, the entire coolant must be
changed.
– Insert lower radiator mounting -1- in lock carrier -2-. n AG. Volkswagen AG do
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– Then turn lower radiator mounting 90°. ir se
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– Add coolant ⇒ page 179 . au ac
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Specified torques
un
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♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 211
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4.4 Removing and installing radiator cowl
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♦ Torque wrench - V.A.G 1331- rrectness o
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Removing
– Remove high-temperature radiator ⇒ page 214 .
– Release locking lugs -2-.
– Pull out radiator cowl -4- in direction of -arrow- from guides
-3-.
Installing
Specified torques
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
page 212
4.5 Removing and installing radiator sfanagen-

AG. Volkswagen AG d
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Special tools and workshop equipment required eo
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– Remove radiator cowl with radiator fan ⇒ page 218 .

m
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Cop py
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Specified torques
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Prote AG.
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,

page 212

21 – Turbocharging/supercharging
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⇒ “1.1 Assembly overview - turbocharger”, page 220
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⇒ “1.2 Assembly overview - solenoid valves”, page 225
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⇒ “1.3 Removing and installing turbocharger”, page 227
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”, page 235 hole
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⇒ “1.5 Renewing vacuum unit for turbocharger, bi-turbo”,
t to the co
page 236
⇒ “1.6 Removing and installing upper connecting pipe, bi-turbo”,
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page 243
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⇒ “1.7 Renewing upper connecting pipe, bi-turbo”, page 244

⇒ “1.8 Removing and installing lower connecting pipe, bi-turbo”,
nf
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page 247
or
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⇒ “1.9 Removing and installing compressor housing and turbine
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housing, bi-turbo”, page 248

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1.1.1 Assembly overview - turbocharger, bi-turbo
220 Rep. gr.21 - Turbocharging/supercharging

1 - Turbocharger
❑ Corrugated pipe con‐
nection must not be
damaged.
AG. Volkswagen AG d
⇒ page 227 ksw
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⇒ page 221
5 - Bolt
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❑ 40 Nm +90°
satelettronica
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7 - Bolt
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Tightening sequence for turbocharger

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Stage Component Specified torque
1 Nuts -1 … 8- Start bolts and tighten by hand
2 Nuts -1 … 8- Tighten to 18 Nm
3 Nuts -1 … 4- Tighten again to 18 Nm
1. Turbocharger 221
1.1.2 Assembly overview - bi-turbo, dismantled
1 - Connecting pipe
❑ Top
nection must not be
damaged.
⇒ page 243
2 - Bolts
❑ Qty. 2
❑ 8 Nm
3 - Bolts
❑ Qty. 2
❑ 8 Nm
4 - Pressure canister
❑ With position sender for
satelettronica
charge pressure posi‐
tioner - G581-
AG. Volkswagen AG d
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⇒ page 227
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8 - Seal
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❑ Renewing ⇒ page 236

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❑ 24 Nm
12 - Nuts
❑ Qty. 2
❑ 8 Nm
❑ For wastegate
❑ Renewing ⇒ page 240

14 - Nuts
❑ Qty. 2
❑ 8 Nm
15 - Retaining clip
16 - Turbocharger
❑ Low-pressure section
❑ Separating high and low pressure side ⇒ page 248
AG. Volkswagen AG d
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19 - Seals
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20 - Bolts
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satelettronica
spec
❑ Qty. 2
es, in part or in w
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❑ 8 Nm
21 - Connecting pipe
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23 - Bolt
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1. Turbocharger 223
1.1.3 Assembly overview - turbocharger, single turbo
1 - Bolts
❑ Qty. 2
❑ 8 Nm
2 - Charge air pipe
nection must not be
damaged.
3 - Heat shield
4 - Bolts
❑ Qty. 2
❑ 8 Nm
5 - Bolts
❑ Qty. 2
❑ 8 Nm
satelettronica
6 - Heat shield
7 - Nuts
❑ Qty. 8 . Volkswagen AG
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❑ Tightening sequence Volkswa not
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⇒ page 225 horis nte
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10 - Bracket
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12 - Seal
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13 - Turbocharger
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⇒ “1.2.1 Assembly overview - solenoid valves, bi-turbo”,
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1. Turbocharger 225
Transporter 2016 ➤ G. Volkswagen AG d
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4-cylinder common rail engine (2.0 l, 4V, turbocharger) o-lkEdition
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solenoid valve 2 - N274- aut ra
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ce
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vacuum system
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⇒ page 265
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⇒ page 235
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⇒ page 265
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⇒ page 235
ss
3 - Charge pressure control
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om
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⇒ page 265
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⇒ page 235
i
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Prote AG.
6 - Nuts
❑ Qty. 6
❑ 2 Nm
7 - Intake manifold flap air flow
control valve - N316-
vacuum system
⇒ page 265
8 - Spreader rivet
❑ Qty. 2

AG. Volkswagen AG d
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c
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1.2.2 Assembly overview - solenoid valves, mono-turbo
itte
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⇒ page 265
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⇒ page 235
3 - Nuts
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⇒ page 265
⇒ page 296
6 - Spreader rivet
❑ Qty. 2
1.3 Removing and installing turbocharger

⇒ “1.3.1 Removing and installing turbocharger, bi-turbo”,
page 227
⇒ “1.3.2 Removing and installing turbocharger, single turbo”,
page 232
1.3.1 Removing and installing turbocharger,

bi-turbo
1. Turbocharger 227
lkswage es n
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Removing
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– Remove upper intake hose -4-.
– Release crankcase breather -2-.
– If fitted, separate electrical connector on crankcase breather.

lkswage es n
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ir se
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tee Transporter 2016 ➤
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auth 4-cylinder common rail engine (2.0 l, 4V, oturbocharger)
r ac - Edition 03.2019
ss
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rrectness of i
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Cop py
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Prote AG.
– Remove floor heat shield ⇒ General body repairs, exterior;
Rep. gr. 66 ; Mouldings/trims/extensions; Removing and in‐
stalling floor heat shield .
– Unplug electrical connectors -1, 2, 3-.

– Separate cable ties if fitted.
– Unclip wiring harness -5- from guides -4-.
– Move wiring harness -5- aside.
1. Turbocharger 229

– Separate electrical connector from injector for reducing agent
- N474- .
– Unclip wiring harness of injector for reducing agent - N474- .
– Lay coolant pipes -2- aside slightly.
– Unscrew bolts -3- and -4-.
– Remove oil supply line ⇒ page 149 .
– Remove oil return line for turbocharger ⇒ page 151 .
– Remove rear exhaust gas recirculation pipe

en AG. V
olksw⇒
agpage
en AG 370 .
satelettronica
ag does
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– Disconnect electrical connector
by
Vo -1-. gu
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– Unscrew bolts -2-.uthor eo
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– Remove heat shield
s -3-.
ce
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nl
pt
du
– Unscrew bolt ⇒ Item 19 (page 25) joining engine support to

an
itte
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front engine mounting.

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– Vehicles with manual gearbox, pull off coolant hoses on cool‐
ant pipe ⇒ Item 6 (page 208) and lay aside.
– Vehicles with dual clutch gearbox, pull off coolant hoses on
coolant pipe ⇒ Item 6 (page 209) and lay aside.
– Unscrew studs -1 … 8- using bit XZN 10 - T10385- .
Note
♦ If necessary, move the engine in longitudinal direction with the

aid of a second mechanic to facilitate turbocharger removal.
♦ Note that the turbocharger is very heavy to avoid any secon‐
dary damage during removal and installation.
– Carefully remove exhaust manifold -9- with aid of third me‐

chanic.
Installing n AG. Volkswagen AG do
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Install in reverse y V order of removal, observing tthe
o o g
ua following:
satelettronica
d b ran
ir se tee
– Renew utho seals, gaskets, O-rings and self-locking nuts
or after re‐
moval.
ss
a ac
ce
e
nl
– Observe tightening sequence for turbocharger ⇒ page 221 .

pt
du
an
itte
y li
– Observe direction of oil return line ⇒ page 151 .

erm
ab
ility
ot p

wit
, is n
h re
– Fill turbocharger with engine oil at connection for oil supply

hole
spec
line.
es, in part or in w
t to the co
– Hose unions and air intake pipes and hoses must be free of
– Renew charge air hoses after each removal.
rrectness of i
– Secure all hose connections with the correct type of hose clips
l purpos

– Change engine oil, and renew oil filter element ⇒ Mainte‐
nf
ercia

rm
m
atio
m
– After installing turbocharger, run engine for about 1 minute at

o
n in
c
idling speed to ensure that oil is supplied to turbocharger. Do

or
thi
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not rev engine immediately.

t
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tester.
1. Turbocharger 231
Specified torques
♦ ⇒ “1.1.1 Assembly overview - turbocharger, bi-turbo”,
page 220
♦ ⇒ “4.1 Assembly overview - oil circuit”, page 147
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 208
1.3.2 Removing and installing turbocharger,

single turbo
♦ Torque wrench - V.A.G 1331- AG. Volkswagen AG d
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♦ Socket XZN 10 - T10385-
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Cop py
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♦ Tool set - T10395A-
gh ht
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Removing
– Unclip retainer -3-.
– Pull off intake hose -4-.
satelettronica
– Pull off charge air pipe -2-.
– Detach heat shield -4-. AG. Volkswagen AG d
agen oes
lksw not
– Unscrew banjo bolt -5-. by
Vo gu
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nl
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erm
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ility
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spec
es, in part or in w
t to the co
rrectness of i
– If present, remove propshaft ⇒ Rep. gr. 39 ; Propshaft; Re‐

moving and installing propshaft .
l purpos

nform
ercia

m
at
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– Separate connectors -1-.

ion
c
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or

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ate
do
riv
– Release and pull off pipe -3-.

p
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– Pull off lower intake hose -6-.
lksw
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Prote AG.
1. Turbocharger 233
– Remove rear exhaust gas recirculation pipe ⇒ page 370 .

– Swing coolant pipe -2- aside slightly.
AG. Volkswagen AG d
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satelettronica
– Swing coolant pipe -2- aside slightly.
rrectness of i
l purpos

– Detach heat shield -4-.
nform
mercia
– Unscrew exhaust gas temperature sender 1 - G235- -5-.
a
com
tion in
– Move exhaust gas temperature sender 1 - G235- -5- aside to
r
te o
prevent if from becoming damaged. thi

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Prote AG.

– Loosen bolt -2-.

– Unscrew studs -1 … 8- using bit XZN 10 - T10385- .

– Carefully remove turbocharger -9-.
Installing
– Observe tightening sequence for turbocharger ⇒ page 225 .
– Fill turbocharger with engine oil at connection for oil supply
line.
– Change engine oil, and renew oil filter element ⇒ Mainte‐
– After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
Note

satelettronica

. Volkswagen AG
gen AG does
– Follow further instructions displayed on ⇒VoVehicle
lksw
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diagnostic not
tester. ed by gu
ara
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Specified torques utho eo
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ss
♦ ⇒ “1.1.3 Assembly overview - turbocharger, single turbo”,
ce
e
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pt
page 224
du
an
itte
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erm
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 208

ab
ility
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es, in part or in w
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1.4 Removing and installing solenoid valves

-N75- / -N274- / -N529-
rrectness of i

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1. Turbocharger 235
Removing
Note
The removal and installation procedure is identical for all three

solenoid valves. n AG. Volkswagen AG do
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– If fitted, remove engine cover panel ⇒ page 33 . ir se
d b ran
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th
– Disconnect electrical connector -1-. au or
ac
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– Remove nut -3-.
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– Remove solenoid valve -2-.
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Installing
h re
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spec
t to the co
Specified torques
♦ ⇒ “1.2 Assembly overview - solenoid valves”, page 225
rrectne
satelettronica
1.5 Renewing vacuum unit for turbocharger,
ss
bi-turbo
o
cial p
f inform
⇒ “1.5.1 Replacing vacuum unit with position sender 2 for charge
mer
pressure positioner G580 ”, page 236
atio
om
n
c
⇒ “1.5.2 Renewing vacuum unit for wastegate”, page 240
i
or
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1.5.1 Replacing vacuum unit with position

iv
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sender 2 for charge pressure positioner
en
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Special tools and workshop equipment required cop Vo
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♦ Turbocharger tester - V.A.G 1397A-
AG.

♦ Or
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♦ Turbocharger tester - V.A.G 1397B- in conjunction withrispres‐
ed ara
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sure hose - V.A.G 1397B/6- ut
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♦ Hand operated vacuum pump - VAS 6213- s
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es, in part or in w
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1. Turbocharger 237
Removing
– Release securing clip -1-.
satelettronica
– Unscrew vacuum line holder from vacuum unit. agen
AG. Volkswagen AG d
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– Unscrew bolts -3-. ed by
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– Remove vacuum unit with position sender
aut
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2 for charge pres‐ eo
ra
sure positioner - G580- -4-. ss c
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nl
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Installing
nf
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m
– If vacuum unit was renewed with position sender 2 for charge

atio
m
pressure positioner - G580- , original dimension -a- of control

o
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c
rod must be determined.

or
thi
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– Transfer calculated dimension -a- to new threaded rod. To do

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this, unscrew nut until dimension -a- is correct.

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– Guided threaded rod -1- of vacuum unit through opening of

lever arm -3-.
– Tighten bolts -4-.
– Screw on nut -2- by hand.
– Connect connector -5-.
. Volkswagen AG
gen AG does
– Read voltage value ⇒ Vehicle diagnostic tester, 01 - Sys-Vol
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not
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tion injection and preglow system EDC 17t,ho01 eo
Engine electronics functions , 01 Reading au ra
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values , Turbocharger 1 turbine bypass valve1 B. 1,
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The description is for the turbocharger tester - V.A.G 1397A- , but
es, in part or in w
satelettronica
turbocharger tester - V.A.G 1397B- in conjunction with pressure
t to the co
hose - V.A.G 1397B/6- can also be used as an alternative.
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐
rrectness of i
uum pump - VAS 6213- to vacuum connection of vacuum unit
-1- of position sender 2 for charge pressure positioner - G580-
l purpos
using a commercially available T-piece -2-.

– Switch on turbocharger tester - V.A.G 1397A- and move slid‐
nform
ercia
ing switch on device to position II.

m
a
com
t
– Generate a vacuum of 500 ± 50 mbar in position sender 2 for
ion in
charge pressure positioner - G580- .
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– Move lever arm -1- in direction of -arrow- and hold in closed

position.
– Turn nut -2- until it comes into contact with lever arm -1-.
– Continue to turn nut -2- until ⇒ Vehicle diagnostic tester dis‐
plays a voltage value of 0.75 V ± 0.05 V for position sender 2
for charge pressure positioner - G580- .
– Then tighten lock nut -3-. Counterhold nut -2- to do this.
1. Turbocharger 239
olkswagen AG
en AG. V
Transporter 2016 ➤ ksw
ag does
not
Vol
4-cylinder common rail engine (2.0 l, 4V,edturbocharger) - Edition 03.2019 guara
by
ris nte
utho eo
– Slowly reduce vacuum. Lever arm -1- now
ss moves
a in direction ra
c
of -arrow- to open position.
ce
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nl
pt
du
an
– Generate a vacuum of 500 ± 50 mbar again in position sender
itte
y li
2 for charge pressure positioner - G580- .
erm
ab
ility
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– Check setting position once again via voltage value 0.75 V ±
wit
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0.02 V of position sender 2 for charge pressure positioner -
h re
hole
G580- ; adjust again if necessary.
spec
– Control flap is now in closed position. Press against lever arm es, in part or in w
t to the co
-1- to determine whether control flap is completely closed.
• Lever arm -1- or control flap must now rest against inner stop.
rrectness of i
• If the flap lever is not resting against the stop, the setting pro‐
l purpos
cedure must be repeated until the setting values agree with

each other.
nform
ercia
– Slowly reduce vacuum.

m
at
– Then secure nut and locknut with sealing paint from repair set
om
io
⇒ Electronic parts catalogue (ETKA) .
n
c
in t
or
his
e
– Push securing clip back onto control rod and turn 90°.
at
do
priv
c
• Distance between heat shield of vacuum unit with position
um
or
satelettronica
f
en
g
sender 2 for charge pressure positioner - G580- and oil return

n
t.
yi Co
line must be 5 mm. Cop py
t. rig
gh ht
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• If necessary, align oil return line slightly. p by
co Vo
by lksw
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Specified torques Prote AG.

page 220
1.5.2 Renewing vacuum unit for wastegate

♦ Turbocharger tester - V.A.G 1397A-
♦ Or

♦ Turbocharger tester - V.A.G 1397B- in conjunction with pres‐

Volkswagen AG
sure hose - V.A.G 1397B/6- swagen AG. does
k not
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♦ Hand operated vacuumsepump
db - VAS 6213- ara
nte
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es, in part or in w
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l purpos
nform
mercia
satelettronica
a
com
tion in
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te o
thi
s
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Cop py
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AG.
Removing
– Detach catalytic converter ⇒ page 335 .
– Remove nut -4-.
– Remove vacuum unit -5-.
1. Turbocharger 241
Installing
– If vacuum unit is to be renewed, original dimension -a- must
AG. Volkswagen AG d
be determined. lksw
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– Transfer calculated
ris
ed
b
dimension -a- to new threaded arod.
ran To do
tee
this, unscrew
utho nut until dimension -a- is correct. or
a ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Guided threaded rod -1- through opening of lever arm -2-.
satelettronica
– Tighten nuts -3-.
nform
ercia
– Screw on nut -4- by hand.

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
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Prote AG.
The description is for the turbocharger tester - V.A.G 1397A- , but

turbocharger tester - V.A.G 1397B- in conjunction with pressure
hose - V.A.G 1397B/6- can also be used as an alternative.
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐
uum pump - VAS 6213- to vacuum connection of vacuum unit
-1- using a commercially available T-piece -2-.
– Switch on turbocharger tester - V.A.G 1397A- and move slid‐
ing switch on device to position II.
– Apply a vacuum of 390 ± 10 mbar to vacuum unit.

– Move lever arm -1- in direction of -arrow- and hold in closed

position.
– Screw nut -2- in direction of vacuum unit until it comes into
contact with lever arm -1-.
– Tighten lock nut -3-. Counterhold nut -2- to do this.
– Release vacuum again.
– Generate a vacuum of 390 ± 10 mbar in vacuum unit.
• Flap lever must now be resting against the stop (closed posi‐
tion).
– Check setting and, if necessary, readjust. . Volkswagen AG
gen AG does
swa
– Repeat test 2 times to ensure that vacuum unit settingyis V ac‐
olk not
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curate and to prevent turbocharger damage. rise db ara
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– ut
Then secure nut and locknut with sealing paints afrom repair set ra
c
⇒ Electronic parts catalogue (ETKA) . s
ce
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nl
pt
du
– Push securing clip back onto control rod and turn 90°.
an
itte
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erm
ab
Specified torques
ility
ot p
satelettronica
wit
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page 220
hole
spec
es, in part or in w
t to the co
1.6 Removing and installing upper connect‐
rrectness of i
ing pipe, bi-turbo
l purpos

nf
ercia
orm
m
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Prote AG.
1. Turbocharger 243
Removing
– Remove bracket for charge air cooler ⇒ page 259 .
Note
To facilitate easier removal of the connecting pipes, ATE brake

cylinder paste or lithium grease can be used as a lubricant ⇒
Electronic parts catalogue (ETKA) .
– Pull off connecting pipe -2-.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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an
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ab
Installing
ility
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satelettronica
wit
is n
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ole,
spec
t to the co
Note
♦ For assembly of the turbocharger and connecting pipes, use
rrectne
the correct repair set ⇒ Electronic parts catalogue (ETKA) .
♦ To facilitate easier assembly of the connecting pipes, ATE
ss
brake cylinder paste or lithium grease can be used as a lubri‐
o
cial p
f
cant ⇒ Electronic parts catalogue (ETKA) .
inform
mer
atio
– Renew oil seal -1-.
om
n
c
i
– Coat seal -1- and both sealing surfaces sparingly with ATE
or
n thi
e
brake cylinder paste or lithium grease ⇒ Electronic parts cata‐

t
sd
va
logue (ETKA) .
i
o
pr
cum
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fo
en
ng
Specified torques
t.
yi Co
Cop py
t. rig
gh ht
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page 220 p by
co Vo
by lksw
cted agen
Prote AG.
1.7 Renewing upper connecting pipe, bi-tur‐

bo

Procedure
– Remove upper connecting pipe ⇒ page 243 .
– Disconnect connecting pipes -2- and -3-.
– Remove seal -1-.
satelettronica
– Remove valve -2-.
AG. Volkswagen AG d
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un
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Assembling
spec
es, in part or in w

t to the co
– Insert valve -2- in new connecting pipe -3-.

rrectness of i
– Insert oil seal -1- in new connecting pipe -3-.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
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t.
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Cop py
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Prote AG.
1. Turbocharger 245
– Re-fit connecting pipes -2- and -3-.

– Check that valve opens and closes without freely.
AG. Volkswagen AG d
agen oes
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aut ra
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un
pt
an
d
itte
– Drill out rivet -2-.
y li
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ab
satelettronica
pe
ility
– Remove type plate -1- from old connecting pipe.
ot
wit
, is n
– Attach type plate -1- to new connecting pipe using rivet from
h re
hole
repair kit ⇒ Electronic parts catalogue (ETKA) .
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
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rp
cum
fo
en
ng
t.
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op py
. C rig
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rig by
py Vo
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by
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Prote AG.
– Renew hose -2-.
– Re-install upper connecting pipe ⇒ page 243 .
Specified torques
page 220
Bolts for connecting pipe 8 Nm

1.8 Removing and installing lower connect‐

ing pipe, bi-turbo
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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aut ra
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Removing
un
pt
an
d
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ab
satelettronica
pe
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hole
spec
Note
es, in part or in w
t to the co
To facilitate easier removal of the connecting pipes, ATE brake
cylinder paste or lithium grease can be used as a lubricant ⇒
rrectness of i
l purpos
– Pull off connecting pipe -2-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
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en
Installing
ng
t.
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op py
Install in reverse order of removal, observing the following: t. C rig
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Vo
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Prote
Note
AG.
♦ For assembly of the turbocharger and connecting pipes, use

the correct repair set ⇒ Electronic parts catalogue (ETKA) .
♦ To facilitate easier assembly of the connecting pipes, ATE
brake cylinder paste or lithium grease can be used as a lubri‐
cant ⇒ Electronic parts catalogue (ETKA) .
– Renew oil seal -1-.

– Coat seal -1- and both sealing surfaces sparingly with ATE
brake cylinder paste or lithium grease ⇒ Electronic parts cata‐
logue (ETKA) .
Specified torques
page 220
1. Turbocharger 247
1.9 Removing and installing compressor

housing and turbine housing, bi-turbo
Removing
satelettronica
– Remove lower connecting pipe ⇒ page 247 .
– Remove nut -3-.
– Remove turbocharger for high pressure -5- from turbocharger
for low pressure -6-.
Installing
. Volkswagen AG
gen AG does
– Renew seal and nuts between high and low pressure
Vol
kside.
swa not
y gu
db ara
– After installation of turbocharger, setting of position
orise sender 2 nte
eo
for charge pressure positioner - G580- must aut be checked and,
h
ra
if necessary, adjusted ⇒ page 236 . ss c
ce
e
nl
pt
Specified torques
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Rep. gr.21 - Turbocharging/supercharging Prote
cted AG.
agen
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 249
⇒ “2.2 Removing and installing charge air cooler”, page 250
⇒ “2.3 Removing and installing charge pressure sender G31 ”,
page 253
⇒ “2.4 Removing and installing charge pressure sender 2 G447
”, page 254
⇒ “2.5 Checking charge air system for leaks”, page 255
⇒ “2.6 Detaching and securing charge air cooler”, page 257
⇒ “2.7 Removing and installing bracket for charge air cooler”,
page 259
⇒ “2.8 Checking charge air cooler for leaks”, page 260
2.1 Assembly overview - charge air system
1 - Clamps
satelettronica
❑ 5.5 Nm
2 - Pressure hose
❑ To remove, the charge
air cooler must be de‐
tached ⇒ page 257
3 - Charge air temperature
sender before charge air cool‐
er - G810-
⇒ page 307 n AG. Volkswagen AG do
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❑ 22 Nm byV
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4 - Clip tho tee
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5 - Coolant hose ss
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7 - Bolts wit
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❑ Number of bolts de‐
hole
pends on equipment
spec
es, in part or in w
level, refer to ⇒ Elec‐

t to the co
tronic parts catalogue

(ETKA)
❑ 20 Nm
rrectness of i
8 - Clamps
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9 - Coolant hose
nform
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10 - Bolts
m
❑ Consider the different

at
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io
versions ⇒ Electronic
n
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parts catalogue (ETKA)

o
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❑ 20 Nm
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11 - Bracket for charge air cooler

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❑ Consider the different versions ⇒ Electronic parts catalogue (ETKA) t. Cop py
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2. Charge air system 249

12 - Clamps
❑ 5.5 Nm
13 - Pressure hose
❑ When there visible bubbles or if the hose is swollen, always renew pressure hose as well.
❑ To remove, the charge air cooler must be detached ⇒ page 257
❑ Consider the different versions ⇒ Electronic parts catalogue (ETKA)
❑ Corrugated pipe connection must not be damaged.
❑ Detaching and attaching ⇒ page 257
15 - Bolts
❑ 8 Nm
16 - Charge air temperature sender after charge air cooler - G811-
AG. Volkswagen AG d
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2.2 Removing and installing
ss charge air cool‐ ac
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Removing
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Note
♦ The description refers to the old version of the charge air cool‐
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ion
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and securing elements depend on the equipment level (refer

in t
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to ⇒ Electronic parts catalogue (ETKA) ).

ate
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♦ When renewing the charge air cooler, the general rule is now
um
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to install only the new version of the charge air cooler or (if
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applicable) to renew additional components ⇒ Electronic parts Cop py
catalogue (ETKA) . ht. rig
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– Clamp off coolant hoses -2- using hose clamps, up to 25 mm
- 3094- .
CAUTION

– Place a cloth underneath to catch escaping coolant.
– Seal open connections using suitable plugs from engine bung
set - VAS 6122- .
satelettronica
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by
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Note
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♦ Number of bolts -1- depends on equipment.
hole
spec
♦ The illustration shows the charge air cooler with 4 bolts.
es, in part or in w
t to the co
– Remove charge air cooler -2-.
rrectness of i
• Corrugated pipe connection must not be damaged.
l purpos
Installing
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♦ When renewing the charge air cooler, the general rule is now
te
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to install only the new version of the charge air cooler or (if
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applicable) to renew additional components ⇒ Electronic parts
o
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catalogue (ETKA) .
t.
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Cop py
♦ Charge air coolers with 4 bolts are still secured with 4 bolts.
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There is no change to the charge air cooler or bracket.
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♦ Charge air coolers with 3 bolts are now secured with just 2
Prote AG.
bolts. The threaded connection on the air inlet side is discon‐

tinued.
♦ Depending on the equipment, the charge air cooler bracket
may still have 3 threaded holes but only 2 bolts are used to
secure it.
♦ The ball head in the bracket and the receiver in the charge air
cooler are discontinued.
♦ The flexible joint for the third threaded connection in the
charge air cooler is discontinued.

• The minimum distance between the charge air cooler and the
fuel lines must be 5 mm.
– If necessary, detach charge air cooler again, and align it so
that the minimum distance is maintained.
Specified torques
2.3 Removing and installing charge pres‐

sure sender - G31-

AG. Volkswagen AG d
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– If fitted, remove engine
utho cover panel ⇒ page 33 . eo
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– Disconnect electrical
s connector -1-.
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nl
pt
du
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ab
– Remove charge pressure sender - G31- -3-.
ility
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, is n
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es, in part or in w
Specified torques
t to the co
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 291
rrectness of i
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2.4 Removing and installing charge pres‐

or c
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sure sender 2 - G447-

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op
♦ Torque wrench - V.A.G 1331- C py
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Vo
co lksw
by
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Prote AG.

Removing
– Before disconnecting hose, spray with suitable releasing
agent.
– Pull off hose -5- carefully and in straight line from charge pres‐
sure sender 2 - G447- -2-.
Installing
– Make sure that hose is securely fitted and that there are no
leaks. . Volkswage n AG n AG d
wage oe
– Secure all hose connections
yV
olks with the correct type
s no
t of
gu hose clips
(same as original
ised b equipment) ⇒ Electronic parts catalogue
ara
n .
r tee
ho
Specified torques
sa
ut or
ac
satelettronica
s
♦ ⇒ “4.1 Assembly overview - exhaust gas temperature regula‐
ce
le
un
pt
tion”, page 355
an
d
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ab
2.5 Checking charge air system for leaks ility
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spec
♦ Charge air system tester - V.A.G 1687-

t to the co
rrectness o
cial p
f inform
mer
atio
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n
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♦ Adapter - V.A.G 1687-

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Procedure
– Detach intake hose -1- from air mass meter - G70- .
– Connect adapter - V.A.G 1687/10- to intake hose -1-.
– Secure adapter - V.A.G 1687/10- and intake hose -1- with
clamp -2-.
– Connect charge air system tester - V.A.G 1687- to adapter
agen
AG-. Volkswagen AG d
oes
V.A.G 1687/10- . V olksw not
g by ua
ed ran
– Seal connection of crankcase breather. oris tee
th or
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Prepare charge air system tester - V.A.G 1687- as follows:
satelettronica
– Unscrew pressure control valve -2- completely.
rrectness of i
– Close valves -3- and -4-.
l purpos
• Rotary knob of pressure control valve -2- must be pulled up

fully.
nf
ercia
orm
m
– Connect compressed air hose -1- to charge air system tester
atio
m
- V.A.G 1687- .
o
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– If water is in inspection glass, allow to escape via drain screw
te
sd
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-6-.
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– Open valve -3-.

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• The pressure must not exceed 0.5 bar.
C py
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– Set pressure to 0.5 bar via pressure control valve -2-.
co Vo
by lksw
cted agen
Prote AG.
– Open valve -4- and wait until system is charged.
– If necessary, re-adjust pressure to 0.5 bar.
– Check charge air system for leaks.
♦ By hearing, touching
♦ Using commercially available leak detector spray
♦ Using ultrasonic tester - V.A.G 1842-
Note
♦ A small amount of air escapes through the valves and enters

the engine and the exhaust gas recirculation cooler. Therefore
a holding pressure test is not possible.
♦ For information on how to use the ultrasonic tester - V.A.G
1842- refer to the ⇒ operating instructions .
♦ Before removing the adapters, depressurise the system by
detaching the hose coupling.

2.6 Detaching and securing charge air cool‐

er
Releasing
satelettronica
– Remove nut -1-.
– Pull off vacuum hoses.
– Move bracket -4- to one side.
AG. Volkswagen AG d
agen oes
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ility
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wit

is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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t.
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Cop py
t. rig
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by
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Prote AG.

AG. Volkswagen AG d
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agen oes
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– Disconnect electrical connector -1-. au
t or
ac
ss
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nl
pt
du
an
itte
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ab
ility
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es, in part or in w
t to the co
rrectness of i
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m
atio
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n in
or c
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satelettronica
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f
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Note C py
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♦ Number of bolts -1- depends on equipment.
by c lksw
cted agen
Prote AG.
♦ The illustration shows the charge air cooler -2- with 4 bolts.
Note
Disregard position -1-.

– Fold floor covering -1- forwards in direction of -arrow- with

coolant hoses still attached.
• Corrugated pipe connection must not be damaged.
AG. Volkswagen AG d
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olksw not
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Install in reverse order ris of removal, noting the following:
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♦ Charge air coolers with 4 bolts are still secured with 4 bolts.
erm
ab
There is no change to the charge air cooler or bracket.
ility
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wit
is n
♦ Charge air coolers with 3 bolts are now secured with just 2
h re
ole,
bolts. The threaded connection on the air inlet side is discon‐
spec
tinued.
t to the co
♦ Depending on the equipment, the charge air cooler bracket
may still have 3 threaded holes but only 2 bolts are used to
secure it.
rrectne
♦ The ball head in the bracket and the receiver in the charge air
cooler are discontinued.
ss
satelettronica
o
cial p
f
♦ The flexible joint for the third threaded connection in the
inform
charge air cooler is discontinued.
mer
atio
m

o
n
c
i
or
n thi
e
Specified torques
t
sd
iva
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pr

um
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en
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t.
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2.7 Removing and installing bracket for
C py
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rig ht
by
charge air cooler
copy Vo
by lksw
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Prote AG.

Removing
lkswage es n
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ir se tee
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u or
a ac
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nl
pt
du
an
itte
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erm
satelettronica
ab
ility
ot p
wit
, is n
– Remove charge air cooler bracket -3-.
h re
hole
spec
Installing
es, in part or in w
Install in reverse order of removal, observing the following: t to the co

Specified torques
rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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op py
2.8 Checking charge air cooler for leaks
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Cooling system tester - V.A.G 1274 B-

♦ Adapter - V.A.G 1274B/14-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv

p
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Procedure
CAUTION

– Clamp off coolant hoses -3- with hose clips, up to 25 mm -

3094- -arrows-.
– Secure commercially available coolant hose -1- to open con‐

nection of charge air cooler.
– Secure coolant hose -1- with a clamp -2-.
– At other end of coolant hose -1-, secure suitable adapter from
hose adapter set - V.A.G 1274B/14- -4-.
– Secure adapter -4- with a clamp -3-.
satelettronica
– Connect cooling system tester - V.A.G 1274 B- -5- to adapter
- V.A.G 1274B/14- -4-.
– Using cooling system tester - V.A.G 1274
nAG. VolkB-
sw,aggenerate
en AG a
pressure of 2.5 bar. lkswage does
not
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• The pressure must be ed
ismaintained for over 10 minutes. nte
or
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• The pressure must
ss not drop by more than 0.2 bar within 10 mi‐
a c
nutes.
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pt
du
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No pressure drop: charge air cooler is leak-tight.

itte
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erm
ab
Pressure drop: charge air cooler is leaking and must be renewed

ility
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⇒ page 250 .
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
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cum
for
en
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t.
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Cop py
t. rig
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Vo
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by
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Prote AG.

23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Filling/bleeding fuel system”, page 263
⇒ “1.2 Checking fuel system for leaks”, page 263
1.1 Filling/bleeding fuel system

NOTICE
Risk of irreparable damage to fuel pump if allowed to run dry.
– Never allow fuel pump to run »dry«.
Proceed as follows to fill high-pressure pump with fuel.

• Vehicle must have fuel.
satelettronica
– Fill fuel system ⇒ Vehicle diagnostic tester, 01 - Systems
capable of self-diagnosis , 01 - Diesel direction
injection and preglow system EDC 17 , 01 - Engine
electronics functions , 01 - Actuating fuel pump .

tester.
• The fuel pump starts up.
G. Volkswagen AG d
• The fuel pump must run for approx. 3 minutes to ensure that lksw
agen
A
oes
not
the high-pressure pump is filled with a sufficient amountbyof fuel.
V o gu
ara
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ris
– After the fuel system has been filled, start the engine.
ut
ho eo
ra
sa c
– Allow engine to run for a few minutes at a moderate
s speed. ce
le
Then, switch it off again.

un
pt
an
d
itte
y li
– Check fuel system for leaks.
erm
ab
ility
ot p
– Delete event memory entry ⇒ Vehicle diagnostic tester.

wit
is n
h re
– Then test drive the vehicle, accelerating to full throttle at least

ole,
spec
once.
t to the co
– Then, check the high-pressure system for leaks again.

rrectne
Note
If there is still air in the fuel system, the engine can change to
ss o
emergency running mode during road test. Switch off engine and
cial p
f i
clear event memory. Then continue the road test.

nform
mer
atio
m
– Delete event memory entry ⇒ Vehicle diagnostic tester.

o
n
c
i
or
1.2 Checking fuel system for leaks

thi
te
sd
iva
o
pr
– Start engine and run at idling speed for a few minutes. Do not
um
r
fo
en
ng
depress accelerator pedal while doing so, and switch engine

t.
yi Co
off again. Fuel system will bleed itself automatically. Cop py
t. rig
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– Check the entire fuel system for leaks. p by
co Vo
by lksw
cted agen
Prote AG.
1. Injection system 263

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Transporter 2016 ➤ rise
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ho eo
ra
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– If leaks are found although the connections have been tight‐
nl
pt
du
ened to the correct torque, the relevant component must be
an
itte
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renewed.
erm
ab
ility
ot p
– Then test drive the vehicle, accelerating to full throttle at least
wit
, is n
once.
h re
hole
spec
– Then, check the high-pressure system for leaks again.
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.
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satelettronica
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
264 Rep. gr.23 - Mixture preparation - injection

AG. Volkswagen AG d
lksw
agen Transporter
oes
not 2016 ➤
o
d by
V
(2.0 l, 4V, turbocharger) - Edition
gu
ara 03.2019
e nte
ris
tho eo
au ra
2 Vacuum system ss c
ce
e
nl
pt
du
an
⇒ “2.1 Connection diagram - vacuum system”, page 265
itte
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erm
ab
2.1 Connection diagram - vacuum system
ility
ot p
wit
, is n
h re
⇒ “2.1.1 Connection diagram - vacuum system, bi-turbo”,
hole
page 265
spec
es, in part or in w
⇒ “2.1.2 Schematic diagram - vacuum system, mono-turbo”, page
t to the co
267
2.1.1 Connection diagram - vacuum system, bi-turbo
rrectness of i
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1 - Air filter
nform
ercia

solenoid valve 2 - N274-
m
at
om
i
on
c
in t
⇒ page 225
or
his
ate
do
priv
c
⇒ page 235
satelettronica
um
for
en
ng
t.
3 - Pulsation damper
yi Co
Cop py
t. rig
4 - Air filter
gh ht
pyri by
Vo
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by c lksw
5 - Turbine changeover valve - Prote
cted AG.
agen
N529-
⇒ page 225
⇒ page 235
7 - Air filter
⇒ page 225
⇒ page 235
9 - Bracket
10 - Intake manifold flap air
flow control valve - N316-
⇒ page 225
⇒ page 296
11 - Air filter
13 - Intake manifold
14 - Vacuum reservoir
15 - Turbocharger
❑ Vacuum hose to VTG vacuum unit
❑ At top of turbocharger
2. Vacuum system 265

16 - To four-wheel drive gearbox
17 - Vacuum pump
❑ In oil pump
19 - Turbocharger
❑ Vacuum hose to position sender 2 for charge pressure positioner - G580-
❑ At bottom of turbocharger
. Volkswagen AG
❑ Removing and installing ⇒ page 236 swa
gen AG does
k not
Vol gu
20 - Turbocharger by ara
ed nte
ris
❑ Vacuum hose to vacuum unit for wastegate
ut
ho eo
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❑ At bottom of turbocharger s
ce
e
nl
satelettronica
pt
du
an
itte
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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
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Prote AG.

2.1.2 Schematic diagram - vacuum system, mono-turbo
1 - Air filter
⇒ page 225
⇒ page 235
4 - Bracket
5 - Intake manifold flap air flow agen AG. Volkswagen AG do
control valve - N316- Vol
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❑ Assembly overview rised ran
tee
⇒ page 225aut
ho
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❑ Removing ss and installing
ce
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⇒ page 296
nl
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satelettronica
6 - Air filter
erm
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8 - Intake manifold
hole
spec
es, in part or in w
⇒ page 291
t to the co
⇒ page 292
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9 - Vacuum reservoir
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10 - To four-wheel drive gear‐

box
nform
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❑ Depending on equip‐
ment
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11 - Vacuum pump
c
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❑ In oil pump
at
do
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⇒ page 133
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❑ Removing and installing ⇒ page 137 Cop py
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13 - Turbocharger Prote AG.
❑ Vacuum hose to VTG vacuum unit

❑ At bottom of turbocharger
2. Vacuum system 267

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Vo gu
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(rail) or eo
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⇒ “3.1 Assembly overview - injectors”, page 268
ce
le
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⇒ “3.2 Assembly overview - fuel rail”, page 270

itte
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rm
ab
pe
⇒ “3.3 Adapting correction values for injectors”, page 271
ility
ot
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, is n
⇒ “3.4 Testing injectors”, page 271
h re
hole
spec
⇒ “3.5 Testing jammed-open injectors”, page 272
es, in part or in w
t to the co
⇒ “3.6 Checking return flow rate of injectors with engine running”,
page 273
⇒ “3.7 Checking return flow rate of injectors at starter speed”,
rrectness of i
page 275
l purpos
⇒ “3.8 Removing and installing injectors”, page 277

⇒ “3.9 Removing and installing high-pressure lines”, page 281
nform
ercia
⇒ “3.10 Removing and installing fuel rail”, page 285

m
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satelettronica
3.1 Assembly overview - injectors
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1 - Fuel return line
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❑ Must not be kinked,
Co
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❑ Do not dismantle.
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❑ Fill and bleed fuel sys‐
Prote AG.
tem after renewing

⇒ page 263
2 - O-ring
3 - Injector
❑ If they are to be reinstal‐
led, the injectors and
high-pressure lines
must always be reinstal‐
led on the same cylin‐
der.
⇒ page 277
4 - High-pressure line
❑ Between fuel rail and in‐
jectors
❑ Install so that compo‐
nent is not under tension
⇒ page 281
❑ 28 Nm
5 - Seal
⇒ page 85
6 - Copper washer

7 - O-ring
8 - Grommet
❑ Renew if damaged
9 - Clamping pieces
❑ Qty. 2
❑ Installation position: ⇒ page 269 .
10 - Bolts
❑ Qty. 2
❑ 8 Nm +270°
Clamping piece installation position

• One clamping piece encompasses 2 injectors each.
• Position clamping piece -1- as shown.
satelettronica
• Insert bolt -2- in clamping piece -1- from above.
AG. Volkswagen AG d
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c
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3. Injectors/high-pressure accumulator (rail) 269

3.2 Assembly overview - fuel rail
1 - Fuel return line n AG. Volkswagen AG do

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2 - Bolt d byV ua
ran
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❑ 8 Nm tho tee
or
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3 - Clip ss
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4 - Fuel return hose
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ab
5 - Clip
ility
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❑ Between high-pressure
hole
spec
pump and fuel rail
es, in part or in w
t to the co
⇒ page 281
❑ 28 Nm
rrectness of i
7 - Bolt
l purpos
❑ 8 Nm
satelettronica
8 - Bolt
nf
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or
❑ 8 Nm
m
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or c
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❑ Between high-pressure
te
sd
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pump and fuel rail

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⇒ page 281
t.
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❑ 28 Nm
t. rig
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10 - Fuel pressure sender -
c by lksw
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⇒ page 301
❑ Can be re-used
⇒ page 303
❑ 100 Nm
❑ Between fuel rail and injectors
❑ Qty. 4
❑ 28 Nm
12 - High-pressure accumulator (rail)
13 - Bolts
❑ Qty. 2
❑ 20 Nm
14 - O-ring
15 - Fuel pressure regulating valve - N276-
❑ 80 Nm

3.3 Adapting correction values for injectors

♦ The function injector delivery calibration serves to correct the
injection rates for each cylinder of a common rail system indi‐
vidually across the entire ignition map range.
♦ The 20-digit adaption values are marked on each injector. The
marked values may consist of letters and/or numbers.
Top view of injector

1- Datamatrix code agen
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2- Part numberd by V gu
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3- Adaption ut value (correction factor; details in illustration are
ho eo
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only an example)
satelettronica
ss c
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nl
♦ After renewing an injector, the 20-digit adaption value must be

pt
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written into the engine control unit.

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♦ After renewing the engine control unit, the adaptation values ab

ility
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for the injectors must be transferred to the new engine control wit
, is n
unit.
h re
hole
spec
♦ Also check that the injector delivery calibration values are cor‐
es, in part or in w
rectly entered for all other injectors. Do not attempt to re-enter

t to the co
these values if the correct values are already stored in the en‐
gine control unit.
rrectness of i

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– Perform adaption of injector correction values ⇒ Vehicle diag‐
nform
ercia
nostic tester, 01 - Systems capable of self-diagnosis ,

m
at
01 - Diesel direction injection and preglow system

om
io
EDC 17 , 01 - Engine electronics functions , 01 -

n
c
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Adapting injector correction values .

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ate
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cum
or
tester.
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Cop py
3.4 Testing injectors
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There are three different tests for checking the operation of the cted agen
Prote AG.
injectors:
♦ ⇒ “3.5 Testing jammed-open injectors”, page 272
♦ ⇒ “3.6 Checking return flow rate of injectors with engine run‐
ning”, page 273
♦ ⇒ “3.7 Checking return flow rate of injectors at starter speed”,
page 275
Note sequence when testing. Checking open injectors
⇒ page 272 must always be carried out first.
The remaining sequence depends on the fault pattern. Check ei‐
ther with the engine running ⇒ page 273 or at cranking speed
⇒ page 275 .

3.5 Testing jammed-open injectors

Special tools and workshop equipment required n AG. Volkswagen AG do
lkswage es n
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♦ Hand operated vacuum pump - VAS 6213- d b ua
ran
ir se tee
tho
u or
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nl
pt
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itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Return flow meter - VAS 6684-
l purpos
nf
ercia
satelettronica
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
t. rig
gh ht
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co lksw
by
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Prote
AG.
Procedure
– Clean return connections before removing using commercially
available cold cleaning solvent.
– Dry cleaned parts.
CAUTION
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

– Reach down to lowest recess -arrow- and release centre piece

-1- from return line connection in direction of -arrow-.
AG. Volkswagen AG d
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– Connect ut suitable adapter from return flow meter - VAS
ho e o 6684-
ra
to return
ss a connection of injector -2- to be checked. c
ce
le
– Connect hand vacuum pump - VAS 6213- -1- to adapter.

un
pt
an
d
itte
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– Seal open connection using a plug from engine bung set - VAS
rm
ab
6122- .
pe
ility
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wit
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– Use hand vacuum pump - VAS 6213- -1- to generate vacuum
h re
of approx. -500 mbar.
hole
satelettronica
spec
es, in part or in w
If injector -2- is OK, pressure remains constant for period of 30
t to the co
seconds.
If injector -2- is defective, pressure rises back to 0 bar within
rrectness of i
2 … 3 seconds.
l purpos
Note
nform
ercia
Observe pressure loss from hand vacuum pump - VAS 6213-

m
-1-.
com
tion in
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– If necessary, repeat test.

s
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– Renew defective injector ⇒ page 277 .

um
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3.6 Checking return flow rate of injectors
C py
t. rig
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with engine running
p by
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Transporter 2016 ➤ aut
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4-cylinder common
s rail engine (2.0 l, 4V, turbocharger) - Edition 03.2019
ce
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du
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ab
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es, in part or in w
t to the co
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nform
ercia

m
at
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ion
♦ Measuring container
c
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or
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Procedure
a
do
priv
cum
or
• Coolant temperature must be at least 80°C.

f
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• Ensure that regeneration is not active. If so, cancel regenera‐ Cop py
tion.
ht. rig
satelettronica
rig ht
py by
co Vo
– Read coolant temperature using ⇒ Vehicle diagnostic tester.
by lksw
cted agen
Prote AG.
– Clamp off return line connection of injector to be measured
using hose clamp up to 25 mm - 3094- .
available cold cleaning solvent.
– Dry cleaned parts.
CAUTION

AG. Volkswagen AG d
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– Fit suitable hose line and hold in a clean beaker or measuring
ility
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container.
wit
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hole
6122- .
spec
es, in part or in w
t to the co
– Install charge air cooler again for testing (charge air route must
be closed).
– Start engine and allow to idle for 2 minutes.
rrectness of i
– Perform test on all injectors in succession.
l purpos
• Return flow volumes between individual injectors may fluctu‐
ate within thresholds.
nform
ercia
• Fuel volume in hose line must be taken account of during
m
at
om
measurement.
ion
c
in t
or
• Specification of individual injector in mono-turbo and bi-turbo
his
ate
in 2 minutes: 0 … 25 ml
do
priv
cum
or
– Then increase engine speed to 2500 rpm for 2 minutes and

f
en
ng
t.
check return flow volume again.
yi
satelettronica
Co
Cop py
t. rig
• Return flow volumes between individual injectors may fluctu‐
gh ht
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ate within thresholds.
op Vo
by c lksw
cted agen
Prote AG.
• Fuel volume in hose line must be taken account of during
measurement.
• Specification of individual injector in mono-turbo in 2 minutes:
0 … 35 ml
• Specification of individual injector in bi-turbo in 2 minutes: 0 …
65 ml
– If specified thresholds are exceeded, affected injector must be
renewed ⇒ page 277 .
– On completion of all work, perform leakage test on fuel system
⇒ page 263 .
– Delete event memory on completion of work ⇒ Vehicle diag‐
nostic tester.
3.7 Checking return flow rate of injectors at

starter speed
♦ Return flow meter - VAS 6684-

lkswage es n
o ot g
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♦ Hose clamps to 25 mm - 3094- ir se
d ran
tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
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satelettronica
h re
ole,
spec
t to the co
rrectne
ss
Procedure
o
cial p
f in
form
mer
atio
– Disconnect electrical connector of fuel pressure regulating
om
valve - N276- ⇒ Item 15 (page 270) .
n
c
i
or
n thi
e
– Check that clamp and fuel return hose -1- are seated correctly.
t
sd
iva
o
pr
c
– Clamp off fuel return hose -1- using hose clamp up to 25 mm
um
r
fo
en
ng
- 3094- .
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t. C rig
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available cold cleaning solvent. p by
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by lksw
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– Dry cleaned parts. Prote AG.
CAUTION


Note
The test can be carried out on all injectors at the same time.
– Fit suitable adapter from return flow meter - VAS 6684- to re‐
spective return line connection of injector.
– Connect hose line of return flow meter - VAS 6684- to adapter.
6122- .
– Install charge air cooler again for testing (charge air route must
be closed).
– Briefly operate starter. Perform procedure 3 times, allowing a
break of 20 seconds between starts.
• Specification of return flow volume: max. 8 cm rise in hose line
– If specified thresholds are exceeded, affected injector must be
satelettronica
renewed ⇒ page 277 .
– On completion of all work, perform leakage test on fuel system
⇒ page 263 .
– Delete event memory on completion of work ⇒ Vehicle diag‐
nostic tester.
3.8 Removing and installing injectors

AG. Volkswagen AG d
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un
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pe
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♦ Puller - T10055-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
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277
by lksw
cted agen
Prote 3. Injectors/high-pressure accumulator (rail)
AG.
AG. Volkswagen AG d
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s c
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un
pt
♦ Assembly sleeve - T10377-
an
d
itte
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rm
ab
pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Puller - T10537-
m
a
com
tion in
r
te o
thi
s
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rp
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t.
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Cop py
satelettronica
ht. rig
rig ht
py by
co Vo
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Prote AG.
♦ Front end hook - 3370-
♦ Cleaning set - VAS 6811-

gen AG
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does Transporter 2016 ➤
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4-cylinder
Volk common rail engine (2.0
not l, 4V, turbocharger) - Edition 03.2019
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Removing autho
or
ac
ss
ce
le
un
pt
an
d
– Remove high-pressure pipes between fuel rail and affected
itte
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injector ⇒ page 281 . rm
ab
pe
ility
– If fitted, place noise insulation to one side.
ot
wit
, is n
h re
– Fit front end hook - 3370- into lowest recess -arrow-, release
hole
spec
centre piece -1- of return line connections in direction of
es, in part or in w
-arrow- and pull off.
t to the co
rrectness of i
l purpos
nform
mercia
a
Note
com
tion in
r
te o
thi
One clamping piece always secures two injectors and can only
s
iva
do
be removed if both injectors are removed.
r
satelettronica
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Screw puller - T10537- onto injector.

• Sequence for removing injectors: first remove injector for cyl‐
inder 2, then for cylinder 1/cylinder 4, and then for cylinder 3.
– Screw puller - T10055- onto puller - T10537- .
– Lift out injectors upwards.
– Place removed injectors on a clean cloth.
Installing
– Only the cleaning set - VAS 6811- may be used to clean the
injector bores in the cylinder head, refer to ⇒ Operating man‐
ual .
Installing new injectors
Note
New injectors are supplied with new oil seals.
satelettronica
– Note installation position of clamping pieces ⇒ page 269 .
– Observe all instructions for installing high-pressure pipes
⇒ page 281 .
Installing used injectors
When a used injector is re-fitted, the following must be replaced:
♦ Copper seal agen
AG. Volkswagen AG d
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♦ O-ring for shaft of injectored by gu
ara
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♦ O-ring for connection aut of fuel return line
h
ra
ss c
– Spray tip of injector with a rust removal spray. Wait approx.
ce
e
nl
pt
5 minutes and wipe off soot and oil particles with a cloth.
du
an
itte
y li
– To remove the old copper seal from the injector, clamp the seal
erm
ab
ility
carefully in a vice so that it is just held between the jaws without

ot p
wit
turning.
, is n
h re
hole
– Then carefully pull and twist the injector out of the copper seal
spec
by hand.
es, in part or in w
t to the co
– Remove deposits under copper seal.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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for
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

– Use assembly sleeve - T10377- to renew seal -1- for injector.

Continuation for used and new injectors
– Coat injector O-rings with assembly oil, engine oil or diesel
fuel.
– Install injectors.
– Carefully press connections of return lines onto injectors. The
catch should engage audibly. Then press release pin down
carefully.
– Tighten union nuts of high-pressure pipes by hand first. Check
they are seated without stress.
– When one or more injectors have been renewed, the adaption
of the correction values for the new injectors must be written
into the engine control unit ⇒ page 271 .
Specified torques
• ⇒ “3.1 Assembly overview - injectors”, page 268
satelettronica
3.9 Removing and installing high-pressure
lines
⇒ “3.9.1 Removing high-pressure pipe between fuel rail and high-
pressure pump”, page 281
⇒ “3.9.2 Removing and installing high-pressure line between fuel
rail and injectors”, page 284
3.9.1 Removing high-pressure pipe between agen AG. Volkswagen AG do

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fuel rail and high-pressure pump d by Volk
sw ot g
ua
r e an
ris tee
Special tools and workshop equipment required tho 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
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♦ Tool insert, 17 mm - V.A.G 1331/6-

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

♦ Socket - T40055-
AG. Volkswagen AG d
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pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Removing
position .
Volkswa
– Loosen oil dipstickswon
ageintake
n AG. manifold.
gen AG
does
olk not
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– Unscrew bolts d by -1-. ara
rise nte
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– Extract a dirt from taper seat of union nuts, clean fuel line
ut r a and
c
line shead before removal using cold cleaning solvent and dry
s
ce
e
off with compressed air.

nl
pt
du
an
itte
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erm
CAUTION
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
– Unscrew union nuts -2- and -3-.
nf
ercia
NOTICE orm
m
Risk of damage to high-pressure lines caused by deformation.

atio
om
n in
High-pressure lines may break.

or c
thi
e
– Never attempt to reshape high-pressure lines.

t
sd
iva
o
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rp
cu
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f
– Remove high-pressure lines -4-.

en
ng
t.
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op py
– Seal open lines and connections with clean blanking plugs
t. C rig
gh ht
from engine bung set - VAS 6122- . pyri by
Vo
co lksw
by
cted agen
Installing Prote AG.
Note
♦ Observe cylinder-specific markings if reusing high-pressure

lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ Check taper seal of respective high-pressure line for defor‐
mation and cracks.
♦ The inside of the line must be free of deformations, constric‐
tions and damage.
♦ Corroded lines should no longer be used.

– Checking fuel system for leaks ⇒ page 263 .
Specified torques

3.9.2 Removing and installing high-pressure

line between fuel rail and injectors
satelettronica
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Removing
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– Extract dirt from taper seat of union nuts, clean fuel line and
ility
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wit
is n
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spec
CAUTION
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ss o
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– Unscrew union nuts -arrows- of respective high-pressure lines
n
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Risk of damage to high-pressure lines caused by deformation.
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High-pressure lines may break.
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– Never attempt to reshape high-pressure lines.
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– Remove respective high-pressure line -1-.

– Seal open lines and connections with clean blanking plugs
from engine bung set - VAS 6122- .
Installing
Note

lines.
checks:
mation and cracks.
tions and damage.

Specified torques
3.10 Removing and installing fuel rail


Removing
– Remove high-pressure pipes between fuel rail and high-pres‐
sure pump ⇒ page 281 .
– Remove high-pressure lines between fuel rail and injectors
⇒ page 284 .
satelettronica
AG. Volkswagen AG d
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Disregard position -1-.
– Remove high pressure reservoir (rail element) -3-.

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Install in reverse order of removal, observing r se following:
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erm
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diagnostic tester, 01 - Systems capable of self-diag-
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is n
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system EDC 17 , 01 - Engine electronics functions ,
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01 - Resetting engine electronics learnt values .
t to the co
tester.
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Specified torques
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4 Air filter
⇒ “4.1 Assembly overview - air filter housing”, page 288
⇒ “4.2 Removing and installing air filter housing”, page 289
4.1 Assembly overview - air filter housing

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1 - Air filter - maintenance indi‐ ed
by ua
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❑ Depending on equip‐ ss a ac
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2 - Air filter housing
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❑ Upper part
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⇒ page 289
hole
spec
3 - Air filter element
es, in part or in w
t to the co
⇒ Maintenance ; Book‐
satelettronica
let 20.1
rrectness of i
4 - Air filter housing
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❑ Lower part
nf
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⇒ page 289
orm
m
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5 - Plug
om
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or c
6 - Bracket
thi
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❑ Installed on wheel hous‐

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8 - Water drainage pipe
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9 - Bracket
❑ Installed on longitudinal
carrier
10 - Pop rivets
❑ Use pop rivet pliers -
VAS 5072A- to replace
11 - Bolt
❑ 8 Nm
12 - Intake hose
13 - Clip
❑ 5.5 Nm
14 - Intake connecting pipe
❑ With heater connection depending on equipment
15 - Bleeder hose
16 - Grommet
17 - Bolt
❑ 8 Nm

18 - Clip
❑ 5.5 Nm
19 - Intake hose
20 - Intake manifold sender - GX9-
❑ With intake manifold sender - G71- .
21 - Bolts olkswage es n
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❑ Qty. 2 d b ua
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❑ 3.5 Nm autho
or
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22 - Clip
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❑ 5.5 Nm
an
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rm
ab
23 - Air mass meter - G70-
pe
ility
ot
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24 - O-ring
hole
spec
es, in part or in w
t to the co
satelettronica
4.2 Removing and installing air filter hous‐
rrectness of i
ing
l purpos
nform
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Removing
– Release locking lug -2-.
– Pull off intake hose -1- from air filter housing.
4. Air filter 289


– Remove intake manifold sender - GX9- -4- and lay aside.
swage es n
– Unscrew bolt -1-. yV
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satelettronica
d b ua
ran
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– Release and pull off water drainage pipe -3- on air filter hous‐
tho tee
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ss
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nl
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nform
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at
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io
– Carefully pull out air filter housing -2- from guides.
n
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Installing
at
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Specified torques
Co
Cop py
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5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 291
⇒ “5.2 Removing and installing intake manifold”, page 292
⇒ “5.3 Removing and installing throttle valve module GX3 ”, page
295
⇒ “5.4 Removing and installing intake manifold flap valve N316 ”,
page 296
⇒ “5.5 Removing and installing vacuum unit for intake manifold”,
page 296
5.1 Assembly overview - intake manifold
1 - Bolts
❑ Qty. 3
❑ 8 Nm
2 - Throttle valve module -
GX3-
satelettronica
nection must not be
damaged.
❑ Removing and installing agen
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3 - Seal horis nte
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4 - Seal
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5 - Clip
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6 - Bolts
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hole
spec
❑ Qty. 2
es, in part or in w
❑ 8 Nm
t to the co
7 - Tube
rrectness of i
❑ Install so that compo‐

l purpos
nent is not under tension

❑ From exhaust gas recir‐
nform
ercia
culation cooler
m
a
com
ti
⇒ page 363
on in
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thi
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⇒ page 369
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❑ 6 Nm
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9 - Vacuum unit
10 - Intake manifold
5. Intake manifold 291

11 - Charge air pressure sender - G31-

12 - Bolts
❑ Qty. 2
❑ 8 Nm
13 - Bolts
❑ Qty. 9
❑ 20 Nm
14 - Seal
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5.2 Removing
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A n AG d
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Special tools andriworkshop
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♦ Torque wrench
ss
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pt
du
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an
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ab
ility
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, is n
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spec
es, in part or in w
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♦ Insert tool, 13 mm - T10535-

nform
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Removing
position .
– Disconnect all connectors of glow plugs.
– Disconnect electrical connector of fuel pressure sender -
G247- ⇒ Item 10 (page 270) .
– Unclip pipe from guides -3-.
– Remove front exhaust gas recirculation pipe ⇒ page 369 .
– If fitted, unscrew bolts -1-.
satelettronica
– If fitted, remove bracket -2-.
– Disconnect electrical connector of coolant valve for cylinder
head - N489- ⇒ Item 2 (page 188) .
– Remove high-pressure line between high-pressure pump and
high-pressure accumulator (fuel rail) ⇒ page 281 .
– Open clips ⇒ page 314 , and pull both fuel return hoses
⇒ page 314 off high-pressure pump.
AG. Volkswagen AG d
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– Release vacuum pipe -1-.

– Detach vacuum pipe -3-.
ss o
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– Remove coolant temperature sender - G62- ⇒ page 200 .

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– Move coolant pipes -2- aside slightly with coolant hoses still
attached along with charge air cooler.
– If fitted, disconnect electrical connectors -1-.
satelettronica
– If fitted, pull off vacuum hose -2-.
– Unclip wiring harness -3- and lay aside.
AG. Volkswagen AG d
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– Loosen bolt -9- using insert tool, 13 mm - T10535- .
– Push intake manifold -10- towards left-hand side of vehicle.
Remove intake manifold -10- when doing this.
Installing
– Renew charge air cooler pressure hoses after removing.
– Renew exhaust gas recirculation pipe following removal.
– Install exhaust gas recirculation pipe free of stress. To achieve
this, start all bolts hand-tight first, and tighten them diagonally
and alternately after.
Specified torques
satelettronica
5.3 Removing and installing throttle valve

module - GX3-
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es, in part or in w
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Removing
– Carefully pull out throttle valve module - GX3- -3- slightly.
– Remove throttle valve module - GX3- -3-.
Installing
– Renew charge air cooler pressure hoses after removing.
Specified torques
lkswage es n
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5.4 Removing and installing intake manifold o tee
satelettronica
th or
u
flap valve - N316-
a ac
ss
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un
pt
Removing
an
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ab
ility
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– Loosen coolant expansion tank on lock carrier to facilitate ac‐
is n
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cessibility; coolant hoses remain connected.
ole,
spec
t to the co
– Release spreader rivets -3-.
– Detach vacuum hoses -4-. rrectne
– Remove intake manifold flap valve - N316- -2-.

s
Installing
s o
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form
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Specified torques
atio
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♦ ⇒ “1.2 Assembly overview - solenoid valves”, page 225

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5.5 Removing and installing vacuum unit for
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intake manifold

Removing
– Remove bracket for exhaust gas recirculation cooler
⇒ page 377 .
satelettronica
– Unclip vacuum pipe -2-.
– Remove vacuum unit -1-.
Installing n AG. Volkswagen AG do
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Specified torques auth or
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♦ ⇒ “5.1 Assembly overview - intake manifold”, page 291 ce
e
nl
pt
du
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page 363
erm
ab
ility
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6 Senders and sensors

⇒ “6.1 Removing and installing fuel pressure regulating valve
N276 ”, page 298
⇒ “6.2 Checking fuel pressure regulating valve N276 ”,
page 300
⇒ “6.3 Removing and installing fuel pressure sender G247 ”, page
301
⇒ “6.4 Removing and installing air mass meter G70 ”, page 303
⇒ “6.5 Removing and installing pressure differential sender G505
”, page 305
⇒ “6.6 Removing and installing charge air temperature sender
ahead of charge air cooler G810 ”, page 307
⇒ “6.7 Removing and installing charge air temperature sender af‐
ter charge air cooler G811 ”, page 307 . Volkswage n AG n AG d
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⇒ “6.8 Removing and installing fuel temperature
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satelettronica
⇒ “6.9 Removing and installing intakes amanifold
ut sender GX9 ”, ra
c
page 309 s
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un
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6.1 Removing and installing fuel pressure
an
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regulating valve - N276-
ab
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♦ Insert tool, 30 mm - T10553-

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Removing
rrectness of i
– Remove fuel rail ⇒ page 285 .
l purpos
– Before removal, clean area around thread for fuel pressure

regulating valve - N276- using e.g. commercial cleaning solu‐
tion.
nform
ercia
satelettronica
• Make sure no dirt gets into opening in high-pressure reservoir.
m
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ion
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• Clean carefully; cleaning solvent must not enter the connector.
in t
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ate
– Dry fuel pressure regulating valve - N276- .
do
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– Mark installation position of fuel pressure regulating valve, and

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reinstall it in this installation position.
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6. Senders and sensors 299

Transporter 2016 ➤ agen
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– Unscrew fuel pressure regulating valve - N276-au-1-.
th
Insert tool, or
ac
30 mm - T10553- can be used for this purposess if necessary.
ce
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nl
pt
– Extract dirt from hole of fuel rail -2- (threads and sealing sur‐
du
an
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face). Do not use tools or other instruments for this purpose.
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– Seal off open connection in high-pressure reservoir with clean
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plug.
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• Fuel pressure regulating valve - N276- must be renewed each
time after removing.
rrectness of i
– The beginning of the thread and the deformable sealing lip of
l purpos
the fuel pressure regulating valve - N276- must be coated with

diesel fuel.
nf
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– Align new regulating valve so that electrical connector is free
orm
of tension.
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electronics learnt values .

tester.
Specified torques
6.2 Checking fuel pressure regulating valve

- N276-
♦ -Measuring container-

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c
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Procedure
pt
du
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ab
CAUTION
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es, in part or in w
t to the co
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– Remove fuel return hose from high-pressure accumulator.

– Seal open fuel return line connection with a clean blanking
nform
ercia
plug from engine bung set - VAS 6122- .

m
at
om
– Connect auxiliary hose to return connection of high-pressure
ion
c
accumulator.
in t
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– Hold test hose in measuring beaker.
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1) Check with engine running

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op
– Start engine and run at idling speed. C py
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• Specification: return rate 0 ml/30 seconds. op Vo
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• Droplets are allowed
AG.
If the specification is not attained, the fuel pressure regulating

valve - N276- is defective.
2) Check with engine running
If condition in "1." is met:
increase engine speed ≥ 2,000 rpm.
• Specification: return volume 0 ml
• If the specification is not attained, the fuel pressure regulating
3) If it is no longer possible to start engine
Carry out check at starter speed.
• Specification: return volume 0 ml
• If the specification is not attained, the fuel pressure regulating
6.3 Removing and installing fuel pressure

sender - G247-

gen AG
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tion in
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satelettronica
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Cop py
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♦ Socket, 27 mm - T40218-
AG.

Removing
– Detach wiring harness from charge air cooler bracket.
– Before removal, clean area around thread for fuel pressure
sender - G247- using, for example, commercially available
cold cleaning solvent.
• Make sure no dirt gets into opening in high-pressure reservoir.
• Clean carefully; cleaning solvent must not enter the connector.
– Dry fuel pressure sender - G247- .
CAUTION
satelettronica
– Unscrew fuel pressure sender - G247- -2-.
– Extract dirt from hole of high pressure accumulator (threads
and sealing surface). Do not use tools or other instruments for
this purpose.
– Seal off opening in high-pressure reservoir with a plug.
Installing
AG. Volkswagen AG d
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au ra
♦ Check that sealing surfaces (deformable
ss sealing lip) and c
threads on fuel pressure sender - G247- are undamaged. Re‐
ce
le
un
pt
using fuel pressure sender - G247- if possible if it has been

an
d
itte
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tested OK.
erm
ab
ility
ot p
♦ Also check sealing surface in hole of fuel rail.

wit
is n
h re
ole,
– The beginning of the thread and the deformable sealing lip of

spec
the fuel pressure sender - G247- must be coated with diesel

fuel.
t to the co

rrectne
Specified torques
ss o
cial p
f in
6.4 Removing and installing air mass meter

form
mer
- G70-
atio
om
n
c

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
satelettronica
– Remove air mass meter - G70- -1-.
Installing
Install in reverse order of removal,n Aobserving the
G. Volkswage following:
n AG
age does
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y Vol gu
b ara
ed
Note horis nte
eo
t
au ra
c
ss
If the air filter element is very dirty or wet, particles of dirt or water
ce
e
nl
may reach the air mass meter and falsify the measured air mass
pt
du
an
value. This would lead to loss of power, since a smaller injection

itte
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erm
quantity is calculated.
ab
ility
ot p
wit
, is n
• Always use Genuine part for air filter element.

h re
hole
spec
• Always renew seal if damaged (infiltrating air).

es, in part or in w
t to the co
• Use a silicone-free lubricant to install the air hose and seal.

• Hose unions and air intake pipes and hoses must be free of
rrectness of i
• Secure all hose connections with the correct type of hose clips
l purpos

– Check air mass meter - G70- and air guide hose (clean air
nf
ercia
side) for salt residue, dirt and leaves.

rm
m
atio
m
– Check intake duct for contamination up to air filter element. If

o
n in
c
contamination is found, remove salt residues, dirt and leaves

or
thi
e
from top and bottom part of air filter housing by flushing it out
t
sd
iva
or using a vacuum cleaner if necessary.

o
r
rp
cu
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m
f
en
ng
Specified torques
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

6.5 Removing and installing pressure differ‐

ential sender - G505-
⇒ “6.5.1 Removing and installing pressure differential sender
G505 , vehicles with bi-turbo”, page 305
⇒ “6.5.2 Removing and installing pressure differential sender
G505 , vehicles with single turbo”, page 305
6.5.1 Removing and installing pressure differ‐

ential sender - G505- , vehicles with bi-
turbo
satelettronica
Removing
– Lay wiring harness aside over heat guard -4-.
– Open heat insulation sleeve -4-. agen
AG. Volkswagen AG d
oes
olksw not
– Disconnect electrical connector -3-. ed by
V gu
ara
ris nte
o
– Unscrew bolt -1-. aut
h eo
ra
ss c
– Before disconnecting hoses, spray with suitable releasing
ce
e
nl
pt
agent.
du
an
itte
y li
– Pull off hoses -5- carefully and in straight line from pressure
erm
ab
ility
differential sender - G505- -2-.

ot p
wit
, is n
Installing
h re
hole
spec

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

Specified torques
l purpos

nform
ercia
tion”, page 355

m
at
om
6.5.2 Removing and installing pressure differ‐

ion
c
in t
or
ential sender - G505- , vehicles with sin‐

his
ate
do
riv
gle turbo
p
cum
for
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

satelettronica
agen oes
olksw not
yV gu
– Unscrew bolts -1-. ised b ara
nte
or eo
h
– Move clear wiring harness -5-. s aut ra
c
s
– Open heat insulation sleeve -4-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Pull off hoses -6-.
h re
ole,
spec
– Remove pressure differential sender - G505- -2- with hoses
-6- and retainer -8-. t to the co

Installing
rrectne
s
leaks.
s o
cial p
f in
Specified torques
form
mer

atio
m
tion”, page 355

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

6.6 Removing and installing charge air tem‐

perature sender ahead of charge air
cooler - G810-
Removing
– Unscrew charge air temperature sender before charge air
cooler - G810- -2-.
Installing
Specified torques
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
6.7 Removing and installing charge air tem‐
th or
au ac
ss
perature sender after charge air cooler -
ce
le
un
pt
G811-
an
d
itte
y li
erm
ab
Removing
ility
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wit
is n
h re
ole,
spec
t to the co
– Unscrew charge air temperature sender after charge air cooler
- G811- -2-.
Installing rrectne

ss o
Specified torques
cial p
f inform

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
6.8 Removing and installing fuel tempera‐
co Vo
by lksw
cted agen
Prote
ture sender - G81-
AG.

Removing
CAUTION
satelettronica
– Unscrew fuel temperature sender - G81- -2-.

Installing
– Checking fuel system for leaks ⇒ pagen A263
G. Vo. lkswagen A
age G do
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Specified torques by Vol ot g
ua
ed ran
ris tee
Component tho Specified torque or
au ac
ss - G81-
Fuel temperature sender 2 Nm
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
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pyri by
Vo
o
308
by c lksw
cted
Rep. gr.23 - Mixture preparation - injection
agen
Prote AG.
6.9 Removing and installing intake manifold

sender - GX9-
Removing
– Unscrew intake manifold sender - GX9- -2- and remove.
Installing
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
satelettronica
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.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

7 Engine control unit

⇒ “7.1 Removing and installing engine (motor) control unit J623
”, page 310
7.1 Removing and installing engine (motor)

control unit - J623-
Removing
– If engine control unit - J623- was renewed, learnt values must
be reset ⇒ Vehicle diagnostic tester, 01 - Systems capable
of self-diagnosis , 01 - Diesel direction injection
and preglow system EDC 17 , 01 - Engine electronics
functions , Bringing into operation .
Note
satelettronica
If the adaption values of the injectors cannot be read from the old
(defective) engine control unit - J623- , the adaption values must
be entered in the new engine control unit - J623- manually and
adjusted.

– Remove electronics box cover ⇒ Electrical system; Rep. gr.
97 ; Relay carrier, fuse carrier, electronics boxes; Removing
and installing electronics box .
– Disconnect connectors -2- and -3- from engine control unit -
J623- -1-.
swage es n
– Pull engine control unit - J623- -1- in -direction by Vof arrow- out of
olk ot g
ua
electronics box -2-. ir se
d ran
tee
tho
or
Installing au ac
ss
ce
e

nl
pt
du
an
itte
– If the engine control unit - J623- has been renewed, the re‐
y li
erm
ab
ducing agent tank - VX85- must be filled completely ⇒ Main‐

ility
ot p
tenance ; Booklet 20.1 ; Descriptions of work; AdBlue®

wit
, is n
(reducing agent) .
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
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m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
310
Prote AG.
Rep. gr.23 - Mixture preparation - injection
lkswage es n
o ot g
byV Transporter
ua 2016 ➤
d ran
ir se
4-cylinder commontho rail engine (2.0 l, 4V, turbocharger) - Edition tee
o 03.2019
au ra
c
ss
ce
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nl
8 High-pressure pump
pt
du
an
itte
y li
erm
ab
⇒ “8.1 Assembly overview - high-pressure pump”, page 311
ility
ot p
wit
⇒ “8.2 Removing and installing high-pressure pump”, page 312
, is n
h re
hole
⇒ “8.3 Checking high-pressure pump”, page 315
spec
es, in part or in w
8.1 Assembly overview - high-pressure pump
t to the co
rrectness of i
1 - Fuel hose
l purpos
2 - Clip
3 - Fuel hose
nform
ercia
4 - Clip
m
at
om
i
on
c
in t
or
❑ Between fuel rail and
his
te
high-pressure pump
a
do
priv
c
um
for
en
g
⇒ page 281
n
t.
satelettronica
yi Co
Cop py
t. rig
gh ht
yri by
❑ Between fuel rail and cop Vo
by lksw
cted
high-pressure pump
agen
Prote AG.

⇒ page 281
⇒ page 312
8 - Ancillary bracket
⇒ page 39
9 - Bolt
❑ 20 Nm +180°
10 - Bolt
❑ Bi-turbo: 20 Nm +90°
❑ Mono-turbo: 20 Nm
+45°
11 - Nut
❑ Use counter-hold tool -
T10051- to loosen and tighten
❑ 95 Nm
12 - High-pressure pump toothed belt pulley
13 - Hub
❑ To remove, use puller -T10489-
14 - Bolt
❑ Bi-turbo: 20 Nm +90°
❑ Mono-turbo: 20 Nm +45°
8. High-pressure pump 311

8.2 Removing and installing high-pressure

pump
♦ Puller - T10489-
satelettronica
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
♦ Pin - T10492-
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
Removing
te
sd
iva
o
r
– Remove high-pressure pipe between fuel rail and high-pres‐

rp
cu
o
sure pump ⇒ page 281 .

f
en
ng
t.
yi Co
op
– Remove charge air cooler ⇒ page 250 .
C py
t. rig
gh ht
yri by
– Remove throttle valve module - GX3- ⇒ page 295 .
op Vo
by c lksw
cted agen
Prote
AG.

– Apply counter-hold tool - T10051- to high-pressure pump

sprocket.
– Tighten nut -1- by hand.
– Pull off locking pin - T10492- , and slowly turn high-pressure
pump shaft to a position in which it is not under tension.
– Unscrew nut -1-, and remove counterhold tool - T10051- .
– Detach high-pressure pump sprocket.
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
Vehicles with single turbocharger
y li
erm
satelettronica
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.
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op py
Continued for all vehicles t. C rig
gh ht
pyri by
– Turn back spindle on puller - T10489- .
co Vo
by lksw
cted agen
Prote AG.
– Fit puller - T10489- , and guide it into guides.
– Engage puller - T10489- by turning hub of high-pressure pump
in clockwise direction.
– Pull off hub of high-pressure pump, counterholding on bell of
puller - T10489- while doing so.


– Pull off fuel return hoses -2-.
– Carefully remove high-pressure pump -5-.
Installing
satelettronica
– Fit hub -arrow- to high-pressure pump shaft.
• The parallel key on the high-pressure pump shaft must engage
in the groove in the hub.
wage
– Place high-pressure pump sprocket on hub. yV
olks es n
ot g
b ua
ed ran
• Contact surface between counterhold and toothedhor belt sprock‐
is tee
et must be free of oil. 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
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.

– Screw nut -1- onto thread of high-pressure pump shaft.

– Fit counterhold tool to toothed belt pulley, and tighten nut -1-
by hand.
– Use counterhold tool - T10051- to turn high-pressure pump
toothed belt pulley until it can be locked in position with locking
pin - T10492- . To do this, insert locking pin - T10492- into fork
on hub and into hole in ancillary bracket located behind fork.
– Loosen nut -1- again.
• It should just be possible to turn high-pressure pump toothed
belt pulley without axial movement.
– Install toothed belt ⇒ page 104 .
– Reset learnt values of volume metering unit ⇒ Vehicle diag‐
nostic tester, 01 - Systems capable of self-diagnosis ,
01 - Diesel direction injection and preglow system
satelettronica
EDC 17 , 01 - Engine electronics functions , 01 - Re-
setting engine electronics learnt values .

tester. G. Volkswagen
A AG do
agen es n
Specified torques olksw ot g
V
d by ua
ran
e
♦ ⇒ “8.1 Assembly hori overview - high-pressure pump”, page 311
s tee
aut or
ac
s
Component s Specified torque
ce
le
un
pt

an
d
itte
y li

rm
ab
pe
ility
ot
wit
8.3 Checking high-pressure pump

, 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.

♦ Socket - T40055-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
♦ Engine bung set - VAS 6122- orise nte
eo
th
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
♦ High-pressure pump tester - VAS 6683-

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.

Procedure
– Extract dirt from taper seat of union nuts, clean fuel line and
line head before removal using cold cleaning solvent and dry
CAUTION
The fuel system is pressurised. AG. Volkswagen AG d
agen oes
Danger of injury through fuel spray. olksw not
V gu
d by ara
– Wear protective goggles. orise nte
h eo
– Wear protective gloves. aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Unscrew union nut -2- from no. 1 cylinder.
ot p
wit
, is n
– Loosen union nut -4- on fuel rail 2 turns.
h re
hole
spec
– Install high-pressure pump tester - VAS 6683- -3- on union nut
es, in part or in w
-2- and tighten by hand.
t to the co
satelettronica
– Install union nut -4- on fuel rail and tighten by hand.
rrectness of i
– Tighten union nuts -2- and -4-.
l purpos
– Seal open connections using clean plugs from engine bung

set - VAS 6122- .
nform
ercia
– Disconnect all 4 connectors of injectors.

m
– Start engine.
at
om
ion
c
• Fuel must be supplied to the high-pressure pump tester - VAS
in t
or
his
e
6683- .
at
do
priv
c
Installing
um
for
en
ng
t.
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Co
Cop py
t. rig
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pyri by
Vo
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by c
Note
lksw
cted agen
Prote AG.

lines.
checks:
mation and cracks.
tions and damage.

Specified torques

9 Lambda probe
⇒ “9.1 Assembly overview - Lambda probe”, page 318
⇒ “9.2 Removing and installing Lambda probe 1 before catalytic
converter GX10 ”, page 319
⇒ “9.3 Removing and installing control unit for sensor electronics
J849 / particulate sensor G784 ”, page 321
⇒ “9.4 Removing and installing control unit for NOx sender 2
J881 / NOx sender 2 G687 ”, page 323
9.1 Assembly overview - Lambda probe

⇒ “9.1.1 Assembly overview - Lambda probe, without barrier”,
page 318
⇒ “9.1.2 Assembly overview - Lambda probe, with slip catalytic
converter”, page 319
9.1.1 Assembly overview - Lambda probe, without barrier
satelettronica
1 - Lambda probe 1 before cat‐
alytic converter - GX10-
❑ With Lambda probe -
G39-
❑ With Lambda probe AG. Volkswagen AG d
heater - Z19- . agen oes
olksw not
V gu
❑ Removing and installing d by ara
ise nte
⇒ page 319 ut
hor eo
a ra
❑ 52 Nm ss c
ce
e
nl
pt
2 - Control unit for sensor elec‐
du
an
itte
tronics - J849- / particulate
y li
erm
ab
sensor - G784-
ility
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❑ Control unit and probe
wit
, is n
form one part

h re
hole
spec
es, in part or in w
⇒ page 321 t to the co

❑ 52 Nm
3 - Control unit for NOx sender
rrectness of i
2 - J881- / NOx sender 2 -

G687-
l purpos

form one part
nf
ercia

rm
m
⇒ page 323
atio
om
n in
❑ 52 Nm
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

9.1.2 Assembly overview - Lambda probe, with slip catalytic converter
1 - Lambda probe 1 before cat‐

alytic converter - GX10-
❑ With Lambda probe -
G39-
❑ With Lambda probe
heater - Z19- .
⇒ page 319
❑ 52 Nm
2 - Control unit for NOx sender
2 - J881- / NOx sender 2 -
G687-
form one part
⇒ page 323
❑ 52 Nm
satelettronica
3 - Control unit for sensor elec‐
tronics - J849- / particulate
sensor - G784-
form one part
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 321 lkswage es n
o ot g
yV ua
❑ 52 Nm ir se
d b ran
o tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
9.2 Removing and installing Lambda probe

rrectness of i
1 before catalytic converter - GX10-

l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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f
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ng
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Cop py
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pyri by
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co lksw
by
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9. Lambda probe 319

en AG-. VEdition
olkswage03.2019
n AG
ag does
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y Vol gu
♦ Socket 22 mm - T10491- ed
b ara
nte
oris eo
th
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
Removing
l purpos

Electrical connectors
nform
ercia
1- For exhaust gas temperature sender 2 - G448- , black

m
at
om
ion
2- For exhaust gas temperature sender 3 - G495- , brown
c
in t
or
his
e
satelettronica
t
3- For temperature sensor 3 for exhaust gas recirculation -

a
do
riv
G949- , beige
p
cum
for
en
ng
4- For Lambda probe 1 before catalytic converter - GX10- ,

t.
yi Co
op
black C py
t. rig
gh ht
yri by
– Disconnect electrical connector -4-. cop Vo
by lksw
cted agen
Prote
– Unclip wiring harness from bracket -5-.
AG.
– Lay aside wiring harness; detach cable ties if necessary.


– Unclip wiring harness from guide -1-.
CAUTION
Danger of severe burns from hot exhaust system.
Risk of burns to hands and other parts of body.
– Allow exhaust system to cool.
– Lay aside wiring harness and separate any cable ties as nec‐
essary.
– Unscrew Lambda probe 1 before catalytic converter - GX10-
-2-.
Installing
– Attach cable ties in all the same places when installing.
• New lambda probes are coated with an assembly paste. The
paste must not get into the slots on the Lambda probe body.
• In the case of a used Lambda probe, grease only the thread AG. Volkswagen AG d
agenthe
satelettronica
with high-temperature paste. The paste must not get
ol into
ksw
oes
not
slots on the Lambda probe body. ed by
V gu
ara
is nte
or
• High-temperature paste ⇒ Electronic parts
au
th catalogue (ETKA) eo
ra
ss c
Specified torques
ce
le
un
pt
an
d
♦ ⇒ “9.1 Assembly overview - Lambda probe”, page 318

itte
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rm
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9.3 Removing and installing control unit for
ot
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sensor electronics - J849- / particulate
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sensor - G784-
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9. Lambda probe 321

Removing
Note
♦ The fitting locations may differ depending on the exhaust

emission standard.
♦ The control unit for sensor electronics - J849- and particulate
sensor - G784- form one part.
CAUTION

Version without slip catalytic converter
satelettronica
– Remove nut -2-.
– Unclip and move aside wiring harness; separate any cable ties
-3- as necessary. agen
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– Unscrew particulate sensor - G784- -4-, and detach it withed by gu
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Version with slip catalytic converter

– Remove nut -2-.
– Unclip and lay aside wiring harness; separate any cable ties
as necessary.
– Unscrew particulate sensor - G784- -4-, and detach it with
control unit for sensor electronics - J849- -3-.
Installing olkswage es n
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h re
Electronic parts catalogue (ETKA)
hole
spec
es, in part or in w
• During installation, it is essential that the wiring harness of the
t to the co
satelettronica
Lambda probe is re-attached in the same places. The lambda
probe cable must be prevented from touching the exhaust
pipe.
rrectness of i
Specified torques
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NOx sender 2 - J881- / NOx sender 2 -

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9. Lambda probe 323

Removing
Note
♦ The fitting locations may differ depending on the exhaust

emission standard.
♦ Control unit for NOx sender 2 - J881- / NOx sender 2 - G687-
form one part.
CAUTION

Version without slip catalytic converter
satelettronica
as necessary.
– Remove nut -4-.
– Unscrew NOx sender 2 - G687- -2-, and detach it together with n AG. Volkswagen A
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Version with slip catalytic converter

as necessary.
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control unit for NOx sender ir se 2 - J881- -3-.
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• In the case of a used Lambda probe, grease only the thread
es, in part or in w
with high-temperature paste. The paste must not get into the
t to the co
slots on the Lambda probe body.
• High-temperature paste ⇒ Electronic parts catalogue (ETKA)
rrectness of i
satelettronica
Specified torques
l purpos
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9. Lambda probe 325

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G. Volkswagen n AG do
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26 – Exhaust system
ed ran
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1 Exhaust pipes and silencers
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⇒ “1.1 Assembly overview - silencers”, page 326
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wit
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⇒ “1.3 Removing and installing front silencer”, page 328
spec
⇒ “1.4 Removing and installing rear silencer”, page 328
t to the co
⇒ “1.5 Aligning exhaust system free of stress”, page 330
⇒ “1.6 Checking exhaust system for leaks”, page 330
rrectne
⇒ “1.7 Installation position of clamp”, page 331
ss o
1.1 Assembly overview - silencers
cial p
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mer
atio
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1 - Bracket
o
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2 - Bolts
satelettronica
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❑ Qty. 2
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en
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4 - Front silencer
❑ Separating exhaust
pipes from silencers
⇒ page 327
❑ Aligning exhaust sys‐
tem free of tension
⇒ page 330 .
⇒ page 328
5 - Clip
❑ Aligning exhaust sys‐
tem free of tension
⇒ page 330 .
⇒ page 331
❑ Tighten threaded con‐
nections evenly.
❑ 31 Nm
6 - Coupling point
❑ Separating exhaust
pipes from silencers
⇒ page 327
❑ During production, front
and rear silencers are
installed as a single
component.
❑ In the event of repairs, use a double clamp to connect them
7 - Rear silencer
❑ With short or long tailpipe depending on equipment
❑ Separating exhaust pipes from silencers ⇒ page 327
326 Rep. gr.26 - Exhaust system

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❑ Aligning exhaust system free of tension ⇒ page 330 .
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1.2 Separating exhaust pipes from silencers hole
spec
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♦ Chain-type pipe cutter - VAS 6254-
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♦ or body saw - VAS 6780-
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Procedure
CAUTION
CAUTION
Risk of injury from swarf being flung into air.
Irritation and injury to skin and eyes possible.
– Mark cutting location -a- = 116.5 mm on front silencer exhaust

pipe -1-.
– Cut through exhaust pipe at right angles at separating point
using chain pipe cutter - VAS 6254- or body saw - VAS 6780- .
1. Exhaust pipes and silencers 327

olks
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– Align double clamp -2- between front silencerrise -1- and rear si‐ nte
tho eo
lencer -3- when installing. s au ra
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• The distance -a- must be approx. 5 mm.
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– Tighten threaded connections -4- of double clamp -2- in this
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position.
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1.3 Removing and installing front silencer
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Removing
– Separating front silencer from rear silencer ⇒ page 327 .
– Loosen double clamp -1-.
CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following work.

– Remove front silencer -3- with aid of second mechanic.
Installing
– Align exhaust system free of stress ⇒ page 330 .
Specified torques
♦ ⇒ “1.1 Assembly overview - silencers”, page 326
1.4 Removing and installing rear silencer


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Removing
Note
Diagram shows version with long tailpipe.
– Separating front silencer from rear silencer ⇒ page 327 .

CAUTION
– Remove rear silencer -2- with aid of second mechanic.

Installing
Specified torques
1. Exhaust pipes and silencers 329

1.5 Aligning exhaust system free of stress

Procedure
CAUTION
• The exhaust system must be aligned when cold.

Centre silencer
– Loosen threaded connections of clamps.
– Push centre silencer -2- towards front, until dimension -a- of
5 mm has been attained on front bracket -1- and dimension
-b- of 7 mm on rear bracket -3-.
– Tighten front clamp. wage
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satelettronica
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Rear silencer
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– Push rear silencer -2- towards front, until dimension -a- of
wit
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9 mm has been attained on front bracket -1- and dimension
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hole
-b- of 11 mm on rear bracket -3-.
spec
es, in part or in w
– Tighten rear clamp.
t to the co
rrectness of i
l purpos
nform
mercia
1.6 Checking exhaust system for leaks

com
tion in
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CAUTION
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– Start engine and run it at idling speed.
Prote AG.
– 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 the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.

1.7 Installation position of clamp

CAUTION
Installation position of clamp

– Install clamp at angle shown in illustration.
• Angle -α- = approx. 45°.
• Bolted connection facing towards right.
• Nuts upwards.
satelettronica
AG. Volkswagen AG d
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331
Prote AG.
1. Exhaust pipes and silencers
AG. Volkswagen AG d
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⇒ “2.1 Assembly overview
aut
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- emission control”, page 332 ra
ss c
⇒ “2.2 Removing and installing catalytic converter”, page 335
ce
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⇒ “2.3 Removing and installing particulate filter”, page 338
itte
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2.1 Assembly overview - emission control
ility
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hole
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⇒ “2.1.2 Assembly overview - emission control, all wheel drive”,
es, in part or in w
t to the co
page 334
2.1.1 Assembly overview - emission control
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1 - Catalytic converter
nf
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⇒ page 335
orm
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2 - Seal
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⇒ page 333
5 - Bracket
6 - Bolts
⇒ page 333
7 - Clip
❑ 8 Nm
8 - Seal
9 - Particulate filter
❑ A slip catalytic converter
can be fitted in the ex‐
haust pipe depending
on the emission stand‐
ard.
⇒ page 338
10 - Clip
❑ 31 Nm
11 - Bolts
❑ 23 Nm
12 - Bolts
❑ 23 Nm

13 - Bracket
14 - Bolt
❑ Observe specified torque and tightening sequence ⇒ page 333
Tightening sequence for catalytic converter, front-wheel drive

Dismantling Measures
and assem‐
bling proce‐
dure
1 Position bracket -1- on centre hex stud -3- and
tighten nut -2- by hand.
2 Place catalytic converter -4- with gasket -5- and
clamp -6- on turbocharger.
3 Place catalytic converter -4- on engine support
-7-.
4 Screw in bolt -9- hand-tight.
5 Tighten clamp -6- to 8 Nm.
satelettronica
6 Screw in bolt -9- on engine support -7- and
tighten to 40 Nm. Use flared ring attachment,
AF 16 - VAS 6854/1- and adapter - VAS 6948-
to tighten.
7 Tighten bolts -10- on bracket to 23 Nm.
8 Tighten nut -2- to 40 Nm.
9 Tighten bolt -8- on bracket -1- to 40 Nm.
lkswage es n
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2. Emission control 333

2.1.2 Assembly overview - emission control, all wheel drive
1 - Catalytic converter
⇒ page 335
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❑ 8 Nm
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spec
5 - Seal
es, in part or in w
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6 - Particulate filter
❑ A slip catalytic converter
rrectness of i
satelettronica
can be fitted in the ex‐
l purpos
haust pipe depending

on the emission stand‐
ard.
nf
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⇒ page 338
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7 - Clip
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agen
10 - Bracket
11 - Bolts
❑ Observe specified tor‐
que and tightening sequence ⇒ page 335
12 - Bracket
13 - Bolt
❑ Observe specified torque and tightening sequence ⇒ page 335

Tightening sequence for catalytic converter, all wheel drive

Dismantling Measures
and assem‐
bling proce‐
dure
1 Install bracket -1- with bolts -2- on bevel box
-8-.
olkswagen AG
2 Place catalytic en AG. V -3-
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5 Install bolt -7- and tighten to 40 Nm.

un
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6 Tighten bolts -2- on bracket -1- to 20 Nm.
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2.2 Removing and installing catalytic con‐
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verter
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♦ Torque wrench - VAS 6854-

♦ Flared ring attachment AF 16 - VAS 6854/1-
♦ Adapter - VAS 6948-
satelettronica
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– Disconnect connectors -1-, -2- and -4-.

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– Open heat insulation sleeve -1-.
CAUTION

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– Unscrew hor bolt -3-. eo
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– Unscrew
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– Loosen nut -5- 2 turns.

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– Remove catalytic converter -1-.

spec
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Vehicles with all-wheel drive

– Remove catalytic converter -1-.
Installing
Vehicles with all-wheel drive
– Note tightening sequence ⇒ page 335 .
Vehicles with front-wheel drive
– Note tightening sequence ⇒ page 333 .
– Tighten bolt ⇒ Item 4 (page 332) using flared ring attachment,
AF 16 - VAS 6854/1- and adapter - VAS 6948- .
n AG. Volkswagen A G do
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♦ ⇒ “2.1 Assembly oris overview - emission control”, page 332 tee o
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2.3 Removing and installing particulate filter
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Removing
CAUTION
– Remove floor heat shieldn⇒ AGGeneral

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– Unscrewutbolt
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– Loosen lock washers -2-.
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– Pull cover -3- downwards a little in direction of -arrow-.
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– Separate cable ties -1- if fitted.
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– Unclip wiring harness from guide -3-.
rrectness of i
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ion
c
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– Remove nut -2-.
– Unclip wiring harness from retainer -3-.
– Loosen double clamp -4-.

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ce
e
nl
pt
du
an
itte
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erm
ab
ility
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CAUTION
h re
hole
Risk of injury caused by escaping reducing agent.
spec
es, in part or in w
The reducing agent may cause eye and skin irritations as well
t to the co
as injuries to the respiratory system and poisoning.
rrectness of i
l purpos

– Make sure that a sufficient amount of fresh air is supplied.
In closed areas, switch on the exhaust gas extractor system.
nform
mercia
at
om
– Place a clean cloth underneath to catch escaping reducing
ion
c
agent.
in t
or
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ate
do
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or
Note
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satelettronica
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The metering line, coolant hoses and electrical connector remain
. C rig
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attached.
rig by
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Prote AG.
– Remove injector for reducing agent - N474- -4-.
CAUTION

– Remove exhaust pipe -1- with aid of second mechanic.
Installing
– If particulate filter was replaced, adapt learnt values for par‐
ticulate filter ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “3.1 Assembly overview - tank for reducing agent”,
page 341

3 SCR system (selective catalytic re‐

duction)
⇒ “3.1 Assembly overview - tank for reducing agent”, page 341
⇒ “3.2 Assembly overview - delivery module for reducing agent”,
page 342
⇒ “3.3 Removing and installing reducing agent tank VX85 ”, page
342
⇒ “3.4 Removing and installing reducing agent supply line”, page
344
⇒ “3.5 Removing and installing delivery unit for reducing agent
metering system GX19 ”, page 346
⇒ “3.6 Removing and installing injector for reduction agent N474
”, page 349
⇒ “3.7 Removing and installing control unit for reducing-agent
heater J891 ”, page 352
⇒ “3.8 Draining reducing agent tank VX85 ”, page 352
satelettronica
3.1 Assembly overview - tank for reducing agent
1 - Control unit for reducing

agent heater - J891-
⇒ page 352
2 - Reducing agent tank - AG. Volkswagen AG d
agen
VX85- Volksw
oes
not
gu
by ara
❑ With reducing agent rise
d
nte
quality sensor - G684- utho eo
ra
and reducing agent ss a c
quality sensor - G849-
ce
le
un
pt
an

d
itte
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⇒ page 342
erm
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3 - Nuts
wit
is n
h re
❑ 20 Nm
ole,
spec
4 - Delivery line
t to the co

⇒ page 344
5 - Delivery unit for reducing
rrectne
agent metering system -

GX19-
ss o
cial p
f i
⇒ page 342
nform
mer

atio
m
⇒ page 346
o
n
c
i
or
6 - Bolts
thi
te
sd
va
i
o
pr
cum
⇒ page 342
r
fo
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ng
t.
yi Co
7 - Coolant hose t. Cop py
rig
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8 - Clamps yri
p by
co Vo
by lksw
cted
agen
Prote AG.
N474-
⇒ page 349
3. SCR system (selective catalytic reduction) 341

10 - Seal
11 - Clip
❑ 8 Nm
12 - Bolt
❑ 20 Nm
13 - Filler neck
3.2 Assembly overview - delivery module for reducing agent
1 - Delivery unit for reducing

agent metering system -
GX19-
⇒ page 346
2 - Spacer sleeves
satelettronica
❑ Qty. 3
❑ Use repair kit as per ⇒
logue (ETKA) . wagen AG. Volkswagen AG does
ks not
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3 - Damper db
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❑ Renew thafter
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❑ Qty.s 3
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nl

pt
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logue (ETKA) .
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4 - Seals
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❑ Qty. 2
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spec

es, in part or in w
t to the co

logue (ETKA) .
5 - Bolts
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❑ Qty. 3
nf
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orm
logue (ETKA) .
m
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❑ 6 Nm
o
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6 - Delivery line
t
sd
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⇒ page 344
f
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t.
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Cop py
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pyri by
3.3 Removing and installing reducing agent

co Vo
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Prote AG.
tank - VX85-

lkswage es n
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satelettronica
rrectness of i
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nform
ercia
Removing
m
at
– Emptying reducing agent tank - VX85- ⇒ page 352 .
om
ion
c
in t
r
– If fitted, remove underbody cladding ⇒ General body repairs,

o
his
e
exterior; Rep. gr. 66 ; Underbody cladding; Removing and

at
do
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installing underbody cladding .

p
cum
for
en
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n
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Cop py
– Unclip wiring harness -2- and lay aside.
t. rig
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pyri by
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cted
CAUTION
agen
Prote AG.

– Release and pull off reducing agent supply line -3-.

– Unclip fuel lines -1- from reducing agent tank - VX85- .

– Release and pull off quick-release couplings for filler pipe
-2-.
– Seal off all open lines and connections with clean plugs from
engine bung set - VAS 6122- .
– Place engine and gearbox jack - VAS 6931- equipped with soft
satelettronica
foam padding under reducing agent tank - VX85- to support
tank.
– Remove nut -2-. AG. Volkswagen AG d
agen oes
olksw not
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– Carefully lower reducing agent ed tank - VX85- -3- using engine
b ara
nte
is
and gearbox jack - VAS 6931-
hor , and guide reducing agent tank eo
ut
- VX85- by hand whiless doing so.
a ra
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Installing
nl
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– Ensure lines are secured properly by pulling.

wit
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– Fill reducing agent ⇒ Maintenance ; Booklet 20.1 ; Descrip‐

hole
tions of work; AdBlue® (reducing agent) .

spec
es, in part or in w

t to the co
rrectness of i
– Adapt SCR system learnt values ⇒ Vehicle diagnostic tester,

01 - Systems capable of self-diagnosis , 01 - Diesel
l purpos
direction injection and preglow system EDC 17 , 01 -

Engine electronics functions , 01 - Adapting SCR
nf
ercia
system learnt values .

orm
m
atio

om
tester.
n in
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Specified torques
t
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f
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page 341
t.
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Cop py
ht. rig
ht
3.4 Removing and installing reducing agent
rig by
copy Vo
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supply line
cted agen
Prote AG.

Removing
– Remove front left underbody cladding ⇒ General body repairs,
– Remove front right underbody cladding ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing
and installing underbody cladding .
satelettronica
CAUTION
Risk of injury caused by escaping reducing agent. AG. Volkswagen AG d
agen oes
The reducing agent may cause eye and skin irritations olksw as well not
y V gu
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– Wear protective goggles. auth
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– Wear protective gloves. s
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ab
pe

ility
ot
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– Place a cloth underneath coupling point to catch any escaping h re

hole
spec
reducing agent.
es, in part or in w
t to the co
– Release plug-in connector -2-.

– Pull off delivery line -1- from injector for reducing agent - N474-
rrectness of i
-3-.
l purpos
nform
mercia
a
com
tion in
r
te o
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fo
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t.
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Cop py
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pyri by
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– Unclip delivery line -3- from retainer -1-.
– Place a cloth underneath coupling point to catch any escaping
reducing agent.
– Release plug-in connector -4-.
– Pull off delivery line -3-.
AG. Volkswagen AG d
– Unclip delivery line -4- -1, 2, 3-. agen oes
lksw not
satelettronica
Vo gu
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– Remove delivery line -4-. rise
d
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Installing ss a ra
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nl
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♦ Clip delivery line on longitudinal member and cross member
erm
ab
first.
ility
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♦ Then secure delivery line to reducing agent tank - VX85- .
h re
hole
♦ Secure delivery line on injector for reducing agent - N474- .
spec
es, in part or in w
t to the co
– If required, fill reducing agent ⇒ Maintenance ; Booklet 20.1 ;
Descriptions of work; AdBlue® (reducing agent) .
rrectness of i
l purpos

nform
ercia

m

at
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system learnt values .

n
c
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or
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p
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3.5 Removing and installing delivery unit for Cop py
t. rig
gh
reducing agent metering system -
ht
pyri by
Vo
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GX19-
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satelettronica
AG. Volkswagen AG d
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olksw not
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nl
pt
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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c
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

Removing
– Remove reducing agent tank - VX85- ⇒ page 342 .
– Place reducing agent tank - VX85- on a clean surface with
delivery module facing upwards.
– Clean area around delivery module.
CAUTION
– Wear protective gloves. AG. Volkswagen AG d
agen oes
– Always wear protective clothes. olksw not
y V gu
d b ara
– Make sure that a sufficient amount of fresh airoriseis supplied. nte
In closed areas, switch on the exhaust gasauextractor
th system. eo
ra
ss c
ce
e
nl
pt
– Separate electrical connectors -1- and -3-.
du
an
itte
y li
– Separate delivery line -2-.
satelettronica
erm
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ility
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– Place a cloth underneath separating point to catch any es‐
wit
, is n
caping reducing agent.
h re
hole
spec
es, in part or in w
t to the co
– Carefully lever out delivery module -5- at recess -4-.
rrectness of i
– Pull delivery module -5- out of reducing agent tank - VX85- .
l purpos
Installing
nf
ercia
o
rm
m
atio
m
• Note installation position of spacer sleeves.

o
n in
or c
• Ensure that all three spacer sleeves are inserted into rubber
thi
te
sd
a
dampers from underneath.

iv
o
r
rp
cu
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• Do not clean the delivery module for reducing agent with com‐
f
en
ng
t.
pressed air.
yi Co
Cop py
t. rig
• Clean all components and connections with water and a lint-
gh ht
yri by
free cloth.
cop Vo
by lksw
cted agen
Prote AG.
• All components must be dry when installing them.
• Moisten seals with a suitable lubricant before installing ⇒
• Check seals for damage.
– Thoroughly clean internal hydraulic sealing points to remove
AdBlue residue and dirt, and dry them afterwards.
– Thoroughly clean contact surfaces of pump in fuel delivery
module to remove AdBlue residue and dirt, and dry them af‐
terwards.
– Clean all components and connections with water and a lint-
free cloth.
– Renew dampers ⇒ Item 3 (page 342) .
– Renew spacer sleeves, observe installation position
⇒ Item 2 (page 342) .
– Renew seals ⇒ Item 4 (page 342) .

– Fit delivery module for reducing agent, and push it into mount‐
ing without canting.
– Apply the required force over the entire surface.
Note
♦ There are letters indicated on the supply unit at the reducing

agent tank - VX85- .
♦ The letters -S1 to S3- indicate the tightening sequence.

01 - Systems capable of self-diagnosis , 01 - Diesel AG. Volkswagen AG d
agen oes
lksw not
direction injection and preglow system EDC 17by,V01 - o gu
ara
d
Engine electronics functions , 01 - Adapting orise SCR nte
eo
system learnt values . th
au ra
ss c
satelettronica
ce
le
un
pt
tester.
an
d
itte
y li
rm
ab
Specified torques
pe
ility
ot
♦ ⇒ “3.2 Assembly overview - delivery module for reducing
wit
, is n
h re
agent”, page 342
hole
spec
es, in part or in w
t to the co
page 341
Tight‐ Designation of bolts on sup‐ Position of bolt Specified torque
rrectness of i
ening ply unit
se‐
l purpos
quenc
e
nform
ercia
1) S1 Bolt with largest distance to seal

m
a
2) S2 Bolt with medium distance to seal 6 Nm
com
tion in
r
3) S3 Bolt with smallest distance to seal

te o
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3.6 Removing and installing injector for re‐
yi Co
Cop py
duction agent - N474-

t. rig
gh ht
pyri by
Vo
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by
Special tools and workshop equipment required cted agen
Prote AG.

4-cylinder common rail engineks(2.0 n AG. Volkswagen AG do - Edition 03.2019
wagel, 4V, turbocharger) es n
ol ot g
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db ran
♦ Hose clamp pliers - VAS 6340- ris
e
tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Clamp off coolant hoses -2- with hose clips, up to 25 mm -

3094- .
nform
mercia
at
CAUTION
om
ion
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or
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e

at
satelettronica
do
priv
c
um
for
en
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n
t.
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op py
. C rig
ht ht
rig by
py
– Reduce excess pressure by covering cap of coolant expan‐ co Vo
by lksw
sion tank with cloths and opening it carefully. cted agen
Prote AG.



– Place a cloth underneath coupling point to catch any escaping
reducing agent.
CAUTION
In closed areas, switch on the exhaust gas extractornsystem.
AG. Volkswagen AG
age does
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b ara
– Release plug-in connector -2-. ris
ed nte
tho eo
– Pull off delivery line -3-. ss
au ra
c
ce
le

un
pt
an
d
itte
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– Remove injector for reducing agent - N474- -5-.
satelettronica
rm
ab
pe
ility
Installing
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– If required, fill reducing agent ⇒ Maintenance ; Booklet 20.1 ;
Descriptions of work; AdBlue® (reducing agent) .
rrectness of i
l purpos
nform
ercia

m
a
com
t
system learnt values . ion in
r
te o
thi
s
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cum
tester.
fo
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ng
t.
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Specified torques
Co
Cop py
t. rig
gh ht
♦ ⇒ “3.1 Assembly overview - tank for reducing agent”, yri
p by
o Vo
page 341
c by lksw
cted agen
Prote AG.


reducing-agent heater - J891-
Removing
– If fitted, remove underbody cladding ⇒ General body repairs,
– Release locking lugs in direction of -arrow-, and remove con‐
trol unit for reducing agent heater - J891- -2- from reducing
agent tank - VX85- .
Installing
satelettronica
3.8 Draining reducing agent tank - VX85-
♦ AdBlue vacuum box - VAS 6557A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Draining
Note
To keep the following description as short as possible, the “NOx

reducing agent AUS 32” (AdBlue®) is simply called a reducing
agent.
– Open fuel tank flap.
CAUTION
satelettronica
– Clean area around filler neck.
– Open cap -1- on reducing agent tank - VX85- .
Prepare AdBlue vacuum box - VAS 6557A- -1- as follows

– Close shut-off taps -A, B, C-. n AG. Volkswagen AG do
lkswage es n
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nl
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Connect coupling -D- to connection on shut-off tap -A-.

nform
ercia
– Pressurise compressed air hose with compressed air.

m
at
om
io
– Open cut-off tap -A-.

n
c
in t
or
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e
A vacuum is now created in the AdBlue vacuum box - VAS 6557A-

at
do
riv
-1-.
p
cum
for
en
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– Close cut-off tap -A- as soon as the pressure gauge shows a

n
t.
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op
vacuum pressure of 0.8 bar. C py
t. rig
gh ht
yri
– Disconnect coupling -D- from connection on shut-off tap -A-.
p by
co Vo
by lksw
cted agen
– Interrupt the compressed air supply through the compressed
Prote AG.
air hose.

– Guide end of hose -E- in filler neck (marking is at edge of filler

neck).
Note
Depending on the equipment level, it might be necessary to use

the AdBlue extraction hose - VAS 6557A/1- .
– If necessary, connect AdBlue extraction hose - VAS 6557A/

1- .
– If required, guide AdBlue extraction hose - VAS 6557A/1- into
filler neck.
– Open shut-off tap -B-.
Note
♦ The reducing agent is then drawn through the filler pipe and
into the AdBlue vacuum box - VAS 6557A- by the vacuum from
the reducing agent tank - VX85- .
satelettronica
♦ If the reducing agent tank - VX85- holds a greater amount of
reducing agent, it must be emptied completely. Repeat pro‐
cedure if necessary.
♦ The capacity of the AdBlue vacuum box - VAS 6557A- is ap‐
prox. 7 litres.
– To empty AdBlue vacuum box - VAS 6557A- , hold connection agen

AG. Volkswagen AG d
oes
olksw
on shut-off tap -C- over suitable container and openbyshut-off not
V gu
taps -A- and -C-. ris
ed ara
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tho or
• Extracted reducing agent must never be used auagain. Informa‐ ac
ss
tion concerning storage and disposal ⇒ ServiceNet → Envi‐
ce
le
ronmental protection → Workshop disposal ! Request country

un
pt
an
d
specific information from importer concerning storage and dis‐

itte
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erm
posal.
ab
ility
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– Flush out AdBlue vacuum box - VAS 6557A- thoroughly using

wit
is n
water when work sequence is complete. h re

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Exhaust gas temperature regulation

⇒ “4.1 Assembly overview - exhaust gas temperature regulation”,
page 355
⇒ “4.2 Removing and installing exhaust gas temperature sender
1 G235 ”, page 356
2 G448 ”, page 358
3 G495 ”, page 359
4 G648 ”, page 361
4.1 Assembly overview - exhaust gas temperature regulation

AG. Volkswagen AG d
agen oes
olksw not
Note d by V gu
ara
rise nte
tho eo
The illustration shows the bi-turbo.ss au ra
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satelettronica
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un
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1 - Bracket
erm
ab
ility
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2 - Pressure differential sender
wit
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- G505-
h re
ole,
spec
⇒ page 305
t to the co
3 - Bolt
❑ 8 Nm
rrectne
4 - Clamps
❑ Qty. 4
ss o
cial p
f
5 - Bracket
inform
mer
6 - Charge pressure sender 2 -

atio
m
G447-
o
n
c
❑ Only bi-turbo
or
n thi
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sd
a

iv
o
pr
⇒ page 254
um
r
fo
en
ng
t.
7 - Bolt
yi Co
Cop py
❑ 8 Nm
t. rig
gh ht
pyri by
Vo
co
8 - Clamps
by lksw
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Prote AG.
❑ Qty. 2
9 - Hose
10 - Bolt
❑ 23 Nm
11 - Oil seals
12 - Banjo union
13 - Exhaust gas temperature
sender 4 - G648-
❑ 45 Nm
⇒ page 361
4. Exhaust gas temperature regulation 355

14 - Exhaust gas temperature sender 3 - G495-

❑ 45 Nm
15 - Union nut
❑ 45 Nm
16 - Control cable
❑ 45 Nm
18 - Heat shield sleeve
❑ With push-button
❑ 45 Nm
20 - Clip
satelettronica
21 - Hose
4.2 Removing and installing exhaust gas

temperature sender 1 - G235-
♦ Torque wrench - V.A.G 1331- n AG. Volkswagen AG do
lkswage es n
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nl
pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co

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

♦ Flared ring spanner tool insert AF17 - V.A.G 1331/10-
AG. Volkswagen AG d
agen oes
Removing Volksw not
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– If fitted,risremove engine cover panel ⇒ page 33 a. nte
e
tho eo
au ra
– Disconnect
ss electrical connector -1-. c
ce
le
un
– Unclip wiring harness -3- from bracket -2- above exhaust gas
pt
an
d
itte
recirculation cooler.
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ab
pe
ility
satelettronica
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
ti
Vehicles with bi-turbo

on in
r
te o
thi

s
iva
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cum
CAUTION
fo
en
ng
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– Lay aside wiring harness -1-; detach cable ties if necessary.


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ility
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es, in part or in w
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bocharger.
Installing
rrectness of i
l purpos
– Coat thread with high-temperature paste; High-temperature
nf
ercia
paste ⇒ Electronic parts catalogue (ETKA) .
orm
m
atio
• Take care to protect exhaust gas temperature sender from
om
n in
knocks and impact; if dropped, the exhaust gas temperature
or c
satelettronica
sender can no longer be used.
thi
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Specified torques
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tion”, page 355 C py
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Removing

G949- , beige
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ility
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CAUTION
, is n
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es, in part or in w
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– Detach wiring harness from retainer -1-; open existing cable
ties if necessary.
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Installing
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♦ Tool set - T10395A- agen

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AG.

CAUTION
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Specified torques
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tion”, page 355
ss o
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Removing
• Engine/exhaust system is cold.

CAUTION

– Loosen lock washers -2-.
– Hold cover -3- down slightly.
satelettronica
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is n
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Installing
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5 Exhaust gas recirculation

⇒ “5.1 Assembly overview - exhaust gas recirculation”,
page 363
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gen AG does
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spec
gas recirculation G949 ”, page 375
es, in part or in w
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⇒ “5.7 Removing and installing bracket for exhaust gas recircu‐
lation cooler”, page 377
rrectness of i
⇒ “5.8 Flushing exhaust gas recirculation cooler and exhaust gas
recirculation valve 1 GX5 ”, page 377
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5.1 Assembly overview - exhaust gas recirculation
nf
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1 - Bracket
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c
❑ For exhaust gas recircu‐

or
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lation cooler
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engine and bracket after
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Co
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❑ Removing and installing Prote AG.
⇒ page 377
2 - Studs
❑ Number of studs de‐
pends on equipment
level.
Note
Studs and nuts

⇒ Item 15 (page 364) are renewed
with bolts following removal ⇒ Elec‐
tronic parts catalogue (ETKA) .
❑ Specified torque for
bolts: 20 Nm
3 - Bolt
❑ 8 Nm
4 - Bolts
❑ Qty. 2
❑ 20 Nm
5 - Bracket
6 - Seal
5. Exhaust gas recirculation 363

7 - Bolts
❑ Qty. 2
❑ 20 Nm
8 - Bolts
❑ Qty. 2
❑ 20 Nm
9 - Tube
❑ Rear
❑ Install so that component is not under tension
❑ Note tightening sequence ⇒ page 370 .
10 - Seal
11 - Temperature sensor 3 for exhaust recirculation - G949-
satelettronica
❑ 45 Nm
12 - Exhaust gas recirculation valve 1 - GX5-
13 - Seal
14 - Exhaust gas recirculation cooler
❑ Check for leaks ⇒ page 372
❑ Flushing ⇒ page 377
15 - Nuts
❑ Number of nuts depends on equipment level
AG. Volkswagen AG d
❑ 20 Nm ksw
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Studs and nuts s
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⇒ Item 2 (page 363) are renewed

un
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with bolts following removal ⇒ Elec‐

itte
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tronic parts catalogue (ETKA) .

rm
ab
pe
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❑ Specified torque for bolts: 20 Nm

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16 - Bolt
spec
es, in part or in w
❑ 8 Nm
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17 - Bolts
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❑ Qty. 6
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❑ 12.5 Nm
18 - Seal
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19 - Bolts
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❑ Qty. 2
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Rep. gr.26 - Exhaust system cted agen
Prote AG.
20 - Tube
❑ Install so that component is not under tension
❑ Front
21 - Temperature sensor 2 for exhaust recirculation - G690-
❑ 60 Nm
22 - Bolts
❑ Qty. 4
❑ 20 Nm
5.2 Removing and installing exhaust gas re‐

circulation cooler
satelettronica
AG. Volkswagen AG d
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Removing
– Unclip wiring harness -5-.
AG. Volkswagen AG d
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– Pull off coolant hoses -4-. Volksw not
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– Remove coolant expansion tank -1-. horis nte
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spec
satelettronica
es, in part or in w
– If fitted, remove cover -1-.
t to the co
rrectness of i
l purpos
– Remove exhaust gas recirculation pipes ⇒ page 369 .
nform
mercia
at
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ion
c
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or
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ate
do
priv
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for
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Cop py
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Prote AG.
– Open retainer -1-.
CAUTION
– Unclip hoses -2-.

– Detach coolant hose from retainer -5-.

– Pull off vacuum hoses -7- and place to one side.
CAUTION
– Release fuel hoses -1-.

– Remove fuel filter bracket -2- with fuel filter.
satelettronica
AG. Volkswagen
2- For exhaust gas
lkswtemperature sender 3 e
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For temperature sensor 3 for exhaust gas recirculation
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spec
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;

t to the co
Removing and installing starter .

rrectness o
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Vehicles with auxiliary heater

inform
mer
– Remove auxiliary heater pipes.

atio
om

c
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– Disconnect connectors -1-, -2- and -3-.

sd
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– Lay wiring harnesses to one side.

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Note
♦ The following description applies to the 150 kW engine with

dual clutch gearbox.
♦ Deviations may be encountered depending on the equipment.
♦ Valve -1- is only fitted on vehicles with dual clutch gearbox.

– Release valve -1- in bracket -4-.
– Move valve -1- with coolant hoses aside slightly.
– Unclip gearbox breather from retainer -4-.
satelettronica
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– If fitted, disconnect electrical connector -1-.

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– Push coolant pipe -5- aside slightly.

rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
t. rig
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AG. Volkswag-eEdition
n
03.2019
n AG do
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– Loosen clamp -5-. ed
by
V ua
ran
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– Pull off coolant hose -6-. au
tho
or
ac
ss
– Push coolant pipe -4- down slightly until nut -2- is accessible.
ce
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un
pt
an
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– Remove nut -2-.
itte
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Note
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♦ Number of nuts -2- and studs -3- varies depending on equip‐
es, in part or in w
ment.
t to the co
♦ Note that the exhaust gas recirculation cooler weighs approx.
8 kg to avoid any secondary damage during removal and in‐
rrectness of i
stallation.
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– Unscrew studs -3-.
– Detach exhaust gas recirculation cooler -1-.
nform
mercia
Installing
a
com
tion in
r
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satelettronica
thi
s
iva
– Renew nuts ⇒ Item 15 (page 364) and studs
do
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⇒ Item 2 (page 363) with bolts following removal ⇒ Electronic
um
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parts catalogue (ETKA) .
en
ng
t.
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op
– Renew exhaust gas recirculation pipes following removal.
C py
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cop Vo
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cted
ieve this, start all bolts hand-tight first, and tighten them diag‐
agen
Prote AG.
onally and alternately after observing tightening procedure
⇒ page 370 .
Specified torques
page 363
tank
5.3 Removing and installing pipes for ex‐

haust gas recirculation system
⇒ “5.3.1 Removing and installing front exhaust gas recirculation
pipe”, page 369
⇒ “5.3.2 Removing and installing rear exhaust gas recirculation
pipe”, page 370
5.3.1 Removing and installing front exhaust

gas recirculation pipe

lkswage es n
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un
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Installing
Install in reverse order of removal, observing the following: rrectnes
s o
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– Renew exhaust gas recirculation pipe following removal.

nform
mer
– Install exhaust gas recirculation pipe free of stress. To achieve

atio
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this, start all bolts hand-tight first, and tighten them diagonally
o
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c
and alternately after.

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Specified torques
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page 363
Co
Cop py
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5.3.2 Removing and installing rear exhaust
gas recirculation pipe

Removing
Coolant hoses connected
– Remove coolant expansion tank ⇒ page 185 .
Vehicles with dual clutch gearbox agen
AG. Volkswagen AG d
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horis selector nte
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– Remove gear oil cooler with attached coolant hoses from
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un
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gearbox and lay aside ⇒ Rep. gr. 34 ; Gear oil circuit; Re‐
an
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moving and installing gear oil cooler .
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Installing
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ss o
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– Renew exhaust gas recirculation pipe -3- following removal.
mer
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o
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achieve this, start all bolts hand-tight first, and tighten them
i
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diagonally and alternately after.
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– Loosen bolts -1- to align flange. Prote
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agen
– Tighten bolts -1- to specified torque again.

Specified torques
page 363
5.4 Removing and installing temperature

sensor 2 for exhaust gas recirculation -
G690-

Removing
– Unscrew temperature sensor 2 for exhaust gas recirculation -
G690- -2-.
Installing
satelettronica
olkswagen AG
Install in reverse order of removal, observing the following:swagen AG. V does
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page 363
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5.5 Checking exhaust gas recirculation cooler for leaks
t to the co
rrectness of i
l purpos
nform
mercia
at
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c
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ate
do
priv
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for
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by
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equipment required
satelettronica
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♦ Cooling system tester - V.A.G 1274 B- ility
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♦ Adapter - V.A.G 1274B/14-

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spec

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Procedure
noise insulation .
– Clamp off coolant hose -1- leading to pump for exhaust gas
recirculation cooler - V400- with hose clips up to 25 mm -
3094- .
– Place drip tray - VAS 6208- beneath engine.
satelettronica
CAUTION
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rrectness of i
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– Connect cooling system tester - V.A.G 1274 B- to adapter -

V.A.G 1274B/14-3- .
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Vol -2- for firm seating.
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nte
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of 2.0 bar. ra
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• For purposes of accessibility, hose clamp up to 25 mm - 3094-
ce
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nl
pt
is attached to coolant hose between coolant pipe and pump
du
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for exhaust gas recirculation cooler - V400- . Should a pres‐
y li
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sure loss be determined, first check coolant hoses and coolant
ility
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• The pressure must not drop by more than 0.2 bar within 10 mi‐
hole
spec
nutes.
es, in part or in w
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• If When the pressure drops by more than 0.2 bar, build-up
pressure again to 1.5 bar, and repeat the test again.
• If the exhaust gas recirculation cooler leaks, renew exhaust
rrectness of i
gas recirculation cooler.
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nform
ercia
5.6 Removing and installing temperature
satelettronica
m
at
sensor 3 for exhaust gas recirculation -
om
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♦ Flared ring spanner tool insert AF17 - V.A.G 1331/10-

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AG. Volkswagen AG d
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t to the co
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o
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inform
mer
atio
m

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c
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G949- , beige
iva
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pr
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fo
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black
t.
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Cop py
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– Disconnect electrical connector -3-. opyri
gh by
Vo
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c lksw
by
cted agen
Prote AG.
– For purposes of accessibility, detach coolant expansion tank

at lock carrier, and lay it aside. Leave electrical connector and
coolant hoses connected.
– Unscrew temperature sensor 3 for exhaust recirculation -
G949- -1- using open ring spanner insert, AF 17 - V.A.G
1331/10- .
Installing
Specified torques
page 363
tank

5.7 Removing and installing bracket for ex‐

haust gas recirculation cooler
Removing
– Remove exhaust gas recirculation cooler ⇒ page 365 .
satelettronica
– Release clips -1-. n AG. Volkswagen AG do
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– Pull off coolant hoses -2-. ir se
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Installing
nform
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– Renew seal between engine and bracket after removal.

m
a
com
Specified torques tion in

r
te o
thi

s
iva
do
page 363
r
rp
cum
fo
en
ng
t.
yi
5.8 Flushing exhaust gas recirculation cool‐
Co
Cop py
t. rig
er and exhaust gas recirculation valve 1
gh ht
pyri by
Vo
co
- GX5-
by lksw
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Prote AG.

lks wage es n
Transporter 2016 ➤ byV
o ot g
ua
ed ran
horis (2.0 l, 4V, turbocharger) - Edition 03.2019
tee
ut or
a ac
ss
♦ Cooler flushing system for exhaust gas recirculation - VAS 542
ce
e
nl
005-
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
♦ Engine speed adjuster - V.A.G 1788/10A-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
satelettronica
n
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Chain-type pipe cutter - VAS 6254-

Procedure
– Select test program for flushing the exhaust gas recirculation
cooler and exhaust gas recirculation valve 1 - GX5- , and follow
instructions displayed on ⇒ Vehicle diagnostic tester; 0001 -
Engine electronics - Diesel (2.0 l) , 0001 - Repair
groups , 26 - Exhaust system , Flushing exhaust gas
recirculation cooler and exhaust gas recirculation
valve -GX5- .
– Remove front exhaust gas recirculation pipe ⇒ page 369 .

– Seal intake manifold -3- with sealing plate - VAS 542 005/7-
-1-.
– Tighten bolts -2- to 8 Nm.
– Remove exhaust gas recirculation temperature sensor 3 -
G949- ⇒ page 375 .

– Remove dirt from tailpipe of rear silencer -1-.

– Connect seal - VAS 542 005/5-2- or seal - VAS 542 005/5-4-
-5- from seal set - VAS 542 005/5- to safety valve - VAS 542
005/5-1- -4-.
– Tighten clamp -2-.
– Then, connect exhaust pipe to seal -5- and safety valve -4-.
– Tighten clamp -2- on tailpipe.
Note
♦ Check wire cord and mounting points for damage before use.
♦ Attachment points for carabiner hooks -3- may vary depending
on the equipment.
– Attach carabiner hook -3- of wire cord to towing eye, and pre‐
tension lightly.
– Attach second carabiner hook -3- at suitable position and pre‐
tension lightly in same manner.
satelettronica
– Remove cap from exhaust gas recirculation valve 1 - GX5-
-1-.
– Disconnect electrical connector for exhaust gas recirculation
valve 1 - GX5- -1-.
– Fit valve adjuster - VAS 542 005/6- -2-, and turn it clockwise
to stop. agen
AG. Volkswagen AG d
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olks not
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Note ris
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This locks the exhaust gas recirculation valve 1 - GX5- mechan‐
ce
e
nl
pt
ically.
du
an
itte
y li
erm
ab
ility
ot p
– Empty the separator of cooler flushing system for exhaust gas
wit
, is n
recirculation - VAS 542 005- ⇒ page 382 .
h re
hole
spec
• The separator must be completely empty.
es, in part or in w
t to the co
– Pour 1 litre of cleaning solution ⇒ Electronic parts catalogue
(ETKA) and 9 litres of water into canister - VAS 542 005/8-
-1-.
rrectness of i
l purpos
nf
ercia
orm
m
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or c
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
The pump - VAS 542 005/1- must be off.
– Connect pump - VAS 542 005/1- to battery positive terminal

-1- and body earth -2-.
– Switch on pump - VAS 542 005/1- briefly until it is filled with
fluid. Then switch off pump - VAS 542 005/1- again straight‐
away.
• It is absolutely essential to switch on pump - VAS 542 005/1-
for a short period.
– Screw hose adapter - VAS 542 005/2- -1- in opening from

temperature sensor 3 for exhaust recirculation - G949- onto
exhaust gas recirculation cooler -2-.
CAUTION
AG. Volkswagen AG d
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Risk of injury from d byswarf
V being flung into air. gu
ara
satelettronica
ise nte
Irritation andthoinjury to skin and eyes possible.
r eo
au ra
– Wear sprotective goggles.
s c
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– At marked position -arrow-, cut through exhaust gas recircu‐

h re
ole,
lation pipe -1- using chain pipe cutter - VAS 6254- .

spec
– Deburr sawn pipe -1-.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
cum
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Secure drainage hose - VAS 542 005/3- -3- to cut-off pipe

-1- with a clamp -4-.
• Make sure that the drain hose - VAS 542 005/3- -3- is not
kinked or twisted.
• Route the drain hose - VAS 542 005/3- -3- in such a way that
you cannot step on it.
– Connect pipe -1- with drain hose - VAS 542 005/3- -3- to ex‐
haust gas recirculation cooler -5-.
Note
♦ Use the old seal for flushing.

♦ All hoses must be routed in such a way that they are free of
stress and abrasion. agen
AG. Volkswagen AG d
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– Secure exhaust extraction ris system to separator of cooler flush‐
ed
nte
ing system for exhaustut gas recirculation - VAS 542 005- .
ho eo
ra
a
satelettronica
ss c
– Continue with the test program, and follow instructions from
ce
e
nl
⇒ Vehicle diagnostic tester.
pt
du
an
itte
y li
– Detach hoses of cooler flushing system for exhaust gas recir‐
erm
ab
culation - VAS 542 005- from vehicle.
ility
ot p
wit
, is n
– Remove sealing plate - VAS 542 005/7- .
h re
hole
spec
– Remove valve adjuster - VAS 542 005/6- .
es, in part or in w
t to the co
– Attach electrical connector to exhaust gas recirculation valve
1 - GX5- and fit cover cap.
– Detach plug - VAS 542 005/5-2- or plug - VAS 542 005/5-4- rrectness of i
from exhaust pipe.
l purpos
– Install temperature sensor 3 for exhaust recirculation - G949-

again.
nform
mercia
at
om
Note
ion
c
in t
or
his
e
Exhaust gas recirculation pipe and seals must be renewed

at
do
riv
⇒ page 363 .
p
cum
for
en
ng
t.
yi
– Install new exhaust gas recirculation pipe.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
– Continue with the test program, and follow instructions from
cted agen
Prote AG.
⇒ Vehicle diagnostic tester.
– Then erase event memory using ⇒ Vehicle diagnostic tester.

Empty trap
– Operate lever -2- and let cleaning solution/water run out of
separator of cooler flushing system for exhaust gas recircula‐
tion - VAS 542 005- and into canister - VAS 542 005/9- -1-.
– Dispose of cleaning solution/water in canister - VAS 542
005/9- -1- properly.
• When rolled up, the internal diameter of the drain hose - VAS
542 005/3- must be at least approx. 50 cm to avoid damage.
satelettronica
AG. Volkswagen AG d
agen oes
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un
pt
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d
itte
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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
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Assembly overview - glow plug system”, page 383
olkswagen AG
en AG. V
⇒ “1.2 Removing and installing glow plug”, page 385olkswag does
not
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ara
⇒ “1.3 Checking glow plug”, page 387 rised
nte
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ut
⇒ “1.4 Removing and installing automatic sglow
s a period control unit ra
c
J179 ”, page 387
ce
le
un
pt
an
d
⇒ “1.5 Removing and installing knock sensor 1 G61 ”, itte
y li
page 387
rm
ab
pe
ility
⇒ “1.6 Removing and installing knock sensor 2 G66 ”,
ot
wit
, is n
page 388
h re
hole
spec
⇒ “1.7 Removing and installing Hall sender G40 ”, page 389
es, in part or in w
t to the co
⇒ “1.8 Removing and installing engine speed sender G28 ”, page
390
satelettronica
⇒ “1.9 Cleaning glow plug bore for cylinder 3 combustion chamber
rrectness of i
pressure sender G679 ”, page 391
l purpos
1.1 Assembly overview - glow plug system
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.
1. Glow plug system 383

AG. Volkswagen AG d
agen oes
o lksw not
V
Transporter 2016 ➤ d by gu
ara
ise nte
thor (2.0 l, 4V, turbocharger) - Edition 03.2019 eo
au ra
ss c
1 - Bolt
ce
e
nl
pt
du
❑ 9 Nm
an
itte
y li
erm
ab
2 - Hall sender - G40-
ility
ot p
wit
⇒ page 389 , is n
h re
hole
spec
3 - Glow plugs
es, in part or in w
t to the co
♦ Glow plug 1 - Q10-
rrectness of i
l purpos
❑ Glow plug without com‐

bustion chamber pres‐
sure sender
nform
ercia
❑ Identifying features of
m
at
glow plugs ⇒ page 385
om
ion
c
in t
or
his
e
⇒ page 385
at
do
priv
c
❑ 17 Nm
um
for
en
ng
satelettronica
t.
4 - Glow plug
yi Co
Cop py
❑ Glow plug 3 - Q12- with
t. rig
gh ht
yri
cylinder 3 combustion
p by
co Vo
by lksw
chamber pressure Prote
cted AG.
agen
sender - G679-
❑ 12 Nm
❑ Clean glow plug hole for
cylinder 3 combustion
chamber pressure
sender - G679-
⇒ page 391
5 - Engine speed sender -
G28-
⇒ page 390
6 - Bolt
❑ 5 Nm
384 Rep. gr.28 - Glow plug system

1.2 Removing and installing glow plug

Special tools and work‐
shop equipment re‐
quired
♦ 10 mm jointed span‐
ner - 3220-
♦ Socket insert AF 12
for glow plugs 4-
cyl.TDI CR diesel -
satelettronica
VAS 6454- for glow
plugs with combus‐
tion chamber pres‐
sure sender
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
♦ Pliers - 3314-
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
Distinguishing features
in t
or
of glow plugs
his
ate
do
riv
1- Glow plug with in‐

p
cum
or
ternal cylinder
f
en
ng
t.
yi
pressure sender
Co
Cop py
t. rig
gh
2- Glow plug without
ht
pyri by
Vo
combustion cham‐
co lksw
by
cted agen
ber pressure send‐ Prote AG.
er

Removing
– Remove noise insulation beneath charge air cooler bracket.
– To do so, position pliers - 3314- with groove -arrow A- on sup‐
satelettronica
port sleeve shoulder -arrow B- as shown in illustration.
– Carefully detach glow plug connectors from glow
en AG. V
olksplugs.
wagen AG
ag does
lksw not
– Clean area around glow plugs.by Vo gu
ara
ed nte
ris
Cleaning procedure: tho eo
s au ra
c
– Use a vacuum cleaners to remove coarse dirt.
ce
e
nl
pt
du
– Spray brake cleaner or suitable cleaning agent into glow pin

an
itte
y li
plug opening, let it work in briefly, and blow out with com‐
erm
ab
pressed air.
ility
ot p
wit
, is n
– Then use an oil-soaked cloth to clean the glow pin plug open‐
h re
ing.
hole
spec
es, in part or in w
– Unscrew glow plug -2-.

t to the co
Note
rrectness of i
Remove cylinder 3 combustion chamber pressure sender - G679-

l purpos
using socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel - VAS

6454- (remove glow plugs without combustion chamber pressure
nf
ercia
sender using U/J extension and socket, 10 mm - 3220- ).

orm
m
atio
m
Installing
o
n in
or c
thi

te
sd
iva
o
r
rp
cu
– If necessary, clean glow plug hole for cylinder 3 combustion

o
m
f
chamber pressure sender - G679- ⇒ page 391 .

en
ng
t.
yi Co
op
– If cylinder 3 combustion chamber sender - G679- was re‐
C py
t. rig
gh
newed, connect ⇒ Vehicle diagnostic tester.
ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.
– Reset learnt values of engine management system ⇒ Vehicle

diagnostic tester.
tester.
Specified torques

1.3 Checking glow plug

Procedure
– Checking glow plugs ⇒ Vehicle diagnostic tester.
– Follow further instructions
AG. Vodisplayed
lkswagen AGon ⇒ Vehicle diagnostic
tester. swagen does
olk no t gu
yV
db ara
1.4 tho
r Removing and installing automatic glow
ise nte
eo
ss au period control unit - J179- ra
c
ce
le
un
Removing
pt
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
satelettronica
h re
ole,
♦ The automatic glow period control unit - J179- is installed in
spec
the electronics box in the engine compartment.
t to the co
♦ The assigned position in the relay carrier depends on the
equipment ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
rrectne

ss

o
cial p
f in
– Remove electronics box cover ⇒ Electrical system; Rep. gr.

form
mer
97 ; Relay carrier, fuse carrier, electronics boxes; Removing

atio
and installing electronics box .

om
n
c
i
or
– Pull off automatic glow period control unit - J179- from slot in
thi
te
electronics box in engine compartment ⇒ Current flow dia‐

sd
iva
o
r
grams, Electrical fault finding and Fitting locations.

p
cum
r
fo
en
ng
Installing
t.
yi Co
Cop py
t.
rig
gh ht
pyri by
Vo
co
1.5 Removing and installing knock sensor 1
by lksw
cted agen
Prote AG.
- G61-

Removing
. Volkswagen AG
position . swagen AG does
k not
Vol gu
– Disconnect connector -1- usingsassembly
ed
by tool - T10118- . ara
nte
satelettronica
ri
ho eo
– Unscrew bolt -3-. aut ra
c
ss
– Remove knock sensor 1 - G61- -2-
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
ility
ot p
wit
, is n
Specified torques
h re
hole
spec
es, in part or in w
t to the co
Bolt securing knock sensor 1 - 20 Nm
G61- rrectness of i
1.6 Removing and installing knock sensor 2

l purpos
- G66-
nform
ercia

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.

Removing
– Vehicles without adaptive cruise control, remove lock carrier
⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier;
Removing and installing lock carrier .
– Vehicles with adaptive cruise control, remove intake manifold
⇒ page 292 .
– Remove knock sensor 2 - G66- -1-
Installing
Specified torques
Component Specified torque agen
AG. Volkswagen AG d
oes
olksw not
Bolt securing knock sensor 2 - 20 Nm d by
V gu
ara
G66- orise nte
eo
h
aut ra
ss c
satelettronica
1.7 Removing and installing Hall sender -
ce
le
un
pt
an
d
G40-
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
a
Removing
iv
o
pr
cum
r
fo

en
ng
t.
yi Co
op
– Disconnect electrical connector -1-. C py
t. rig
gh ht
yri by
– Unscrew bolt -2-. op Vo
by c lksw
cted agen
Prote
– Remove hall sender - G40- -3-.
AG.
Installing
Specified torques

AG. Volkswagen AG d
agen oes
o lksw not
y V gu
Transporter 2016 ➤ rise
d b ara
nte
autho
(2.0 l, 4V, turbocharger) - Edition 03.2019 eo
ra
ss c
ce
le
1.8 Removing and installing engine speed
un
pt
an
d
itte
sender - G28-
y li
erm
ab
ility
ot p
wit
is n
h re
♦ Torque wrench - V.A.G 1331- ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi
satelettronica
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hexagon key extension, 4 mm - T10370-


agen oes
olksw not
yV gu
– If fitted, remove ed noise
b insulation ⇒ General body repairs,
ara
nte ex‐
is
terior; Rep.thgr.
or 66 ; Noise insulation; Removing and installing eo
noise insulation
ss au . ra
c
ce
e
– Disconnect connector -1- using assembly tool - T10118- .

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Pull off engine speed sender - G28- .
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
rrectness of i
47
l purpos
1.9 Cleaning glow plug bore for cylinder 3

combustion chamber pressure sender -
nf
ercia
orm
G679-
m
atio
m
satelettronica
o
n in
c

or
thi
te
sd
a
♦ Reamer - VAS 541 001-

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.

AG. Volkswagen AG d
agen oes
olksw not
Transporter 2016 ➤ d by
V gu
ara
e nte
horis
(2.0 l, 4V, turbocharger) - Edition 03.2019 eo
aut ra
ss c
Scaling and corrosion
ce
e
nl
pt
du
an
Over the years, the glow plug threads -3- may come into contact
itte
y li
with water, dirt and even coolant. As the result of this, scaling and
erm
ab
corrosion may occur on the threads, the glow plug shaft and the
ility
ot p
cylinder head -1-. These lead to a higher loosening torque (higher
wit
, is n
h re
than the fracture torque of the glow plug -2-). Thus, the renewal
hole
of the glow plug -2- is made particularly difficult. In addition, there
spec
may also be coking in the lower section of the glow plug due to
es, in part or in w
t to the co
carbonised combustion residue -4-. In the case of the glow plug
with cylinder 3 combustion chamber pressure sender - G679- ,
these may affect the proper functioning of the glow plug.
rrectness of i
l purpos
Note
nf
ercia
♦ Cleaning can be avoided by driving under load conditions.
orm
m
♦ When cleaning needs to be done, make sure to proceed ex‐
atio
m
actly as instructed by the manual.

o
n in
or c
thi
te
sd
a
Procedure
iv
o
r
rp
cu
o
m
– Remove throttle valve module - GX3- ⇒ page 295 .
f
en
ng
satelettronica
t.
yi Co
op
• Observe fracture torque when removing glow plugs.
C py
t. rig
gh ht
pyri by
Glow plug thread Fracture torque
o Vo
by c lksw
cted agen
Prote AG.
8 mm 20 Nm
10 mm 35 Nm
12 mm 45 Nm
If fracture torque has been reached
• Do not turn further! Glow plug might break.
Procedure
Heating up
– Run engine until warm. This will heat up the glow plug -1- and
burn it clean.
Etching
– Generously apply commercially available rust remover or mul‐
tifunction oil to beginning of thread -2- of glow plug -1-, and
leave it to act for approx. 5 minutes.
Unscrewing
– Try again to unscrew glow plug -1- from cylinder head -3- using
a suitable tool ⇒ page 385 .
CAUTION
Make sure not to turn further than the fracture torque.
• Stop turning before the fracture torque is reached, and try to
heat the glow plug up again.

Cleaning
– Clean the threads, the conical sealing seat and the glow plug
channel -arrows- using reamer - VAS 541 001- .
There are often combustion residues or particles of dirt in the cyl‐
inder head bore that occur in particular due to carbonised depos‐
its between the glow plug and the cylinder head. In the case of
cylinder heads with a 10 mm thread, these residues can be re‐
moved using reamer - VAS 541 001- .
– Initially clean glow plug bore with a cloth.
– Screw reamer - VAS 541 001- as far as stop into cylinder head.
Note
The glow plug bore is cleaned with the reamer - VAS 541 001- .
– Screw reamer - VAS 541 001- out again.

– Blow out glow plug bore with compressed air.
– Then, install new cylinder 3 combustion chamber pressure
satelettronica
sender - G679- .
– Tighten cylinder 3 combustion chamber pressure sender -
G679- to specified torque.
Specified torques
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
393
by lksw
cted agen
Prote 1. Glow plug system
AG.

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Workshop Manual Transporter 2016 4-29

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Service

4-cylinder common rail engine (2.0 l, 4V, turbocharger)

CXE CXF CXG CXG CXH CXG CXH CXE

Service Department. Technical Information

28 - Glow plug system

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B8055F189

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.5 Removing and installing damper weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.6 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.5 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

3.4 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

3.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

3.5 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

1.2 Assembly overview - solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1.5 Renewing vacuum unit for turbocharger, bi-turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

1.6 Removing and installing upper connecting pipe, bi-turbo . . . . . . . . . . . . . . . . . . . . . . . . . . 243

1.7 Renewing upper connecting pipe, bi-turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

3.1 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

3.2 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

3.4 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

3.5 Testing jammed-open injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

3.7 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

5.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295