Volkswagen Golf 2015 Repair Manual
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Volkswagen Golf 2015 Repair Manual

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Service
Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition
Engine ID
Edition 04.2015
Service Department. Technical Information
CNT
CXB
CNS
A
A
A
CXB
CNS
CXC
B
B
A
CXC
B

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Summary of Contents for Volkswagen Golf 2015

  • Page 1 Service Repair Manual Golf 2015 ➤ Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition Engine ID Edition 04.2015 Service Department. Technical Information...
  • Page 2 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 © 2016 Volkswagen AG, Wolfsburg D4B80416622...

  • Page 3: Table Of Contents

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Contents 00 - General, Technical Data ..........
  • Page 4 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Crankshaft Needle Bearing, Replacing ........
  • Page 5 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Oil Level Thermal Sensor G266 , Removing and Installing ......190 Engine Oil Cooler .
  • Page 6 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Charge Pressure Actuator V465 , Adjusting ........263 Charge Air System .
  • Page 7 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Overview - Emissions Control ..........348 Catalytic Converter, Removing and Installing .
  • Page 8 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Contents...

  • Page 9: General, Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 00 – General, Technical Data Safety Precautions (Edition 04.2015) ⇒ 1.1 Safety Precautions, Working on Fuel Supply System , page 1 ⇒ 1.2 Start/Stop System Safety Precautions , page 1 ⇒...

  • Page 10: Ignition System Safety Precautions

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Ignition System Safety Precautions There Is a Risk of Injury Due to Electric Shock. With the engine running the ignition system is under high voltage.

  • Page 11: Identification

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Identification ⇒ 2.1 Engine Number/Engine Characteristics , page 3 Engine Number/Engine Characteristics Engine Number The engine number ( engine codes and serial number ) are lo‐...
  • Page 12 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Code Letters CXCA CNTA Emissions values SULEV SULEV Displacement liter Output kW at RPM 155 at 4300 to 6200 155 at 4300 to 6200...

  • Page 13: Repair Information

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Repair Information ⇒ 3.1 Clean Working Conditions , page 5 ⇒ 3.2 Engine Contaminants , page 5 ⇒ 3.3 Contact Corrosion , page 5 ⇒...

  • Page 14: Cooler And Condenser Assembly

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Due to the limited space inside the engine compartment, be especially careful when working near moving or hot parts to avoid damaging the lines.

  • Page 15: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Hand Vacuum Pump - VAS6213- ♦ Engine Bung Set - VAS6122- 4. Special Tools...

  • Page 16: Engine Assembly

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 10 – Engine Assembly Engine, Removing and Installing ⇒ 1.1 Engine, Removing , page 8 ⇒ 1.2 Engine and Transmission, Separating , page 19 ⇒...
  • Page 17 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Procedure CAUTION The coolant system is under pressure when the engine is warm. Risk of scalding due to hot steam and hot coolant.
  • Page 18 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Open the retaining tabs in direction of -arrows-, remove the upper air duct -1-. – Disconnect the vacuum hose -1-. – Loosen the clamp -2- and remove the air guide hose.
  • Page 19 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Vehicles without Auxiliary Heater – Lift the clamps -arrows-, remove the coolant hoses from the heater heat exchanger. – Hold the coolant hoses downward and drain the coolant.
  • Page 20 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the connectors -1 and 2- from the holder and discon‐ nect them. Then free up the electric wires. – Remove the bolt -2- and the screw-type clamp.
  • Page 21 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Lift the clamp -arrow- and remove the upper left coolant hose from the radiator. Note Use the Pry Lever - 80-200- for removing the spiral clips in the following procedure.
  • Page 22 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Open the retainers with a screwdriver in direction of -arrow-, remove the cover -1- for the engine compartment E-box up‐ ward. – Remove the nut -arrow-, disconnect and free up the wires.
  • Page 23 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Clamp the hose/line assembly -A- to the slave cylinder with the Hose Clamps - Up To 25mm - 3094- . – Pull hose/line assembly clip -arrow- out as far as stop.
  • Page 24 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows- for the engine mount (about two turns). – Remove the fan shroud. Refer to ⇒ 4.5 Fan Shroud, Removing and Installing , page 249 –...
  • Page 25 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -1- on the A/C Compressor Regu‐ lator Valve - N280- . – Remove the bolts -arrows-. – Remove the A/C compressor from the bracket with the refrig‐...
  • Page 26 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the Adapter - T10359/3- , as shown in the illustration, on the Engine/Gearbox Jack - Engine Support - T10359A- . – Tighten Engine/Gearbox Jack - Pin - T10359/2- with support element -A- from the Transmission Support - 3282- to the en‐...

  • Page 27: Engine And Transmission, Separating

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the transmission mount bolts -arrows- completely. – Carefully lower the engine/transmission sub-assembly in di‐ rection of -arrow 1-. – Carefully guide the engine/transmission sub-assembly for‐...
  • Page 28 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Bolts - Engine to Transmission Procedure • Engine/transmission assembly removed and secured on the Engine/Gearbox Jack - Engine Support - T10359A- .
  • Page 29 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the Transmission Lift Hook - T40013- on the transmis‐ sion and close locking device. – Engage the Shop Crane - VAS6100- with Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/2- on the trans‐...
  • Page 30 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Procedure • Engine/transmission assembly removed and secured on the Engine Support - T10497- . – Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

  • Page 31: Engine, Securing On Engine And Transmission Holder

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Attach the Engine Sling - 2024A- hooks to the transmission lifting eyes and secure it with the securing pin -arrow-. – Hook the Shop Crane - VAS6100- with the Engine Support Bridge - Special Hook (2 pc.) - 10-222A/20- on the Engine...

  • Page 32: Engine, Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Unclip the right engine cover mount -1-. – Hook the Engine Sling - 2024A- to the engine and to the Shop Crane - VAS6100- .
  • Page 33 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Tightening Specifications Note The tightening specifications apply only to lightly greased, ♦ oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are ♦...
  • Page 34 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – If the alignment sleeves -A- for centering the engine and trans‐ mission are missing inside the cylinder block, then install the sleeves.
  • Page 35 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the bolts -arrows- for the transmission mount by hand until it is in position. Note Only tighten the bolts to the specification when installing the sub‐...
  • Page 36 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the subframe. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 ; Subframe; Subframe without Steering Gear, Removing and Installing .

  • Page 37: Subframe Mount

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Subframe Mount ⇒ 2.1 Overview - Subframe Mount , page 29 ⇒ 2.2 Engine Mount, Removing and Installing , page 30 ⇒ 2.3 Transmission Mount, Removing and Installing , page 31 ⇒...

  • Page 38: Engine Mount, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ❑ Tightening specification and sequence. Refer to ⇒ 2.4 Pendulum Support, Removing and Installing , page 33 10 - Bolt ❑ Replace after removing ❑...

  • Page 39: Transmission Mount, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows- and engine mount -1-. Installing Install in reverse order of removal. Note the following: – Check the adjustment of the assembly mounts. Refer to ⇒...
  • Page 40 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Unclip the wiring guide -1- upward and move it slightly to the side in direction of -arrows-. – Support the engine in its installed position. Refer to ⇒...

  • Page 41: Pendulum Support, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Pendulum Support, Removing and In‐ stalling Removing Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦...
  • Page 42 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Tool Development – If the adapter for Engine Support Bridge - Engine Support 4 - 10-222A/4- does not have the indicated holes -arrow- shown they must be added.
  • Page 43 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Push the Engine Support Bridge - Engine Support 18 - 10-222A/18- and two Engine Support - Movable Joint - T40091/3- on the Engine Support Bridge - 10-222A- .

  • Page 44: Subframe Mount, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Subframe Mount, Adjusting Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Bolts - Engine Mount Procedure –...

  • Page 45: Subframe Mount, Checking Adjustment

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Pay attention that on the transmission side the support arm and the transmission mount remain parallel. • Dimension -x- = dimension -x-.

  • Page 46: Engine Cover

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Engine Cover ⇒ 3.1 Engine Cover, Removing and Installing , page 38 Engine Cover, Removing and Installing Removing – Carefully pull the engine cover off the bolts one after the other in direction of -arrows-.

  • Page 47: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools ♦ Engine Sling - 2024A- ♦ Shop Crane - VAS6100- ♦ Engine And Transmission Holder - VAS6095- 4. Special Tools...
  • Page 48 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Engine Support Bridge - 10-222A- ♦ Engine Support Bridge - Engine Support 18 - 10-222A/18- ♦ Engine Support Bridge - Engine Support 29 - 10-222A/29- ♦...
  • Page 49 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Transmission Lift Hook - T40013- ♦ Shop Crane - VAS6100- ♦ Engine Bung Set - VAS6122- ♦ Shop Crane - Drip Tray - VAS6208-...
  • Page 50 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Engine and Gearbox Jack - VAS6931- ♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/ ♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/ ♦...
  • Page 51 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Engine Sling - Engine Bracket - 2024A/1- from Engine Sling - 2024A- ♦ Hose Clamps - Up To 25mm - 3094- ♦ Transmission Support - 3282-...

  • Page 52: Crankshaft, Cylinder Block

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 13 – Crankshaft, Cylinder Block Cylinder Block, Belt Pulley Side ⇒ 1.1 Overview - Cylinder Block, Belt Pulley Side , page 44 ⇒ 1.2 Ribbed Belt, Removing and Installing , page 46 ⇒...
  • Page 53 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 6 - Vibration Damper ❑ With ribbed belt pulley ❑ Removing and installing. Refer to ⇒ 1.4 Vibration Damper, Removing and Installing , page 47 ❑...

  • Page 54: Ribbed Belt, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Ribbed Belt Routing Vibration damper Ribbed Belt Tensioning Damper Generator A/C Compressor Ribbed Belt, Removing and Installing Special tools and workshop equipment required ♦...

  • Page 55: Ribbed Belt Tensioner, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Start engine and check whether ribbed belt runs correctly. Tightening Specifications ♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation;...
  • Page 56 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Bolts - Timing Chain Cover ♦...
  • Page 57 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows- for the timing chain cover. The bolts must be replaced. – Place the Counterhold Tool - T10531/1- as shown on the vi‐...
  • Page 58 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Tighten the adjusting bolt -A- hand-tight, to secure the chain sprocket to the crankshaft. – Remove the knurled bolt -arrows-. Remove the Counterhold Tool - T10531/1- and vibration damper -A-.
  • Page 59 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Install Vibration Damper – If necessary remove the Collar Nut -B- and the Assembly Tool - Turning Over Tool -A- from the tensioning pins.
  • Page 60 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the Collar Nut -A- and loosen the tensioning bolt -B-. – Remove the Tensioning Pins and remove with Assembly Tool - Turning Over Tool .

  • Page 61: Auxiliary Components Bracket, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Assemble in reverse order of disassembly. Tightening Specifications ♦ Refer to ⇒ 1.1 Overview - Cylinder Block, Belt Pulley Side , page 44 Auxiliary Components Bracket, Remov‐...
  • Page 62 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connectors: 1 - For Oil Pressure Switch - F22- -2- 3 - For Reduced Oil Pressure Switch - F378- -4- 5 - For Piston Cooling Nozzle Control Valve - N522- -7- –...

  • Page 63: Engine Support, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Coat the new O-rings -4- with coolant. – Install the connection pieces -2- into the engine oil cooler -1-. – Press the accessory assembly bracket with the engine oil cooler -1- onto the connection, mount the bolts and tighten.
  • Page 64 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -1, 2 and 3- and engine support. Installing Install in reverse order of removal. Note the following: – Install the engine mount. Refer to ⇒...

  • Page 65: Cylinder Block, Transmission Side

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Cylinder Block, Transmission Side ⇒ 2.1 Overview - Cylinder Block, Transmission Side , page 57 ⇒ 2.2 Flywheel, Removing and Installing , page 58 ⇒...

  • Page 66: Flywheel, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ❑ For the dual-mass flywheel Note Only six bolts are installed, two bolt openings remain open. Installing Intermediate Plate – Hook in intermediate plate at sealing flange and push it onto the alignment sleeves -arrows-.

  • Page 67: Sealing Flange, Removing And Installing, Transmission Side

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Insert the Flywheel Retainer - 3067- into the hole in the cylin‐ der block -A-. Tightening Specifications ♦ Refer to ⇒ 2.1 Overview - Cylinder Block, Transmission Side , page 57 Sealing Flange, Removing and Instal‐...
  • Page 68 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -1 through 6-. – Remove sealing flange. Installing Note Be sure to check the expiration date of the silicone sealant.
  • Page 69 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Position the Seal Installer - Sealing Flange Guide Sleeve - T20097- on the crankshaft pins -A-. – Lightly coat the seal with engine oil.

  • Page 70: Crankshaft

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Crankshaft ⇒ 3.1 Overview - Crankshaft , page 62 ⇒ 3.2 Crankshaft Dimensions , page 64 ⇒ 3.3 Main Bearing Shells Allocation , page 64 ⇒...
  • Page 71 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ⇒ 3.6 Crankshaft, Measuring Radial Clearance , page 67 ❑ Do not turn crankshaft when measuring radial play ❑ Crankshaft dimensions. Refer to ⇒...

  • Page 72: Crankshaft Dimensions

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Crankshaft Dimensions (Dimensions in mm) Reconditioning Crankshaft Bearing Connecting Rod Pin Diameter Bearing Pin Diame‐ Dimension Basic dimension 58.00 47.80 The preparation of worn crankshafts is not provided.

  • Page 73: Crankshaft Needle Bearing, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Bearing Cap Bearing Shell Identification: The identification on the crankshaft is for the lower bearing shell. – Write down the letters and then use the table to find the color identification.
  • Page 74 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Remove Needle Bearing – Remove the needle bearing -1- from the crankshaft -2- using a standard internal puller such as the Puller - Kukko Internal - 14-19mm - 21/2- and counter support Puller - Kukko Counter‐...

  • Page 75: Crankshaft, Measuring Axial Clearance

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Crankshaft, Measuring Axial Clearance Special tools and workshop equipment required ♦ Dial Gauge Holder - VW387- ♦ Dial Gauge - 0-10mm - VAS6079- Procedure –...

  • Page 76: Sensor Wheel, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the crankshaft bearing and secure with the old bolts -1 to 10-. Refer to ⇒ Fig. Crankshaft, Tightening Sequence , page 63 .

  • Page 77: Balance Shaft

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Balance Shaft ⇒ 4.1 Overview - Balance Shaft , page 69 ⇒ 4.2 Balance Shaft, Removing and Installing , page 70 ⇒ 4.3 Balance Shaft Sealing Ring, Replacing, Intake Side , page...

  • Page 78: Balance Shaft, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 9 - Bolt ❑ 4 Nm 45° ❑ Replace after removing Balance Shaft Pipe - Installed Position The openings -arrow- must face the chain side.
  • Page 79 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove timing chain upper cover. Refer to ⇒ 2.2.1 Upper Timing Chain Cover, Removing and Installing , page 106 – Remove the lower timing chain cover. Refer to ⇒...
  • Page 80 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Lubricate the balance shaft mountings -arrows- with engine oil. – Install the intake side balance shaft and tighten the bolt -2-. – Replace the O-ring -1- and coat with engine oil.
  • Page 81 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Tighten the bolt -1- for the intermediate sprocket: tightening sequence. Refer to ⇒ Fig. Intermediate Sprocket Tightening Sequence , page 118 – Check the markings on the intermediate sprocket/balance shaft -arrow-.
  • Page 82 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the lower timing chain cover. Refer to ⇒ 2.2.2 Lower Timing Chain Cover, Removing and Installing , page 108 – Remove the camshaft timing chain. Refer to ⇒...

  • Page 83: Balance Shaft Sealing Ring, Replacing, Intake Side

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the exhaust side balance shaft. – Before tightening the bolt -1- make sure the balance shaft lies level on the crankshaft.
  • Page 84 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Pry out the seal in direction of -arrow A-. – Clean the running and sealing surface. – Coat the sealing surface of the balance shaft -2- with trans‐...

  • Page 85: Piston And Connecting Rod

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Piston and Connecting Rod ⇒ 5.1 Overview - Piston and Connecting Rod , page 77 ⇒ 5.2 Pistons, Removing and Installing , page 78 ⇒...

  • Page 86: Pistons, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 6 - Locking Ring ❑ Replace after removing 7 - Piston Pin ❑ Coat with oil before installing 8 - Piston ❑ Removing and installing. Refer to ⇒...
  • Page 87 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Bolts - Connecting Rod ♦...

  • Page 88: Pistons And Cylinder Bore, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Tightening Specifications ♦ Refer to ⇒ 5.1 Overview - Piston and Connecting Rod , page 77 Pistons and Cylinder Bore, Checking ⇒ 5.3.1 Pistons and Cylinder Bore, Checking, Engine Codes CXBA, CXBB, CNSA and CNSB , page 80 ⇒...
  • Page 89 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Piston Ring Groove Clearance, Checking Special tools and workshop equipment required ♦ Feeler Gauge – Clean the piston ring groove before checking. Piston Ring...
  • Page 90 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Basic Dimension Cylinder Bore Diame‐ in mm 82.51 Note The cylinder bore must not be measured when the cylinder block is mounted on the Engine and Transmission Holder - VAS6095- because the measurements may be incorrect.
  • Page 91 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Piston Ring Wear Limit Dimensions in mm 2nd Compression ring 0.40 to 0.50 0.80 Oil scraping ring 0.20 to 0.40 0.80 Piston Ring Groove Clearance, Checking Special tools and workshop equipment required ♦...

  • Page 92: New Connecting Rod, Separating

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Using a Cylinder Dial Bore Gauge - VAS6078- measure in a diagonal sequence at three positions transversely -A- and lon‐ gitudinally -B-.
  • Page 93 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Clean the bearing cap and journal. – Place the Plastigage ® over the entire width of the bearing journal or into the bearing shells.

  • Page 94: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Locking Pin - T10060A- ♦ Seal Installer, Intermediate Shaft - T10356/1- ♦ Counterhold - Vibration Damper - T10355- ♦...
  • Page 95 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Seal Installer - Sealing Flange Guide Sleeve - T20097- ♦ Dial Gauge - 0-10mm - VAS6079- ♦ Shop Crane - Drip Tray - VAS6208- ♦...
  • Page 96 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Pilot Drift - VW222A- ♦ Dial Gauge Holder - VW387- ♦ Internal puller, for example Puller - Kukko Internal - 14-19mm - 21/2- ♦...
  • Page 97 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Flywheel Retainer - 3067- ♦ Engine Support Bridge - Spindle - 10-222A/11- ♦ Plastigage ® Individual components of the Assembly Tool - T10531- : ♦...

  • Page 98: Cylinder Head, Valvetrain

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 15 – Cylinder Head, Valvetrain Cylinder Head ⇒ 1.1 Overview - Cylinder Head , page 90 ⇒ 1.2 Overview - Camshaft Housing , page 93 ⇒...
  • Page 99 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Alignment Pin 2 - Cylinder Head Gasket ❑ Replace after removing ❑ Installed position: the part number faces the cylinder head 3 - Cylinder Head ❑...
  • Page 100 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 14 - O-Ring ❑ Coat with coolant ❑ Replace after removing 15 - Connection ❑ For coolant hose 16 - Bolt ❑ 9 Nm 17 - Mount ❑...

  • Page 101: Overview - Camshaft Housing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Checking Cylinder Head for Distortion – Check the cylinder head at several locations for distortion us‐ ing a Straight Edge - 500mm - VAS6075- and a feeler gauge.

  • Page 102: Cylinder Head, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 12 - Bolt ❑ Tightening specification and sequence. Refer to ⇒ Fig. Vacuum Pump - Tightening Specifications , page 94 13 - Seal ❑...
  • Page 103 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Seal - Turbocharger to Engine ♦ Bolts - Cylinder Head ♦ Gasket - Cylinder Head Note Before installing the cylinder head the engine support and the ♦...
  • Page 104 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen the hose clamp -2-. – Free up the coolant hose -3-. – Remove the bolts -arrows-. – Disconnect the connector -1- from the Charge Air Pressure Sensor - G31- , and remove the right air guide pipe.
  • Page 105 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolt -1- and the nut -3- and then remove the bracket -2- for the intake manifold. – Disconnect the connectors:...
  • Page 106 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -3- for Knock Sensor 1 - G61- from the bracket. – Disconnect the connectors -2 through 4-. – Disconnect the connectors and free up the wires.
  • Page 107 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the nuts -arrows-. – Remove the turbocharger from the cylinder head and tie up behind. – Remove the bolts -arrows-. – Remove the cylinder head bolts in the sequence -1 to 10-.

  • Page 108: Vacuum Pump, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Pay attention to centering pins in cylinder block -arrows-. ♦ Cylinder head gasket installed position: the part number must be readable from the intake side.

  • Page 109: Compression Pressure, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Unclip the vacuum line -2- from the bracket -arrow-. – Disconnect the vacuum hose -2-. – Remove the bolts -1, 2 and 3- and carefully move the coolant line slightly to the side.
  • Page 110 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Compression Tester Kit - VAG1763- ♦ Compression Tester Kit - Adapter 1 - VAG1381/1- ♦ Compression Tester Kit - Adapter 5A - VAG1381/5A-...
  • Page 111 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Check the compression pressure using the Compression Tester Kit - VAG1763- , Compression Tester Kit - Adapter 1 - VAG1381/1- and Compression Tester Kit - Adapter 5A - VAG1381/5A- .

  • Page 112: Timing Chain Cover

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Timing Chain Cover ⇒ 2.1 Overview - Timing Chain Cover , page 104 ⇒ 2.2 Timing Chain Cover, Removing and Installing , page 106 ⇒...
  • Page 113 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 15 - Plug ❑ Replace after removing 16 - Bolt ❑ Replace after removing ❑ Tightening sequence with 15 bolts. Refer to ⇒ Fig. Lower Cover for Timing Chain - Tightening Sequence for 15 Bolts , page 106 ❑...

  • Page 114: Timing Chain Cover, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Lower Cover for Timing Chain - Tightening Sequence for 15 Bolts Tighten the Steel Bolts -1 through 15- in Three Stages in the Se‐...
  • Page 115 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen hose clamps -1-, remove coolant hose and push to the right side. – Press the release button on the EVAP canister hose -2-, re‐...
  • Page 116 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Installing – Replace seals. – Install the cover on the cylinder head the tighten the bolts hand tight. While doing so make sure that the seal lays correctly on the cylinder head.
  • Page 117 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the Oil Pressure Regulation Valve - N428- . Refer to ⇒ 4.8 Oil Pressure Regulation Valve N428 , Removing and Installing , page 206 –...
  • Page 118 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Make sure both alignment bushings for centering the cover -arrows- are present. – Cut the tube nozzle at the front marking (nozzle diameter: ap‐...
  • Page 119 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Immediately attach the cover and tighten the bolts. Note Tighten the bolts -3 and 6- with an additional turn after installing the vibration damper. The bolts must be removed again to install the vibration damper.

  • Page 120: Vibration Damper Sealing Ring, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Immediately attach the cover and tighten the bolts. Note Tighten the bolts -1 and 4- with an additional turn after installing the vibration damper. The bolts must be removed again to install the vibration damper.
  • Page 121 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Seal - Vibration Damper Removing – Remove the vibration damper. Refer to ⇒ 1.4 Vibration Damper, Removing and Installing , page 47 •...

  • Page 122: Chain Drive

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Chain Drive ⇒ 3.1 Overview - Camshaft Timing Chain , page 114 ⇒ 3.2 Overview - Balance Shaft Drive Chain , page 116 ⇒...
  • Page 123 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Bolt ❑ 4 Nm + 90° ❑ Replace after removing 2 - Chain Tensioner ❑ Is under tension ❑ Secure using Tensioner...

  • Page 124: Overview - Balance Shaft Drive Chain

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 14 - Three Stage Chain Sprocket ❑ Crankshaft ❑ Installed position. Refer to ⇒ Fig. Three Stage Chain Sprocket - Installed Position , page 116...
  • Page 125 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Guide Pin ❑ 20 Nm 2 - Tensioning Rail ❑ For the timing chain 3 - Balance Shaft ❑ Exhaust side ❑...

  • Page 126: Camshaft Timing Chain, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 18 - Balance Shaft Drive Chain ❑ Removing and installing. Refer to ⇒ 3.4 Balance Shaft Drive Chain, Removing and Installing , page 130 Mounting Pins - Installation Position •...
  • Page 127 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Tensioning Pins - T10531/2- ♦ Turning Over Tool - T10531/3- ♦ Collar Nut - T10531/4- Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.
  • Page 128 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the left and right pilot valves using the Assembly Tool - T10352/2- in the direction of the -arrow-. – Remove the bolts -arrows- and remove the bearing bracket.
  • Page 129 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Secure the chain tensioner with the Tensioner Locking Tool - T40267- . – Remove the Chain Tensioner Lever - T40243- . – Bolt the Camshaft Lock - Component 2 - T40271/2- to the cyl‐...
  • Page 130 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows- and remove the chain tensioner -1-. – Press the oil pump chain tensioner bracket in direction of -arrow- and lock with Locking Pin (3 pc.) - T40011- .
  • Page 131 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the chain tensioner -1- for the balance shaft timing chain. – Remove the bolts -1-. Remove the tensioning rail -2- and the glide rails -3 and 4-.
  • Page 132 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Draw a marking -2- on the three stage chain sprocket tooth -1- with a waterproof marker. – Turn the intermediate sprocket and balance shaft to the mark‐...
  • Page 133 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Engage the camshaft timing chain with the painted links -arrows- on the camshaft pins. – Lay the oil pump drive timing chain onto the three stage chain sprocket.
  • Page 134 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Position the painted chain link in the balance shaft drive chain -arrow- at the marking on the three stage chain sprocket. In‐...
  • Page 135 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the guide rail -2- and tighten the bolts -1-. – Install the upper glide rail -1-. For the following steps a second technician is necessity.
  • Page 136 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the chain tensioner -1- and tighten the bolts -arrows-. – Install the chain tensioner -2-. The wire clip -arrow- must come in to contact with the oil pan upper section opening.
  • Page 137 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the bolts -arrows- and tighten them. Tightening specifi‐ cation. Refer to -item 4- ⇒ Item 4 (page 91) – Lubricate the holes -arrows- with engine oil.

  • Page 138: Balance Shaft Drive Chain, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the turning over tool and install the lower timing chain cover. Refer to ⇒ page 109 Note Tighten the bolts -1 and 4- with an additional turn after installing the vibration damper.

  • Page 139: Valve Timing, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Note If due to complaints (for example noises) an elongated camshaft timing chain is suspected, the chain length can be checked as described as follows.
  • Page 140 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Turn the crankshaft with the socket SW 24 on the vibration damper in the direction of the engine rotation until the mark‐...

  • Page 141: Valvetrain

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Valvetrain ⇒ 4.1 Overview - Valvetrain , page 133 ⇒ 4.2 Camshaft, Removing and Installing , page 136 ⇒ 4.3 Camshaft Adjustment Valve 1 N205 , Removing and In‐...
  • Page 142 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Exhaust Valve ❑ Do not rework, only lap‐ ping is permitted ❑ Valve dimensions. Re‐ fer to ⇒ 5.3 Valve Dimen‐...
  • Page 143 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 14 - Bolt ❑ Replace after removing ❑ Loosening. Refer to ⇒ Fig. Loosening the Cylinder Head Cover , page 135 ❑ Tightening sequence. Refer to ⇒...

  • Page 144: Camshaft, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Camshaft, Removing and Installing ⇒ 4.2.1 Camshaft, Removing and installing. Engine Codes CXBA, CNSA, CXBB, and CNSB , page 136 ⇒ 4.2.2 Camshaft, Removing and Installing, Engine Codes CNTA, CXCA, CXCB , page 148 4.2.1...
  • Page 145 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove bolts -1, 2 and 3-. Carefully swing coolant line back‐ ward slightly. NOTICE Risk of destroying the coolant pipes through deformation.
  • Page 146 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the lower timing chain cover. Refer to ⇒ 2.2.2 Lower Timing Chain Cover, Removing and Installing , page 108 Note The pilot valve has left-hand threads.
  • Page 147 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the Chain Tensioner Lever - T40243- -arrows-. – Press the chain tensioner locking ring -1- together and hold it. – Slowly press and hold the Chain Tensioner Lever - T40243- in the direction of -arrow-.
  • Page 148 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the guide rail -1- by unlocking the latch -arrow- with a screwdriver and pushing the guide rail forward. – Press the oil pump chain tensioner bracket in direction of -arrow- and lock with Locking Pin (3 pc.) - T40011- .
  • Page 149 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Turn the intake camshaft in the direction of the -arrow 1- using the Adapter - T40266- . Slide the Camshaft Lock - T40271/2- out of the chain sprocket splines -2- and bring the camshaft into the rest position.
  • Page 150 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Insert the exhaust camshaft -1- in the cylinder head cover. Turn the cam lobes from cylinder 4 -arrows- upward. – Turn the intake camshaft -1- and the exhaust camshaft -2- until the markings -arrows- are in the -position shown-.
  • Page 151 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Lightly push on the cylinder head cover by hand and while doing this turn the camshaft slightly until the cylinder head cover lays free of tension on the cylinder head.
  • Page 152 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Install the Camshaft Timing Chain – Engage the camshaft timing chain with the painted links -arrows- on the camshaft pins. – Place the camshaft timing chain on the intake camshaft, ex‐...
  • Page 153 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the upper glide rail -1-. For the following steps a second technician is necessity. I - Turn the exhaust camshaft with the Adapter - T40266- slightly in the direction of -arrow A- and push the Camshaft Lock - Com‐...
  • Page 154 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Attach the bearing mount. Do not tilt it when doing this. Hand- tighten the bolts -arrows-. – Remove the Tensioner Locking Tool - T40267- .
  • Page 155 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Check the adjustment. The painted chain links -arrows- must line up with the markings on the chain sprockets. – Install the pilot valves -item 7- ⇒...
  • Page 156 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Note Tighten the bolts -1 and 4- with an additional turn after installing the vibration damper. The bolts must be removed again to install the vibration damper.
  • Page 157 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Camshaft Locks - T40271- ♦ Adapter - T40266- ♦ Sealant - D 154 103 A1- Removing Note The sealing surfaces of the lower cylinder head cover and on ♦...
  • Page 158 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -1- from the EVAP Canister Purge Regulator Valve 1 - N80- . – Press the release button on the crankcase ventilation hose -2- and remove the hose.
  • Page 159 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows- and remove the bearing bracket. – Remove the bolts -arrows-. – Install the Chain Tensioner Lever - T40243- -arrows-.
  • Page 160 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Bolt the Camshaft Lock - Component 2 - T40271/2- to the cyl‐ inder head and slide into the splines on the chain sprocket in the direction of -arrow 2-.
  • Page 161 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -1- and remove the glide rail -2-. – Remove the camshaft timing chain from the camshaft bearing and guide downward.
  • Page 162 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the camshaft and cover the open engine compo‐ nents. Camshafts, Installing Note Sealing surfaces must be completely free of oil and grease.
  • Page 163 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Apply the sealant on the clean sealing surface of the cylinder head cover as illustrated -arrows-. ♦ Sealant bead thickness: 2 to 3 mm.
  • Page 164 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Turn the crankshaft on the hex fitting to the TDC point . In the TDC point flat area -1- is upward. Install Camshaft Timing Chain –...
  • Page 165 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the guide rail -2- and tighten the bolts -1-. – Install the upper glide rail -1-. For the following steps a second technician is necessity.
  • Page 166 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Turn the intake camshaft with the Adapter - T40266- in the direction of -arrow 1- until the Camshaft Lock - Component 2 - T40271/2- can be pushed out of the chain sprocket splines in the direction of -arrow 2-.
  • Page 167 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Tighten the bearing bracket bolts -arrows-. Tightening speci‐ fication. Refer to ⇒ 3.1 Overview - Camshaft Timing Chain , page 114 – Install the chain tensioner -2-. The wire clip must come in to contact with the oil pan upper section opening -arrow-.

  • Page 168: Camshaft Adjustment Valve 1 N205 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Note Tighten the bolts -1 and 4- with an additional turn after installing the vibration damper. The bolts must be removed again to install the vibration damper.

  • Page 169: Camshaft Adjustment Valve 1 N205 And Exhaust Camshaft Adjustment Valve 1 N318 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Mandatory Replacement Parts ♦ Bolts - Camshaft Adjustment Valve 1 ♦ O-ring - Camshaft Adjustment Valve 1 ♦ Seal - Camshaft Adjustment Valve 1 Removing –...

  • Page 170: Sliding Bar Ball, Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows- and Camshaft Adjustment Valve 1 - N205- -4- and Exhaust Camshaft Adjustment Valve 1 - N318- -2-. Installing Install in reverse order of removal.

  • Page 171: Valve Stem Seals, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Valve Stem Seals, Removing and In‐ stalling ⇒ 4.6.1 Valve Stem Seals, Removing and Installing, Cylinder Head Installed , page 163 ⇒ 4.6.2 Valve Shaft Seals, Removing and Installing, Cylinder Removed , page 166 4.6.1...
  • Page 172 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the Valve Cotter Tool Kit - Adapter - T40012- in the spark plug threads. – Connect compressed air with at least 6 bar (87 psi) pressure.
  • Page 173 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the valve stem seals using Puller - Valve Seal - 3364- . – If the Puller - Valve Seal - 3364- cannot be used because there is not enough space, drive the roll pin -arrow- out using a drift and remove the impact attachment.
  • Page 174 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Intake Side Exhaust Side Note If the valve retainers were removed from the assembly car‐ ♦ tridge, they must then be inserted into the Valve Insertion Device - VAS5161/18- .
  • Page 175 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Engine And Transmission Holder - VAS6095- ♦ Cylinder Head Tensioning Device - VAS6419- Remove Valve Stem Seals – Remove the camshafts. Refer to ⇒...
  • Page 176 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 For Exhaust Side – Install the Retainer - VAS5161/6- with Forks M6/M8 Threaded - VAS5161/5- in the outer thread of the Valve Cotter Tool Kit - Guide Plate 19B - VAS5161/19B- .
  • Page 177 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Intake Side Exhaust Side Note If the valve retainers were removed from the assembly car‐ ♦ tridge, they must then be inserted into the Valve Insertion Device - VAS5161/18- .

  • Page 178: Intake And Exhaust Valves

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Intake and Exhaust Valves ⇒ 5.1 Valve Guides, Checking , page 170 ⇒ 5.2 Valves, Checking , page 170 ⇒ 5.3 Valve Dimensions , page 170...

  • Page 179: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Puller - Valve Seal - 3364- ♦ Seal Installer - Valve Stem - 3365- ♦...
  • Page 180 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Assembly Tool - T10352/2- ♦ Counterhold - Vibration Damper - T10355- ♦ Locking Pin (3 pc.) - T40011- ♦ Chain Tensioner Lever - T40243- ♦...
  • Page 181 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Central Valve Assembly Tool - T10352- ♦ Counterhold - Vibration Damper - T10355- ♦ Chain Tensioner Lever - T40243- ♦ Tensioner Locking Tool - T40267- ♦...
  • Page 182 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Spark Plug Removal Tool - 3122B- ♦ Puller - Valve Seal - 3364- ♦ Seal Installer - Valve Stem - 3365- ♦ Valve Cotter Tool Kit - Adapter - T40012- ♦...
  • Page 183 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Assembly Tool - T10531- ♦ ♦ Mount - T10531/1- ♦ Tensioning Pins - T10531/2- ♦ Turning Over Tool - T10531/3- ♦ Collar Nut - T10531/4- ♦...
  • Page 184 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Adapter - T40266- ♦ Seal Installer - Crankshaft - T40274- ♦ Compression Tester Kit - Adapter 5A - VAG1381/5A- ♦ Compression Tester Kit - VAG1763-...
  • Page 185 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Dial Gauge - 0-10mm - VAS6079- ♦ Compression Tester Kit - Adapter 1 - VAG1381/1- ♦ Engine Bung Set - VAS6122- ♦ Dial Gauge Set - VAS6341- ♦...
  • Page 186 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Hose Clip Pliers - VAS6362- Rep. Gr.15 - Cylinder Head, Valvetrain...

  • Page 187: Lubrication

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 17 – Lubrication Oil Pan/Oil Pump ⇒ 1.1 Overview - Oil Pan/Oil Pump , page 179 ⇒ 1.2 Engine Oil , page 182 ⇒...
  • Page 188 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Nut ❑ 9 Nm 2 - Oil Level Thermal Sensor - G266- ❑ Removing and instal‐ ling. Refer to ⇒ 1.6 Oil Level Ther‐...
  • Page 189 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 16 - Bolt ❑ 9 Nm 17 - Chain Tensioner 18 - O-Ring ❑ Replace after removing ❑ Coat with engine oil 19 - Oil Pressure Regulation Valve - N428- ❑...

  • Page 190: Engine Oil

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Engine Oil The oil capacity it determined by attempting. For reasons of tol‐ erance, the oil temperature and dripping time cause variance in the actual oil capacity.
  • Page 191 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Removing – Remove the noise insulation -1-. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
  • Page 192 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Hand Drill with Plastic Brush Attachment ♦ Protective Eyewear ♦ Silicone sealant. Refer to Parts Catalog. Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

  • Page 193: Oil Pan Upper Section, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolt -1- and remove the oil baffle -2-. Installing – Install a new oil baffle. Tightening specification. Refer to -item 7- ⇒...
  • Page 194 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Bolts - Lower Timing Chain Cover Removing • The transmission is removed. – Remove the oil pan lower section. Refer to ⇒ 1.3 Oil Pan Lower Section, Removing and Installing , page –...
  • Page 195 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -1 through 14-. – First pry the upper section oil pan out on the transmission side. When prying out, be careful not to bend the timing chain cover.

  • Page 196: Oil Pump, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Note The lubrication system could be plugged with excess sealant. Do not apply sealant bead thicker than indicated. – Apply the silicone sealant on the clean sealing surface of the upper oil pan section as shown -arrows-.
  • Page 197 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Chain Tensioner Locking Tool - T40265- Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦...

  • Page 198: Oil Level Thermal Sensor G266 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows- and the oil pump. Installing Install in reverse order of removal and note the following: – Make sure there are both alignment bushings for centering the oil pump.
  • Page 199 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -3-. – Remove the nuts -1- and the Oil Level Thermal Sensor - G266- -4-. Installing Install in reverse order of removal. Note the following: –...

  • Page 200: Engine Oil Cooler

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Engine Oil Cooler ⇒ 2.1 Overview - Engine Oil Cooler , page 192 ⇒ 2.2 Engine Oil Cooler, Removing and Installing , page 192 ⇒...
  • Page 201 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Seal - Engine Oil Cooler...

  • Page 202: Mechanical Switch Valve, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Mechanical Switch Valve, Removing and Installing Removing Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦...

  • Page 203: Crankcase Housing Ventilation

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Crankcase Housing Ventilation ⇒ 3.1 Overview - Crankcase Ventilation , page 195 ⇒ 3.2 Oil Separator, Removing and Installing , page 196 Overview - Crankcase Ventilation...

  • Page 204: Oil Separator, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Oil Separator - Tightening Sequence – Tighten the bolts in the sequence -1 through 7-. Bolts Tightening Sequence and Tor‐ que Specification -1 through 7- 9 Nm.

  • Page 205: Oil Filter/Oil Pressure Switch

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Oil Filter/Oil Pressure Switch ⇒ 4.1 Overview - Oil Filter , page 197 ⇒ 4.2 Overview - Oil Pressure Switch/Oil Pressure Regulator Valve , page 198 ⇒...

  • Page 206: Overview - Oil Pressure Switch/Oil Pressure Regulator Valve

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Overview - Oil Pressure Switch/Oil Pressure Regulator Valve 1 - Bolt ❑ 4 Nm + 90° turn ❑ Replace after removing 2 - Oil Pressure Regulation Valve - N428- ❑...

  • Page 207: Oil Pressure Switch F1 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 12 - Oil Pressure Switch, Level 3 - F447- ❑ 20 Nm ❑ Checking. Refer to Vehicle Diagnostic Tester ❑ Removing and installing. Refer to ⇒...

  • Page 208: Reduced Oil Pressure Switch F378 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the Oil Pressure Switch -1-. Installing Note To prevent oil loss, insert the Oil Pressure Switch - F1- in the opening immediately.

  • Page 209: Oil Pressure Switch, Level 3 F447 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the Reduced Oil Pressure Switch -1-. Installing Install in reverse order of removal. Note the following: Note Insert the Reduced Oil Pressure Switch - F378- immediately to prevent losing any engine oil.

  • Page 210: Oil Pressure, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows-, loosen the screw-type clamp and remove the air guide pipe. – Disconnect the connector -1- from the Oil Pressure Switch, Level 3 - F447- .
  • Page 211 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 • The engine oil temperature at least 80 °C (176 °F) (the coolant fan must start up once). Note The oil pump is regulated and has two pressure stages. The ♦...
  • Page 212 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the connector -1- from the Oil Pressure Regulation Valve - N428- . Unclip the cable and route downward so that is not in the belt drive unit. With the connector removed the oil pump only pumps in the higher pressure stage.

  • Page 213: Piston Cooling Nozzle Control Valve N522 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – The threaded hole in the Oil Pressure Gauge Kit - VAG1342- must be closed. If necessary install the Oil Pressure Switch, Level 3 - F447- .

  • Page 214: Oil Pressure Regulation Valve N428 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolt -1- and remove the Piston Cooling Nozzle Control Valve - N522- -2-. Installing Install in reverse order of removal. Note the following: Note Replace the O-rings.
  • Page 215 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolt -2- and the Oil Pressure Regulation Valve - N428- . Installing Install in reverse order of removal. Note the following: Note Replace the O-ring after removing.

  • Page 216: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Used Oil Collection and Extraction Unit - SMN372500- ♦ Elbow Assembly Tool - T10118- ♦...
  • Page 217 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Oil Pressure Gauge Kit - VAG1342- ♦ Shop Crane - Drip Tray - VAS6208- ♦ Not Illustrated: ♦ Oil Drain Plug Assembly Tool - T10549-...

  • Page 218: Cooling System

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 19 – Cooling System Cooling System/Coolant ⇒ 1.1 Connection Diagram - Coolant Hoses , page 210 ⇒ 1.2 Coolant System, Checking for Leaks , page 216 ⇒...
  • Page 219 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Radiator ❑ Change the coolant af‐ ter replacing 2 - Engine Coolant Tempera‐ ture Sensor on Radiator Outlet - G83- 3 - Engine Temperature Con‐...
  • Page 220 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1.1.2 Coolant Hose Connection Diagram, Ve‐ hicles with a DSG Transmission with‐ ® out Recirculation Pump - V55- Note Blue = large coolant circuit.
  • Page 221 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 13 - Restrictor 14 - Check Valve 15 - After-Run Coolant Pump - V51- 16 - Engine Coolant Temperature Sensor - G62- 17 - Coolant Shut-Off Valve - N82-...
  • Page 222 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Radiator ❑ Change the coolant af‐ ter replacing 2 - Engine Coolant Tempera‐ ture Sensor on Radiator Outlet - G83- 3 - Engine Temperature Con‐...
  • Page 223 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1.1.4 Coolant Hose Connection Diagram, Ve‐ hicles with DSG Transmission and ® Auxiliary Cooler Note Blue = large coolant circuit. ♦ Red = small coolant circuit.

  • Page 224: Coolant System, Checking For Leaks

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 12 - Restrictor 13 - Check Valve 14 - After-Run Coolant Pump - V51- 15 - Engine Coolant Temperature Sensor - G62- 16 - Coolant Shut-Off Valve - N82-...

  • Page 225: Coolant, Draining And Filling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Position the Cooling System Tester - VAG1274B- with the adapter -VAG1274/8- on the coolant expansion tank. – Generate approximately 1 bar pressure (14.5 psi) using the cooling system tester hand pump.
  • Page 226 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the cap -arrow- from the coolant expansion tank. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
  • Page 227 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Note The water portion of the coolant influences the effectiveness ♦ of the coolant. Based on the contents, the country or even the region specific quality can be different.
  • Page 228 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Connect coolant hose and lower right coupling -1- to the radi‐ ator. Refer to ⇒ Fig. Connect the Coolant Hose to the Coupling , page 245 –...
  • Page 229 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Open valve -B- by turning level in direction of flow. • The suction jet pump generates pressure in the coolant sys‐ tem; indicator on display instrument must move into green area.
  • Page 230 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Check the coolant level. • The coolant level must be between the min and max mark‐ ings when the engine is cold.

  • Page 231: Coolant Pump/Thermostat

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Coolant Pump/Thermostat ⇒ 2.1 Overview - Coolant Pump/Thermostat , page 223 ⇒ 2.2 Overview - Electric Coolant Pump , page 226 ⇒ 2.3 Overview - Engine Coolant Temperature Sensor , page 228 ⇒...
  • Page 232 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Connection 2 - O-Ring ❑ Replace after removing ❑ Coat with coolant 3 - Centering Pin 4 - Bolt ❑ Tightening specification and sequence.
  • Page 233 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 17 - Connecting Piece 18 - Spring 19 - Seal ❑ Replace after removing 20 - Engine Temperature Control Actuator - N493- ❑ Removing and installing. Refer to ⇒...

  • Page 234: Overview - Electric Coolant Pump

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Overview - Electric Coolant Pump After-Run Coolant Pump - V51- , Coolant Shut-Off Valve - N82- 1 - Coolant Hose 2 - Coolant Shut-Off Valve - N82- ❑...
  • Page 235 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Bolt ❑ 9 Nm 2 - Coolant Hose 3 - Nut ❑ 9 Nm 4 - Coolant Hose 5 - Transmission Coolant Valve - N488- ❑...

  • Page 236: Overview - Engine Coolant Temperature Sensor

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Overview - Engine Coolant Temperature Sensor 1 - Clamp ❑ Make sure it is secure 2 - O-Ring ❑ Replace after removing 3 - Engine Coolant Tempera‐...
  • Page 237 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Removing Note During installation, all heat insulation sleeves must be installed at the same location. CAUTION The coolant system is under pressure when the engine is warm.

  • Page 238: Coolant Shut-Off Valve N82 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Open the heat protection sleeve -3-. – Disconnect the connector -1-. – Clamp the coolant hoses on the After-Run Coolant Pump - V51- with the Hose Clamps - Up To 25mm - 3094- .

  • Page 239: Transmission Coolant Valve N488 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -2-. – Clamp the coolant hoses on Coolant Shut-Off Valve - N82- with the Hose Clamps - Up To 25mm - 3094- .

  • Page 240: Coolant Pump, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen the hose clamp -arrow- and remove the charge air hose -1- with the air guide pipe downward. – Disconnect the connector -1-.
  • Page 241 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen the hose clamp -arrow- and remove the charge air hose -1- with the air guide pipe downward. – Remove the bolt -arrow- on the left and right.
  • Page 242 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -1- from the Oil Pressure Switch -2-. – Remove the bolts -arrows- and remove the toothed belt cover. – Loosen the bolts -1 to 4- and remove the toothed belt from the coolant pump.

  • Page 243: Coolant Pump Toothed Belt, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Coolant Pump Toothed Belt, Removing and Installing Special tools and workshop equipment required ♦ Torque Wrench 1331 Insert - Ring Wrench - 12mm - T10360- ♦...
  • Page 244 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Lift the clamp -1-, remove the upper coolant supports and set them aside. – Disconnect the connector -1- from the Oil Pressure Switch -2-.

  • Page 245: Engine Temperature Control Actuator N493 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Engine Temperature Control Actuator - N493- , Removing and Installing Removing Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

  • Page 246: Engine Coolant Temperature Sensor G62 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -1 to 5-. – Remove the Engine Temperature Control Actuator - N493- from the centering pin and disconnect it from the engine oil cooler.

  • Page 247: Engine Coolant Temperature Sensor On Radiator Outlet G83 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen the hose clamp -2-. – Remove bolt -1-, push the left air guide pipe left. – Disconnect the connector -1-. Note Place a cleaning cloth underneath, to catch coolant leaking ♦...
  • Page 248 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Quickly open the coolant expansion tank cap -arrow- and re‐ lease any remaining pressure in the cooling system and then close it again until it locks.

  • Page 249: Coolant Pipes

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Coolant Pipes ⇒ 3.1 Overview - Coolant Pipes , page 241 ⇒ 3.2 Front Coolant Pipes, Removing and Installing , page 241 ⇒ 3.3 Upper Coolant Pipes, Removing and Installing ,...

  • Page 250: Upper Coolant Pipes, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Open the retainer in direction of -arrow- and remove the cover -2-. – Free up the coolant hose -2-. – Open the retaining tabs in direction of -arrows-, remove the upper air duct -1-.
  • Page 251 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Hose Clip Pliers - VAS6362- Removing – Remove the ignition coils with power output stages cylinder 3 . Refer to ⇒ 1.3 Ignition Coils with Power Output Stages, Removing and Installing , page 357 –...

  • Page 252: Radiator/Coolant Fan

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Radiator/Coolant Fan ⇒ 4.1 Overview - Radiator/Coolant Fan , page 244 ⇒ 4.3 Overview - Fan Shroud and Radiator Fan , page 247 ⇒...

  • Page 253: Overview - Auxiliary Cooler

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 8 - Air Guide 9 - Air Guide 10 - Radiator Mount 11 - Condenser ❑ Removing and installing. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; Refrigerant Circuit;...
  • Page 254 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - Air Guide 2 - Auxiliary Cooler ❑ Removing and instal‐ ling. Refer to ⇒ 4.7 Auxiliary Cooler, Removing and Instal‐ ling , page 251...

  • Page 255: Overview - Fan Shroud And Radiator Fan

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Overview - Fan Shroud and Radiator Fan 1 - Bolt ❑ 5 Nm 2 - Fan Shroud ❑ Removing and instal‐ ling. Refer to ⇒...
  • Page 256 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove upper left coolant hose from radiator -arrow-. – Remove the fan shroud. Refer to ⇒ 4.5 Fan Shroud, Removing and Installing , page 249 –...

  • Page 257: Fan Shroud, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Installing – If there are small impressions on the fins, pay attention to the following. Refer to ⇒ 3.5 Cooler and Condenser Assembly , page 6 –...

  • Page 258: Coolant Fan, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the radiator fan connector -1-. To do this push the securing device -A- in the direction of -arrow A- and push the release downward.

  • Page 259: Auxiliary Cooler, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 4.6.2 Coolant Fan 2 - V177- , Removing and Installing Removing Note During installation, all cable ties must be installed at the same location.
  • Page 260 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the air guide -A- in the direction of -arrows- from the auxiliary cooler. Note Place a cloth underneath to catch any escaping coolant.

  • Page 261: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Cooling System Tester - Adapter - VAG1274/8- ♦ Hose Clip Pliers - VAS6340- ♦ Cooling System Charge Kit - VAS6096- ♦...
  • Page 262 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Cooling System Tester - VAG1274B- ♦ Cooling System Tester - Adapter - VAG1274/8- ♦ Cooling System Tester - Adapter - VAG1274/9- ♦ Hose Clip Pliers - VAS6340-...
  • Page 263 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Hose Clamps - Up To 25mm - 3094- ♦ Not Illustrated: ♦ Hose Clip Pliers - VAS6362- ♦ Torque Wrench 1410 - VAG1410-...

  • Page 264: Turbocharger, Supercharger

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 21 – Turbocharger, Supercharger Turbocharger ⇒ 1.1 Overview - Turbocharger , page 256 ⇒ 1.2 Turbocharger, Removing and Installing , page 258 ⇒ 1.3 Charge Pressure Actuator V465 , Adjusting , page 263 Overview - Turbocharger Overview - Turbocharger, Part I.
  • Page 265 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 15 - Bolt ❑ 9 Nm 16 - Connection 17 - O-Ring ❑ Replace after removing 18 - Bolt ❑ 9 Nm Overview - Turbocharger, Part II 1 - Bolt ❑...

  • Page 266: Turbocharger, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 16 - Bolt ❑ 9 Nm 17 - Bolt ❑ 9 Nm 18 - Coolant Supply Line 19 - O-Ring ❑ Replace after removing ❑...
  • Page 267 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Seal - Turbocharger ♦ Bolts- Pendulum Support Note If mechanical damage (such as a destroyed compression ♦ wheel) is found on the turbocharger, just replacing the turbo‐...
  • Page 268 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – If applicable, remove bolt -1- for the ground cable. Remove the coolant hose -2-. – Remove the available connectors -arrows-. – Release the catch in direction of -arrow- and remove the wiring duct -4- upward from the bracket.
  • Page 269 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolt -1-. Just loosen bolt -3-. – Remove the turbocharger bracket -2-. – Disconnect the connectors -1 and 3-. On Vehicles with the Engine Code CXDA –...
  • Page 270 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Pull the engine toward the rear with the Tensioning Strap - T10038- approximately 20 mm. – Remove the nuts -arrows-. – Remove the turbocharger from the cylinder head and pry up upward.

  • Page 271: Charge Pressure Actuator V465 , Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Charge Pressure Actuator - V465- , Ad‐ justing Special tools and workshop equipment required ♦ Mini Torque Wrench - VAS6854- ♦ Vehicle Diagnostic Tester...

  • Page 272: Charge Air System

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Charge Air System ⇒ 2.1 Overview - Charge Air System , page 264 ⇒ 2.2 Overview - Charge Air Hose Connections , page 265 ⇒...

  • Page 273: Overview - Charge Air Hose Connections

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 15 - Charge Air Pressure Sensor - G31- ❑ Removing and installing. Refer to ⇒ 2.4 Charge Air Pressure Sensor G31 , Removing and Installing , page 269 16 - O-Ring ❑...
  • Page 274 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Open the retainer in direction of -arrow- and remove the cover -2-. – Free up the coolant hose -2-. – Open the retaining tabs in direction of -arrows-, remove the upper air duct -1-.
  • Page 275 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the center guide -A- from the lock carrier -arrows-. – Remove the left and right radiator mount catches in direction of -arrows- with a side cutter. Push the upper coolant radiator slightly to the engine.
  • Page 276 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Installing Install in reverse order of removal. Note the following: – If there are small impressions on the fins, pay attention to the following.

  • Page 277: Charge Air Pressure Sensor G31 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Charge Air Pressure Sensor - G31- , Removing and Installing Removing Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.
  • Page 278 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Connect the Turbo System Tester Kit - Adapter 10 - VAG1687/10- with the Adapter - VAG1687/14- to the turbo‐ charger. – Connect the Turbo System Tester Kit - VAG1687- to the adapter.

  • Page 279: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Tensioning Strap - T10038- ♦ Turbo System Tester Kit - VAG1687- ♦ Engine Bung Set - VAS6122- ♦...
  • Page 280 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Turbo System Tester Kit - Adapter 10 - VAG1687/10- ♦ Turbo System Tester Kit - Adapter - VAG1687/14- ♦ Ultrasonic Tester - VAG1842S-...

  • Page 281: Multiport Fuel Injection

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 24 – Multiport Fuel Injection Fuel Injection System ⇒ 1.1 Overview - Component Location, Fuel Injection System , page 273 ⇒ 1.2 High Fuel Pressure, Reducing , page 283...
  • Page 282 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Heater For Oxygen Sensor 1 After Catalytic Converter - Z29- ❑ Component location. Refer to ⇒ Fig. Oxygen Sensor 1 after Catalytic Converter -GX7- -1- , page 283 ❑...
  • Page 283 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Oxygen Sensor Heater - Z19- ❑ Component location. Refer to ⇒ Fig. Oxygen Sensor 1 before Catalytic Converter -GX10- -1- , page 283 ❑...
  • Page 284 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 17 - Engine Speed Sensor - G28- ❑ 4 Nm + 45° ❑ Component location. Refer to ⇒ Fig. Engine Speed Sensor -G28- -1- , page 282 ❑...
  • Page 285 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 EPC Throttle Drive Angle Sensor 2 - G188- ❑ After replacing or removing and installing the Throttle Valve Control Module - GX3- must be adapted to the Engine Control Module - J623- .
  • Page 286 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 B - Fuel Injector, Intake-Manifold Fuel Injection ❑ Only installed on vehicles with the engine codes CXDA and CHHB ❑ Component location. Refer to ⇒...
  • Page 287 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Accelerator Pedal Module - GX2- 2 - Accelerator Pedal Module Connector Installed Location of the Brake Lamp Switch - F- / Brake Pedal Switch - F63- and Vacuum Sensor - G608- .
  • Page 288 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Fuel Pump Control Module - J538- -1- Ignition Coils and Adjusting Elements 1 - Ignition Coil 1 with Power Output Stage - N70-...
  • Page 289 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Intake Manifold Fuel Injectors 1 - Cylinder 1 Fuel Injector 2 - N532- only installed on vehicles with the engine codes CXDA and CHHB...
  • Page 290 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Intake Manifold Runner Position Sensor - G336- -1- Connectors 1 - For combustion chambers fuel injectors 2 - For Knock Sensor 1 - G61- 3 - For Oil Pressure Switch, Level 3 - F447- 4 - For Intake Manifold Runner Control Valve - N316- , Fuel Pres‐...

  • Page 291: High Fuel Pressure, Reducing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Oxygen Sensors 1 - Oxygen Sensor 1 after Catalytic Converter - GX7- connector 2 - Oxygen Sensor 1 before Catalytic Converter - GX10- connec‐...
  • Page 292 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 The fuel rail will continue to be filled with fuel, but it will no longer be under high pressure. CAUTION Fuel system is under pressure.

  • Page 293: Fuel Injectors

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Fuel Injectors ⇒ 2.1 Overview - Fuel Injector , page 285 ⇒ 2.2 Fuel Injectors, Removing and Installing , page 285 ⇒ 2.4 Fuel Injector Seals, Replacing , page 288 ⇒...
  • Page 294 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the fuel rail. Refer to ⇒ 4.4 Fuel Rail, Removing and Installing, Direct Fuel Injec‐ tion , page 309 Removing Fuel Injectors, in the Event That They Are Stuck in the Fuel Rail Carefully remove the fuel injectors out of the fuel rail.

  • Page 295: Intake Manifold-Fuel Injectors, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Guide the Puller - T10133/2A- in the groove on the fuel injec‐ tor. – Install the Removal Tool Injector/Combustion Chamber Seal Tool Set - 16A - T10133/16A- .

  • Page 296: Fuel Injector Seals, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove bolts -arrows- from the fuel rail. – Carefully remove the fuel rail and fuel injector upward. – Disconnect the connectors on the fuel injectors.
  • Page 297 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Mount - Fuel Injector ♦...
  • Page 298 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Slide the combustion chamber seal with the Injector/Combus‐ tion Chamber Seal Tool Set Assembly Sleeve - T10133/6- onto the Injector/Combustion Chamber Seal Tool Set Assem‐...

  • Page 299: Fuel Injectors, Cleaning

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Use the included Injector/Combustion Chamber Seal Tool Set Nylon Brush - T10133/4- to thoroughly clean the high-pressure fuel injector bores in the cylinder head before installing the fuel injectors.
  • Page 300 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Note Fill the ultrasonic device up to the upper edge of the holes with ♦ cleaner (see the magnified area of the illustration).

  • Page 301: Air Filter

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Air Filter ⇒ 3.1 Overview - Air Filter Housing , page 293 ⇒ 3.2 Air Filter Housing, Removing and Installing , page 294...

  • Page 302: Air Filter Housing, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 18 - Air Guide ❑ On the air filter housing lower section Air Filter Housing, Removing and Instal‐ ling Removing – Remove the bolts -1 and 3-.
  • Page 303 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the vacuum hose -1-. – Loosen the clamp -2- and remove the air guide hose. – Carefully remove the air filter housing -3-.

  • Page 304: Intake Manifold

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Intake Manifold ⇒ 4.1 Overview - Intake Manifold , page 296 ⇒ 4.2 Overview - Intake Manifold Lower Section with Fuel Rail , page 300 ⇒...
  • Page 305 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Sensor - G42- 4 - Intake Air Temperature Sensor - G42- with Manifold Absolute Pressure Sensor - G71- ❑ 5 Nm 5 - O-Ring ❑...
  • Page 306 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ❑ Fuel rail to cylinder head 4.1.2 Overview - Intake Manifold, with Intake-Manifold Fuel Injection 1 - Intake Manifold ❑ Removing and instal‐...
  • Page 307 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 12 - High Pressure Line Union Nut ❑ 27 Nm ❑ Lubricate the high pressure line with engine oil 13 - High Pressure Line Connection ❑...

  • Page 308: Overview - Intake Manifold Lower Section With Fuel Rail

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Overview - Intake Manifold Lower Sec‐ tion with Fuel Rail ⇒ 4.2.1 Overview - Intake Manifold Lower Section with Fuel Rail, Direct Fuel Injection , page 300 4.2.1...
  • Page 309 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ❑ Lubricate the high pressure line with engine oil 10 - High Pressure Line Union Nut ❑ 27 Nm ❑ Lubricate the high pressure line with engine oil...
  • Page 310 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 4.2.2 Overview - Intake Manifold Lower Sec‐ tion with Fuel Rail, Multiport Fuel Injec‐ tion Note Only for vehicles with engine codes CHHB and CXDA 1 - Bolt ❑...
  • Page 311 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ❑ Lubricate the high pressure line with engine oil ❑ Do not install a tensioned high pressure line (pay attention to cleanliness). 11 - Fuel Line Connections ❑...

  • Page 312: Intake Manifold, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Intake Manifold, Removing and Instal‐ ling Special tools and workshop equipment required ♦ Torx Socket - T30 - T10347- ♦ Flare Nut Attachment - 17mm - T10456-...
  • Page 313 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Free up the coolant hose -3-. – Remove the connector -1- from the Charge Air Pressure Sen‐ sor - G31- . – Remove the bolts -arrows-.
  • Page 314 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the connector and vacuum hoses from the Intake Manifold Runner Control Valve - N316- -1-. – Free up the wiring harness -1 and 2- from the air guide pipe.
  • Page 315 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Counterhold the connection -A- and loosen the union nut -arrow-. – Loosen the union nut on the fuel rail with the Flare Nut Attach‐...
  • Page 316 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -1- from the Intake Manifold Runner Position Sensor - G336- . – Remove the nuts -A- from the intake manifold and remove the bolts -arrows- using the Torx Socket - T30 - T10347- .

  • Page 317: Fuel Rail, Removing And Installing, Direct Fuel Injection

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Tighten the nuts -A- hand-tight. – Tighten the bolts -arrows- evenly, working from the inside to the outside. Use the Torx Socket - T30 - T10347- .
  • Page 318 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Removing – Open the retainer in direction of -arrow- and remove the cover -2-. – Remove the engine cover. Refer to ⇒ 3.1 Engine Cover, Removing and Installing , page 38 –...

  • Page 319: Throttle Valve Control Module, Cleaning

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Free up the coolant hose -3-. – Remove the connector -1- from the Charge Air Pressure Sen‐ sor - G31- . – Remove the bolts -arrows-.
  • Page 320 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the Throttle Valve Control Module - GX3- . Refer to ⇒ 4.5 Throttle Valve Control Module GX3 , Removing and Installing , page 309 –...

  • Page 321: Sensors

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Sensors ⇒ 5.1 Overview - Structure Borne Sound Actuator and Control Module , page 313 ⇒ 5.2 Fuel Pressure Sensor G247 , Removing and Installing , page 314 ⇒...

  • Page 322: Fuel Pressure Sensor G247 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 7 - Bolt/Nut ❑ 3 Nm ❑ For the Structure Borne Sound Control Module - J869- 8 - Bolt ❑ 9 Nm 9 - Connector ❑...
  • Page 323 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the left and right bolt -arrow-. – Unclip and remove the lower section -1- of the air duct. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

  • Page 324: Fuel Pressure Sensor G247 , Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the connector -arrow- from the generator, otherwise the socket can get hooked to the connector. – Loosen and remove the Fuel Pressure Sensor - G247- -1- us‐...
  • Page 325 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Open the Digital Manometer - VAS6394/1- sealing plug -2- and install the removed Fuel Pressure Sensor - G247- in the opening using the tightening specification.

  • Page 326: Low Fuel Pressure Sensor G410 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Connect the Digital Manometer - VAS6394/1- to the Pressure Sensor Tester Adapter - VAS6394/2- . – Start the engine. – Compare the pressure shown in the Digital Manometer -...
  • Page 327 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Disconnect the connector -6- from the Low Fuel Pressure Sensor - G410- . – Remove the clamps -2-. – Remove the Low Fuel Pressure Sensor - G410- -1- from the fuel rail.
  • Page 328 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Carefully slide the Low Fuel Pressure Sensor - G410- -1- all the way into the fuel rail. – To secure the Low Fuel Pressure Sensor - G410- , slide the clip -2- into the groove.

  • Page 329: Engine Control Module

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Engine Control Module ⇒ 6.1 Engine Control Module J623 , Removing and Installing , page 321 Engine Control Module - J623- , Remov‐...
  • Page 330 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Installing Install in reverse order of removal. Note the following: – Place the Engine Control Module - J623- in the bracket with the lower edge forward in direction of -arrow A- and locked on the upper edge.
  • Page 331 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Remove the shear bolts -arrows- to remove the protective hous‐ ing -1- as follows: – Make a recess in the head of the shear bolt -1- for a screw‐...
  • Page 332 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the shear bolt -1- with a screwdriver -2-. – Remove the protective housing from the Engine Control Mod‐ ule - J623- .

  • Page 333: High Pressure Pump

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 High Pressure Pump ⇒ 7.1 Overview - High Pressure Pump , page 325 ⇒ 7.2 High Pressure Pump, Removing and Installing , page 328 Overview - High Pressure Pump ⇒...
  • Page 334 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Installing , page 328 4 - O-Ring ❑ Replace if damaged 5 - Roller Tappet ❑ Remains inserted in the vacuum pump after removing the high pressure pump 6 - High Pressure Pump Bolt ❑...
  • Page 335 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1 - High Pressure Pump Bolts ❑ 20 Nm ❑ Replace after removing ❑ Tighten uniformly 2 - Fuel Pressure Regulator Valve - N276- 3 - Connector ❑...

  • Page 336: High Pressure Pump, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ❑ If the connection was loosened, it must be replaced. 12 - Fuel Supply Line 13 - Spring Clamp ❑ Replace after removing High Pressure Pump, Removing and In‐...
  • Page 337 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Free up the wiring harness -1 and 2- from the air guide pipe. – Loosen the screw-type clamp -3-. – Remove the bolts -arrows-.
  • Page 338 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen the union nut on the fuel rail -arrow- with the Flare Nut Attachment - 17mm - T10456- . – Counterhold on the hex fitting -A- and loosen the union nut -arrow-.
  • Page 339 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Installing – Replace the high pressure pump O-ring if damaged. – Inspect the roller tappet for damages before installing and re‐ place if necessary.
  • Page 340 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Install the pipe clamp -arrow-. Assemble in reverse order of disassembly. Note Check the fuel system for leaks after completing all work.

  • Page 341: Heated Oxygen Sensor

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Heated Oxygen Sensor ⇒ 8.1 Overview - Heated Oxygen Sensor , page 333 ⇒ 8.2 Oxygen Sensor 1 before Catalytic Converter GX10 , Re‐...

  • Page 342: Oxygen Sensor 1 After Catalytic Converter Gx7 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 The Oxygen Sensor 1 before Catalytic Converter - GX10- is com‐ posed of: ♦ Heated Oxygen Sensor - G39- ♦ Oxygen Sensor Heater - Z19- Removing –...
  • Page 343 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Removing – Disconnect the Oxygen Sensor 1 after Catalytic Converter - GX7- connector -1-. – Remove the Heated Oxygen Sensor -1- using a tool from the Ring Spanner 7-Piece Set - 3337- .

  • Page 344: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Elbow Assembly Tool - T10118- ♦ Injector/Combustion Chamber Seal Tool Set - T10133C- ♦ Torx Socket - T30 - T10347- ♦...
  • Page 345 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 ♦ Socket - 27mm - T40218- ♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A- -1- with nozzle attachment -2- from the Wiring Harness Repair Set - VAS1978B- .

  • Page 346: Exhaust System, Emission Controls

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 26 – Exhaust System, Emission Controls Exhaust Pipes/Mufflers ⇒ 1.1 Overview - Muffler , page 338 ⇒ 1.2 Exhaust Pipes/Mufflers, Separating , page 342 ⇒...
  • Page 347 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 3 - Bolt ❑ 20 Nm 4 - Bracket 5 - Retaining Loop ❑ Replace if damaged 6 - Rear Muffler ❑ Original equipment as one unit with rear muffler. For repairs, replace each separately ❑...
  • Page 348 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1.1.2 Overview - Muffler, Golf with 1.8L Engine 1 - Retaining Loop ❑ Replace if damaged 2 - Bolt ❑ 20 Nm 3 - Mount ❑...
  • Page 349 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 1.1.3 Overview - Muffler, Golf Wagon 1 - Retaining Loop ❑ Replace if damaged 2 - Bolt ❑ 20 Nm 3 - Mount ❑...

  • Page 350: Exhaust Pipes/Mufflers, Separating

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Exhaust Pipes/Mufflers, Separating ⇒ 1.2.1 Golf , page 342 ⇒ 1.2.2 Golf Wagon , page 342 1.2.1 Golf Special tools and workshop equipment required ♦...

  • Page 351: Muffler, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Procedure – Separate the exhaust pipe at a right angle at the separating point -arrow- using a Chain Pipe Cutter - VAS6254- .
  • Page 352 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen the screws for the front clamping sleeve -arrow-. CAUTION Risk of accident due to the heavy weight of the muffler. – A second technician is required for the following work steps.

  • Page 353: Exhaust System, Installing Without Tension

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Loosen the screws for the front clamping sleeve -arrow-. CAUTION Risk of accident due to the heavy weight of the muffler. – A second technician is required for the following work steps.

  • Page 354: Exhaust System, Checking For Leaks

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Push the exhaust system far enough forward until the pre-load on the retaining loops at the exhaust pipe -a- = 5 mm.

  • Page 355: Clamping Sleeve Installation Position

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Clamping Sleeve Installation Position Installation Position for Rear Clamping Sleeve – Install the clamping sleeve in the shown position. • Threaded connections point left •...

  • Page 356: Emissions Control

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Emissions Control ⇒ 2.1 Overview - Emissions Control , page 348 ⇒ 2.2 Catalytic Converter, Removing and Installing , page 349 Overview - Emissions Control 1 - Bolt ❑...

  • Page 357: Catalytic Converter, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 10 - Nut Tightening specification and sequence. Refer to ⇒ Fig. Catalytic Converter - Tightening Specification and Sequence , page 349 11 - Nut ❑...
  • Page 358 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Mandatory Replacement Parts ♦ Seal - Catalytic Converter Removing Note During installation, all cable ties must be installed at the same location. – Remove the connector -2- from the bracket and disconnect it.
  • Page 359 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolts -arrows-. – Loosen the clamping sleeve -arrow- and push it toward the rear. – Remove the catalytic converter with the front exhaust pipe.

  • Page 360: Secondary Air Injection System

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Secondary Air Injection System ⇒ 3.1 Overview - Secondary Air Injection System , page 352 ⇒ 3.2 Secondary Air Injection Pump Motor V101 , Removing and Installing , page 353 ⇒...

  • Page 361: Secondary Air Injection Pump Motor V101 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 11 - Secondary Air Injection Pump Motor - V101- ❑ Secondary Air Injection Pump Motor - V101- , Removing and installing. Refer to ⇒...
  • Page 362 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery Tray, Removing and Installing . – Free up the wiring harness -1 and 2- from the air guide pipe.

  • Page 363: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Chain Pipe Cutter - VAS6254- ♦ Pneumatic Body Saw - VAS6780- 4. Special Tools...

  • Page 364: Ignition/Glow Plug System

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 28 – Ignition/Glow Plug System Ignition System ⇒ 1.1 Overview - Ignition System , page 356 ⇒ 1.3 Ignition Coils with Power Output Stages, Removing and Installing , page 357 ⇒...

  • Page 365: Test Data And Spark Plugs

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 6 - Camshaft Position Sensor 3 - G300- ❑ Removing and installing. Refer to ⇒ 1.5.2 Camshaft Position Sensor 3 G300 , Removing and Installing , page 360 7 - O-Ring ❑...
  • Page 366 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Removing: – Remove the engine cover. Refer to ⇒ 3.1 Engine Cover, Removing and Installing , page 38 – If equipped remove the ground cable -arrows-.

  • Page 367: Knock Sensor 1 G61 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Carefully remove the ignition coil vertically upward using the Puller - T10530- . Note Ignition coils with power output stage and spark plug connec‐...

  • Page 368: Camshaft Position Sensor, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Installing Install in reverse order of removal. Note the following: – Note the installed position of the Knock Sensor 1 - G61- .

  • Page 369: Engine Speed Sensor G28 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 – Remove the bolt -1- and camshaft position sensor -2-. Installing Install in reverse order of removal. Note the following: – Replace the O-ring.

  • Page 370: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Special Tools Special tools and workshop equipment required ♦ Puller - T10530- Rep. Gr.28 - Ignition/Glow Plug System...

  • Page 371: Revision History

    Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Revision History DRUCK NUMBER: K0059240821 Fac‐ Edit Notes Quality tory Edi‐ Type Checke Edi‐ tion d By tion 04.2 04/1 Lo‐ Swapped items Eric P.
  • Page 372 Golf 2015 ➤ , Golf Variant 2015 ➤ Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015 Fac‐ Edit Notes Quality tory Edi‐ Type Checke Edi‐ tion d By tion 02.2 01/0 Fac‐ N/A Wagon added Tom P. 6/20 tory Up‐...
  • Page 373 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 374 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 375 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

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