Volkswagen Workshop Service and Repair Manuals

Removing –  Remove engine cover panel → Chapter. –  Remove windscreen wiper arms: → Electrical system; Rep. gr.92. –  Remove plenum chamber bulkhead → General body repairs; Rep. gr.50. –  Remove noise insulation or skid plate → General body repairs, exterior; Rep. gr.50.

–  Pull vacuum line -1- off vacuum pump -2-.

–  Remove vacuum lines upwards from air filter -1- together with bracket. –  Pull connector off charge pressure control solenoid valve -N75--3-. –  Unbolt charge pressure control solenoid valve -N75- with bracket at -2-. –  Place charge pressure control solenoid valve -N75- with vacuum lines on engine. –  Remove air filter housing together with air mass meter and connecting pipe → Chapter. –  Remove vacuum line between vacuum pump and brake servo.

–  To do this, thread vacuum line -arrow 1- out of retainer on cylinder head. Pre-heater line -arrow 2 - is not necessarily installed.

–  Separate connectors -1- from exhaust gas temperature sender 1 -G235-. Remove fuel filter with bracket.

–  To do this, open quick-release fasteners -A- and -B- of fuel lines. –  Catch any escaping fuel.

–  Use a finger to release locking lug of fuel pre-heater valve. –  Pull fuel pre-heater valve upwards out of coolant expansion tank guide.

–  Unclip replaceable filter cartridge from lower part of fuel filter. –  Remove replaceable filter cartridge upwards. –  Separate fuel supply line and return line on engine side. –  Remove replaceable filter cartridge and fuel hoses together with fuel pre-heater valve. –  Catch any escaping fuel. –  Remove fuel filter lower part.

–  Filler neck: Unclip windscreen washer system reservoir -1-. –  Filler neck: Unclip windscreen washer system reservoir -2-.

–  Remove crankcase breather hose -1-, press release buttons for this.

–  Unscrew bolt -arrow- (attached), twist intake hose -A- clockwise out of its retainer and remove. –  Remove cylinder head cover → Chapter.

–  Unclip vacuum lines -arrow- and lay to side.

–  Pull off vacuum line -arrow-. –  Lay vacuum lines to side.

–  Unscrew vacuum line attachment -arrow-.

–  Pull connectors off throttle valve module -J338--2-. –  Open clamp -3- and pull off charge air hose. –  Remove bolt from oil dipstick attachment -4-.

–  Disconnect electrical connector -4- at coolant temperature sender -G62-.

–  Separate electrical connector -1- on oil pressure switch -F1-. –  Remove bolt -arrow-.

–  Unscrew bolts -2, 5- and -arrows-. –  Free electrical lines and hoses on left charge air pipe. –  Loosen hose clip -3- and remove left charge air pipe.

–  Unscrew bolts -arrows- and remove pulsation damper -2-. –  Carefully push charge air pipe to side as far as possible.   Caution Ensure that decoupling element of connecting pipe is not bent and thus stretched. There is a danger of cracking. Disconnect catalytic converter to create space for removing and installing the oil supply line with turbocharger support.

–  Remove securing clamp -1- between catalytic converter and turbocharger.

–  Unscrew bolts -1- and nuts -2-.

–  Now you can access the securing bolt on the retaining clamp -arrow- for the oil return line on the turbocharger support. Remove bolt -arrow-.

–  Remove connecting pipes -A- to exhaust gas recirculation cooler. –  Remove oil supply line and turbocharger support → Chapter. –  Drain coolant → Chapter.

–  Remove coolant hoses from connections, loosen hose clips -1- and -2- for this.

–  Separate connector for Hall sender -G40--arrow-. –  Remove assembly mounting and engine support.

–  Set up support bracket -10 - 222 A- with necessary adapters as illustrated and support engine in installation position.   Note t  The assembly mounting may only be removed if the engine is supported with support bracket 10-222A! t  The engine bracket must be loosened only when the assembly mounting has been removed.

–  Unbolt engine assembly mounting -arrows- and remove completely. –  Remove engine bracket → Chapter. –  Remove toothed belt from camshaft and high-pressure pump → Chapter. –  Toothed belt tensioning roller can now be removed. –  Install engine bracket again, tightening old bolts by hand → Chapter. –  Install assembly mountings again, tightening old bolts by hand → Chapter. –  Remove support bracket -10 - 222 A-. –  Detach camshaft pulley from hub. –  Remove camshaft hub and pull off camshaft hub using puller -T10052-.

–  Counterhold hub with counterhold -T10051- and loosen securing bolt -1- of hub. –  Loosen hub securing bolt about 2 turns.

–  Fit puller -T10052- and align it with holes in hub. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.   Note When doing this, hold puller with 30 mm spanner. –  Remove hub from taper of camshaft.

–  Unscrew securing bolt -arrow- for toothed belt guard.

–  Maintain sequence when loosening cylinder head bolts.   Note t  A second mechanic is required to remove the cylinder head. t  The toothed belt tensioning roller is pulled off the stud when the cylinder head is lifted out. –  First lift cylinder head on gearbox side and guide it out of toothed belt guard. Make sure that toothed belt tensioner does not fall down.