Golf Mk6: Power unit
Also for this vehicle: Golf (5K1) L4-2.0L DSL Turbo (CJAA) (2011), Golf (5K1) L5-2.5L (CBUA) (2011), Golf GL L4-2.0L (AEG) (2001), Golf GL L4-2.0L (AVH) (2002), Golf GL L4-2.0L (AZG) (2001), Golf GLS L4-1.8L Turbo (AWW) (2001), Golf GLS L4-2.0L (AEG) (2001), Golf GLS L4-2.0L (AVH) (2002), Golf GLS L4-2.0L (AZG) (2001), Golf GTI L4-1781cc 1.8L SOHC (HT) (1985), Golf GTI L4-1781cc 1.8L SOHC (RD) (1987), Golf GTI L4-1984cc 2.0L DOHC (9A) (1990), Golf GTI L4-2.0L (ABA) (1997), Golf GTI V6-2792cc 2.8L DOHC (AAA) SFI (1998), Golf III L4-1984cc 2.0L SOHC (1993), Golf III L4-2.0L (ABA) (1995), Golf L4-1.8L Turbo (AWD) (2000), Golf L4-1.8L Turbo (AWW) (2003), Golf L4-1.9L DSL Turbo (AHU) (1997), Golf L4-1.9L DSL Turbo (ALH) (1999), Golf L4-1.9L DSL Turbo (BEW) (2004), Golf L4-1588cc 1.6L DSL SOHC (1987), Golf L4-1588cc 1.6L DSL SOHC Turbo (1985), Golf L4-1781cc 1.8L SOHC (1987), Golf L4-1781cc 1.8L SOHC (ACC) Can (1993), Golf L4-1781cc 1.8L SOHC (RV) (1990), Golf L4-1781cc 1.8L SOHC (RV, PF) (1989), Golf L4-1896cc 1.9L DSL Turbo (1Z) (1997), Golf L4-2.0L (ABA) (1996), Golf L4-2.0L (AEG) (1999), Golf L4-2.0L (AVH) (2003), Golf L4-2.0L (AZG) (2004), Golf L4-2.0L (BEV) (2004), Golf L4-2.0L DSL Turbo (CJAA) (2010), Golf L5-2.5L (CBUA) (2010), Golf Mk1, Golf Mk2, Golf Mk3, Golf Mk4, Golf Mk5.
Steering & suspension
Body & interior
General
Transmission
Engine
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
4-cylinder injection engine (1.6 l roller rocker finger)184 pages
Technical data2 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons32 pages
Dismantling and assembling engine7 pages
Removing and installing sealing flanges and flywheel or drive plate13 pages
- Assembly overview - sealing flange
Removing and installing crankshaft sealing flange (flywheel end)3 pages
- Removing and installing flywheel
- Removing and installing drive plate
Crankshaft6 pages
Dismantling and assembling pistons and conrods6 pages
Assembly overview - pistons and conrods3 pages
- Checking pistons, piston rings and cylinder bores
- Piston and cylinder dimensions
Engine cylinder head, valve gear29 pages
Cylinder head11 pages
Removing, installing and tensioning toothed belts3 pages
- Checking semi-automatic toothed belt tensioner
- Compression test
Repairing valve gear18 pages
Engine lubrication › Parts of lubrication system9 pages
Engine cooling18 pages
Removing and installing parts of cooling system17 pages
- Assembly overview - parts of cooling system - engine side, engine codes BGU, BSE and BSF
- Assembly overview - parts of cooling system, engine side, engine codes CCSA, CMXA
- Assembly overview - parts of cooling system, body side (radiator with 2 radiator fans)
- Assembly overview - parts of cooling system, body side (radiator with one radiator fan)
- Coolant hose schematic diagram - engine codes BGU, BSE and BSF
- Coolant hose schematic diagram - engine codes CCSA, CMXA
- Removing and installing thermostat
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Removing and installing radiator
- Checking cooling system for leaks
- Assembly overview - engine preheating (engine codes CCSA, CMXA)
Fuel supply, gas operation32 pages
Fuel tank9 pages
Repairing fuel supply15 pages
Electronic power control (EPC)4 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas27 pages
Injection system18 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Assembly overview - intake manifold with attachments, engine code BGU
- Assembly overview - intake manifold with attachments, engine codes BSE, BSF, CCSA, CMXA
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter with attachments
Removing and installing intake manifold lower part, engine code BGU3 pages
- Removing and installing intake manifold lower part, engine codes BSE, BSF, CCSA, CMXA
- Removing and installing complete intake manifold, engine codes BSE, BSF, CCSA, CMXA
- Removing and installing injectors
Checking components9 pages
Checking injectors for leaks and quantity injected5 pages
- Checking fuel pressure regulator and holding pressure
Checking intake manifold change-over2 pages
Exhaust system24 pages
Exhaust system, engine codes BGU, BSE, BSF, CCSA8 pages
- Assembly overview - exhaust system
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Aligning exhaust system stress free
- Removing and installing Lambda probe G39
- Removing and installing Lambda probe after catalytic converter G130
Exhaust system, engine code CMXA9 pages
- Assembly overview - exhaust manifold and front exhaust pipe with catalytic converter
- Assembly overview - exhaust system
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Aligning exhaust system free of stress
- Removing and installing Lambda probe G39
- Removing and installing Lambda probe after catalytic converter G130
Exhaust gas recirculation system, engine code BGU2 pages
Secondary air system, engine codes BGU, BSE, CCSA, CMXA5 pages
Ignition system, glow plug system › Repairing ignition5 pages
4-cylinder injection engine (1.4 l engine)150 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons21 pages
Dismantling and assembling engine4 pages
Cylinder block, sealing flange14 pages
- Assembly overview - aluminium cylinder block
- Renewing crankshaft oil seal - pulley end
- Poly V-belt pulley securing bolt tightening procedure
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft dimensions
Engine cylinder head, valve gear24 pages
Cylinder head16 pages
- Assembly overview
- Checking valve timing
Checking semi-automatic toothed belt tensioning roller3 pages
- Checking compression
Valve gear8 pages
Engine lubrication › Parts of lubrication system12 pages
Engine cooling › Parts of cooling system17 pages
- Assembly overview - parts of cooling system (radiator with two fans), body side
- Assembly overview - parts of cooling system (radiator with one fan), body side
- Assembly overview - parts of cooling system - thermostat side
- Assembly overview - parts of cooling system - coolant pump side
- Coolant hose schematic diagram
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator
- Removing and installing coolant pump
Fuel supply, gas operation34 pages
Parts of fuel supply system28 pages
- Assembly overview - dismantling and assembling fuel tank with add-on parts and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Emptying fuel tank3 pages
- Removing and installing fuel gauge senderG
- Assembly overview - fuel filter with add-on parts (engine code BCA)
- Removing and installing fuel filter
- Crash fuel shut-off
Checking fuel pump (vehicles ? model year 2006)5 pages
Checking fuel pump (vehicles model year 2006 ?)5 pages
- Bleeding fuel system
Electronic power control (EPC)3 pages
Activated charcoal filter system3 pages
Mixture preparation system, electronic inj.,Gas24 pages
Injection system14 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Assembly overview - intake manifold (engine code BCA)
- Assembly overview - intake manifold (engine codes BUD and CGGA)
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter housing (engine code BCA)
- Assembly overview - air filter housing (engine codes BUD and CGGA)
- Removing and installing air filter housing (engine codes BUD and CGGA)
- Cleaning throttle valve moduleJ338
Checking components9 pages
- Checking intake air preheater (only engine codes BCA)
Checking injectors for leaks and quantity injected (vehicles ? model year 2006)3 pages
Checking injectors for leaks and quantity injected (vehicles model year 2006 ?)3 pages
- Checking fuel pressure regulator and holding pressure
- Engine control unitJ623
Exhaust system › Parts of the exhaust system4 pages
Ignition system, glow plug system › Ignition system6 pages
4-cylinder injection engine (1.4 l direct injection engine, turbocharger)146 pages
Engine assy,cylinder block,crankcase › Removing and installing engine (Golf, Golf Plus, Eos, Scirocco)7 pages
Enginecrankshaft group, pistons34 pages
Dismantling and assembling engine10 pages
- Assembly overview - parts l and ll
- Assembly overview - part I, belt drive
- Assembly overview - part II, cylinder block
Removing and installing valve timing housing (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)3 pages
- Removing and installing ancillary bracket
Removing and installing sealing flanges and flywheel or drive plate14 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing crankshaft pulley
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Dismantling and assembling pistons and conrods6 pages
Engine cylinder head, valve gear16 pages
Engine lubrication › Removing and installing parts of lubrication system7 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator fanV7 and radiator fan 2V177 (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)
- Checking cooling system for leaks
- Removing and installing radiator (Golf, Golf Plus, Golf Cabriolet, Scirocco, Eos)
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
Fuel supply, gas operation28 pages
- Separating push-on couplings
Fuel tank (Golf, Golf Plus, Golf Cabriolet, Scirocco)6 pages
Repairing fuel supply system (Golf, Golf Plus, Golf Cabriolet, Scirocco, Eos)11 pages
Repairing electronic power control (EPC)3 pages
Activated charcoal filter system (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)4 pages
Exhaust turbocharger, G-charger11 pages
Mixture preparation system, electronic inj.,Gas20 pages
Injection system18 pages
- Assembly overview - parts l and II, intake manifold
- Assembly overview - part I, intake manifold
- Assembly overview - part II, intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Removing and installing intake manifold
- Assembly overview - high-pressure pump
- Checking fuel pressure senderG247
- Removing and installing high-pressure pump
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Safety precautions
- Rules for cleanliness
- Technical data
Engine control unitJ6232 pages
Exhaust system › Removing and installing parts of exhaust system5 pages
Ignition system, glow plug system › Repairing ignition system5 pages
4-cylinder diesel engine (2.0 l engine, common rail)232 pages
Technical data14 pages
Safety instructions6 pages
Repair instructions4 pages
Engine assy,cylinder block,crankcase14 pages
Removing and installing engine5 pages
Assembly mountings7 pages
Assembly overview - assembly mountings2 pages
Supporting engine in installation position2 pages
Adjusting assembly mountings2 pages
Enginecrankshaft group, pistons39 pages
Cylinder block (pulley end)17 pages
Assembly overview - poly V-belt drive4 pages
Removing and installing tensioner for poly V-belt2 pages
- Removing and installing ancillary bracket
Removing and installing engine bracket2 pages
- Assembly overview - cylinder block (pulley end)
- Removing and installing sealing flange on pulley end
- Renewing crankshaft oil seal - belt pulley end
Cylinder block, gearbox end11 pages
- Assembly overview - cylinder block, gearbox end
Removing and installing sealing flange on gearbox side9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Pistons and conrods7 pages
Assembly overview - pistons and conrods3 pages
- Separating new conrod
Engine cylinder head, valve gear21 pages
Engine lubrication28 pages
Sump, oil pump11 pages
Assembly overview - sump / oil pump3 pages
- Removing and installing oil sump
Removing and installing oil pump2 pages
Oil filter, oil pressure switch6 pages
- Assembly overview - oil filter, oil pressure switch
- Removing and installing oil filter housing
Checking oil pressure and oil pressure switch3 pages
Balancer shaft module7 pages
Engine cooling29 pages
Cooling system, coolant14 pages
Coolant hose schematic diagram4 pages
Checking cooling system for leaks3 pages
Assembly overview - engine preheater3 pages
Coolant pump, regulation of cooling system4 pages
Coolant pipes5 pages
Radiator/radiator fan6 pages
Assembly overview - radiator/radiator fan3 pages
- Removing and installing radiator
- Removing and installing radiator cowling with radiator fan
Exhaust turbocharger, G-charger14 pages
Turbocharger8 pages
Assembly overview - turbocharger3 pages
Removing and installing turbocharger3 pages
- Renewing vacuum unit for turbocharger
Charge air system6 pages
Fuel preparation system Diesel injection38 pages
Injectors/high-pressure accumulator (rail)6 pages
Vacuum system8 pages
Assembly overview - vacuum system3 pages
Air filter5 pages
Intake manifold3 pages
Senders and sensors7 pages
- Checking fuel pressure regulating valve
- Removing and installing fuel pressure regulating valve
- Removing and installing fuel pressure sender
Assembly overview - actuator for structure-borne sound and control unit for structure-borne sound3 pages
Exhaust system27 pages
Exhaust pipes, silencers10 pages
Separating exhaust pipes, silencers2 pages
Aligning exhaust system free of stress3 pages
- Checking exhaust system for leaks
- Installation position of clamp
Cleansing exhaust emissions12 pages
Assembly overview - cleansing exhaust emissions6 pages
- Assembly overview - front exhaust pipe with particulate filter, engine codes CBAA, CBBB, CBAB, CBBA, CBDB, CBDC, CBAC, CBDA
- Assembly overview - particulate filter with NOx storage catalytic converter, engine code CJAA
- Assembly overview - exhaust flap control unitJ883 with SCR catalytic converter
- Note installation position of securing clamps and exhaust gas temperature sender
- Routing cables/lines of exhaust system components, engine code CJAA
Removing and installing particulate filter2 pages
Removing and installing particulate filter with NOx storage catalytic converter3 pages
Exhaust gas recirculation system5 pages
Assembly overview - exhaust gas recirculation system3 pages
- Removing and installing temperature sensor for exhaust gas recirculation
Ignition system, glow plug system › Glow plug system8 pages
4-cylinder injection engine (1.8 and 2.0 l engine, chain drive)211 pages
Technical data2 pages
Engine assy,cylinder block,crankcase9 pages
Removing and installing engine5 pages
Enginecrankshaft group, pistons22 pages
Crankshaft11 pages
Engine cylinder head, valve gear26 pages
Chain drive14 pages
- Assembly overview - timing chain covers
- Removing and installing inlet camshaft control valve 1N205
- Removing and installing upper timing chain cover
- Removing and installing lower timing chain cover (Golf, Eos, Scirocco)
- Renewing oil seal for vibration damper
- Camshaft timing chain - exploded view
- Removing and installing camshaft timing chain
- Assembly overview - balancer shaft timing chain
- Removing and installing balancer shaft module
- Removing and installing inlet side balancer shaft
- Removing and installing exhaust side balancer shaft
Engine lubrication18 pages
Sump and oil pump7 pages
- Engine oil
Oil filter, engine oil cooler and oil pressure switch (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA)4 pages
Oil filter, engine oil cooler and oil pressure switch (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB)6 pages
Engine cooling22 pages
Coolant pump, thermostat, coolant pipes12 pages
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Removing and installing toothed belt for coolant pump
- Renewing oil seal for coolant pump drive
- Removing and installing thermostat
- Removing and installing coolant temperature senderG62
- Assembly overview - coolant pipes
- Removing and installing coolant pipes (front)
- Removing and installing small coolant pipe
- Continued coolant circulation pumpV51 - exploded view
- Removing and installing continued coolant circulation pumpV51
Radiator and radiator fans6 pages
Assembly overview - radiator, fan cowl and radiator fan (Passat, CC, Golf, Eos, Scirocco)2 pages
- Removing and installing radiator cowl
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator (Passat, CC, Golf, Eos, Scirocco)
Fuel supply, gas operation40 pages
- Rules for cleanliness
Fuel tank (Golf, Scirocco)9 pages
- Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA)
- Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA)4 pages
- Emptying fuel tank (engine codes CBFA, CCTA, CCTB)
- Removing and installing fuel tank
Repairing fuel supply system (Golf, Eos, Scirocco)11 pages
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
Checking fuel pumpG68 pages
- Checking function and voltage supply
- Checking fuel pressure
- Checking fuel pressure when the engine is running (engine codes CCZA, CCZB, CDAA, CDAB)
- Checking holding pressure
- Checking fuel delivery rate (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA)
- Checking fuel delivery rate (engine codes CCZA, CCZB, CDAA, CDAB)
- Checking current draw
Electronic power control (EPC)3 pages
Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB, CDAA)3 pages
Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)9 pages
Exhaust turbocharger, G-charger23 pages
Turbocharger13 pages
Charge air system10 pages
- Assembly overview - charge air cooler (Golf, Scirocco)
- Assembly overview - sound generator (Golf, Scirocco)
Actuator for structure-borne soundR214 and control unit for structure-borne soundJ8693 pages
- Turbocharging - overview
- Removing and installing charge air cooler (Golf, Eos)
- Removing and installing charge air duct to sound generator (Golf, Scirocco)
- Checking charge air system for leaks
Mixture preparation system, electronic inj.,Gas27 pages
Injection system19 pages
- Technical data
- Overview of fitting locations
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing air filter element
- Removing and installing air mass meterG70
- Assembly overview - intake manifold
- Fuel rail - exploded view
Removing and installing intake manifold with fuel rail2 pages
- Removing and installing injectors
- Renewing Teflon seal on injector
- Cleaning injectors
- Removing and installing fuel pressure senderG247
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Assembly overview - high-pressure pump with fuel pressure regulating valveN276
- Removing and installing high-pressure pump
Checking components3 pages
Engine control unitJ623 (Passat 2011 ?, Golf, Eos, Scirocco from 11/08; CC from 11/10)3 pages
Exhaust system14 pages
Exhaust system (Golf, Eos, Scirocco)10 pages
- Assembly overview - exhaust system (engine code CAWB)
- Assembly overview - exhaust system (engine code CBFA)
- Assembly overview - exhaust system (Golf 2009?, engine codes CCZA, CCZB)
- Assembly overview - exhaust system (Golf 2009 ?, engine codes CCTA, CDAA)
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Installation position and specified torque of clamp
- Removing and installing catalytic converters with front exhaust pipe
- Checking exhaust system for leaks
Secondary air system - engine code CBFA4 pages
Ignition system, glow plug system › Repairing ignition system8 pages
4-cylinder injection engine (1.4 l direct injection engine, turbocharger and supercharger)131 pages
Technical data7 pages
Engine assy,cylinder block,crankcase5 pages
Enginecrankshaft group, pistons29 pages
Cylinder block (pulley end)8 pages
- Assembly overview - poly V-belt drive
- Assembly overview - cylinder block, belt pulley end
Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet)2 pages
- Removing and installing ancillary bracket
- Renewing crankshaft oil seal - pulley end
- Removing and installing crankshaft pulley
Cylinder block, gearbox end11 pages
- Assembly overview - cylinder block, gearbox end
Removing and installing sealing flange on gearbox side9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Engine cylinder head, valve gear25 pages
Cylinder head9 pages
Valve gear8 pages
Cover for timing chain4 pages
Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet)3 pages
Engine lubrication7 pages
Engine cooling13 pages
Cooling system, coolant4 pages
Coolant pump, regulation of cooling system5 pages
- Assembly overview - thermostat
- Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
- Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
- Removing and installing coolant circulation pumpV50 (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
Radiator, radiator fan4 pages
- Assembly overview - radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet)
- Removing and installing radiator fanV7 and radiator fan 2V177 (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet)
- Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
Exhaust turbocharger, G-charger14 pages
Charge air system5 pages
Mixture preparation system, electronic inj.,Gas19 pages
High-pressure pump3 pages
Exhaust system7 pages
Exhaust pipes, silencers5 pages
- Assembly overview - silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
- Removing and installing front exhaust pipe (Golf Plus, Eos, Scirocco, Golf, Tiguan, Touran, Golf Cabriolet)
- Separating exhaust pipes/silencers (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
- Installation position of clamp
Cleansing exhaust emissions2 pages
Ignition system, glow plug system › Ignition system5 pages
4-cylinder diesel engine (1.6 l engine, common rail)249 pages
Technical data10 pages
- Engine number, engine data
General repair notes5 pages
Rules for cleanliness3 pages
- Testing vacuum system
Engine assy,cylinder block,crankcase15 pages
Removing and installing engine7 pages
Assembly mountings7 pages
- Removing and installing engine cover panel
Enginecrankshaft group, pistons44 pages
Cylinder block (pulley end)15 pages
- Assembly overview - poly V-belt drive without air conditioning compressor
- Assembly overview - poly V-belt drive (vehicles with idler roller and air conditioner compressor)
- Assembly overview - poly V-belt drive (vehicles with tensioning element and air conditioner compressor)
- Removing and installing poly V-belt (vehicles without air conditioner compressor)
- Removing and installing poly V-belt (vehicles with idler roller)
- Removing and installing poly V-belt (vehicles with tensioning element)
Removing and installing tensioner for poly V-belt2 pages
- Removing and installing vibration damper
Ancillary bracket (removing and installing)3 pages
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing sealing flange - pulley end
Cylinder block, gearbox end13 pages
- Assembly overview - cylinder block, gearbox end
- Removing and installing flywheel (vehicles with dual-mass flywheel)
- Assembly overview - removing and installing flywheel (vehicles with single flywheel)
Removing and installing sealing flange on gearbox side9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- a) Securing seal with sender wheel on assembly toolT10134
- b) Securing assembling toolT10134 with sealing flange on crankshaft flange
- c) Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Pistons and conrods10 pages
Engine cylinder head, valve gear32 pages
Cylinder head10 pages
- Assembly overview - cylinder head cover
Removing and installing cylinder head cover2 pages
- Assembly overview - cylinder head
- Removing and installing vacuum pump
- Checking compression
Toothed belt drive6 pages
- Assembly overview - toothed belt drive (Golf, Passat, Touran)
Removing, installing and tensioning toothed belt4 pages
Valve gear16 pages
Engine lubrication21 pages
Engine oil cooler3 pages
Oil filter, oil pressure switch7 pages
Engine cooling23 pages
Cooling system, coolant11 pages
Coolant pump, regulation of cooling system9 pages
- Assembly overview - coolant pump and thermostat (Polo, Golf, Passat)
- Assembly overview - coolant pump and 4/2-way valve with thermostat (Polo, Golf, Passat, Touran)
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking thermostat
- Removing and installing 4/2-way valve with thermostat
Electric coolant pump2 pages
Exhaust turbocharger, G-charger16 pages
Turbocharger5 pages
Assembly overview - turbocharger2 pages
Charge air system11 pages
Removing and installing charge air cooler2 pages
Fitting charge air system hose connections5 pages
- Checking charge air system for leaks
Fuel preparation system Diesel injection59 pages
Injection system7 pages
Injectors, high pressure accumulator15 pages
- Assembly overview - injectors
- Adapting correction values for injectors
Testing injectors3 pages
- Checking pressure retention valve in fuel return line.
- Removing and installing high-pressure accumulator (rail)
Removing and installing high-pressure lines4 pages
Senders and sensors9 pages
- Removing and installing fuel pressure regulating valveN 276
- Checking fuel pressure regulating valve N 276
- Removing and installing fuel pressure senderG 247
- Checking fuel pressure senderG 247
- Checking fuel metering valveN 290,
Removing and installing pressure differential senderG 5053 pages
Lambda probe5 pages
Assembly overview - Lambda probe2 pages
Removing and installing Lambda probe2 pages
Air filter5 pages
Assembly overview - air filter housing2 pages
Removing and installing air filter housing2 pages
Intake manifold7 pages
Exhaust system24 pages
Exhaust pipes, silencers6 pages
Assembly overview - exhaust system2 pages
Aligning exhaust system free of stress3 pages
Cleansing exhaust emissions6 pages
Assembly overview - cleansing exhaust emissions3 pages
Removing and installing particulate filter2 pages
Exhaust gas temperature regulation8 pages
- Assembly overview - exhaust gas temperature regulation
Removing and installing parts of exhaust gas temperature regulation6 pages
Ignition system, glow plug system › Glow plug system5 pages
4-cylinder injection engine (1.2 l direct injection engine, turbocharger)124 pages
Technical data6 pages
Engine assy,cylinder block,crankcase5 pages
Removing and installing engine3 pages
Enginecrankshaft group, pistons28 pages
Cylinder block (pulley end)6 pages
Cylinder block, gearbox end13 pages
- Assembly overview - cylinder block, gearbox end
Removing and installing crankshaft sealing flange on gearbox side9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- Mounting seal with sender wheel on assembly toolT10134
- Mounting assembly toolT10134 with sealing flange on crankshaft flange
- Bolting assembly toolT10134 onto crankshaft flange
- Pressing sender wheel onto crankshaft flange using assembly toolT10134
- Checking sender wheel installation position on crankshaft
- Re-pressing sender wheel
- Removing and installing ancillary bracket (top)
- Removing and installing ancillary bracket (bottom)
Pistons and conrods6 pages
- Assembly overview - pistons and conrods
Checking piston and cylinder bore3 pages
- Separating new conrod
Engine cylinder head, valve gear26 pages
Cylinder head8 pages
- Assembly overview - cylinder head
Removing and installing cylinder head cover and camshaft4 pages
- Removing and installing cylinder head
- Checking compression
Valve gear7 pages
Cover for timing chain3 pages
Chain drive8 pages
- Assembly overview - timing chain
- Checking valve timing
- Adjusting valve timing
Removing and installing timing chain and chain drive for oil pump4 pages
Engine lubrication9 pages
Engine cooling12 pages
Cooling system, coolant4 pages
Coolant pump, regulation of cooling system4 pages
Exhaust turbocharger, G-charger8 pages
Turbocharger5 pages
Mixture preparation system, electronic inj.,Gas20 pages
Exhaust system6 pages
Cleansing exhaust emissions2 pages
Ignition system, glow plug system › Ignition system4 pages
4-cylinder diesel engine (2.0 l engine, common rail, generation II)231 pages
Technical data14 pages
Safety instructions6 pages
- Safety precautions when working on fuel supply system
- Safety precautions during road tests in which testing and measuring equipment is used
- Safety precautions when working on vehicles with a start/stop system
- Safety precautions when working on cooling system
- Safety precautions when working on the SCR system
Repair instructions4 pages
Engine assy,cylinder block,crankcase18 pages
Removing and installing engine9 pages
Separating engine and gearbox3 pages
- Securing engine on engine and gearbox support
Assembly mountings7 pages
Assembly overview - assembly mountings2 pages
Supporting engine in installation position2 pages
Enginecrankshaft group, pistons38 pages
Cylinder block (pulley end)19 pages
Removing and installing tensioner for poly V-belt2 pages
- Removing and installing ancillary bracket
Removing and installing engine bracket2 pages
Assembly overview - cylinder block (pulley end)3 pages
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing sealing flange on pulley end
Cylinder block, gearbox end6 pages
- Assembly overview - cylinder block, gearbox end
- Removing and installing flywheel
Renewing crankshaft sealing flange - flywheel end3 pages
Pistons and conrods9 pages
Assembly overview - pistons and conrods4 pages
- Assembly overview - pistons and conrods
- Piston and cylinder dimensions
- Bearing shells - installation position
- Piston and cylinder dimensions
- Separating new conrod
- Checking radial clearance of conrods
Engine cylinder head, valve gear31 pages
Cylinder head9 pages
Toothed belt drive5 pages
- Assembly overview - toothed belt
Removing and installing toothed belt3 pages
Valve gear12 pages
- Assembly overview - valve gear
- Measuring axial play of camshaft
- Measuring radial play of camshaft
- Removing and installing camshaft
Removing and installing camshaft oil seal3 pages
- Checking hydraulic compensation elements
Removing and installing valve stem seals3 pages
Inlet and exhaust valves5 pages
Engine lubrication27 pages
Sump, oil pump12 pages
Engine oil cooler3 pages
Balancer shaft module6 pages
- Assembly overview - balancer shaft module
Removing and installing balance shaft module4 pages
Engine cooling24 pages
Cooling system, coolant6 pages
Coolant pump, regulation of cooling system7 pages
- Assembly overview - coolant pump, thermostat
- Removing and installing coolant pump
- Removing and installing 4/2-way valve with thermostat
Removing and installing coolant temperature sender3 pages
Coolant pipes7 pages
Exhaust turbocharger, G-charger10 pages
Fuel preparation system Diesel injection40 pages
High-pressure pump3 pages
Engine control unit5 pages
Removing and installing engine control unit2 pages
Removing and installing engine control unit with protective housing2 pages
Exhaust system24 pages
Exhaust pipes, silencers7 pages
Cleansing exhaust emissions7 pages
Assembly overview - cleansing exhaust emissions3 pages
- Removing and installing particulate filter
Removing and installing catalytic converter2 pages
Exhaust gas temperature regulation6 pages
- Assembly overview - exhaust gas temperature regulation
Removing and installing exhaust gas temperature sender4 pages
Ignition system, glow plug system › Glow plug system5 pages
4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH15 pages
- Engine cooling › Parts of cooling system
Fuel supply, gas operation › Fuel tank (four-wheel drive)9 pages
- Exhaust turbocharger, G-charger › Charge air system
Mixture preparation system, electronic inj.,Gas › Engine control unitJ623 (Golf 2009 ?)3 pages
- Exhaust system › Exhaust system
Fuel supply system - Diesel engines56 pages
Technical data8 pages
Fuel supply, gas operation48 pages
Procedure when filling with incorrect fuel7 pages
- Step 1 (Engine was started with incorrect fuel)
- Step 2 (Engine was not started with incorrect fuel)
- Step 3 (There are filings in fuel delivery unit and fuel tank)
- Step 4 (There are no filings in fuel delivery unit or fuel tank)
- Step 5 (There are filings in high-pressure pump)
- Step 6 (There are no filings in high-pressure pump)
Fuel tank11 pages
Assembly overview - fuel tank3 pages
Removing and installing fuel tank3 pages
Fuel delivery unit, fuel gauge sender6 pages
- Detaching push-on connectors
Fuel filter7 pages
Assembly overview - fuel filter3 pages
Removing and installing fuel filter3 pages
Accelerator mechanism3 pages
Fuel pump13 pages
Checking fuel pump8 pages
- Checking delivery pressure of fuel system pressurisation pumpG6, engine codes CBAA, CBAB, CBBB, CBDA, CBDB, CBDC, CJAA, CFFA, CF
- Checking delivery rate of fuel system pressurisation pumpG6, engine codes CBAA, CBAB, CBBB, CBDA, CBDB, CBDC, CJAA, CFFA, CFFB,
- Checking delivery rate of fuel supply pumpG6, engine codes CAYB, CAYC
- Checking supplementary fuel pumpV393 or fuel pump 2V277 (inline EFP), engine codes CBAA, CBAB, CBBB, CBDA, CBDB, CBDC, CJAA
- Checking supplementary fuel pumpV393 or fuel pump 2V277 (inline EFP), engine codes CFFA, CFFB, CFGB, CFHB, CFHC, CLCA
- Checking current consumption of fuel system pressurisation pumpG6
- Checking voltage supply of fuel system pressurisation pumpG6
Removing and installing fuel pump2 pages
Fuel supply system - Petrol engines60 pages
Technical data6 pages
Fuel supply, gas operation54 pages
Fuel tank (front-wheel drive)11 pages
Fuel delivery unit, fuel gauge sender5 pages
- Separating push-on couplings
Activated charcoal filter system18 pages
Assembly overview - activated charcoal filter system4 pages
Removing and installing activated charcoal filter2 pages
Checking fuel tank breather2 pages
Overview of activated charcoal filter system3 pages
Removing and installing fuel system diagnosis pump2 pages
Accelerator mechanism3 pages
Fuel pump13 pages
Checking fuel pump12 pages
- Checking function and voltage supply
- Checking function and voltage supply (engine codes CBTA, CBUA)
- Checking fuel pressure
- Checking holding pressure
- Testing fuel pressure with engine running (CCZB, CDAA, CDLG)
- Checking fuel pressure regulator and holding pressure (engine codes CBTA, CBUA)
- Checking fuel delivery rate
- Checking fuel delivery rate (engine codes CCZB, CDAA, CDLG)
- Checking fuel delivery rate (engine codes CBTA, CBUA)
- Checking current draw
- Checking fuel pump non-return valve (engine codes CBTA, CBUA)
4-cyl. direct injection engine (2.0 l 4V turbocharger, toothed belt drive)162 pages
Technical data8 pages
Engine assy,cylinder block,crankcase6 pages
Removing and installing engine4 pages
- Assembly mountings
- Engine cover
Enginecrankshaft group, pistons27 pages
Cylinder block (pulley end)10 pages
Crankshaft6 pages
Pistons and conrods6 pages
Engine cylinder head, valve gear23 pages
Cylinder head7 pages
Toothed belt drive4 pages
Valve gear12 pages
Engine lubrication17 pages
Oil filter, oil pressure switch6 pages
Assembly overview - oil filter housing, oil pressure switch2 pages
- Removing and installing oil filter housing
- Checking oil pressure and oil pressure switch
- Removing and installing oil pressure switchF1
Balancer shaft module6 pages
- Assembly overview - balancer shaft module
Removing and installing balance shaft module4 pages
Engine cooling24 pages
Cooling system, coolant6 pages
Coolant pump, regulation of cooling system11 pages
- Removing and installing coolant pump
- Removing and installing thermostat
Removing and installing coolant temperature sender3 pages
Exhaust turbocharger, G-charger14 pages
Mixture preparation system, electronic inj.,Gas32 pages
Senders and sensors7 pages
Actuator for structure-borne soundR214 and control unit for structure-borne soundJ8693 pages
- Removing and installing fuel pressure senderG247
- Checking fuel pressure senderG247
- Removing and installing air mass meterG70
Intake manifold7 pages
- Assembly overview - intake manifold
Removing and installing intake manifold with fuel rail2 pages
- Removing and installing intake manifold flap motorV157 and intake manifold flap potentiometerG336
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
Engine control unitJ6233 pages
Exhaust system › Exhaust pipes, silencers7 pages
Ignition system, glow plug system › Ignition system4 pages