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Service

Workshop Manual
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Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
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21 - Turbocharging/supercharging
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24 - Mixture preparationrise-dinjection ran
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26 - Exhaust system
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B803919C7


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 4

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2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 5
2.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7


3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7


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3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8


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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25


2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Removing and installing motor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 36
2.7 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Contents i
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

3.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66


3.6 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.7 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Assembly overview - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.3 Renewing oil seal for balance shaft (inlet side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.5 Checking radial clearance of nconrods
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1.2 Removing and installing upper timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84


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1.3 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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2.1 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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2.2 Assembly overview - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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2.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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2.4 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.5 Checking chain elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectne 113
3.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115


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3.3 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123


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3.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124


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4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127


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4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127


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4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131


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4.3 Installing ball for sliding piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155


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4.4 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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4.5 Removing and installing camshaft control valve 1 N205 / exhaust camshaft control valve 1
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4.6 Removing and installing actuator for camshaft adjustment N580 / N605 . . . . . . . . . . . . . . 165
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5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166


5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 170
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.6 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

ii Contents
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.3 Removing ageand


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switching valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184


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4.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184


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4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 185
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4.3 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 186
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4.4 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 186

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4.5 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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4.6 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 188

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4.7 Removing and installing stage 3 oil pressure switch F447 . . . . . . . . . . . . . . . . . . . . . . . . 189
4.8 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194


1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

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1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198


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1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
com

tion in
1.4 Flushing cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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1.5 Flushing cooling system, quick reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s 224
iva

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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226


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2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226


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2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4
Prote
cted Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AG.
agen 231
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.6 Removing and installing auxiliary pump for heating V488 . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.7 Removing and installing coolant shut-off valve N82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.8 Removing and installing coolant valve for gearbox N488 . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.9 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 239
2.10 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 241
2.11 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 242
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.2 Removing and installing coolant pipe at front of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.3 Removing and installing coolant pipe on top of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3.4 Removing and installing coolant pipe on radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.3 Assembly overview - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.5 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
4.6 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.7 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
1.3 Adjusting charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Contents iii
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270


2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274


1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.2 Releasing high pressure in fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.g.en. A. G . ..V.o.lk.sw
. a. g.e.n.A.G.d.o . . . . . . . . 288
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3.1 Assembly overview - intake manifold . . . . . . . . . . . .y.V. . . . . . . . . . . . . . . . . . . . . . .no. t.g.u . . . 288
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3.2 Removing and installing intake manifold . . . . .o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.n.te 289
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3.3 Removing and installing throttle valve moduleauGX3 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 ra
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3.4 Cleaning throttle valve module . . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

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4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

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4.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
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4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
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4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

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4.4 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
hole

spec
4.5 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
es, in part or in w

t to the co
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
5.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

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5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
l purpos

5.3 Removing and installing fuel pressure sender for low-pressure G410 . . . . . . . . . . . . . . . . 312
5.4 Removing and installing intake air temperature sender G42 / intake manifold pressure sender

nform
ercia

G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.5 Removing and installing actuator for structure-borne sound R214 . . . . . . . . . . . . . . . . . . 314
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6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

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6.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

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6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
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7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321


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7.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 t. Cop py
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7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 gh ht
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8 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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8.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 325

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329


1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1.2 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
1.3 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
1.5 Align end exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.6 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.7 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
2.3 Removing and installing exhaust flap control unit J883 / J945 . . . . . . . . . . . . . . . . . . . . . . 341
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.1 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 344

iv Contents
AG. Volkswagen A
Golf 2013 ➤ , Golf 2015o➤ agen
ksw, Golf 2017 ➤ , Golf Variant
es n 2014 ➤ , Golf V ...
G do
V l ot g
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger,
ed by chain drive, generation III) Volkswagen
ua
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s
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- Edition
tee
o 12.2017
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3.3 Removing and installing sender 1 for secondary air pressure G609 . . . . . . . . . . . . . . . . . . 344

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3.4 Removing and installing secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . 344

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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

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1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

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1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

spec
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1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 347

t to the co
1.3 Removing and installing knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

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1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
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Contents v
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

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vi Contents
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

00 – Technical data
1 Identification
(VRL011114; Edition 12.2017)
⇒ “1.1 Engine number/engine data”, page 1

1.1 Engine number/engine data


Engine number
The engine number (“code letters” and “serial number”) can be
found at the joint between the engine and gearbox.
The engine code is also stamped on the cylinder block behind the
oil filter.
In addition, there is a sticker on the right of the timing chain cover
with “engine code” and “serial number”.
The first 3 digits denote the mechanical design of the engine and
are stamped on the engine. The fourth digit shows the engine
output and torque and varies according to engine control unit. The
four-character engine code can be found on the identification
plate as well as on the vehicle data sticker. It can also be read
from the engine control unit.
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♦ Fitting locations of vehicle data sticker auth or
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♦ ⇒ Maintenance ; Booklet 36.1 ; Vehicle data sticker

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♦ ⇒ Maintenance ; Booklet 43.1 ; Vehicle data sticker


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Codes CJXB CJXC CYFB
urposes, in part or in wh

Displacement l 1.984 1.984 1.984


Power kW at rpm 206/5100 to 6500 221/5500 to 6200 215/5400 ... 6200 t to the co
Torque Nm at rpm 380/1800 to 5100 380/1800 to 5500 380/1900 ... 5300
rrectne

Bore ∅ mm 82.5 82.5 82.5


Stroke mm 92.8 92.8 92.8
ss o
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Compression ratio 9.3:1 9.3:1 9.3:1


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RON 981) 981) 981)


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Ignition/injection system FSI FSI FSI


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MPI MPI MPI


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Exhaust gas recirculation No No No


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Exhaust gas temperature regulation No No No


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Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐


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Knock control yes yes yes
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Charge air cooler yes cted
yes yes
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Lambda regulation yes yes yes
Camshaft timing adjustment yes yes yes
Variable intake manifold yes yes yes
Secondary air system No No No
Valves per cylinder 4 4 4

1. Identification 1
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Codes CJXB CJXC CYFB


Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder shut-off No No No
• 1) Unleaded petrol RON 95 can also be used, though power
is reduced

Codes CJXD CJXG DJHA


Displacement l 1.984 1.984 1.984
Power kW at rpm 213/5400 to 6500 228/5800 to 6500 228/5500 to 6500
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Torque Nm at rpm 380/1850 olks
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oe s noto 5700 400/2000 to 6500
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Bore ∅ mm ed
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Stroke tho
mm 92.8 92.8 o 92.8
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RON 981) 981) 981)

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Ignition/injection system FSI FSI FSI
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MPI MPI MPI
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Exhaust gas recirculation No No No

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Exhaust gas temperature regulation No No No

spec
urposes, in part or in wh

Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐

t to the co
er er er
Knock control yes yes yes

rrectne
Charge air cooler yes yes yes
Lambda regulation yes yes yes

ss
Camshaft timing adjustment yes yes yes

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Variable intake manifold yes yes yes

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Secondary air system No No No


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Valves per cylinder 4 4 4


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Firing order 1-3-4-2 1-3-4-2 1-3-4-2


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Cylinder shut-off No No No
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• 1) Unleaded petrol RON 95 can also be used, though power


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Codes DJHB DJJA DLRA


Displacement l 1.984 1.984 1.984
Power kW at rpm 213/5400 to 6500 215/5400 to 6200 215/5400 to 6200
Torque Nm at rpm 380/1850 to 5300 380/1900 to 5300 380/1900 to 5300
Bore ∅ mm 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8
Compression ratio 9.3:1 9.3:1 9.3:1
RON 981) 95 95
Ignition/injection system FSI FSI FSI
MPI
Exhaust gas recirculation No No No
Exhaust gas temperature regulation No No No
Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐
er er er
Knock control yes yes yes
Charge air cooler yes yes yes

2 Rep. gr.00 - Technical data


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
AG. Volkswagen A - Edition 12.2017
n G do
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Codes DJHB by DJJA ua
ran DLRA
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Lambda regulation au yes
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Camshaft timing adjustment yes yes yes

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Variable intake manifold

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Secondary air system No No No

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Valves per cylinder 4 4 4

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Firing order 1-3-4-2 1-3-4-2 1-3-4-2

h re
hole
Cylinder shut-off No No No

spec
es, in part or in w
• 1) Unleaded petrol RON 95 can also be used, though power

t to the co
is reduced

rrectness of i
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mercia

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ion
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1. Identification 3
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2 Safety information
⇒ “2.1 Safety regulations for working on fuel supply”, page 4
⇒ “2.2 Safety measures when working on vehicles with a start/
stop system”, page 4
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 5
⇒ “2.4 Safety precautions when working on ignition system”, page
5
⇒ “2.5 Safety precautions when working on the cooling system”,
page 6

2.1 Safety regulations for working on fuel


supply

WARNING

The fuel line is under pressure.


Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

WARNING

Risk of injury due to fuel which is under very high pressure


♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
AG. Volkswagen AG d
(4 … 7 bar). lkswagen oes
no
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by
♦ Prior to opening the high-pressure
ris
ed system, the fuel pres‐ ara
nte
sure in the high-pressureutsystem must be reduced to a
ho eo
ra
residual pressure of approx.
ss
a 6 bar. Procedure c
⇒ page 284 .
ce
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erm

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2.2 Safety measures when working on ve‐


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hicles with a start/stop system


, is n

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spec
es, in part or in w

WARNING
t to the co

Risk of injury due to automatic start of engine on vehicles with


a start/stop system.
rrectness of i

♦ In vehicles with an activated start/stop system (indicated


l purpos

by a message in the dash panel insert), the engine may


start automatically.
nform
ercia

♦ Therefore, ensure that the start/stop system is deactivated


m

when working on vehicle (switch ignition off, switch ignition


at
om

io

on again as required).
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Prote AG.
Rep. gr.00 - Technical data
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.3 Safety precautions when using testers


and measuring instruments during a
road test

WARNING

Risk of accidents due to distraction and inadequate securing


of test and measuring equipment.
♦ Operation of test and measuring equipment while driving
results in distraction.
♦ Increased risk of injury due to inadequately secured test
and measuring equipment.
n AG. Volkswagen AG
♦ Test and measuring
olks
wageequipment must always
does
not be secured
on the reard bseat.
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ris
♦ A second
ut
ho person must operate the test and measuring
eo
ra
equipment.
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♦ The person operating the test and measuring equipment

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must be seated in the rear.


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♦ Never operate the test and measuring equipment while

ility
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sitting in the front passenger seat.


wit
is n

h re
ole,

♦ In the event of an accident, the person may receive seri‐


ous injuries when the front passenger airbag is triggered. spec
urposes, in part or in wh

t to the co

2.4 Safety precautions when working on ig‐


rrectne

nition system
s

To prevent injuries to persons and/or damage to the injection and


s o
cial p

ignition system, the following must be observed:


f inform
mer

♦ Persons wearing a cardiac pacemaker must at all times main‐


atio

tain a safe distance from high-voltage components such as


om

ignition system and xenon lights.


n
c

i
or

n thi
e

♦ Do not open any fuel line connections while the engine is run‐
t

sd
iva

ning.
pr

cum
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fo

en
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♦ Always switch off the ignition before connecting or discon‐


t.
yi Co
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necting electrical wiring for the injection or ignition system or
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♦ If the event memory has been cleared, a new readiness codeProte
cted AG.
agen
must be generated.
♦ Always switch off ignition before cleaning engine.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control unit
could be damaged.
♦ If the engine is to be turned at starter speed without actually
starting (e.g. compression test), disconnect the four connec‐
tors from the ignition coils. Use puller - T40039- to do this. Also
remove fuse from fuel pump control unit - J538- .

2. Safety information 5
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.5 Safety precautions when working on the


cooling system

WARNING

The cooling system is under pressure when the engine is hot!


Danger of scalding by steam and hot coolant.
AG. Volkswagen n AG do
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Cover filler cap on expansion tank Vol with a cloth and open care‐ ot gu
ks sn
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fully to release pressure. rised ara
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Caution

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Danger of overheating due to incorrectly fitted cap.

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♦ You should hear and feel it click into place.

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

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mer

atio
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c

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Prote AG.

6 Rep. gr.00 - Technical data


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 7
⇒ “3.2 Foreign objects in engine”, page 7
⇒ “3.3 Contact corrosion”, page 7
⇒ “3.4 Routing and attachment of lines”, page 8
⇒ “3.5 Fitting radiator and condensers”, page 8
⇒ “3.6 Checking vacuum system”, page 8

3.1 Rules for cleanliness

Note

Even slight soiling can cause faults. You must therefore comply
with the following cleanliness rules when working on the fuel sup‐
ply system, injectors or the turbocharger:

♦ Carefully clean connection points and the surrounding area


with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use only lint-free cloths. Volkswa AG. gen AG
agen does
♦ If repair work cannot be performed immediately, Volcarefully cov‐
ksw not
gu
er or seal components. d by ara
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♦ Install only clean parts; do not remove au new parts from pack‐
t ra
c
ss
aging until immediately before installing. Do not use parts that
ce
e

have been stored outside their packaging (e.g. in tool boxes).


nl

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♦ When the system is open, do not work with compressed air or
erm

move the vehicle. ab


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wit
♦ Make sure that no fuel gets onto the fuel hoses. Should this
, is n

h re
occur, the fuel hoses must be cleaned immediately.
hole

spec

♦ Protect disconnected electrical connectors from dirt and water,


es, in part or in w

t to the co

and reconnect them only when dry.

3.2 Foreign objects in engine


rrectness of i

♦ To prevent the ingress of foreign bodies during work on the


l purpos

engine, seal open channels of the intake and exhaust sections


with suitable bungs, for example from the engine bung set -
VAS 6122- .
nform
mercia

at
om

io

Note
n
c

in t
or

his
ate

In the event of mechanical damage to the turbocharger, refer to


do
riv

⇒ page 259 .
p

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3.3 Contact corrosion
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Contact corrosion can occur if non-approved fasteners are used
co lksw
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on the vehicle (bolts, nuts, washers etc.). Prote AG.

For this reason, only connecting elements with a special surface


coating have been fitted.

3. Repair instructions 7
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

In addition, rubber, plastic and adhesives are made of non-con‐


ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .
♦ We recommend only original genuine parts. They have been
tested and are compatible with aluminium.
♦ We recommend the use of VW accessories.
♦ Damage resulting from contact corrosion is not covered by the
warranty.

3.4 Routing and attachment of lines


♦ Mark fuel lines, vacuum lines, pipes/hoses for activated char‐
coal filter system and electrical wiring etc. before removal so gen AG
. Volkswagen AG
does
they can be re-installed in the original positions and correctly Volkswa not
gu
connected. Where necessary, make sketches or take photo‐ ed by ara
nte
graphs. thoris
eo
au ra
♦ Because of the limited space in the engine compartment,
ss en‐ c

ce
le

sure sufficient clearance to all moving or hot components to


un

pt
prevent damage to the lines.

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ab
3.5 Fitting radiator and condensers
pe

ility
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Even if installed correctly, the radiator, the condenser and the

h re
hole

charge air cooler may have small dents in their fins. This does not

spec
mean that these components have been damaged. It is not per‐
es, in part or in w

missible to renew radiators, condensers or charge air coolers only

t to the co
because of such minor dents.

3.6 Checking vacuum system

rrectness of i
l purpos

Special tools and workshop equipment required


♦ Hand operated vacuum pump - VAS 6213-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

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ng

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Cop py
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Prote AG.

Procedure
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
– If a fault has been entered in the event memory, make sure to
check not only all vacuum lines leading to the specified com‐
ponent, but also those leading to other components.

8 Rep. gr.00 - Technical data


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– If pressure cannot be built-up using hand vacuum pump - VAS


6213- or pressure immediately drops again, check hand vac‐
uum pump and connecting hoses for leaks.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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erm

ab
ility
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, is n

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spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

atio
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or c

thi
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rp

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Prote AG.

3. Repair instructions 9
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

10 – Removing and installing engine


1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
⇒ “1.2 Separating engine and gearbox”, page 18
⇒ “1.3 Securing engine on engine and gearbox support”,
page 23
⇒ “1.4 Installing engine”, page 25

1.1 Removing engine

Special tools and workshop


equipment required

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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ab
ility
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wit
, is n

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
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n in
or c

thi
te

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♦ Release lever - 80 - 200-
lksw
cted agen
Prote AG.
♦ Spring-type clip pliers - VAS 6362-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Stepladder - VAS 5085-
♦ Drip tray for workshop hoist - VAS 6208-

10 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

♦ Engine support - T10359 -


♦ Pin - T10359/2-
♦ Adapter - T10359/3-
♦ Safety glasses
♦ Safety gloves
Procedure

Note

The engine is removed downwards with gearbox.

– Remove engine cover panel ⇒ page 38 .


– Remove air filter housing together with air intake hose
⇒ page 287 .
– Unscrew bolts -arrows-.
– Unclip lower part of air duct -1- and remove it.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
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h
ut ra
Use removal
s lever - 80-200- to unclip the binding clips.
s a c
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rm

ab
pe

ility
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, is n

h re
hole

spec
es, in part or in w

t to the co

– Disconnect connectors -1 and 2- from engine control unit -


J623- .
rrectness of i

– Remove connectors -3 and 4- from retainer, and disconnect


l purpos

them.
– Move electrical lines free.
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

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

1. Removing and installing engine 11


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

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


box in engine compartment.

– Using a screwdriver, release catch -arrow-. Pull cover -1- for


electronics box in engine compartment upwards.

n AG. Volkswagen AG do
lkswage es n
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ir se tee
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u or
– Remove nut -arrow-, detach electrical wiring and movessclear.
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ility
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wit
, is n

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

Vehicles with manual gearbox

nform
– Disconnect electrical connector -2-.
mercia

– Push back cover for battery positive terminal -1-, and unbolt
at
om

io

battery positive cable from starter solenoid switch.


n
c

in t
or

– Unscrew nut -3- and remove earth wire.


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ate

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Depending on vehicle version, the earth wire is secured to the
ht
pyri by
Vo
o
starter bolt.
c by lksw
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Prote AG.

12 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Disconnect connectors -1 and 2- at front left of gearbox. agen


AG. Volkswagen AG d
oes
olksw not
– Disconnect gear selector cable and gate selector cable ed b from
y V gu
ara
gearbox. Then, unbolt cable support bracket, and horislay it to one nte
eo
side together with cables ⇒ Rep. gr. 34 ; Selector
aut mechanism; ra
c
Removing and installing selector mechanism s .
s

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le
un

pt
– Detach line leading to clutch slave cylinder ⇒ Rep. gr. 30 ;

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itte

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Clutch mechanism; Removing and installing clutch slave cyl‐

erm

ab
inder .

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is n

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ole,

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urposes, in part or in wh

t to the co
Vehicles with dual clutch gearbox

rrectne
– Disconnect electrical connector -1-.
– Push back cover for battery positive terminal -3-, and unbolt

s
battery positive cable from starter solenoid switch.

s o
cial p

f in
– Loosen nut -arrow-, and remove earth wire.

form
mer

atio
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n
Note
c

i
or

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sd
va

Depending on vehicle version, the earth wire is secured to the


i

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pr

cum
r

starter bolt.
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en
ng

t.
yi Co
Cop py
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gh ht
Caution pyri by
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Prote AG.
Risk of damage to the control unit (mechatronic unit) due to
electrostatic discharge
♦ Do not touch contacts in the gearbox connector with
hands.

– Touch earth connection (without gloves) in order to discharge


yourself.
– Disconnect connector -2- for mechatronic unit for dual clutch
gearbox - J743- . To do this, turn rotary fastener in anti-clock‐
wise direction.
– Disconnect selector lever cable from gearbox, and pull it out
of cable support bracket ⇒ Rep. gr. 34 ; Selector mechanism;
Removing and installing selector mechanism .
Continuation for all

– Remove electrical connectors -1 and 2- from retainer, and dis‐


connect them. Move lines to one side.

1. Removing and installing engine 13


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Separate vacuum hose -2-.


– Press release tabs on vacuum hose -1-. Remove hose from
vacuum pump.
– Remove radiator cowl ⇒ page 256 .

– Release hose clips -1- and -2-, and remove air intake hose.
– Seal open lines and connections with clean plugs from engine
bung set - VAS 6122- .

– Lay coolant hose -3- to one side.


– Unscrew bolts -arrows-.
– Release hose clip -2-.
– Separate electrical connector -1- from charge pressure sender
- G31- . agen
AG. Volkswagen AG d
oes
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V
– Remove right air intake pipe. ed by gu
ara
ris nte
o eo
– Remove front parts of left and right front wheel housing
aut liners
h
ra
⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
s housing
s c
liner; Assembly overview – front wheel housing liner . ce
le
un

pt
an
d
itte

– Remove subframe without steering rack ⇒ Running gear, y li


erm

ab
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐ ility
ot p

ling subframe without steering rack . wit


is n

h re

– Remove front exhaust pipe with catalytic converter


ole,

spec

⇒ page 339 .
urposes, in part or in wh

t to the co

Make yourself familiar with the relevant safety precautions before


starting work on the cooling system ⇒ page 6 .
rrectne

– Open filler cap -arrow- for coolant expansion tank.


– Place drip tray for workshop hoist - VAS 6208- underneath.
ss o
cial p

f inform
mer

atio
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by c lksw
cted agen
Prote AG.

14 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engineo(2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
AG. V lkswagen AG d
lkswagen oes
n - Edition 12.2017
o ot g
yV ua
edb ran
– Disconnect
ho
ris electrical connector -1-. Lift retaining teeclip -2-, and
loosen
aut hose clip -3-. or
ac
ss
– Pull off coolant hose and connection, and drain coolant.

ce
e
nl

pt
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itte

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erm

ab
ility
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, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
– Lift retaining clips -arrows- and disconnect coolant hoses from
l purpos

heat exchanger for heater.


– Hold coolant hoses downwards to allow coolant to drain.

nform
ercia

Make yourself familiar with the relevant safety precautions before


m

at
starting work on the fuel system ⇒ page 4 .
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cted
– Disconnect hose couplings -1- and -2- ⇒ Fuel supply system
agen
Prote AG.
- petrol engines; Rep. gr. 20 ; Plug-in connectors; Discon‐
necting plug-in connectors . Detach hoses from coolant ex‐
pansion tank -3-.

– Loosen hose clips -1 and 2-, and detach coolant hoses.

1. Removing and installing engine 15


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant AG. Vo2014
lkswage➤
n ,GGolf V ...
agen chain drive,Ageneration
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, does
III) Volkswagen R GmbH
olksw not
yV gu
- Edition 12.2017 sedb ara
n
ri tee
ho
ut or
– Lift retaining clip -arrow- and disconnect
ss coolant hose (top left)
a ac
from radiator.

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le
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pt
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d
Vehicles with dual clutch gearbox

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ab
ility
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ole,

spec
urposes, in part or in wh

t to the co
rrectnes
– Release retaining clips -1 and 2-, and detach coolant hoses

s o
for auxiliary radiator at front left.
cial p

f inform
Continuation all vehicles
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Prote AG.

– Unscrew bolts -arrows- for gearbox mounting approx. 2 turns.

– Unscrew bolts -arrows- for engine mounting approx. 2 turns.


– Remove air conditioner compressor (with refrigerant lines con‐
nected) from bracket, and tie it up to right side ⇒ Air condi‐
tioning system; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing air conditioner compressor from and
to bracket .
– Unbolt drive shafts from flange shafts on left and right ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing
and installing drive shaft .
– Tie up drive shafts to rear.

Note

Make sure not to damage the surface protection of the drive


shafts.

16 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Remove bolt -arrow- and push bracket for electrical wiring


harness to one side.

– Secure adapter -T10359/3- to engine support - T10359- , as


shown in illustration.
– Use locking element -A- from gearbox support - 3282- to se‐
cure pin -T10359/2- to engine support.
– Insert engine support - T10359- in engine and gearbox jack -
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– Fit engine support - T10359- to cylinder block. Screw bolt -A-
with spacer sleeve into cylinder block. rrectne

Component Specified torque


s

Bolt -A- 20 Nm
s o
cial p

f in

– Secure engine with locking element -B-, and slightly lift engine
form
mer

with gearbox.
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1. Removing and installing engine 17


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Remove bolts -arrows- for engine mounting.

– Remove bolts -arrows- securing gearbox mounting.

Caution

Risk of damage to the vacuum lines, electrical wiring and the


engine compartment
♦ Check that all vacuum lines and electrical wiring between
engine, gearbox and body have been detached.
♦ When lowering, carefully guide engine/gearbox assembly
out of engine compartment.

– Carefully lower engine/gearbox assembly.

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1.2 Separating engine and gearbox


⇒ “1.2.1 Separating engine and gearbox, vehicles with manual
nf
ercia

gearbox”, page 18
rm
m

atio
m

⇒ “1.2.2 Separating engine and gearbox, vehicles with dual clutch


o

n in
c

gearbox”, page 21
or

thi
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sd
a

1.2.1 Separating engine and gearbox, vehi‐


iv

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cles with manual gearbox


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Special tools and workshop equipment required t. C rig
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Prote AG.

18 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

♦ Workshop hoist - VAS 6100- agen


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♦ Lifting tackle - T40013-

rrectness of i
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mercia

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or

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♦ Hook - 10 - 222 A /2-
py by
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Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10359- .
– Release electrical wires from retainer -arrow- and lay them to
one side.

1. Removing and installing engine 19


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Unscrew bolts -1 and 2-, and remove starter from gearbox.

– Move electrical wiring harnesses -1, 2- clear at air pipe.


– Loosen screw-type clip -3-.
– Remove bolts -arrows- and detach air pipe.

– Unscrew bolts -arrows- and detach gearbox support.

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– Attach lifting tackle - T40013- to gearbox and close lock.


y li
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ab
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– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /


ot p

wit

2- to lifting tackle.
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

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

20 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

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

Note

Ignore -items 4, 5- and -A-.

– Pull gearbox off engine.

1.2.2 Separating engine and


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Special tools and workshop
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equipment required tee
or
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♦ Workshop hoists - VAS 6100-

ce
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un

pt
an
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ab
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urposes, in part or in wh

t to the co
rrectness o

♦ Adapter - 10 - 222 A /20-


cial p

f inform
mer

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♦ Hook -2024 A /1-

1. Removing and installing engine 21


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

♦ Engine bung set - VAS 6122-

Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10359- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
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es, in part or in w

t to the co
– Unscrew nuts -arrows-, and remove bracket at front of sump.

rrectness of i
l purpos

Note

The studs are welded to the front of the sump.


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– Disconnect electrical connector -2-.
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Note

Place a cloth underneath to absorb escaping coolant.

– Loosen hose clips -arrows- and remove coolant hoses from


gear oil cooler.
– Unscrew bolts -1- and lay coolant valve for gearbox - N488- to
one side.
– Seal open lines and connections with clean plugs from engine
bung set - VAS 6122- .

22 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Attach hook of lifting tackle - 2024 A- to gearbox lifting eye and


secure with pin -arrow-.
– Attach hook -2024 A /1- gto
en workshop
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does
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es, in part or in w

t to the co
rrectness of i
l purpos

– Unscrew bolts -1 to 8- securing gearbox to engine.

nform
mercia

at
Note
om

ion
c

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Disregard -Item A-. his


ate

do
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cum
or

– Pull gearbox off engine.


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1.3 Securing engine on engine and gearbox support

1. Removing and installing engine 23


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Special tools and workshop


equipment required

AG. Volkswagen AG d
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pe

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tion in
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♦ Lifting tackle - 2024 A-


r
rp

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en
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♦ Workshop hoist - VAS 6100-


n

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♦ Engine and gearbox support - VAS 6095-
t. rig
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Procedure
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• Gearbox detached from engine ⇒ page 18 .
– Release catch -arrow- and detach mounting -1- for engine
cover panel.

24 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Attach lifting tackle - 2024 A- to engine on workshop hoist -


VAS 6100- .

Note

To adjust to the centre of gravity of the assembly, the perforated


rails of the support hooks must be positioned as shown.

WARNING

Risk of accidents due to loose components of the lifting tackle


♦ The support hooks and pins on the lifting tackle must be
secured with locking pins -arrows-.

– Using workshop hoist - VAS 6100- , lift engine off engine and
gearbox jack - V.A.G 1383 A- . wage
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– Remove dowel sleeves for gearbox,
horis and, on gearbox side, bolt nte
eo
engine to engine and gearbox
s aut support - VAS 6095- . ra
c
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urposes, in part or in wh

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1.4 Installing engine rrectness

Procedure
o
cial p

f inform
mer

Caution
atio
om

n
c

i
or

Observe the following during all assembly work, particularly in


thi
e

the engine compartment due to the restricted space:


t

sd
iva

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pr

cum
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♦ Route lines of any kind and cables so that original routing


fo

en
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is restored.
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♦ Ensure that there is sufficient clearance to all moving or
ht. rig
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Note

♦ Renew bolts that are tightened with turning further angle.


♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Reinstall all cable ties in the same locations when installing.

1. Removing and installing engine 25


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Guide engine/gearbox assembly into body.


– First screw bolts -arrows- for engine mountings into stop by
hand.

AG. Volkswagen AG d
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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

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fo

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26 Rep. gr.10 - Removing and installing engine


AG. Volkswagen AG d
agen oes
olksw not
V
Golfed b2013 ➤ , Golf 2015 ➤ , Golf 2017gu➤
y ara, Golf Variant 2014 ➤ , Golf V ...
nte
ris(2.0 l, 4 V, turbocharger, chain drive, generation
4-cyl. direct injection enginetho eo III) Volkswagen R GmbH
u ra
ss a c - Edition 12.2017

ce
e
nl

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

an
itte

y li
hand.

erm

ab
ility
ot p

wit
, is n
Note

h re
hole

spec
The bolts are tightened to final torque only after adjusting the as‐
es, in part or in w

t to the co
sembly mountings ⇒ page 29 .

– Remove engine bracket - T10359- from engine.

rrectness of i
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
l purpos

40 ; Drive shaft; Assembly overview - drive shaft .


Vehicles with manual gearbox:

nf
ercia

or
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;

m
m

atio
m

Removing and installing clutch slave cylinder .


o

n in
or c

– Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐

thi
te

sd
lector mechanism; Assembly overview - selector cables .
iva

o
r
rp

cu
Vehicles with dual clutch gearbox:
o

m
f

en
ng

t.
yi Co
– Install and adjust selector lever cable ⇒ Rep. gr. 34 ; Selector Cop py
t. rig
mechanism; Removing and installing selector lever cable . opyri
gh by
Vo
ht
c lksw
Continued for all vehicles:
by
cted agen
Prote AG.

– Install air conditioner compressor ⇒ Heating, air conditioning;


Rep. gr. 87 ; Air conditioner compressor; Assembly overview
- drive unit of air conditioner compressor .
– Install poly V-belt ⇒ page 41 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Assembly overview - battery .
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, electron‐
ics boxes and ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Install air filter housing ⇒ page 287 .
– Fit engine cover panel ⇒ page 38 .
– Check oil level.
– Connect coolant hoses.
– Add coolant ⇒ page 199 .

Note

Never reuse old coolant.

– Install subframe ⇒ Running gear, axles, steering; Rep. gr.


40 ; Subframe; Removing and installing subframe without
steering rack .
– Adjust assembly mountings ⇒ page 36 .
– Install front wheel housing liners ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .

1. Removing and installing engine 27


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Caution

Danger of destroying control units through excessive


swa
gvoltage
en AG. V
olkswagen AG
does
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Vol gu
♦ Never use battery charging equipmentsfor
ed boost starting.
by ara
nte
ri
ho eo
aut ra
ss c
– After renewing engine, adapt the chain elongation. To do so,

ce
le
un

pt
select 01 - Chain elongation adaption diagnosis in

an
d
itte
Guided Functions ⇒ Vehicle diagnostic tester.

y li
erm

ab
ility
ot p

Specified torques

wit
is n

h re
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 29
ole,

spec
urposes, in part or in wh

♦ ⇒ “2.1 Assembly overview - emission control”, page 338

t to the co
♦ ⇒ “1.1 Assembly overview - silencers”, page 329
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 286

rrectne
♦ Securing gearbox to engine ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Specified torques for gearbox .

ss o
cial p

f inform
Note
mer

atio
om

♦ The specified torques are only valid for nuts and bolts which

n
c

i
or

n
have been slightly greased, oiled, phosphate-treated or black-

thi
te

oxided.

sd
iva

o
pr

cum
r

♦ Additional lubricant such as engine oil or gear oil may be used,


fo

en
ng

but do not use lubricant containing graphite.


t.
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Cop py
. rig
♦ Do not use degreased parts.
ht ht
rig by
copy Vo
♦ Tolerance for specified torques ± 15%.
by lksw
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Prote AG.

Component Nm
Bolts and nuts M6 10
M7 15
M8 20
M10 40
M12 65

28 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 29
⇒ “2.2 Supporting engine in installation position”, page 31
⇒ “2.3 Removing and installing motor mounting”, page 34
⇒ “2.4 Removing and installing gearbox mounting”, page 34 AG. Volkswagen
n AG do
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⇒ “2.5 Removing and installing pendulum support”,y Vpage ot g
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⇒ “2.6 Checking adjustment of assembly mountings
tho
ris (engine and tee
or
gearbox mountings)”, page 36 s au ac
s

ce
le
⇒ “2.7 Adjusting assembly mountings”, page 36
un

pt
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2.1 Assembly overview - assembly mountings

y li
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1 - Bolt

h re
ole,

spec
❑ Renew after removal
urposes, in part or in wh

❑ Specified torque and

t to the co
tightening sequence
⇒ page 50

rrectne
2 - Engine support
❑ Removing and installing

ss
⇒ page 49

o
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f in
3 - Engine mounting

form
mer

❑ With support arm

atio
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❑ Removing and installing

n
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⇒ page 34

thi
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4 - Bolt
pr

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❑ Renew after removal

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❑ 40 Nm +90° C py
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❑ Renew after removal Prote AG.

❑ 20 Nm +90°
6 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
7 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
8 - Pendulum support
❑ Removing and installing
⇒ page 36
9 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence ⇒ page 36
10 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence ⇒ page 36
11 - Bolt
❑ Renew after removal

2. Assembly mountings 29
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017
❑ Specified torque and tightening sequence ⇒ page 36
12 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
13 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
14 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ page 34
15 - Bolt
❑ Renew after removal
❑ 50 Nm +90°

AG. Volkswagen AG d
agen oes
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tho eo
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pt
du

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itte

y li
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ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
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Cop py
t. rig
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pyri by
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by
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Prote AG.

30 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.2 Supporting engine in installation position

Special tools and workshop


equipment required

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

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for

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Cop py
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♦ Support - 10 - 222 A- cop Vo
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♦ Adapter - 10 - 222 A /18-
AG.

♦ Adapter - 10 - 222 A /29-


♦ -T40091/1- and -T40091/3- from engine support basic set -
T40091-

2. Assembly mountings 31
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

♦ -T40093/3- and -T40093/3-6- from engine support supplement


set - T40093-
♦ Hook - 10 - 222 A /20-
Preparing tools
– If adapter -10 - 222 A /4- does not yet have the hole -arrow-,
it must now be drilled into it.
• Dimension -a- = 225 mm.
• Hole diam. = 12.5 mm.
– Remove engine cover panel ⇒ page 38 .

– Release catch -arrow- and detach mounting -1- for engine


AG. Volkswagen AG d
cover panel. lksw
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db ran
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ho
aut or
ac
ss

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nl

pt
du

an
itte

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erm

ab
ility
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wit
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hole

spec
es, in part or in w

t to the co
– Unclip right mounting -1- for engine cover panel from retainer
-2-.

rrectness of i
l purpos

nf
ercia

orm
m

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om

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or c

thi
te

sd
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o

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t.
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op
– On both sides of vehicle, insert adapter - 10 - 222 A /29- be‐ C py
t. rig
tween upper wheel housing longitudinal member and under‐
gh ht
yri by
lying wing mounting plate.
cop Vo
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cted agen
Prote AG.
♦ Installation position:
“L” = -1-: adapter is to be inserted on right side of vehicle ( adapter
is engaged in recess of wing).

“R” (not shown in figure), adapter is to be inserted on left side of


vehicle.
Arrow -2- always points in direction of travel.

32 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Push adapter - 10 - 222 A /18- and two connecting pieces -


. Volkswagen AG
T40091/3- onto support bracket - 10-222 wage.n AG
A- does
ks n ol ot g
yV ua
– Secure support bracket - 10-222 eA-
d b to adapters - 10 - 222 A / ran
ris
29- . ut
ho tee
or
sa ac
– Remove upper part of washers fluid reservoir ⇒ Electrical sys‐

ce
e
tem; Rep. gr. 92 ; Windscreen washer system; Removing and

nl

pt
du

an
installing washer fluid reservoir .
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
– If present, pull off wires in front area of flange on both longi‐
ercia

o
tudinal members -arrow-. Do not disconnect pipe/hose sys‐

rm
m

atio
tem.
om

n in
c

– Place adapters - T40093/3-6- onto both longitudinal members


or

thi
e

(the figure shows the right longitudinal member).


t

sd
iva

o
r
rp

cu
– If necessary, carefully unclip any pipes for air conditioning
o

m
f

en
ng

system in front area. Do not disconnect pipe/hose system ⇒


t.
yi Co
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Cop py
ht. rig
System overview - refrigerant circuit . rig ht
py by
co Vo
by lksw
• Each of the adapters - T40093/3-6- locks with pin -A- behind Prote
cted AG.
agen
the web of the longitudinal member -arrow-.

– Bolt on spindles - T40093 /3- .


– Connect spindles - T40093 /3- to support bracket - T40091/1-
using square tubes - 10-222 A- , and tighten.
– Then hook spindles into lifting eyes of engine, using hook - 10
- 222 A /20- and, if necessary, shackle - 10 - 222 A /12- .
– Take up weight of engine/gearbox assembly and support
bracket on spindles .

2. Assembly mountings 33
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.3 Removing and installing motor mounting


Removing
– Disconnect electrical connector -1-.
– Free hoses -2- from fittings and lay them to one side.
– Using a screwdriver, release catches -arrow-. Lay coolant ex‐
pansion tank to one side.
– Support engine in its installation position ⇒ page 31 .
– Take up weight of engine/gearbox assembly slightly with spin‐
dle; do not lift.

– Unscrew bolts -arrows- and remove engine mounting -1-.


Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings ⇒ page 36 .
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 29

2.4 Removing and installing gearbox


mounting
Removing
n AG. Volkswagen AG do
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
olks
wage es n
ot g
Removing and installing battery tray . d byV ua
ran
e
ris tee
– Remove engine control unit - J623- from bracket (lines
ut
ho remain or
connected) ⇒ page 325 . ss
a ac
ce
le
un

– Unscrew nuts -arrows- and remove bracket -1-.


pt
an
d
itte

y li
erm

ab
ility
ot p

Note
wit
is n

h re
ole,

Different types of brackets are fitted depending on version.


spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
iva

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pr

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r
fo

en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by

34
cted agen
Prote AG.
Rep. gr.10 - Removing and installing engine
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

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


one side.
– Support engine in its installation position ⇒ page 31 .

AG. Volkswagen AG d
agen oes
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pt
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itte

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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Unscrew bolts -2-. Then unscrew bolts -arrows-, and remove

rrectness of i
gearbox mounting -1-.
l purpos

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

at
om

Note
on
c

in t
or

his
te

Renew bolts that are tightened with turning further angle.


a

do
priv

cum
for

en
g

– Tighten gearbox mounting on longitudinal member.


n

t.
yi Co
Cop py
t. rig
gh ht
yri
Caution
p by
co Vo
by lksw
cted agen
Prote AG.
Risk of damage to threads in the gearbox support by starting
bolts at an angle.
♦ Gearbox support and support arm of gearbox mounting
must be perfectly parallel to each other before screwing in
bolts. If necessary, lift gearbox at rear using trolley jack.
♦ Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.

– Lift gearbox with spindle of support bracket until gearbox sup‐


port makes contact with support arm of gearbox mounting.
– Checking adjustment of assembly mountings ⇒ page 36 .
– Remove support bracket - 10 - 222 A- from engine.
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 29
♦ Battery; Assembly overview - battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Assembly overview - battery

2. Assembly mountings 35
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.5 Removing and installing pendulum sup‐


port
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Unscrew bolts -1, 2 and 3-, and remove pendulum support.
Installing
Install in reverse order of removal, observing the following:
Specified torques
Stage Bolts Specified torque/turning further angle
1. -2 and 3- 50 Nm
2. -1- 130 Nm
3. -1 … 3- Turn 90° further
♦ Noise insulation; Assembly overview - noise insulation ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation

2.6 Checking adjustment of assembly


mountings (engine and gearbox mount‐
ings)
AG. Volkswagen AG d
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The following specifications must be obtained:rised ara
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• There must be a distance of -a- = 10 mm aut between engine ra
s c
support -2- and engine mounting -1-.
s ce
e
nl

pt
du

• Side surface of the engine support casting should be located


an
itte

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parallel to support arm of engine mounting.


erm

ab
ility
ot p

• Distance -b- = distance -b-.


wit
, is n

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hole

spec

Note
es, in part or in w

t to the co

Check distance -a- = 10 mm using, for example, a suitable rod.


rrectness of i

– If the dimension is too small or too high, adjust assembly


mountings ⇒ page 36 .
l purpos

2.7 Adjusting assembly mountings


nform
mercia

Procedure
at
om

ion
c

– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;


in t
or

his

Removing and installing battery tray .


ate

do
priv

– Support engine in its installation position ⇒ page 31 .


um
for

en
ng

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

36 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Unscrew engine mounting bolts -arrows- one after the other


and renew them (if not already renewed when installing en‐
gine).
– First screw bolts in loosely.

– Using assembly lever, adjust engine/gearbox assembly until


specifications listed below are attained:
• There must be a distance of -a- = 10 mm between engine
support -2- and engine mounting -1-. AG. Volkswagen AG d
agen oes
olksw not
V gu
• Side surface of the engine support casting should be slocated
d by ara
i e nte
parallel to support arm of engine mounting. thor eo
au ra
c
• Distance -b- = distance -b-. ss

ce
e
nl

pt
du

an
itte

y li
Note
erm

ab
ility
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wit
Check distance -a- = 10 mm using, for example, a suitable rod.
, is n

h re
hole

spec
– Tighten bolts for engine mounting.
es, in part or in w

t to the co
– Unscrew gearbox mounting bolts -arrows- one after the other
and renew them (if not already renewed when installing en‐

rrectness of i
gine).
l purpos

– First screw bolts in loosely.

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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op py
– On gearbox side, ensure that support arm and gearbox mount‐ t. C rig
gh ht
ing are parallel. yri
p by
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cted
• Distance -x- = distance -x-.
agen
Prote AG.

– Tighten bolts for gearbox mounting.


Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 29
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery

2. Assembly mountings 37
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

3 Motor cover
⇒ “3.1 Removing and installing engine cover”, page 38

3.1 Removing and installing engine cover


Removing

AG. Volkswagen AG d
Note agen oes
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Do not pull off motor cover panel abruptly or only onthone
or side. eo
au ra
ss c
– Carefully pull engine cover panel off the four retaining pins

ce
e
nl

pt
du
-arrows- one after the other.

an
itte

y li
erm

ab
Installing

ility
ot p

Install in reverse order of removal, observing the following:

wit
, is n

h re
hole

– To avoid damage, do not strike the engine cover panel with

spec
your fist or with any kind of tool.
es, in part or in w

t to the co
– Position engine cover panel, paying attention to oil filler neck
and dipstick.

rrectness of i
– Press engine cover panel into rubber grommets first on left
side and then on right side.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

38 Rep. gr.10 - Removing and installing engine


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block (pulley end)”,
page 39
⇒ “1.2 Removing and installing poly-V belt”, page 41
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 42
⇒ “1.4 Removing and installing bracket for ancillaries”,
page 42
⇒ “1.5 Removing and installing vibration damper”, page 44
⇒ “1.6 Removing and installing engine support”, page 49
⇒ “1.7 Renewing crankshaft oil seal - belt pulley end”,
page 50

1.1 Assembly overview - cylinder block (pulley end)

1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Poly V-belt routing
⇒ page 41
❑ Removing and installing
⇒ page 41
❑ When installing, make
sure it is properly seated
on pulleys. AG. Volkswagen AG d
agen oes
lksw not
2 - Tensioning device for poly byV
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ara
V-belt rised
nte
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❑ Swing with open-end s aut ra
c
spanner to slacken poly s
ce
le

V-belt.
un

pt
an
d
itte

❑ Lock with locking pin -


y li
erm

ab

T10060 A- .
ility
ot p

❑ Removing and installing


wit
is n

⇒ page 42
h re
ole,

spec

3 - Bolt
urposes, in part or in wh

t to the co

❑ Renew after removal


❑ 8 Nm +45°
rrectne

4 - Bolt
❑ Renew after removal
ss

❑ Moisten O-ring with oil.


o
cial p

f i

❑ Use counter-hold tool -


nform

T10355- to loosen and


mer

atio

tighten
om

n
c

❑ 150 Nm +90°
i
or

n thi
te

sd
a

5 - O-ring
iv

o
pr

cum

❑ Not a replacement part.


r
fo

en
ng

Included in items sup‐


t.
yi Co
op
plied with bolt. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 39


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

6 - Vibration damper
❑ With poly V-belt pulley
❑ Removing and installing ⇒ page 44
7 - Ancillary bracket
❑ With oil filter and engine oil cooler
❑ Removing and installing ancillary bracket ⇒ page 42 .
❑ Removing and installing engine oil cooler ⇒ page 179
8 - Seal
❑ Renew after removal
9 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence ⇒ page 40
10 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
11 - Alternator
❑ Assembly overview ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
12 - Dowel sleeves
❑ For air conditioner compressor. agen
AG. Volkswagen AG d
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13 - Air conditioner compressor d by V gu
ara
ise nte
❑ Do not unscrew or disconnect refrigerant lines
uthor eo
a ra
❑ Assembly overview ⇒ Heating, air conditioning;
ss Rep. gr. 87 ; Air conditioner compressor; Assembly c
overview - drive unit of air conditioner compressor .

ce
e
nl

pt
du

an
itte

14 - Bolt

y li
erm

ab
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly over‐

ility
ot p

view - drive unit of air conditioner compressor .

wit
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h re
hole

spec
es, in part or in w

Ancillary bracket - specified torques and tightening sequence

t to the co
– Fit bracket for ancillaries (first tighten bolt -4- by hand).

Note rrectness of i
l purpos

Renew bolts that are tightened with a turning further angle.


nf
ercia

orm
m

– Tighten bolts in sequence -1 … 5- in 3 stages as follows:


atio
om

n in
c

1. Tighten bolts by hand.


or

thi
te

sd
iva

2. Tighten bolts to 20 Nm.


o
r
rp

cu
o

m
f

en
ng

3. Turn bolts 90° further.


t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

40 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Poly V-belt routing


1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
ss c

ce
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nl

pt
du

1.2 Removing and installing poly-V belt

an
itte

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erm

ab
Special tools and workshop equipment required

ility
ot p

wit
, is n

♦ Locking pin - T10060 A-

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
e

Removing
at

do
priv

cum
or

– Remove noise insulation ⇒ General body repairs, exterior;


f

en
g

Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐


n

t.
yi Co
op
sulation . C py
ht. rig
rig ht
by
– Remove washer fluid reservoir ⇒ Electrical system; Rep. gr. copy Vo
by lksw
92 ; Windscreen washer system; Removing and installing cted agen
Prote AG.
washer fluid reservoir .

Caution

If a used poly V-belt runs in the opposite direction when it is


refitted, this can cause severe damage
♦ Before removing the poly V-belt, use a piece of chalk or a
felt pen to mark the running direction.

– To slacken poly V-belt turn tensioning device in direction of


-arrow-.
– Lock tensioning device in place with locking pin - T10060 A- .
– Remove poly V-belt.

1. Cylinder block (pulley end) 41


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Installing
Install in reverse order of removal. During this procedure, observe
the following:
– Fit poly V-belt as shown in figure.
1- Vibration damper AG. Volkswagen AG d
agen oes
olksw not
2- Tensioning device for poly V-belt d byV gu
ara
ise nte
r
3- Alternator ut
ho eo
ra
s a c
s
4- Air conditioner compressor

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
– Turn tensioning device in -direction of arrow-, and pull out
ot

locking pin - T10060 A- .

wit
, is n

h re
hole

– Release tensioner.

spec
es, in part or in w

– Check that poly V-belt is properly seated.

t to the co
– Start engine and check that poly V-belt runs properly.

rrectness of i
Specified torques
♦ Noise insulation; Assembly overview - noise insulation ⇒
l purpos

General body repairs, exterior; Rep. gr. 66 ; Noise insulation;


Assembly overview - noise insulation

nform
mercia

a
com

tio
1.3 Removing and installing tensioner for

n in
r
te o

thi
poly V-belt

s
iva

do
r
rp

cum
Removing
fo

en
ng

t.
yi Co
– Remove poly V-belt ⇒ page 41 . Cop py
ht. rig
rig ht
– Remove washer fluid reservoir ⇒ Electrical system; Rep. gr. py by
co Vo
92 ; Windscreen washer system; Removing and installing
by lksw
cted agen
Prote
washer fluid reservoir .
AG.

– Unscrew bolts -arrows- and pull tensioning device -1- for poly
V-belt off ancillary bracket.
Installing
Install in reverse order of removal, observing the following:
– Install poly V-belt ⇒ page 41 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page
39

1.4 Removing and installing bracket for an‐


cillaries
Removing
– Drain coolant ⇒ page 198 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove air conditioner compressor (with refrigerant lines con‐
nected) from bracket, and tie it up to right side ⇒ Air condi‐
tioning system; Rep. gr. 87 ; Air conditioner compressor;

42 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Removing and installing air conditioner compressor from and


to bracket .
– Disconnect connectors -1, 2 and 3-.
– Remove oil filter element ⇒ Maintenance ; Booklet ; Engine
oil: Draining; Renewing oil filter and replenishing engine oil .

– Unclip retainer for wiring harness -2-. Remove bolt -1- for dip‐
stick guide tube.
– Unclip guide tube from timing chain cover
n AG. Volks(top)
wagenin
AGdirection of
wage does
-arrow-. y Volks not
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ed ran
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au ac
ss

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pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

– Move wiring harness clear. spec


es, in part or in w

t to the co
– Place drip tray - VAS 6208- beneath engine.
– Unscrew bolts -1 … 5- and detach bracket for ancillary units
rrectness of i

from coolant pump housing.


l purpos

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

orm
m

atio

Note
om

n in
or c

thi

♦ Renew bolts that are tightened with a turning further angle.


te

sd
iva

o
r
rp

cu

♦ Renew O-rings and seals.


o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Cylinder block (pulley end) 43


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Moisten new O-rings -4- with coolant.


– Insert connecting piece -2- into coolant pump housing -3-.
– Push engine oil cooler -1- onto connection. Start bolts, then
tighten them to specified torque ⇒ page 40 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Assembly overview
- drive unit of air conditioner compressor .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install poly V-belt ⇒ page 41 .
– Add coolant ⇒ page 199 .
– Install oil filter and check oil level ⇒ Maintenance ; Booklet ;
Engine oil: Draining; Renewing oil filter and replenishing en‐
gine oil .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page
39
♦ ⇒ “1.1 Assembly overview - cover for timing chain”,
page 82
♦ Alternator; Assembly overview - alternator ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Alternator; Assembly overview - alternator .

1.5 Removing and installing vibration damp‐


er
Special tools and workshop equipment required
♦ Counter-hold tool - T10355-

n AG. Volkswagen AG do
lkswage es n
o ot g
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d ran
ir se tee
tho
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an
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itte

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erm

ab
ility
ot p

wit
is n

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ole,

spec

♦ Assembly tool - T10531-


urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

Components of assembly tool - T10531- :


en
ng

t.
yi Co
♦ Support - T10531/1- Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by

44
cted agen
Prote AG.
Rep. gr.13 - Crankshaft group
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

♦ Clamping pin - T10531/2-


♦ Turning over tool - T10531/3-
♦ Collar nut - T10531/4-
The vibration damper securing bolt -A- is used to secure the vi‐
bration damper -1- and the timing chain sprocket -2-
AG. Voon crankshaft
lkswagen AG
-3-. Before removing the vibration damper, agen
ksw lock the timing chain es not
do
ol
sprocket in position relative to crankshaft
db
y V as described below. gu
ar
e an
ris tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Removing
– Remove washer fluid reservoir ⇒ Electrical system; Rep. gr.
92 ; Windscreen washer system; Removing and installing

rrectness of i
washer fluid reservoir .
l purpos

– Remove poly V-belt ⇒ page 41 .


– Pull locking pin - T10060 A- out of tensioning device for poly

nf
ercia

o
V-belt.

rm
m

atio
m

– Turn vibration damper to TDC position -arrow- using counter-


o

n in
c

hold tool - T10355- .


or

thi
te

sd
a

• Notch on vibration damper must align with arrow marking on


iv

o
r

cover for timing chains (bottom).


rp

cu
o

m
f

en
ng

t.
• The marking on the cover is located at »4 o'clock position«.
yi Co
Cop py
t. rig
gh ht
yri
– Loosen vibration damper bolt by 1/2 turn using counter hold
p by
o Vo
by c lksw
cted
tool - T10355- .
agen
Prote AG.

– If vibration damper was turned while loosening bolt, reset TDC


position.

– Unscrew bolts -arrows- for timing chain cover. Bolts must be


renewed.

1. Cylinder block (pulley end) 45


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Fit support - T10531/1- to vibration damper, as shown in illus‐


tration, and tighten knurled screws -arrows- by hand.
– Unscrew vibration damper bolt completely.

– Check if turning over tool -A- slides easily over clamping


pieces -B-. If necessary, turn tensioning bolt -arrow-.

Note

Do not turn the tensioning bolt any more, otherwise the clamping
pin - T10531/2- will be jammed when it is screwed into the crank‐
shaft.

– Screw clamping pin - T10531/2- into crankshaft, and tighten it


hand-tight with a 12 mm open-end spanner -A-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

– Tighten tensioning bolt -A- by hand in order to lock the chain


h re
ole,

sprocket in position relative to crankshaft.


spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

46 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Unscrew knurled screws -arrows-.


– Remove support - T10531/1- and vibration damper -A-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
Turning crankshaft without vibration damper
un

pt
an
d
itte

y li
– Fit turning over tool -A- on clamping pin. Pay attention to tooth‐
rm

ab
ed contours of chain sprocket while doing so. In TDC position
pe

ility
ot

the flat section of the tool faces upwards.

wit
, is n

h re
– Tighten turning over tool with flange nut -B-.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Now, the crankshaft can be turned on hexagon -arrow-.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installing
Install in reverse order of removal, observing the following:
– If necessary, remove flange nut -B- and turning over tool -A-
from clamping pin.

1. Cylinder block (pulley end) 47


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Fit vibration damper in TDC position. Pay attention to teeth of


chain sprocket -arrow- while doing so.

– Fit turning over tool -A- on clamping pin. The hexagon faces
towards vibration damper while doing so.
– Screw on flange nut -B-. Move vibration damper slightly back
and forth while doing so, in order to ensure that vibration
damper is properly seated on teeth.
– Tighten flange nut, until vibration damper cannot be turned any
more.

– Fit support - T10531/1- to vibration damper, as shown in illus‐


tration, and tighten knurled screws -arrows- by hand.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

– Unscrew flange nut -A-, and loosen clamping pin -B-.


es, in part or in w

t to the co

– Unscrew clamping pin , and remove it together with turning


over tool .
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

48 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Screw in new vibration damper bolt with lubricated O-ring -1-


by hand.

– Unscrew knurled screws -arrows-, and remove support -


T10531/1- .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re

– Tighten vibration damper bolt using counter hold tool -


hole

spec

T10355- .
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
te

– Screw in new bolts -arrows-.


a

do
priv

cum
or

Specified torques
f

en
ng

t.
yi Co
♦ ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page
. Cop py
39
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.6 Removing and installing engine support


Removing
– Removing engine mounting ⇒ page 34 .

1. Cylinder block (pulley end) 49


AG. Volkswagen AG d
agen o
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017Vo➤ , Golf Variant 2014 ➤ , eGolf
lksw s no V ...
t gu
by
4-cyl. direct injection engine (2.0 l,rise4 V, turbocharger, chain drive, generation
d ara III) Volkswagen R GmbH
nte
- Edition 12.2017 autho eo
ra
ss c

ce
le
– Raise engine by dimension -a- using spindle - 10 - 222 A /11-

un

pt
-item 1-.

an
d
itte

y li
rm

ab
• Dimension -a- = about 30 mm.

pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Unscrew bolts -1, 2 and 3-, and remove engine support.

nform
ercia

Installing
m

a
com

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

n in
r
te o

thi
– Install engine mounting ⇒ page 34 .

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Engine support - specified torque and installation sequence

Note

Renew bolts.

– Tighten bolts in stages in the sequence shown.


Stage Bolts Specified torque/turning further angle
1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
3. -1 … 3- Turn 90° further

1.7 Renewing crankshaft oil seal - belt pul‐


ley end
Special tools and workshop equipment required
♦ Thrust piece - T10354-

50 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

♦ Thrust plate - T10375-

♦ Flange nut - 10531/4- from assembly tool - T10531-

♦ Extractor hook - T40274-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an

Removing
itte

y li
erm

ab

– Remove vibration damper ⇒ page 44 .


ility
ot p

wit
, is n

• Clamping pin - T10531/2- is inserted.


h re
hole

spec

– Using extractor hook - T40274- , pull out seal -arrow-.


es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

51
co Vo
by lksw
cted 1. Cylinder block (pulley end)
agen
Prote AG.
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Installing
Install in reverse order of removal, observing the following:
– Clean contact surface and sealing surface.
– Slide seal -arrow- onto thrust piece - T10354- .
• Closed side of oil seal faces towards thrust piece - T10354- .

– Slide seal -arrow- with thrust piece - T10354- onto clamping


pin - T10531/2- , and fit it to lower timing chain cover.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
– In addition, fit thrust pad - T10375- , and screw on flange nut
pe

ility
- 10531/4- .
ot

wit
, is n

h re
– Using a 21 mm open-end spanner, tighten flange nut until seal
hole

has been pressed in to stop.

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ Renew bolt for vibration damper.
l purpos

♦ Renew O-ring.

nform
ercia

– Install vibration damper ⇒ page 44 .


m

a
Specified torques
com

tion in
♦ ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page
r
te o

thi

39
s
iva

do
r
rp

cum
fo

en
ng

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

52 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2 Cylinder block, gearbox end


⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 53
⇒ “2.2 Removing and installing flywheel”, page 54
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 55

2.1 Assembly overview - cylinder block, gearbox end

1 - Flywheel
❑ Can be installed only in
one position - bores are
offset
❑ Removing and installing
⇒ page 54
2 - Dowel sleeve
3 - Sealing flange, gearbox
side
❑ Renew after removal
❑ With seal
❑ Removing and installing
⇒ page 55 n AG. Volkswagen AG do
swage es n
❑ Do not oil or grease oil yV
olk ot g
ua
seal sealing lip. ir se
d b ran
tee
o
❑ Before installing, re‐ auth or
ac
move oil residue from ss ce
e

crankshaft journal using


nl

pt
du

a clean cloth.
an
itte

y li
erm

❑ Do not remove guide


ab
ility

sleeve until sealing


ot p

wit

flange has been slid on‐


, is n

h re

to crankshaft journal.
hole

spec

4 - Cylinder block
es, in part or in w

t to the co

5 - Bolts
❑ Observe tightening se‐
rrectness of i

quence ⇒ page 54
❑ 9 Nm
l purpos

6 - Adapter
nform
ercia

❑ Illustration does not


show version installed in
m

at

vehicle.
om

ion
c

in t

❑ Must seat on dowel


or

his
e

sleeves.
at

do
priv

❑ Do not damage or bend when assembling.


um
for

en
g

❑ Is fitted onto sealing flange ⇒ page 54


n

t.
yi Co
Cop py
7 - Dowel sleeve
t. rig
gh ht
pyri by
Vo
o
8 - Bolts
c by lksw
cted agen
Prote AG.
❑ Renew after removal
❑ For dual-mass flywheel
❑ 60 Nm +90°

2. Cylinder block, gearbox end 53


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Install intermediate plate.


– Engage intermediate plate on sealing flange, and press onto
dowel sleeves -arrows-.

Sealing flange at gearbox end - tightening sequence AG. Volkswagen AG d


agen oes
olksw not
yV gu
– Tighten bolts -1 to 8- in the sequence shown. ised b ara
nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
2.2 Removing and installing flywheel

rrectness of i
Special tools and workshop equipment required
l purpos

♦ Counter-hold tool - 3067-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
• Gearbox is removed.

Caution

Risk of severe damage to the flywheel


♦ Screw out bolts -B- not with an air wrench or power impact
wrench but by hand.
♦ When removing the bolts, make sure that the bolt heads
do not come into contact with the flywheel.
♦ Rotate dual-mass flywheel -A- so that bolts -B- align cen‐
trally with the holes -arrows-.

54 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Insert counterhold tool - 3067- in hole -B- in cylinder block.


– Loosen and remove flywheel bolts.
Installing
Install in reverse order of removal, observing the following:

AG. Volkswagen AG d
agen
olksw Note oes
not
byV gu
ara
ed
is nte
Renew ut
hbolts that are tightened with turning further angle.
or eo
ra
s a c
s

ce
e
nl

pt
du

an
itte

y li
– Insert counterhold tool - 3067- in hole -A- of cylinder block.
erm

ab
ility
ot p

Specified torques

wit
, is n

h re
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
hole

spec
53
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm

2.3 Removing and installing sealing flange


m

atio
om

on gearbox side
n in
or c

thi
te

sd
a

⇒ “2.3.1 Distinguishing features for sealing flange, gearbox side”,


iv

o
r
rp

cu

page 55
o

m
f

en
ng

t.
yi
⇒ “2.3.2 Removing and installing sealing flange on gearbox side,
Co
op py
version A sealing lip faces outwards”, page 56
. C rig
ht ht
rig by
py
⇒ “2.3.3 Removing and installing sealing flange on gearbox side,
co Vo
by lksw
cted agen
version B sealing lip faces engine”, page 58
Prote AG.

2.3.1 Distinguishing features for sealing


flange, gearbox side
Differentiating criteria

Note

There are 2 versions of the sealing flange.

– Check which version must be installed.


♦ Version A: sealing lip -1- faces gearbox (outwards).
♦ Version B: sealing lip -1- faces engine. This sealing flange also
has a dust lip -2-.
– Removing and installing version A ⇒ page 56 .
– Removing and installing version B ⇒ page 58 .

2. Cylinder block, gearbox end 55


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.3.2 Removing and installing sealing flange


on gearbox side, version A sealing lip
faces outwards
Special tools and workshop equipment required
AG. Volkswagen AG d
agen
♦ Assembly sleeve - T20097- Volksw
oes
not
gu
by ara
d
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Hand drill with plastic brush attachment

rrectness of i
♦ Safety glasses
l purpos

♦ Sealant ⇒ Electronic parts catalogue (ETKA)

nform
ercia

Removing
m

a
– Remove flywheel ⇒ page 54 .
com

tion in
r

– Detach intermediate plate from sealing flange and dowel pins


te o

thi
-arrows-.

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew bolts -1 to 8-.


– Remove sealing flange.

56 Rep. gr.13 - Crankshaft group


AG. Volkswagen AG d
agen oes
olksw not
yV gu
Golf 2013 ➤ , Golf 2015 ed ➤ , Golf 2017 ➤ , Golf Variant 2014
b ara➤ , Golf V ...
nte
ris
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger,
ut
ho chain drive, generation III) Volkswagen e oR GmbH
ra
a
ss - Edition 12.2017
c

ce
le
un

pt
Installing

an
d
itte

y li
erm

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

ility
ot p

wit
is n

h re
ole,
Note

spec
urposes, in part or in wh

t to the co
♦ Observe use-by date of silicone sealant.
♦ Install the sealing flange within 5 minutes after application of
the silicone sealant.

rrectne
– In order to prevent the lubrication system from being soiled,

ss
cover the open section of the sump with a clean cloth.

o
cial p

f inform
mer

WARNING

atio
om

n
c

i
Risk of eye injury.
or

n thi
te

sd
va

♦ Wear safety goggles.


i

o
pr

cum
r
fo

en
ng

t.
yi Co
op
– Remove sealant residue.
C py
ht. rig
rig ht
py by
– Clean sealing surfaces. co Vo
by lksw
cted agen
Prote
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
AG.

2 mm).

– Apply silicone sealant -arrow- to clean sealing surface of seal‐


ing flange.
• Thickness of sealant bead: 2 to 3 mm.

– Clean crankshaft journal.


– Check assembly sleeve - T20097- ; it must be free of any de‐
formation or sharp edges.
– Fit assembly sleeve - T20097- onto crankshaft journal -A-.
– Fit sealing flange over assembly sleeve - T20097- onto crank‐
shaft journal.
– Remove assembly sleeve - T20097- .
– Tighten bolts; observe tightening sequence ⇒ page 54 .
• After installing the sealing flange, wait about 30 minutes for
the sealant to dry. Only then fill with engine oil.
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
53

2. Cylinder block, gearbox end 57


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

2.3.3 Removing and installing sealing flange


on gearbox side, version B sealing lip
faces engine
Special tools and workshop equipment required
♦ Guide piece - T10122/6- or guide piece - T10122/6A- from fit‐
ting tool - T10122B- or fitting tool - T10122C-

♦ Assembly aid - T10122/1- from fitting tool - T10122B- or fitting


tool - T10122C-

♦ Hand drill with plastic brush attachment


AG. Volkswagen A n G do
wage es n
♦ Safety glasses Volks ot g
by ua
ed ran
♦ Sealant ⇒ Electronicoris parts catalogue (ETKA) tee
th or
au ac
Removing ss
ce
le
un

pt

– Remove flywheel ⇒ page 54 .


an
d
itte

y li
erm

– Detach intermediate plate from sealing flange and dowel pins


ab
ility

-arrows-.
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen

58
Prote AG.
Rep. gr.13 - Crankshaft group
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Unscrew bolts -1 to 8-.


– Remove sealing flange.

Installing
Install in reverse order of removal, observing the following:
– In order to prevent the lubrication system from being soiled,
cover the open section of the sump with a clean cloth.

WARNING

Risk of eye injury. agen


AG. Volkswagen AG d
oes
olksw not
♦ Wear safety goggles.
d by V gu
ara
rise nte
tho eo
au ra
s c
– Remove sealant residue. s
ce
e
nl

pt
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– Clean sealing surfaces.


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ility
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Note
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spec

Observe use-by date of silicone sealant.


es, in part or in w

t to the co

– Cut off nozzle on tube at front marking (∅ of nozzle approx.


2 mm).
rrectness of i

– Apply silicone sealant -arrow- to clean sealing surface of seal‐


l purpos

ing flange.
• Thickness of sealant bead: 2 to 3 mm.
nf
ercia

orm
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Prote AG.

2. Cylinder block, gearbox end 59


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Note

♦ Check sealing flange; it must be free of kinks and damage.


♦ The sealing lip must face engine following installation. Other‐
wise, oil leaks may occur.
♦ Install the sealing flange within 5 minutes after application of
the silicone sealant.

– Check guide - T10122/6- -B-; it must be clean and free of sharp


edges.
– Attach assembly aid - T10122/1- -A- to guide - T10122/6-
-B-.
– Push sealing flange -C-, with outer side leading, onto guide
piece - T10122/6- -B-.
– Remove assembly aid -A-. AG. Volkswagen AG d
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– Put guide -A- with sealing flange -B- onto crankshaft journal.
rrectness of i

Note
l purpos

It is not necessary to tighten the bolts -arrows-.


nf
ercia

or

– Push sealing flange -B- over guide -A- onto crankshaft journal.
m
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– Remove guide -A-.


n in
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– Tighten bolts; observe tightening sequence ⇒ page 54 .


t

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cu

• After installing the sealing flange, wait about 30 minutes for


o

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the sealant to dry. Only then fill with engine oil.


t.
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Specified torques
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♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
co lksw
by
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53 Prote AG.

60 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 61
⇒ “3.2 Removing and installing sender wheel”, page 62
⇒ “3.3 Renewing needle bearing in crankshaft”, page 63
⇒ “3.4 Allocation of main bearing shells”, page 65
⇒ “3.5 Crankshaft dimensions”, page 66
⇒ “3.6 Measuring axial clearance of crankshaft”, page 67
⇒ “3.7 Measuring radial clearance of crankshaft”, page 67

3.1 Assembly overview - crankshaft

Note

Secure engine to repair stand using engine and gearbox support


- VAS 6095- when dismantling/assembling engine ⇒ page 23 .

1 - Cylinder block
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❑ With oil groove. thoris nte
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❑ Moisten with oil. au ra
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❑ Do not interchange
nl

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used bearing shells


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(mark).
erm

ab
ility
❑ Marking of crankshaft
ot p

bearing shells (classifi‐ wit


, is n

h re
cation) ⇒ page 65
hole

spec

3 - Crankshaft
es, in part or in w

t to the co

❑ After removing, place it


down so that the sender
wheel
rrectness of i

⇒ Item 8 (page 62) is


not damaged and the
l purpos

crankshaft does not rest


on the sender wheel
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ercia

❑ If the crankshaft is re‐


newed, the bearing
m

at
om

shells must be reas‐


ion
c

signed to bearing cap


in t
or

his
e

⇒ page 65 .
at

do
riv

❑ Axial clearance
p

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or

⇒ page 67
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❑ Radial clearance . Cop py
⇒ page 67
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when checking radial Prote AG.
clearance
❑ Crankshaft dimensions
⇒ page 66 .
4 - Bearing shell for bearing
cap
❑ Without oil groove.
❑ Moisten with oil.

3. Crankshaft 61
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017
❑ Do not interchange used bearing shells (mark).
❑ Marking of crankshaft bearing shells (classification) ⇒ page 65
5 - Bolt
❑ Renew after removal
❑ Tightening sequence ⇒ page 62
6 - Bearing cap
❑ Bearing cap 1: belt pulley end.
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
7 - Bolt
❑ Renew after removal
❑ Sender wheel must be renewed if bolts are loosened ⇒ page 62
❑ 10 Nm +90°
8 - Sender wheel
❑ For engine speed sender - G28-
❑ Can be installed only in one position - bores are offset
❑ Always renew sender wheel if securing bolts have been unscrewed
❑ Removing and installing ⇒ page 62
9 - Thrust washers
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❑ Moisten with oil.
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10 - Bolt ss
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❑ Renew after removal
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❑ Tightening sequence ⇒ page 62


itte

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Crankshaft tightening sequence


h re
hole

spec

– Tighten crankshaft bolts in the sequence -1 … 5- as follows:


es, in part or in w

t to the co

1. Tighten bolts -1 … 10- and -arrows A- by hand.


2. Tighten bolts -1 … 10- initially to 65 Nm.
rrectness of i

3. Turn bolts -1 … 10- 90° further using a rigid wrench.


l purpos

4. Tighten bolts -arrows A- initially to 20 Nm.


5. Turn bolts -arrows A- 90° further using a rigid wrench.
nform
mercia

at
om

ion
c

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or

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ate

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priv

cum
for

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Prote
3.2 Removing and installing sender wheel
AG.

– Remove engine.
– Remove sealing flange on gearbox side ⇒ page 55 .
– Remove upper part of sump ⇒ page 174 .
– Remove balancer shaft timing chain ⇒ page 107 .
– Unscrew conrod bearing cap.

62 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Remove crankshaft bearing cap.


– Remove crankshaft and unscrew sender wheel.
– Renew sender wheel -2- each time bolts -1- are loosened.

Note

♦ The second time the bolts are tightened, the contact points in
the sender wheel for the countersunk heads are deformed so
much that the bolt heads seat on the crankshaft -3-, -arrows-
and the sender wheel is loose under the bolts.
♦ The sender wheel can only be installed in one position, the
holes are offset.

Specified torques
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 61

3.3 Renewing needle bearing in crankshaft


Only vehicles with a dual clutch gearbox
Special tools and workshop equipment required
♦ Counter support, e.g. KUKKO
Volkswa
22-1 - VAS 251 621-
AG. gen AG
agen does
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spec
urposes, in part or in wh

t to the co

♦ Internal puller - VAS 251 635-


rrectness o
cial p

f inform
mer

atio
om

n
c

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or

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t.
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Cop py
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Prote AG.

3. Crankshaft 63
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

♦ Drift - VW 207 C-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Note
un

pt
an
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itte

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Always renew needle bearing -arrow- when separating engine
erm

ab
ility
and gearbox.
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectnes
Removing

s o
cial p

f
• Gearbox has been removed.

inform
mer

– Position internal puller - VAS 251 635- -A- behind needle

atio
m

bearing -arrow-.
o

n
c

i
or

– Pull out needle bearing -1- with internal puller - VAS 251 635- n thi
te

sd
a

-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
iv

o
pr

-B- from crankshaft -2- in -direction of arrow-.


um
r
fo

en
ng

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

64 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Installing
– Clean bearing seat in crankshaft.
– Coat bearing seat with high-temperature paste ⇒ Electronic
parts catalogue (ETKA) .
– Drive in needle bearing to installation depth using mandrel -
VW 207 C- in -direction of arrow-.
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lkswage es n
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urposes, in part or in wh

t to the co
Installation depth: dimension -a- = 2.0 mm.

rrectne
Note

s
If the needle bearing has been driven in too far, it must be re‐

s o
cial p

newed, because it will be damaged when it is pulled out.

f inform
mer

atio
om

n
c

i
or

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te

sd
iva

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pr

cum
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fo

en
ng

t.
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Cop py
t. rig
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pyri by
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co lksw
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Prote AG.

3.4 Allocation of main bearing shells


Bearing shells of the correct thickness are allocated to the cylin‐
der block at the factory. Coloured dots are used to identify the
thickness of the bearing shells.
Which bearing shell is to be inserted at each place in the cylinder
block (upper bearing shell) is marked by letters on the lower seal‐
ing surface or on the front side of cylinder block.
Which bearing shell is to be inserted at each place in bearing cap
(lower bearing shell) is marked by letters on the crankshaft.
The first letter is allocated to bearing cap one, the second to bear‐
ing cap two, etc.

3. Crankshaft 65
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

Marking on bearing shell for cylinder block:

Note

The marking on the cylinder block can be found engraved either


in the sump sealing surface or in the front end (gearbox side) of AG. Volkswagen AG d
the cylinder block. lksw
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ab
Identification on cylinder block is allocated to upper bearing shell

ility
ot p
(bearing shell for cylinder block).

wit
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– Note letters and identify colour code to be installed based on

h re
hole

table.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
om

ion
c

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or

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ate

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priv

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for

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Marking on bearing shell for bearing cap:
ht
pyri by
Vo
o
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Identification on crankshaft is allocated to lower bearing shell
cted agen
Prote AG.
(bearing shell for bearing cap).
– Note letters and identify colour code to be installed based on
table.
S = black
R = red
G = yellow
B = blue
W = white

3.5 Crankshaft dimensions


(Dimensions in mm)
Honing dimension Main journal ∅ Conrod journal ∅
1)

Basic dimension 58.00 47.80

66 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

1)No provision has yet been made to recondition worn crank‐


shafts.

3.6 Measuring axial clearance of crankshaft


Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-

♦ Dial gauge - VAS 6079-

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gen AG does
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Procedure y Volk not
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– Screw dial gauge
thoris
- VAS 6079- with universal dial gauge holder
eo
- VW 387-
s auonto cylinder block and set against crank web with
ra
c
s
projection of approx. 2 mm.
ce
le
un

pt

– Press crankshaft against dial gauge by hand and set gauge to


an
d
itte

y li

“0”.
rm

ab
pe

ility

– Push crankshaft away from dial gauge and read off value.
ot

wit
, is n

h re

Axial clearance:
hole

spec

• New: 0.070 ... 0.231 mm


es, in part or in w

t to the co

• Wear limit: 0.30 mm


rrectness of i

3.7 Measuring radial clearance of crank‐


shaft
l purpos

Special tools and workshop equipment required


nform
ercia

♦ Plastigage
m

a
com

tio

Procedure
n in
r
te o

thi
s
iva

do
r

Note
rp

cum
fo

en
ng

t.
yi Co
♦ Do not interchange used bearings. t. Cop py
rig
gh ht
♦ Bearing shells worn down to nickel layer must be renewed. pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Crankshaft 67
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

– Remove crankshaft bearing cap, and clean bearing cap and


bearing journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shells.
• The Plastigage must rest in the middle of the bearing shell.
– Fit crankshaft bearing cap, and tighten it to 1 Nm using old
bolts -1 to 10- ⇒ page 62 . Make sure not to rotate crankshaft
while tightening.

Note

Disregard bolts -arrows A-.

– Remove crankshaft bearing cap again.


– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.017 to 0.037 mm
• Wear limit: 0.15 mm

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

68 Rep. gr.13 - Crankshaft group


Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
- Edition 12.2017

4 Balancer shaft
⇒ “4.1 Assembly overview - balance shaft”, page 69
⇒ “4.2 Removing and installing balance shaft”, page 70
AG. Volkswagen AG d
⇒ “4.3 Renewing oil seal for balance shaft (inlet side)”, agen oes
olksw not
V
page 74 d by gu
ara
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4.1 Assembly overview - balance shaft th
au ra
ss c

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un

pt
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d
1 - Bolt

itte

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erm

ab
❑ Renew after removal

ility
ot p
❑ 4 Nm +45°

wit
is n

h re
ole,
2 - Balancer shaft

spec
urposes, in part or in wh

❑ Exhaust side

t to the co
❑ Must always be re‐
newed if removed.
❑ Lubricate bearing with

rrectne
engine oil
❑ Renewing ⇒ page 72

ss o
cial p

f
3 - Gear ring for needle bearing

inform
mer

❑ Not a replacement part.

atio
Included in items sup‐
om

plied with balance shaft.

n
c

i
or

n thi
e

4 - Tube for balancer shaft


t

sd
iva

o
pr

c
❑ Fitting position

um
r
fo

⇒ page 70

en
ng

t.
yi Co
op py
5 - Cylinder block t. C rig
gh ht
pyri by
6 - Oil seal for balance shaft,
co Vo
by lksw
cted
inlet side
agen
Prote AG.

❑ Renewing ⇒ page 74
7 - Balancer shaft
❑ Inlet side
❑ Must always be re‐
newed if remo