Volkswagen Touran II (5T1) 2016-2020 Workshop Manuals & Wiring Diagram Manual - PDF DOWNLOAD by www.heydownloads.com

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

21 - Turbocharging/supercharging

23 - Mixture preparation - injection

26 - Exhaust system

28 - Glow plug system

Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Service

rights reserved.

reproduction without prior agreement from publisher.

Volkswagen AG, Wolfsburg D4B802791EF

All

2019

thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof Contents 00 - Technical data 1 1 Safety information 1 1.1 Safety regulations for working on fuel supply 1 1.2 Safety measures when working on vehicles with start/stop system 2 1.3 Safety precautions when using testers and measuring instruments during a road test 2 1.4 Safety precautions when working on the cooling system 2 1.5 Safety precautions when working on SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.6 Safety precautions when working on exhaust system 4 2 Identification 5 2.1 Engine number/engine data 5 3 Repair notes 10 3.1 Rules for cleanliness 10 3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3 Contact corrosion 10 3.4 Routing and attachment of lines 11 3.5 Fitting radiator and condensers 11 4 Technical data 12 4.1 Coolant 12 10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1 Removing and installing engine 13 1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2 Separating engine and gearbox 22 1.3 Securing engine on engine and gearbox support 27 1.4 Installing engine 28 2 Assembly mountings 33 2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.4 Removing and installing pendulum support 37 2.5 Supporting engine in installation position 38 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings) 47 2.7 Adjusting assembly mountings 47 3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 13 - Crankshaft group 50 1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 1.1 Assembly overview - cylinder block (pulley end) 50 1.2 Removing and installing poly-V belt 52 1.3 Removing and installing tensioner for poly V-belt 53 1.4 Removing and installing vibration damper 54 1.5 Removing and installing engine support 54 1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 1.7 Assembly overview - sealing flange, belt pulley end 56 1.8 Removing and installing sealing flange on pulley end 57 2 Cylinder block, gearbox end 61 2.1 Assembly overview - cylinder block, gearbox end 61 2.2 Removing and installing flywheel 62 2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3 Crankshaft 72 3.1 Assembly overview - crankshaft 72 Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019 Contents i

thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof 3.2 Crankshaft dimensions 73 3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 3.4 Measuring axial clearance of crankshaft 75 4 Pistons and conrods 77 4.1 Assembly overview - pistons and conrods 77 4.2 Removing and installing pistons 79 4.3 Measuring piston projection at TDC 81 4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 4.5 Checking radial clearance of conrods 84 15 - Cylinder head, valve gear 85 1 Cylinder head 85 1.1 Assembly overview - cylinder head 85 1.2 Assembly overview - cylinder head cover 87 1.3 Removing and installing cylinder head 89 1.4 Removing and installing cylinder head cover 98 1.5 Removing and installing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 1.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 1.7 Checking compression 105 2 Toothed belt drive 107 2.1 Assembly overview - toothed belt cover 107 2.2 Assembly overview - toothed belt 108 2.3 Removing and installing toothed belt guard 109 2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 2.5 Removing toothed belt from camshaft 125 3 Valve gear 129 3.1 Assembly overview - valve gear 129 3.2 Measuring axial play of camshaft 132 3.3 Removing and installing camshaft oil seal 133 3.4 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 3.5 Removing and installing camshaft control valve 1 N205 137 3.6 Checking hydraulic compensation elements 137 3.7 Removing and installing valve stem seals 138 3.8 Removing and installing control valve for the camshaft adjuster 145 4 Inlet and exhaust valves 148 4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 4.3 Valve dimensions 149 17 - Lubrication 150 1 Sump, oil pump 150 1.1 Assembly overview - sump/oil pump 150 1.2 Engine oil: 155 1.3 Removing and installing sump 156 1.4 Removing and installing lower part of sump 159 1.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 1.6 Removing and installing oil pump 168 1.7 Removing and installing oil level and oil temperature sender G266 169 2 Engine oil cooler 171 3 Oil filter, oil pressure switch 172 3.1 Assembly overview - oil filter housing, oil pressure switch 172 3.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 3.3 Removing and installing oil pressure switch for reduced oil pressure F378 175 3.4 Checking oil pressure 176 3.5 Removing and installing oil filter housing 177 Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019 ii Contents

thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof 3.6 Removing and installing oil pressure regulating valve N428 179 4 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 4.1 Removing and installing oil supply line 181 4.2 Removing and installing oil return line for turbocharger 182 19 - Cooling 184 1 Cooling system/coolant 184 1.1 Connection diagram - coolant hoses 184 1.2 Checking cooling system for leaks 195 1.3 Draining coolant 198 1.4 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 1.5 Checking filling quality of cooling system 210 1.6 Checking electric vacuum pump VAS 6096/2 212 1.7 Flushing cooling system 212 1.8 Flushing cooling system, quick reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 2 Coolant pump, regulation of cooling system 235 2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 2.2 Assembly overview - electric coolant pump 239 2.3 Assembly overview - coolant temperature sender 245 2.4 Removing and installing electric coolant pump 246 2.5 Removing and installing coolant pump 261 2.6 Removing and installing thermostat 261 2.7 Checking thermostat 264 2.8 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 265 2.9 Removing and installing coolant temperature sender G62 265 2.10 Removing and installing radiator outlet coolant temperature sender G83 266 3 Coolant pipes 268 3.1 Assembly overview - coolant pipes 268 3.2 Removing and installing coolant pipes 269 4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 4.1 Assembly overview - radiator/radiator fan 284 4.2 Assembly overview - radiator cowl and radiator fan 289 4.3 Assembly overview - radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 4.4 Removing and installing radiator 293 4.5 Removing and installing water radiator for charge air cooling circuit 298 4.6 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 4.7 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 4.8 Removing and installing radiator blind 305 4.9 Removing and installing radiator blind control motor V544 307 21 - Turbocharging/supercharging 311 1 Turbocharger 311 1.1 Assembly overview - turbocharger 311 1.2 Removing and installing turbocharger 318 1.3 Renewing vacuum unit for turbocharger 335 1.4 Removing and installing connection for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 2 Charge air system 343 2.1 Assembly overview - charge air system 343 2.2 Removing and installing charge pressure sender G31 345 2.3 Checking charge air system for leaks 345 2.4 Removing and installing air pipe 347 2.5 Checking charge air cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019 Contents iii

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ...

l, 4 V, turbocharger, EA 288) - Edition 02.2019

thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof 1.1 Schematic overview - fuel system 354 1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 1.3 Filling/bleeding fuel system 369 1.4 Checking fuel system for leaks 370 2 Vacuum system 371 2.1 Connection diagram - vacuum system 371 2.2 Checking vacuum system 372 3 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 3.1 Assembly overview - injectors 373 3.2 Assembly overview - fuel rail 375 3.3 Adapting correction values for injectors 376 3.4 Testing injectors 376 3.5 Checking return flow rate of injectors with engine running 376 3.6 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 3.7 Testing jammed-open injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 3.8 Removing and installing injectors 387 3.9 Removing and installing high-pressure lines 392 3.10 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 4 Air filter 399 4.1 Assembly overview - air filter housing 399 4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 5 Intake manifold 402 5.1 Assembly overview - intake manifold 402 5.2 Removing and installing intake manifold 404 5.3 Removing and installing throttle valve module J338 407 6 Senders and sensors 410 6.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne sound, Golf GTD 410 6.2 Removing and installing fuel pressure regulating valve N276 412 6.3 Checking fuel pressure regulating valve N276 418 6.4 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 6.5 Removing and installing air mass meter G70 421 6.6 Removing and installing pressure differential sender G505 423 6.7 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 427 6.8 Removing and installing NOx sender 2 G687 428 6.9 Removing and installing charge air temperature sender ahead of charge air cooler G810 429 6.10 Removing and installing charge air temperature sender after charge air cooler G811 430 6.11 Removing and installing fuel temperature sender G81 430 6.12 Removing and installing control unit for NOx sender GX30 . . . . . . . . . . . . . . . . . . . . . . . . 432 6.13 Removing and installing temperature and pressure sender for low-pressure fuel system GX20 438 7 Engine control unit 440 7.1 Removing and installing engine (motor) control unit J623 440 7.2 Removing and installing engine control unit J623 (with protective housing) 441 8 High-pressure pump 446 8.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 8.2 Removing and installing high-pressure pump 447 9 Lambda probe 450 9.1 Assembly overview - Lambda probe 450 9.2 Removing and installing Lambda probe 452 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456 1 Exhaust pipes and silencers 456 1.1 Assembly overview - silencers 456

4-cylinder common rail (1.6 l and

iv Contents

2.0

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ...

- Edition 02.2019

thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof 1.2 Aligning exhaust system free of stress 463 1.3 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 1.4 Separating exhaust pipes from silencers 465 1.5 Removing and installing rear silencer 468 1.6 Removing and installing silencer 469 1.7 Checking exhaust system for leaks 472 1.8 Assembly overview - front exhaust pipe 472 1.9 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 1.10 Align end exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476 2 Emission control 477 2.1 Assembly overview - emission control 477 2.2 Removing and installing catalytic converter 481 2.3 Removing and installing particulate filter 482 2.4 Removing and installing emission control module 483 2.5 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . 490 3 SCR system (selective catalytic reduction) 492 3.1 Assembly overview - tank for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492 3.2 Assembly overview - reducing agent delivery line 496 3.3 Assembly overview - delivery module for reducing agent 497 3.4 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497 3.5 Removing and installing front section of reducing agent supply line . . . . . . . . . . . . . . . . . . 503 3.6 Removing and installing delivery module for reducing agent 508 3.7 Removing and installing injector for reduction agent N474 510 3.8 Removing and installing control unit for reducing-agent heater J891 512 3.9 Assembly overview - injector for reducing agent N474 513 3.10 Draining reducing agent tank 514 3.11 Removing and installing rear section of reducing agent supply line 517 3.12 Removing and installing filler pipe for reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . 520 3.13 Disconnecting reducing agent supply line 523 3.14 SCR - resetting learnt values 525 4 Exhaust gas temperature regulation 527 4.1 Assembly overview - exhaust gas temperature regulation 527 4.2 Removing and installing exhaust gas temperature sender 1 G235 530 4.3 Removing and installing exhaust gas temperature sender 2 G448 . . . . . . . . . . . . . . . . . . 532 4.4 Removing and installing exhaust gas temperature sender 3 G495 537 4.5 Removing and installing exhaust gas temperature sender 4 G648 541 5 Exhaust gas recirculation 546 5.1 Assembly overview - exhaust gas recirculation 546 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5 550 5.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 550 5.4 Removing and installing exhaust gas recirculation valve 1 GX5 . . . . . . . . . . . . . . . . . . . . 556 5.5 Removing and installing exhaust gas recirculation valve 2 GX6 557 5.6 Removing and installing exhaust gas recirculation temperature sensor G98 558 5.7 Checking exhaust gas recirculation cooler for leaks 561 28 - Glow plug system 562 1 Glow plug system 562 1.1 Assembly overview - glow plug system 562 1.2 Removing and installing glow plug 563 1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 565 1.4 Removing and installing Hall sender G40 566 1.5 Removing and installing engine speed sender G28 566

4-cylinder common rail (1.6 l and 2.0

turbocharger,

288)

Contents v

l, 4 V,

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni

thgirypocybdetcetorP

.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof

vi Contents

00 –Technical data

1Safety information

(VRL012766; Edition 02.2019)

⇒ “1.1 Safety regulations for working on fuel supply”, page 1

⇒ “1.2 Safety measures when working on vehicles with start/stop system”, page 2

⇒ “1.3 Safety precautions when using testers and measuring in‐struments during a road test”, page 2

⇒ “1.4 Safety precautions when working on the cooling system”, page 2

⇒ “1.5 Safety precautions when working on SCR system”, page 2

⇒ “1.6 Safety precautions when working on exhaust system”, page 4

1.1Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

Whenthebatteryisconnectedandthedriverdooropens,thedoor contact switch activates the fuel pump. Escaping fuel can ignite and cause a fire.

–Disconnect voltage supply to fuel pump before opening the fuel system.

Risk of injury from highly pressurised fuel.

The fuel system is pressurised. Injury from fuel spray possible. Before opening the fuel system:

–Wear protective goggles.

–Wear protective gloves.

– Toreleasepressure,wrapacleanclotharoundtheconnection and carefully loosen the connection.

Malfunction caused by air in the fuel supply system

After repair work has been performed on the fuel tank or the fuel delivery unit, air will be drawn in by the metering pump and con‐veyedtotheauxiliary/supplementaryheater.Airinthefuelsupply systemmaycausethemalfunctionoftheauxiliary/supplementary heater.

–Fill fuel take-off pipe with fuel.

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019 1. Safety information 1

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

1.2Safety measures when working on vehicles with start/stop system

Risk of injury due to unexpected motor start

If the vehicle’s start/stop system is activated, the engine can start unexpectedly. A message in the dash panel insert indicates whether the start/stop system is activated.

–Deactivate start/stop system by switching off the ignition.

1.3Safety precautions when using testers and measuring instruments during a road test

Risk of injury caused by unsecured testing and measuring instru‐ments

When the front passenger airbag is triggered in an accident, in‐sufficiently secured testing and measuring instruments become dangerous projectiles.

–Secure testing and measuring instruments on the rear seat. or

– Have a second person operate the test and measuring equip‐ment on the rear seat.

1.4Safety precautions when working on the cooling system

Danger of scalding by hot coolant

On a warm engine, the cooling system is under high pressure. Danger of scalding by steam and hot coolant.

–Wear protective gloves.

–Wear protective goggles.

–Reduce excess pressure by covering cap of coolant expan‐sion tank with cloths and opening it carefully.

1.5Safety precautions when working on SCR system

Risk of injury due to reducing agent

The reducing agent may cause eye and skin irritations as well as injuries to the respiratory system and poisoning.

–Wear protective goggles.

–Wear protective gloves.

–Always wear protective clothes.

–Make sure that a sufficient amount of fresh air is supplied. In closed areas, switch on the exhaust gas extractor system.

2 Rep. gr.00 - Technical data

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Risk of damage caused by reducing agent

Ifreducingagentgetsontotrimpanelsandbodycomponents,the reducing agent may solidify after a while and thus damage the surface.

– Make sure that no reducing agent gets onto the trim panels or body components.

–If any reducing agent does get onto surfaces, remove it im‐mediately using water and a cloth.

Risk of injury due to reducing agent

The reducing agent may cause eye and skin irritations as well as injuries to the respiratory system and poisoning.

–Wear protective goggles.

–Wear protective gloves.

–Always wear protective clothes.

–Make sure that a sufficient amount of fresh air is supplied. In closed areas, switch on the exhaust gas extractor system.

Risk of damage caused by reducing agent

Ifreducingagentgetsontotrimpanelsandbodycomponents,the reducing agent may solidify after a while and thus damage the surface.

– Make sure that no reducing agent gets onto the trim panels or body components.

–If any reducing agent does get onto surfaces, remove it im‐mediately using water and a cloth.

When removing and installing components of the SCR system, note the following:

♦ The tank for reducing agent must be empty when working on the SCR system. Information on when the tank for reducing agent has to be emptied can be obtained from the respective description of work. Emptying tank for reduction agent ⇒ page 514

Automatic return of reducing agent

• After the ignition has been switched off, the reducing agent is returned from the metering line leading to the reducing agent injector - N474- back to the reducing agent tank.

• Before any work is done in this area, it is necessary to wait until all the reducing agent has been returned to the tank; this can take up to 10 minutes after the ignition is switched off.

• Similarly, it is not permissible to disconnect the battery until all the reducing agent has been returned to the tank, i.e. 10 mi‐nutes after the ignition is switched off ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

1. Safety information 3

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

1.6Safety precautions when working on exhaust system

Risk of poisoning due to chemical substances

Exhaust gas temperature senders may contain chemical sub‐stances. There is a risk of poisoning or injuries to respiratory system.

–Never open an exhaust gas temperature sender by cutting, sawing or any other means.

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

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

–Always wear protective gloves and eye protection when cut‐ting the exhaust system.

–When cutting, use an extraction system or otherwise ensure sufficient ventilation.

NOTICE

Risk of damage to damper element.

♦ Do not allow the flexible joint to kink by more than 10°.

♦ Install flexible joint so that it is not under tension.

♦ Do not damage wire mesh on decoupling element.

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4 Rep. gr.00 - Technical data

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

2Identification

⇒ “2.1 Engine number/engine data”, page 5

2.1Engine number/engine data

♦ The engine number (“engine code” and “serial number”) is lo‐cated at the front at the joint between engine and gearbox -arrow-.

♦ Additionally there is a sticker attached to the upper toothed belt guard with “engine code” and “serial number”.

♦ The engine codes have four characters, starting with the letter “C”.

♦ Thefirst3charactersstandfortheengine'scubiccapacityand mechanical structure. They are stamped into the cylinder block together with the serial number.

♦ The fourth character denotes the engine's performance and torque rating and depends on the engine control unit.

Note

♦ The4-characterenginecodecanbefoundonthetypeplate (inversionsforsomecountriesonly)aswellasonthevehicle datastickerandtheenginecontrolunit.

♦ Forfittinglocationsoftheidentificationplate(country-specific) andvehicledatasticker,referto⇒Maintenance;Booklet .

Fuel: according to DIN EN 590 Firing or‐der 1-3-4-2

Codes CLHA CLHB CRKB CRBC CRGA CRVA CRLB CUNA CXXA Injection system Bosch Bosch Bosch Bosch Bosch Bosch Bosch Bosch Delphi Exhaust emissions fulfil EU5/ EU5 plus EU5 EU5/ EU6/ EU6 plus EU5 EU4 EU4 EU6 EU6 EU6 Dis‐place ment l 1.598 1.598 1.598 1.968 1.968 1.968 1.968 1.968 1.598 Pow‐er kW at rpm 77/3000 … 4000 66/3000 … 4000 81/3000 … 4000 110/350 0 … 400 0 130/350 0 … 400 0 81/3500 … 4000 110/350 0 … 400 0 135/350 0 … 400 0 66/3000 … 4000 Tor‐que Nm at rpm 250/150 0 to 2750 230/150 0 to 2750 250/150 0 to 2750 320/175 0 to 3000 350/175 0 … 300 0 250/125 0 … 250 0 340/175 0 … 300 0 380/175 0 … 300 0 250/150 0 to 3000 Bore Dia met er, mm 79.5 79.5 79.5 81.0 81.0 81.0 81.0 81.0 79.5 Strok e mm 80.5 80.5 80.5 95.5 95.5 95.5 95.5 95.5 80.5 Compres‐sion ratio 16.2 16.2 16.2 16.2 16.2 16.2 16.2 15.8 16.2

2. Identification 5

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

according to DIN EN 590

Firing or‐der 1-3-4-2 Exhaust gas recir‐culation yes

6 Rep. gr.00 - Technical data

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

according to DIN EN 590

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Firing or‐der 1-3-4-2 Exhaust gas recir‐culation yes Exhaust gas tem‐perature regulation yes yes yes yes yes yes yes yes yes

2. Identification 7

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

DIN EN 590

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Codes CRMB CKFC CRLD DCYB DCYA DJFA DGCA DJGA CRKA Balancer shafts no no yes yes yes yes yes yes no Charging Turbocharger Charge air cooling yes Lambda regulation 2 lamb‐da probes 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 2 lamb‐da probes 1 lamb‐daprobe 1 lamb‐daprobe Emission control module or particulate filter instal‐led Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module SCR cata‐lytic con‐verter no no no no no yes no yes no Valves per cylinder 4 Codes CRVC DFEA DFEB DFGA DFGB DFHA DFZA DGDA DGDB Injection system Bosch Bosch Bosch Bosch Bosch Bosch Bosch Bosch Bosch Exhaust emissions fulfil EU4 EU6 EU6 EU6 EU6 EU6 EU6 EU6 plus EU6 plus Dis‐place ment l 1.968 1.968 1.968 1.968 1.968 1.968 1.968 1.598 1.598 Pow‐er kW at rpm 105/350 0 … 400 0 110/300 0 … 400 0 81/3100 … 4500 110/350 0 … 400 0 81/3100 … 4500 140/350 0 … 400 0 81/3100 … 4500 85/3000 … 4000 85/3000 … 4000 Tor‐que Nm at rpm 320/175 0 to 3000 340/175 0 to 3000 280/150 0 to 3000 340/175 0 to 3000 280/150 0 to 3000 400/175 0 to 3250 280/150 0 to 3000 250/150 0 to 2750 280/150 0 to 2750 Bore Diam eter, mm 81.0 81.0 81.0 81.0 81.0 81.0 81.0 79.5 79.5 Strok e mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5 80.5 80.5 Compres‐sion ratio 16.0 16.2 16.2 16.2 16.2 15.5 16.2 16.2 16.2 Fuel: according to

Firing order 1-3-4-2 Exhaust gas recircu‐lation yes Exhaust gas temper‐ature regu‐lation yes Balancer shafts no yes yes yes yes yes no no no Charging Turbocharger Charge air cooling yes; water-cooled

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8 Rep. gr.00 - Technical data

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

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Codes CRVC DFEA DFEB DFGA DFGB DFHA DFZA DGDA DGDB Lambda regulation 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe 1 lamb‐daprobe Emission control module or particulate filter instal‐led Particu‐late filter Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module Emis‐sion control module SCR cata‐lytic con‐verter no yes yes yes yes yes yes yes yes Valves per cylinder 4

2. Identification 9

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

3Repair notes

⇒ “3.1 Rules for cleanliness”, page 10

⇒ “3.2 Foreign objects in engine”, page 10

⇒ “3.3 Contact corrosion”, page 10

⇒ “3.4 Routing and attachment of lines”, page 11

⇒ “3.5 Fitting radiator and condensers”, page 11

3.1Rules for cleanliness

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:

♦ Thoroughly clean all unions and surrounding areas with en‐gine or brake system cleanser before disconnecting. Dry cleaned area thoroughly.

♦ 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 lint-free cloths only.

♦ If repair work cannot be performed immediately, carefully cov‐er or seal components.

♦ Install only clean parts; do not remove new parts from pack‐aging until immediately before installing. Do not use parts that have been stored outside of their packaging (e.g. in tool box‐es).

♦ If system is open, do not work with compressed air. Do not move vehicle unless necessary.

♦ Protectdisconnectedelectricalconnectorsfromdirtandwater, and reconnect them only when dry.

3.2Foreign objects in engine

To prevent the ingress of foreign bodies during work on the en‐gine, seal all open connections. To do this, use suitable plugs from the engine bung set - VAS 6122- .

Note

Intheeventofmechanicaldamageonturbocharger,observe ⇒page318.

3.3Contact corrosion

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

For this reason, only connecting elements with a special surface coating have been fitted.

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

If there are doubts about the suitability of parts, always use new parts ⇒ Electronic parts catalogue .

Please note:

♦ Use Genuine parts, because they have been are tested and compatible with aluminium. 10 Rep. gr.00 - Technical data

♦ Use Volkswagen parts.

♦ Damageresultingfromcontactcorrosionisnotcoveredbythe warranty.

3.4Routing and attachment of lines

Risk of damage to lines

Lines may become damaged by moving or hot components. –Route lines in their original positions.

– Make sure there is sufficient clearance between the lines and moving or hot components.

3.5Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the chargeaircoolermayhavesmalldentsintheirfins.Thisdoesnot mean that these components have been damaged. It is not per‐missibletorenewradiators,chargeaircoolersorcondensersonly because of such minor dents.

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019 3. Repair notes 11

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4Technical data

⇒ “4.1 Coolant”, page 12

4.1Coolant Note

♦ Thewaterusedformixinghasamajorinfluenceontheeffec‐tivenessofthecoolant.Becausethewaterqualitydiffersfrom countrytocountryandevenfromregiontoregion,thequality ofthewatertobeusedinthecoolingsystemhasbeenspeci‐fiedbyVolkswagen.Distilledwaterfulfilsallrequirements. Therefore,onlyeverusedistilledwaterwhenmixingcoolant fortoppinguporrenewingcoolant.

♦ Useonlycoolantadditiveswhichconformwiththe⇒ Elec‐tronicpartscatalogue(ETKA).Othercoolantadditivesmay reducecorrosionprotectionsubstantially.Theresultingdam‐agecouldleadtolossofcoolantandsubsequentsevere damagetotheengine.

♦ Mixedintheproperproportions,coolantinhibitsfrostandcor‐rosiondamageaswellasscaling.Suchadditivesalsoraise theboilingpointofthecoolant.Forthisreason,thecooling systemmustbefilledall-year-roundwithcoolantadditives.

♦ Becauseofitshighboilingpoint,thecoolantimprovesengine reliabilityunderheavyloads,particularlyincountrieswithtrop‐icalclimates.

♦ ONLYrefractometer-T10007A-maybeusedfordetermining currentanti-freezevalue.

♦ Frostprotectionmustbeguaranteeddownto-25°Casamin‐imumand,incountrieswitharcticconditions,downtoapprox. -36°C.Increasingthefrostprotectionispermissibleonlyifcli‐maticconditionsrequirestrongerfrostprotection.Itmay,how‐ever,beincreasedonlytoamaximumof-48°C.Otherwise, thecoolingeffectwillbeimpaired.

♦ Donotreducethecoolantconcentrationbyaddingwatereven inwarmerseasonsandinwarmercountries.Frostprotection mustbeguaranteeddowntoatleast-25°C.

♦ Readoffanti-freezefiguresforrespectivereplenishedcoolant additives.

♦ Thetemperaturereadofftherefractometer-T10007A-corre‐spondsthe»iceflocculationpoint«.Flakesoficemaystart forminginthecoolantbelowthistemperature.

♦ Neverreuseoldcoolant.

♦ Useonlyawater/coolantadditivemixtureasaslipagentfor coolanthoses.

Coolant mixture ratio

• Coolant (40%) and distilled water (60%) for frost protection to -25°C

• Coolant (50 %) and distilled water (50 %) for frost protection to -36 °C

• Coolant: ⇒ Electronic parts catalogue (ETKA) .

12 Rep. gr.00 - Technical data

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

10 –Removing and installing engine

1Removing and installing engine

⇒ “1.1 Removing engine”, page 13

⇒ “1.2 Separating engine and gearbox”, page 22

⇒ “1.3 Securing engine on engine and gearbox support”, page 27

⇒ “1.4 Installing engine”, page 28

1.1Removing engine

NOTICE

When installing a new short engine, it is compulsory to fix and tighten the clamping jaws of the injectors with the specified tor‐que after installing the high-pressure lines

⇒ “3.1 Assembly overview - injectors”, page 373 . Clamping jawsareonlysecured»hand-tight«forsettingtheinjectorswhile installing high-pressure lines. Non-observance of these notes may lead to damage to engine.

Special tools and workshop equipment required

♦ Release lever - 80 - 200-

♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐box jack - VAS 6931-

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Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019 1. Removing and installing engine 13

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

♦ Engine bung set - VAS 6122-

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♦ Drip tray for workshop hoist - VAS 6208-

♦ Spring-type clip pliers - VAS 6362-

♦ Locking pin - T10060 A-

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14 Rep. gr.10 - Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

♦ Engine support -T10497- with pin -T10497/1-

♦ Protective mat - VAS 531003-

♦ Safety goggles

♦ Safety gloves

♦ Commercially available stepladder

Sequence of operations

Note

♦ Theengineisremoveddownwardstogetherwiththegearbox.

♦ Attachcabletiesinallthesameplaceswheninstalling.

♦ Attachallheat-shieldingsleevesinthesameplaceswhenin‐stalling.

CAUTION

The cooling system is under pressure when the engine is hot! Danger of scalding by steam and hot coolant.

Cover filler cap on expansion tank with a cloth and open care‐fully to release pressure.

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

–Remove engine cover panel ⇒ page 49

–Remove air filter housing ⇒ page 400

– If fitted, remove control unit for NOx sender - GX30- from bat‐tery tray ⇒ page 438

–Remove battery tray -1- ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery tray .

–Remove connecting piece on turbocharger ⇒ page 341 .

1. Removing and installing engine

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Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

– Release and detach connector -2- from charge pressure con‐trol solenoid valve - N75- -1-.

–Remove nuts -arrows-

–Place charge pressure control solenoid valve - N75- -1- with vacuum lines on engine.

Releaseandpulloffconnectorsonplenumchamberbulkhead ⇒ page 368

–Lay wires on plenum chamber bulkhead to one side.

–Pull vacuum hose -2- off turbocharger vacuum unit.

–Disconnect vacuum hose -1- from T-piece.

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–Release catch -arrow- and disconnect vacuum hose -1-.

Vehicles with SCR system:

–Release electrical connector, and pull it off injector for reduc‐ing agent - N474- -3-.

–Lay wiring harness to one side.

– Placeaclothunderneathcouplingpointtocatchanyescaping reducing agent.

–Release and pull off reducing agent line -2- ⇒ page 523

– Unclipreducingagentlinefromtoothedbeltguardandcoolant expansion tank.

–Seal off all open lines and connections with clean plugs from engine bung set - VAS 6122- .

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16 Rep. gr.10 - Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

Continued for all vehicles:

–Open plug-in connectors -A- and -B- for fuel lines and pull off fuellines.Disconnectplug-inconnectors⇒ Rep.gr. 20;Plugin connectors; Disconnecting plug-in connectors .

–Unbolt fuel filter, and place it on engine with fuel lines con‐nected ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .

–Disconnect electrical connector -1-.

–Disconnect bracket -2- with fuel hoses.

–Remove coolant hoses from engine. To do this, open retain‐ers.

– Usingascrewdriver,releasefasteners-arrow-andmovecool‐ant expansion tank to one side.

–Separate connector -2- on engine control unit - J623⇒ page 440 .

–Remove electrical connectors -3- and -4- from retainer, re‐lease them, and pull them off.

–Move electrical lines free.

1. Removing and installing engine

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– Release catches -arrows- and detach cover -1- for electronics box in engine compartment.

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

–Release catch using a screwdriver -arrow- and detach cover -1- for electronics box in engine compartment upwards.

–Remove nut -arrow-, detach electrical wiring and move clear.

– Fortheworkstepsbelowuseremovallever-80-200-tounclip the binding clips.

–Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐sulation .

Vehicles with manual gearbox

–Detach lines from starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Assembly overview - starter .

– Release and pull off electrical connectors on gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox .

– Detachclutchslavecylinderwithclutchlineconnected⇒ Rep. gr. 30 ; Clutch mechanism; Removing and installing clutch slave cylinder . Do not open hydraulic system.

–Lay clutch slave cylinder with clutch line connected to one side.

–Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ; Selector mechanism; Removing and installing selector mech‐anism .

Vehicles with dual clutch gearbox:

–Release and pull off connector for mechatronic unit for dual clutch gearbox - J743- ⇒ Rep. gr. 34 ; Mechatronic unit .

–Detach lines from starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Assembly overview - starter .

–Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ; Selector mechanism; Removing and installing selector mech‐anism .

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18 Rep. gr.10 - Removing and installing engine

–If fitted, release electrical connector for auxiliary hydraulic pump 1 for gearbox oil - V475- -a-, and pull off connector -b-.

Continued for all vehicles

–Remove front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

–Remove left and right front wheel housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing liners; As‐sembly overview - front wheel housing liner .

–Remove pendulum support ⇒ page 37

–Remove subframe together with steering rack ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing subframe with steering rack .

–Remove heat shield for right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐stalling drive shaft heat shield .

–Remove right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .

–Disconnect left drive shaft from gearbox ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐stalling drive shaft .

– Release and pull off connector on oil level and oil temperature sender - G266- .

–Remove front exhaust pipe ⇒ page 464

Vehicles with lambda probe 1 after catalytic converter - GX7- :

–Release and pull off connector of lambda probe 1 after cata‐lytic converter - GX7- ⇒ page 453

–Move clear wire, and place it on engine.

Vehicles with air conditioner:

–Remove poly V-belt ⇒ page 52

– Remove air conditioner compressor with refrigerant lines con‐nected from engine ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing air conditioner com‐pressor from and installing to bracket .

Detach air conditioner compressor with refrigerant hoses con‐nected from bracket, and tie it up on the right side.

Vehicles with all-wheel drive:

–Remove propshaft on bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - propshaft .

Continued for all vehicles

– Release fasteners -arrows- and detach noise insulation -1- for sump.

–To do this, pull pins out of spreader rivets.

–Remove radiator cowl ⇒ page 302

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1. Removing and installing engine 19

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

–Attach protective mat - VAS 531003- to vehicle as shown in illustration.

–Place drip tray for workshop hoist - VAS 6208- underneath.

–Drain coolant ⇒ page 198

–Unbolt brackets for electric coolant from engine ⇒ page 239

–Release and pull off connectors on coolant pumps.

– Pushcoolantpumpswithcoolanthosesconnectedtooneside in order to free some space.

–Place a cloth underneath heat exchanger for heater to catch escaping coolant.

– Liftretainingclips-arrows-anddisconnectcoolanthosesfrom heat exchanger for heater.

– Liftretainingclip-arrow-anddisconnectcoolanthose(topleft) from radiator.

–Lift retaining clip -arrow- and disconnect coolant hose (top right) from water radiator for charge air cooling circuit.

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20 Rep. gr.10 - Removing and installing engine

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

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

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

Vehicles with 3 gearbox securing bolts:

Vehicles with 2 gearbox securing bolts:

–Attach engine support -T10497- with pin -T10497/1- to cylin‐der block with bolt -1- (tighten to approx. 20 Nm).

– Insertengineandgearboxjack-V.A.G1383A-inenginesup‐port -T10497- .

–Raise engine/gearbox assembly slightly.

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1. Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

Note

Useastepladdertounscrewtheboltsfortheassemblymounting.

–Remove bolts -arrows- for engine mounting.

–Remove bolts -arrows- securing gearbox mounting.

Vehicles with 3 gearbox securing bolts:

Vehicles with 2 gearbox securing bolts:

NOTICE

Danger of damage to vacuum lines or electrical wiring and to 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.

–Lower engine/gearbox assembly.

1.2Separating engine and gearbox

⇒ “1.2.1 Separating engine and gearbox, vehicles with manual gearbox”, page 22

⇒“1.2.2Separatingengineandgearbox,vehicleswithdualclutch gearbox”, page 24

1.2.1Separating engine and gearbox, vehi‐cles with manual gearbox

Special tools and workshop equipment required

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22 Rep. gr.10 - Removing and installing engine

♦ Hook - 10 - 222 A /2-

♦ Workshop hoist - VAS 6100-

♦ Lifting tackle - T40013-

Sequence of operations

• Engine/gearbox assembly removed and attached to engine support -T10497- .

–Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and installing starter .

–Unscrew bolts -arrows- and detach gearbox support.

Vehicles with all-wheel drive

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Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

–Unscrew bolts -1 and 2-, and remove bracket for bevel box.

Continued for all vehicles

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

–Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A / 2- to lifting tackle.

–Unscrew bolts -1, 2, 5, 6, 7, 8- from gearbox to engine con‐nection.

–Detach gearbox from engine. Pay attention to intermediate plate while doing so.

1.2.2Separating engine and gearbox, vehi‐cles with dual clutch gearbox

Special tools and workshop equipment required

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24 Rep. gr.10 - Removing and installing engine

♦ Adapter - 10 - 222 A /20-

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♦ Hook of -2024 A /1- lifting tackle - 2024 A-

♦ Workshop hoist - VAS 6100-

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Sequence of operations

• Engine/gearbox assembly removed and attached to engine bracket - T10497- .

Note

Aftereachtimetheengineandgearboxhavebeenseparated,the needlebearinginthecrankshaftmustberenewed⇒page73

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Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

– Remove coolant hoses from gear oil cooler, loosen hose clips -arrows- for this.

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

–Secure hook with pin -arrow-.

– Attach workshop hoist - VAS 6100- to lifting tackle using hook - 10 - 222 A /20- .

– Free wiring harnesses -arrows- and electrical connector -1- at bracket.

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

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26 Rep. gr.10 - Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

–Unscrew remaining bolts -1, 3, 5, 6, 7, 8, 9, 10- from gearbox to engine connection.

Note

Bolt-3-isonlyaccessibleafterremovingstarter.

–Pull gearbox off engine.

1.3 Securingengineonengineandgearbox support

Before carrying out repair work, secure engine with engine and gearbox bracket - VW 540- or universal mounting - VAS 6095/1to engine and gearbox support - VAS 6095- .

Special tools and workshop equipment required

♦ Engine and gearbox support - VW 540-

♦ Lifting tackle - 3033-

1. Removing and installing engine

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Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

♦ Engine and gearbox support - VAS 6095-

♦ Workshop hoist - VAS 6100-

Sequence of operations

–Separate gearbox from engine ⇒ page 22

–Connect lifting tackle - 3033- as shown.

Position 3 - Flywheel end

Position 9 - Vibration damper end

Lift engine out of engine support - VAS 6100- using workshop hoist - T10497- .

– Secure engine on engine and gearbox support - VW 540- us‐ing universal mounting - VAS 6095/1- or engine and gearbox support - VAS 6095- .

1.4Installing engine

Specified torques

NOTICE

When installing a new short engine, it is compulsory to fix and tighten the clamping jaws of the injectors with the specified tor‐que after installing the high-pressure lines

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28 Rep. gr.10 - Removing and installing engine

Note

Golf 2013 ➤ , Golf 2017

, Golf Sportsvan 2015

, Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0

♦ Afternewcomponentshavebeeninstalled(engine/shorten‐gine,cylinderhead,camshafthousingorturbocharger),theoil pressurecontrolmustbesettomax.pressureforapprox. 1000km,giventhefunctionisavailableintheenginecontrol unit.Thiswillcompensatefortheincreasedfrictionduringruninofnewcomponents,andabettertransportofwear-related particlesisguaranteed.Todothis,connectvehiclediagnostic tester,switchonignition,andselectthefollowingmenuop‐tions:

♦ Diagnosis-capable systems

♦ 0001 - Engine electronics functions

♦ 0001 - Adaption

♦ Oil pressure control/activate run-in function

♦ Assembly mountings

⇒ “2.1 Assembly overview - assembly mountings”, page 33

♦ Securing gearbox to engine ⇒ Rep. gr. 34 ; Removing and installing gearbox; Installing gearbox

Sequence of operations

Note

♦ Renewboltsthataretightenedwithturningfurtherangleafter eachremoval.

♦ Renewself-lockingnutsandboltsaswellasgaskets,seals andO-ringsaftereachremoval.

♦ Hoseunionsandairintakepipesandhosesmustbefreeof oilandgreasebeforeinstallation.

♦ Secureallhoseconnectionswithhoseclipscorrespondingto theseriesequipment⇒ Electronicpartscatalogue.

♦ Attachcabletiesinallthesameplaceswheninstalling.

–Install intermediate plate ⇒ page 62 .

turbocharger, EA 288) - Edition 02.2019 1. Removing and installing engine

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

➤

l, 4 V,

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

– If there are no dowel sleeves -A- in the cylinder block for cen‐tring the engine and gearbox, insert new dowel sleeves.

Note

Theillustrationshowsavehiclewithmanualgearbox.

Vehicles with manual gearbox

– Ifaneedlebearingisfittedincrankshaft,removeneedlebear‐ing ⇒ page 73

–If clutch release bearing is worn, renew it ⇒ Rep. gr. 30 ; Clutch mechanism; Repairing clutch release mechanism .

–Lightly grease input shaft splines ⇒ Electronic Part Cata‐logue .

–Check centring of clutch plate.

Vehicles with all-wheel drive

–Install bracket for bevel box ⇒ Rep. gr. 34 ; Bevel box .

Vehicles with dual clutch gearbox

– If no needle bearing is fitted in crankshaft, install needle bear‐ing ⇒ page 73

Continued for all vehicles

–Tighten gearbox to engine.

–Install gearbox support.

–Take up engine/gearbox assembly with engine supportT10497- .

–Guide engine/gearbox assembly into body.

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

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30 Rep. gr.10 - Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

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

Note

Theboltsaretightenedtofinaltorqueonlyafteradjustingtheas‐semblymountings⇒page47

–Remove engine support -T10497- from engine.

–Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐sembly overview - starter .

–Install charge air cooling pump - V188- ⇒ page 246 .

–Install air pipe ⇒ page 343

–Install connection ⇒ page 311

–Install front exhaust pipe ⇒ page 464

–Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly overview - drive shaft .

Vehicles with all-wheel drive:

–Install propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; As‐sembly overview - propshaft .

Vehicles with air conditioner:

– 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 52

Vehicles with lambda probe 1 after catalytic converter - GX7-

– Connect connector of lambda probe 1 after catalytic converter - GX7- ⇒ page 452

Vehicles with SCR system:

–Install control unit for NOx sender - GX30- to battery tray ⇒ page 438

–Connect reducing agent line ⇒ page 523 .

Continued for all vehicles

– Install fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .

–Install engine control unit ⇒ page 440

–Install radiator cowl ⇒ page 302

– Connect clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐nism; Removing and installing clutch slave cylinder .

–Bleed clutch hydraulics ⇒ Rep. gr. 30 ; Clutch mechanism; Bleeding clutch mechanism .

–Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐lector mechanism; Assembly overview - selector cables .

–Install subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing subframe with steer‐ing rack .

– Install front wheel housing liners ⇒ General body repairs, ex‐terior; Rep. gr. 66 ; Wheel housing liner; Assembly overview - front wheel housing liner .

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1. Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

–Adjust assembly mountings ⇒ page 47

– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview - battery .

–Observe electrical connections and routing ⇒ Electrical sys‐tem; Rep. gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Overview of fitting locations - relay carriers, fuse carri‐ers, electronics boxes and ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

–Connect vacuum hoses ⇒ page 371

–Install air filter housing ⇒ page 400

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–Check oil level ⇒ Maintenance ; Booklet .

NOTICE

Danger of destroying control units through excessive voltage.

♦ Never use battery charging equipment for boost starting.

–Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; As‐sembly overview - battery .

–Bleed fuel system ⇒ page 369

–Connect coolant hoses with plug-in connector to heat ex‐changer for heater ⇒ page 288

–Add coolant ⇒ page 200

Note

Neverreuseoldcoolant.

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32 Rep. gr.10 - Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

2Assembly mountings

⇒ “2.1 Assembly overview - assembly mountings”, page 33

⇒ “2.2 Removing and installing engine mounting”, page 34

⇒ “2.3 Removing and installing gearbox mounting”, page 35

⇒ “2.4 Removing and installing pendulum support”, page 37

⇒ “2.5 Supporting engine in installation position”, page 38

⇒ “2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)”, page 47

⇒ “2.7 Adjusting assembly mountings”, page 47

2.1Assembly overview - assembly mountings

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1 - Bolt

❑Renew after removal

❑Tightening sequence

⇒ page 55

2 - Engine support

❑ Removing and installing

⇒ page 54

3 - Engine mounting

❑With support arm

❑ Removing and installing

⇒ page 34

4 - Bolt

❑Renew after removal

❑40 Nm +90°

5 - Bolt

❑Renew after removal

❑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 37

9 - Bolt

❑Renew after removal

❑Specified torque and tightening sequence ⇒ page 38

10 - Bolt

❑Renew after removal

❑Specified torque and tightening sequence ⇒ page 38

11 - Bolts

❑Renew after removal

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2. Assembly mountings

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

❑Specified torque and tightening sequence ⇒ page 38

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 35

15 - Bolt

❑Renew after removal

❑50 Nm +90°

16 - Bolt

❑Specified torque ⇒ Rep. gr. 34 ; Assembly mountings; Assembly overview - assembly mountings

17 - Gearbox support

❑For vehicles with manual gearbox

18 - Bolt

❑Specified torque ⇒ Rep. gr. 34 ; Assembly mountings; Assembly overview - assembly mountings

2.2Removing and installing engine mount‐ing

Removing

–Remove engine cover panel ⇒ page 49

–Disconnect electrical connector -1-.

–Disconnect bracket -2- with fuel hoses.

– Usingascrewdriver,releasefasteners-arrow-andmovecool‐ant expansion tank to one side.

–Move clear bracket -3- with fuel hoses.

–Remove nut -2- and bolts -1-.

–Move fuel filter -4- clear to one side.

–Support engine and gearbox in installation position

⇒ page 38

– Takeupweightofengine/gearboxassemblyslightlywithspin‐dle; do not lift.

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Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof

34 Rep. gr.10 - Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

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

Installing

Install in reverse order of removal, observing the following:

–Checking adjustment of assembly mountings ⇒ page 47

Specified torques

♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 33

♦ ⇒ “1.1 Assembly overview - turbocharger”, page 311

♦ Assembly overview - fuel filter ⇒ Rep. gr. 20 ; Fuel filter; As‐sembly overview - fuel filter .

♦ Assembly overview - windscreen wiper system ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system; Assembly overview - windscreen wiper system .

2.3Removing and installing gearbox mounting

Removing

–Remove connecting piece on turbocharger ⇒ page 341 .

–Remove air filter housing ⇒ page 400

–Remove battery tray -1- ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery tray .

–Remove engine control unit - J623- from bracket ⇒ page 440

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

Note

Differenttypesofbracketsarefitteddependingonversion.

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2. Assembly mountings

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

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

–Remove nut -arrow- and detach earth wire.

–Support engine and gearbox in installation position

⇒ page 38

Takeupweightofengine/gearboxassemblyslightlywithspin‐dle; do not lift.

.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof

–

36 Rep. gr.10 - Removing and installing engine

Golf 2013 ➤ , Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ... 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288) - Edition 02.2019

–Remove bolts -arrows- and detach gearbox mounting -1-.

Installing

Install in reverse order of removal, observing the following:

Note

Renewboltsthataretightenedwithturningfurtherangleafter eachremoval.

–Tighten gearbox mounting on longitudinal member.

NOTICE

Risk of damaging thread in gearbox support if bolts are started at an angle.

♦ Gearboxsupportandsupportarmofgearboxmountingmust be perfectly parallel to each other before screwing in bolts. If necessary, lift gearbox at rear using trolley jack.

♦ Do not remove support bracket - 10-222A- until the bolts se‐curingtheassemblymountinghavebeentightenedtospeci‐fied 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 47

–Remove support bracket - 10 - 222 A- from engine.

Specified torques

♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 33

♦ ⇒ “1.1 Assembly overview - turbocharger”, page 311

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

♦ Windscreen wiper system; Assembly overview - windscreen wiper system ⇒ Electrical system; Rep. gr. 92 ; Windscreen wipersystem;Assemblyoverview-windscreenwipersystem.

2.4 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, 3-, and remove pendulum support.

Installing

Install in reverse order of removal, observing the following:

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2. Assembly mountings 37

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL