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
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
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
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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Copyright © 2019 Volkswagen AG, Wolfsburg K0059111420
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Releasing pressure in high-pressure area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) . . . . . . . . . . . . 8
1.2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) . . . . . . . . . . . . . . 18
1.3 Removing engine (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Installing engine (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5 Removing engine (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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1.6 Installing engine (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.7 Removing engine (Sharan) n AG. Volkswagen AG
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1.8 Installing engine d b(Sharan) . . . . . . . . . . . . . . . . . . .u.ar.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.9 Removing enginetho (Passat, Passat CC) . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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a (Passat, Passat CC) . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . . . . . . . . . . . 60
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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2.1 Assembly overview - assembly mountings (Touran, Golf Plus, Eos, Scirocco, Golf, Golf
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Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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2.2 Assembly overview - assembly mountings (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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2.3 Assembly overview - assembly mountings (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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2.4 Assembly overview - assembly mountings (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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2.5 Assembly overview - assembly mountings (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . 67

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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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1.2 Assembly overview - cylinder block, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.3 Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan,
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Passat, Passat CC, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.4 Removing and installing poly V-belt (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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1.6 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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1.7 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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2.2 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2 Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.3 Checking cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.5 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Contents i
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.2 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.1 Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.2 Removing and installing valve timing housing (Touran, Tiguan) . . . . . . . . . . . . . . . . . . . . 132
3.3 Removing and installing valvekstiming housing (Passat CC, Passat) . . . . . . . . . . . . . . . . . . 138

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4.2 Adjusting
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4.4 Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . . 159
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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1.1 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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1.2 Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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1.3 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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2.1 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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1.1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf
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1.2 Schematic diagram for coolant hoses (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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1.3 Schematic diagram for coolant hoses (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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1.4 Coolant hose schematic diagram (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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1.5 Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf
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1.6 Draining and filling coolant (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.7 Draining and filling coolant (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1.8 Draining and filling coolant (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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1.9 Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Scirocco, Golf, Golf
Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.10 Checking cooling system for leaks (Sharan, Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.11 Checking cooling system for leaks (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.1 Assembly overview - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.2 Assembly overview - thermostat (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.3 Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

ii Contents
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.4 Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan,
Scirocco, Golf, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
2.5 Removing and installing coolant circulation pump V50 (Polo, Touran, Golf Plus, Eos, Tiguan,
Scirocco, Golf, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.6 Removing and installing coolant pump (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.7 Removing and installing coolant pump belt pulley (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . 230
2.8 Removing and installing coolant circulation pump V50 (Sharan) . . . . . . . . . . . . . . . . . . . . 234
2.9 Removing and installing coolant pump belt pulley (Passat, Passat CC) . . . . . . . . . . . . . . 236
2.10 Removing and installing coolant pump (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . 242
2.11 Removing and installing coolant circulation pump V50 (Passat, Passat CC) . . . . . . . . . . 249
2.12 Assembly overview - heater element for engine preheater Z97 (Passat, Passat CC) . . . . 251
2.13 Removing and installing heater element for engine preheater Z97 (Passat, Passat CC) . . 253
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3.1 Assembly overview - radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf, Touran, Golf
Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3.2 Assembly overview - parts of cooling system, body side (Tiguan) . . . . . . . . . . . . . . . . . . . . 258
3.3 Assembly overview - radiator/radiator fan (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.4 Assembly overview - radiator/radiator fan (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3.5 Assembly overview - radiator/radiator fan (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . 262

satelettronica
3.6 Removing and installing radiator fan V7 and radiator fan 2 V177 (Eos, Golf Plus, Scirocco,
Golf, Touran, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.7 Removing and installing radiator fan V7 and radiator fan 2 V177 (Polo) . . . . . . . . . . . . . . 264
3.8 Removing and installing radiator, radiator fan V7 and radiator fan 2 V177 (Sharan) . . . . . . 265
3.9 Removing and installing radiator (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.10 Removing and installing fan cowling (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3.11 Removing and installing radiator fan V7 and radiator fan 2 V177 (Passat, Passat CC) . . 271
3.12 Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
........................................................................ 272
3.13 Removing and installing radiator and radiator fan V7 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 273
3.14 Removing and installing radiator with charge air cooler wage
n(Polo)
AG. Volks.w.a.ge . n. A. G. d.o.e. . . . . . . . . . . . . 275
olks s no
yV t gu
21 - Turbocharging/supercharging . . . . . . . .ris.ed.b . . . . . . . . . . . . . . . . . . . . . . .a.ran.te. . . . . 278
ho e
1 Exhaust turbocharger . . . . . . . . . . . s.au.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.ac. . . 278
s
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

ce
le
un

pt
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

an
d
itte

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1.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
rm

ab
pe

1.4 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

ility
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1.5 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
, is n

h re
hole

2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 spec

2.1 Assembly overview - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
es, in part or in w

t to the co

2.2 Removing and installing supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

2.3 Removing and installing supercharger (Tiguan with four-wheel drive) . . . . . . . . . . . . . . . . 307
2.4 Removing and installing drive unit seal for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . 315
rrectness of i

3 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

l purpos

3.1 Assembly overview - charge air system (Eos, Golf Plus, Golf, Touran, Scirocco, Tiguan,
Sharan, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
nform
ercia

3.2 Assembly overview - charge air system (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

m

3.3 Assembly overview - charge air system (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . 322
a
com

tio

3.4 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

n in
r
te o

thi

3.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

s
iva

do

3.6 Removing and installing charge air cooler (Eos, Golf Plus, Golf, Golf Cabriolet, Touran) . . 327
r
rp

cum
fo

3.7 Removing and installing charge air cooler, Sharan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

en
ng

t.
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3.8 Removing and installing charge air cooler (Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Co
Cop py
.
3.9 Removing and installing charge air cooler, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
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3.10 Removing and installing charge air cooler (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . 335
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Prote AG.
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Contents iii
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

1.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.2 Assembly overview - air filter (Polo) . . . . . . . . . . . . . . . . . . . ..V.ol.ks. w. a.g.e . . . . . . . . . . . . . . . . 341
n AG n AG
1.3 Removing and installing air filter housing . . . . . . .o.lks. w. a.g.e . . . . . . . . . . . . . .do.e.s .no. . . . . . . . . 342
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1.4 Removing and installing air filter housing (Polo) ed b . . . . . . . . . . . . . . . . . . . . . . . . . u. a.ra. . . . .
nte
343
ris
2 Intake manifold . . . . . . . . . . . . . . . . . . .au.th.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. o.r a. 344
2.1 Assembly overview - intake manifold . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c 344

ce
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nl
2.2 Removing and installing regulating flap control unit J808 and throttle valve module J338

pt
du

an
........................................................................ 349

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erm

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2.3 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

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3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

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3.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
hole

spec
3.2 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
es, in part or in w

3.3 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

t to the co
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4.1 Checking fuel pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

rrectness of i
4.2 Actuator for structure-borne sound R214 and control unit for structure-borne sound J869
l purpos

(Polo, left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

4.3 Assembly overview - actuator for structure-borne sound R214 and control unit for structure-

satelettronica
borne sound J869 (Polo, right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

nform
ercia

5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

m

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5.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

ion
c

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5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
or

his
ate

6 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

do
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6.1 Removing and installing engine control unit J623 (Golf Plus, Touran) . . . . . . . . . . . . . . . . 373

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for

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6.2 Removing and installing engine control unit J623 with protective housing (Golf Plus,
t.
yi Co
op
Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
C py
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6.3 Removing and installing engine control unit J623 (Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . yri
377
p by
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6.4 Removing and installing engine control unit J623 with protective housing (Eos► 10.2008) Prote
cted AG.
agen
........................................................................ 378
6.5 Removing and installing engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . 380
6.6 Removing and installing engine control unit J623 with protective housing (Tiguan) . . . . . . 381
6.7 Removing and installing engine control unit J623 (Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . 383
6.8 Removing and installing engine control unit J623 with protective housing (Scirocco►
09.2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
6.9 Removing and installing engine control unit J623 (Golf, Golf Cabriolet) . . . . . . . . . . . . . . 386
6.10 Removing and installing engine control unit J623 (Passat, Passat CC) . . . . . . . . . . . . . . 387
6.11 Removing and installing engine control unit J623 with protective housing (Golf, Eos
11.2008►, Scirocco 10.2008►, Passat, Passat CC, Golf Cabriolet) . . . . . . . . . . . . . . . . . . 388
6.12 Removing and installing engine control unit J623 (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . 391
6.13 Removing and installing engine control unit J623 with protective housing (Polo) . . . . . . . . 392
6.14 Removing and installing engine control unit J623 (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . 393
6.15 Removing and installing engine control unit J623 with protective housing (Sharan) . . . . . . 394

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
1.1 Assembly overview - silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) . . . . 397
1.2 Assembly overview - silencers (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
1.3 Assembly overview - silencers (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
1.4 Assembly overview - silencers (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
1.5 Assembly overview - silencer (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1.6 Removing and installing front exhaust pipe (Tiguan with four-wheel drive) . . . . . . . . . . . . 402
1.7 Removing and installing front exhaust pipe (Golf Plus, Eos, Scirocco, Golf, Tiguan, Touran,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
1.8 Removing and installing front exhaust pipe (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
1.9 Removing and installing (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

iv Contents
 AG. Volkswagen AG d
agen oes
olksw not
V
d by Eos 2006 ➤ , Golf 2009 ➤
gu , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
ara
ise nte
4-cylinder
thor direct-injection engine (1.4 l, EA 111, turbocharger,
eo supercharger) - Edition 02.2019
au ra
ss c
1.10 Separating exhaust pipes, silencers (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

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1.11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
d
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........................................................................ 408
erm

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1.12 Separating exhaust pipes, silencers (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
ot p

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1.13 Separating exhaust pipes, silencers (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

h re
ole,

1.14 Separating exhaust pipes/silencers (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 412

spec
urposes, in part or in wh

1.15 Aligning exhaust system free of stress (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . 414

t to the co
1.16 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

rrectne
2.1 Assembly overview - exhaust gas treatment (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
2.2 Assembly overview - exhaust gas treatment (Tiguan with four-wheel drive) . . . . . . . . . . . . 418

ss o
2.3 Assembly overview - exhaust gas treatment (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
cial p

f inform
2.4 Assembly overview - exhaust gas treatment (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
mer

2.5 Assembly overview - exhaust gas treatment (Passat, Passat CC) . . . . . . . . . . . . . . . . . . 422

atio
om

2.6 Removing and installing catalytic converter (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

n
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i
or

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2.7 Removing and installing (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

thi
te

sd
iva

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pr

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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

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satelettronica
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1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Co
Cop py
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
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1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 429
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by lksw
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1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote AG.
431
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

Contents v
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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vi Contents
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

00 – Technical data
1 Engine number/engine data
(VRL012774; Edition 02.2019)
– Detach hose from activated charcoal filter at hose clip
-arrow-.

Engine code and engine number can be foundgeon the

. Vosticker
lkswagen AG

satelettronica
AG
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-arrow- on the control housing. Volksw not
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Starting with the letter “C”, new four-digit
ris
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introduced. The first 3 places show utho the mechanical design of en‐ eo
ra
a
gine and are stamped on the engine
ss as previously. The fourth digit c

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denotes the performance and torque rating of the engine and de‐
un

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code can be found on the type plate, the vehicle data label and
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Note

spec
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Vehicles for certain export countries have no type plate. Fitting
locations for vehicle data sticker and identification plate: ⇒ Main‐
tenance ; Booklet rrectness of i
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Engine code CAVA CAVD CAVC CAVB CAVE CKMA

Manufac‐
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Golf 05.08► 05.08► 05.08► 05.08► --- ---

tion in

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2005►
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Golf --- 02.09► --- --- --- ---

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2009► Cop
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Eos 05.08► 05.08► 05.08► 05.08► --- ---
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2006▶
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Tiguan 05.08► 05.11► --- --- --- ---
agen
Prote AG.
2008►
Sciroc‐ --- 05.08► 05.08► 05.08► --- ---
co
2009►
Touran --- --- 11.08► 11.08► --- ---
2003►
Golf --- 07.08► 07.08► 07.08► --- ---
2009►
Golf --- 06.11► --- --- --- ---
Cabrio‐
let
2012►

1. Engine number/engine data 1

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Engine code CAVA CAVD CAVC CAVB CAVE CKMA

Sharan 07.10► n AG. Volksw---
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--- ks---
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05.10► ri --- --- --- ntee o
2010► au ra
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Passat --- --- --- --- --- 11.10►

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Passat --- --- --- --- --- 01.11►
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Exhaust EU5 EU5 EU5 EU5 EU5 EU5
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Dis‐ cm3 1390 1390 1390 1390 1390 1390
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Pow kW at 110/5800 118/5800 103/5600 125/6000 132/6200 118/5800

er rpm

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Tor‐ Nm at 240/1500-400 240/1500-400 220/1250-40 240/1500-4 250/2000-4 240/1750-4000

satelettronica
que rpm 0 0 00 500 500
m

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Bor Diamet 76.5 76.5 76.5 76.5 76.5 76.5

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or

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Stro mm 75.6 75.6 75.6 75.6 75.6 75.6

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Compres‐ 10 10 10 10 10 10
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RO min. 95 unleaded 95 unleaded 95 unleaded 95 unlea‐ 98 unlea‐ Bioethanol E85
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ded RON 95
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Injection, ig‐ Motronic MED Motronic MED Motronic Motronic Motronic Motronic MED
nition 17 17 MED 17 MED 17 MED 17 17.5.1
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Type of mix‐ Homogene‐ Homogene‐ Homogene‐ Homogene‐ Homogene‐ Homogeneous
ture forma‐ ous ous ous ous ous
tion
Charging Turbocharger Turbocharger Turbocharg‐ Turbo‐ Turbo‐ Turbocharger
and mechani‐ and mechani‐ er and me‐ charger and charger and and mechanical
cal super‐ cal super‐ chanical su‐ mechanical mechanical supercharger
charger charger percharger super‐ super‐
charger charger
1)E85 means that the fuel contains up to 85% bioethanol. Any
mixture ratio below 85% is permissible.

Engine CTHA CTHB CTHC CTHD, CNWA CTHE

code CTKA
Manu‐
fac‐
tured
Gol --- --- --- 05.12► 10.10► ---
f
Plu
s
200
9►
Eos --- --- --- 05.12► --- ---
200
6▶

2 Rep. gr.00 - Technical data

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Engine CTHA CTHB CTHC CTHD, CNWA CTHE

code CTKA
Ti‐ 05.12► --- --- 05.12► --- ---
gua n AG. Volkswagen AG do
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200 ir se
d ran
tee
8► utho
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200 es, in part or in w
3►

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Gol --- --- --- 05.12► --- ---
f
200

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Sha 05.12► --- --- --- --- ---

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Ex‐ EU5 EU5 EU5 EU5 EU4 EU5 Prote
cted AG.
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stand‐
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Di cm3 1390 1390 1390 1390 1390 1390
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P kW 110/58 125/60 103/56 118/58 118/58 132/62
o at 00 00 00 00 00 00
w rpm
er
T Nm 240/15 240/15 220/12 240/15 240/15 250/20
or at 00-400 00-450 50-400 00-450 00-450 00-450
q rpm 0 0 0 0 0 0
u
e
B Dia 76.5 76.5 76.5 76.5 76.5 76.5
or met
e er,
mm
St mm 75.6 75.6 75.6 75.6 75.6 75.6
ro
k
e

1. Engine number/engine data 3

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Engine CTHA CTHB CTHC CTHD, CNWA CTHE

code CTKA
Com‐ 10 10 10 10 10 10
press‐
ion ra‐
tio
R min 95 un‐ 95 un‐ 95 un‐ 95 un‐ 95 un‐ 98 un‐
O . leaded leaded leaded leaded leaded leaded
N
Injec‐ Motron‐ Mo‐ Motron‐ Motron‐ Motron‐ Mo‐
tion, ig‐
ic MED tronic ic MED ic MED ic MED tronic
nition 17 MED 17 17 17 MED
17 17
Firing 1-3-4-2 1-3-4- 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-
order 2 2
Type Homo‐ Homo‐ Homo‐ Homo‐ Homo‐ Homo‐
of mix‐ gen‐ gen‐ gen‐ gen‐ gen‐ gen‐
ture eous eous eous eous eous eous
forma‐
tion
Charg‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐

satelettronica
ing charger charg‐ charger charger charger charg‐
and er and and and and er and
me‐ me‐ me‐ me‐ me‐ me‐
chani‐ chani‐ chani‐ chani‐ chani‐ chani‐
cal su‐ cal su‐ cal su‐ cal su‐ cal su‐ cal su‐
per‐ per‐ per‐ per‐ per‐ per‐
charger charg‐ charger charger charger charg‐
er er

AG. Volkswagen AG d
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Rep. gr.00 - Technical data Prote AG.
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2 Safety precautions
⇒ “2.1 Safety regulations for working on fuel supply”, page 5
⇒ “2.2 Safety precautions when working on ignition system”, page
5
⇒ “2.3 Releasing pressure in high-pressure area”, page 6

2.1 Safety regulations for working on fuel

supply

Caution

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brakegen AG
. Volkswagen AG
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fluid and vacuum) and electrical wiring in their original
Volkswapo‐ not
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♦ To avoid damaging lines, make sure there
au is sufficient
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clearance to all moving or hot components.
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When removing and installing fuel gauge sender - G- or fuel pump
erm

ab
(fuel delivery unit) from a full or partly full fuel tank, observe the

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following:

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hole

Remove fuel pump fuse. Fuse assignment ⇒ Current flow dia‐

spec
grams, Electrical fault finding and Fitting locations
es, in part or in w

t to the co
WARNING

rrectness of i
Fuel system is under pressure! Wear eye protection and gloves
to avoid injuries and skin contact. Wrap a cloth around the
l purpos

connection before loosening hose connections. Then release

pressure by carefully pulling hose off connection.

nf
ercia

orm
m

atio
m

♦ Even before work commences, the extraction hose of an ac‐

o

n in
c

tivated fume extraction system has to be placed in the vicinity

or

thi
e

of the assembly opening of the fuel tank to extract any escap‐

t

sd
iva

ing fumes. If no exhaust gas extraction system is available, a

o
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rp

cu

radial fan with a displacement greater than 15 m3/h can be

o

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t.
used providing that motor is not in air flow.
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
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2.2 Safety precautions when working on ig‐
cted agen
Prote AG.

nition system
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.

2. Safety precautions 5
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

If test and measuring instruments are operated from the front

passenger seat and the vehicle is involved in an accident, a per‐
son sitting in this seat may receive serious injuries when the
airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull all 4-pin connectors -arrows- off ignition coils with final
output stage. ⇒ page 429
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er. Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations

2.3 Releasing pressure in high-pressure

area

satelettronica
WARNING
G. Volkswagen AG d
The injection system consists of a high-pressure section (max‐ lksw
agen
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imum approx. 120 bar) and a low-pressure section (approx. 6by Vo gu
ara
bar). or
ise
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Prior to opening the high-pressure area, e.g. when removing
ss
a ra
c
the high-pressure pump, fuel rail, injectors, a fuel line, or the

ce
le
un

fuel pressure sender - G247- , the fuel pressure in the high-

pt
an
d
itte

pressure area must be reduced to a residual pressure of

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erm

ab
approx. 6 bar. The appropriate procedure is described as fol‐

ility
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lows.

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spec
– Connect ⇒ Vehicle diagnostic tester and perform Guided
urposes, in part or in wh

Function “Releasing fuel high-pressure”.

t to the co
– Switch off ignition.

rrectne
WARNING
ss
The fuel lines are pressurized! Wear protective goggles and
o
cial p

f i

protective clothing to avoid injury and contact with the skin.

nform

Before opening the high-pressure section, wrap a cloth around

mer

atio

the connection.
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– Wrap a clean cloth around the connection and carefully open

iv

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pr

to release residual pressure of approx. 6 bar. Catch the es‐

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fo

caping fuel.
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– After completing work, read event memory of engine control
. C rig
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unit and clear all event entries that may have been created as py by
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a result of pulling off the connector.
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Note

If the event memory was cleared, the readiness code must be

generated ⇒ Vehicle diagnostic tester “Guided Functions”.

6 Rep. gr.00 - Technical data

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3 General repair instructions

⇒ “3.1 Rules for cleanliness”, page 7

3.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only: do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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ed
ris nte
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es, in part or in w

t to the co
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tion in
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te o

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3. General repair instructions 7

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran,
Golf Cabriolet)”, page 8
⇒ “1.2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran,
Golf Cabriolet)”, page 18
⇒ “1.3 Removing engine (Tiguan)”, page 20
⇒ “1.4 Installing engine (Tiguan)”, page 28
⇒ “1.5 Removing engine (Polo)”, page 31
⇒ “1.6 Installing engine (Polo)”, page 39
⇒ “1.7 Removing engine (Sharan)”, page 40 agen
AG. Volkswagen AG d
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⇒ “1.8 Installing engine (Sharan)”, page 48 ed b y ara
nte
ris
o eo
⇒ “1.9 Removing engine (Passat, PassatauCC)”,
th
page 50 ra
ss c

satelettronica
⇒ “1.10 Installing engine (Passat, Passat CC)”, page 60

ce
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nl

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an
1.1 Removing engine (Golf Plus, Eos, Scir‐
itte

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ab
occo, Golf, Touran, Golf Cabriolet)

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Note
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♦ Crankcases were installed with different size threaded holes.
♦ Check these holes before dismantling/assembling and install

rrectness of i
the respective engine support.
l purpos

♦ The engine support - T40075- can continue to be used if con‐

verted as described in the respective work sequence.
nform
ercia

♦ The fitting of engine support - T40075- and engine support -

T40075A- on the crankcase is described in the respective
m

at
om

work sequence.
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or

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Converting engine support - T40075-

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or

– Scribe dimensions -a- and -b- as shown.

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Dimension -a- = 24.5 mm t. Cop py
rig
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Dimension -b-: 49.0 mm p by
co Vo
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– Mark position with a centre punch. Prote AG.

– Drill a hole with a 13.0 mm bit.

– Identify engine support with an -A- behind tool designation.

8 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d

satelettronica
ise nte
or eo
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aut ra
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ab
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♦ Engine support - T40075- with adapters /4, /5, /6 or engine

rm
m

support - T40075A- (not illustrated) with adapters /4, /5, /6

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om

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♦ Torque wrench - V.A.G 1331-

or

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♦ Engine and gearbox jack - V.A.G 1383 A-

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♦ Engine and gearbox support - VAS 6095-

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♦ Drip tray for workshop hoist - VAS 6208- C py
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Prote AG.

1. Removing and installing engine 9

 AG. Volkswagen AG d
agen oes
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Eos 2006 ➤ , Golf 2009 by
V ➤ , Golf Cabriolet 2012 ➤ o,t Golf
ol n
gu Plus 2005 ➤ , ...
d ara
4-cylinder direct-injection
rise engine (1.4 l, EA 111, turbocharger,
nte supercharger) - Edition 02.2019
ho eo
aut ra
ss c

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nl

pt
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ility
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es, in part or in w

t to the co
rrectness of i
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ion
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his
ate

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for

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t.
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pyri by
Vo
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♦ Hose clamp pliers - VAS 6340-

♦ Stepladder - VAS 5085-
♦ Torque wrench - V.A.G 1332-
♦ Guide pins - T10093-

Note

The battery earth must be disconnected for the remaining proce‐

dure. Therefore, first check whether a coded radio is fitted. Then
obtain anti-theft coding first if necessary.

10 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

– Unbolt heat shield over turbocharger -arrows-.

– Remove air filter ⇒ page 342 .
– Open and close expansion tank cap to release pressure in
cooling system.
– Drain coolant ⇒ page 185 .

satelettronica
Note

Pull coolant hoses off engine with hose clip pliers - VAS 6340- .

– Release hose guides -arrows- and remove coolant hose -1-

from coolant reservoir.

– Remove hose -2- from activated charcoal filter system sole‐

noid valve 1 - N80- to activated charcoal filter.

AG. Volkswagen AG d
agen oes
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nl

pt
du

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ab
ility
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spec
es, in part or in w

t to the co
rrectness of i
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m

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or c

thi
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11
cted agen
Prote AG.
1. Removing and installing engine
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 7 .
– Remove noise insulation.
– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier; Service po‐
sition .
The engine is removed downwards together with the gearbox.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Remove battery and battery tray. ⇒ Electrical system;agRep.
en AG. V
olkswagen AG
does
gr. 27 ; Removing and installing battery . Volksw not
g by ua
ed ran
– All cable ties which were opened or cut when
ho
ris the engine was tee
removed must be replaced with new cable t ties in the same or

satelettronica
au ac
positions when engine is installed. ss

ce
le
un

pt
– Disconnect all electrical wiring from gearbox, alternator and

an
d
itte

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starter and lay to side.
rm

ab
pe

ility
– Pull off or disconnect all other electrical connections as nec‐
ot

wit
essary from engine and lay to side.
, is n

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hole

spec
WARNING
es, in part or in w

t to the co
Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around

rrectness of i
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.
l purpos

nform
ercia

– Pull vacuum and breather hoses off engine.

m

– Pull connectors off thermal switch and radiator fan.

com

tion in

– Remove plenum chamber bulkhead ⇒ General body repairs;

r
te o

thi

Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

s
iva

do
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rp

– Remove engine control unit - J623- . ⇒ page 373

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ng

t.
yi Co
op
– Open all line guide fasteners -arrows-.
C py
t. rig
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– Remove wiring from engine control unit. cop Vo
by lksw
cted agen
Prote AG.
– Secure lines/wiring to engine with a cable tie.

12 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove hoses for activated charcoal filter -arrows-.

n AG. Volkswagen AG do
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– Pull activated charcoal filter -1- upwardsssout of bracket.
a ac

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ab
ility
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is n

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ole,

spec
urposes, in part or in wh

satelettronica
t to the co
rrectnes
– Unbolt bracket -arrows-.

s o
cial p

f in
– Remove wiring for Lambda probe after catalytic converter -

form
mer

G130- and for alternator from cable guides -arrows-.

atio
om

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c

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or

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te

sd
iva

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cum
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en
ng

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

– Pull connector off Lambda probe after catalytic converter -

G130- and remove.

1. Removing and installing engine 13

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Open hose clip -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from catalytic converter -arrows-.

AG. Volkswagen AG d
agen oes
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– Unbolt exhaust ised bpipe together with flexible joint -arrows-.
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ole,

spec
urposes, in part or in wh

t to the co
rrectne

– Loosen securing bolts of clamp -arrows- and pull exhaust pipe

to rear.
ss o
cial p

f inform
mer

atio
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c

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cum
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Cop py
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– If fitted, unscrew bolts -arrows- and remove bracket -1-.
lksw
cted agen
Prote AG.

14 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Disconnect pendulum support -arrows-.

– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
– Remove strut -1-.

AG. Volkswagen AG d
agen oes
olksw not
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– Detach slave cylinder -arrows-
rised and place to one side. Do not ara
nte
open pipes. ut
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– Remove hydraulic clutch slave cylinder ⇒ 6-speed manual
s

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nl

gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism .

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Note

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satelettronica
Do not depress clutch pedal.
hole

spec
es, in part or in w

t to the co
– Remove poly V-belt. ⇒ page 75
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing system; Rep. gr. 87 .

rrectness of i
l purpos

Note

nform
ercia

The air conditioning system lines must not be opened.

m

at
om

ion

– Secure air conditioner compressor to lock carrier.

c

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or

his
te

– Ensure that lines are not kinked.

a

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cum
or

– Remove right drive shaft; unbolt left drive shaft at gearbox,

f

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ng

raise and secure ⇒ Running gear, axles, steering; Rep. gr.

t.
yi Co
op
40 ; Repairing drive shafts; Removing and installing drive
C py
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shafts . rig ht
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– Bring lock carrier into service position ⇒ General body repairs, cted agen
Prote AG.
exterior; Rep. gr. 50 ; Body - front; Lock carrier; Service po‐
sition .
Work sequence with engine support - T40075-

Engine support - T40075- with adapters -/4-, -/5- and -/6- is re‐
quired to lower engine with gearbox.

1. Removing and installing engine 15

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s au l, EA 111, turbocharger, supercharger) - Edition r a 02.2019
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– Screw adapter T40075/4 into crankcase to stop.

an
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erm

ab
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-/6- on crankcase.

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form
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ing bolt -1-.

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– Tighten all bolts on engine support - T40075- to 20 Nm.

Work sequence with engine support - T40075A-

Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐
quired to lower engine with gearbox.

16 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw adapter T40075A /4 into the crankcase to stop.

– Position the engine support - T40075A- with adapters -/5- and
-/6- on crankcase.

– Secure engine support - T40075A- hand-tight to crankcase

using bolt -1-.

satelettronica
– Tighten all bolts on engine support - T40075A- to 20 Nm.
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .

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– Unbolt engine side of assembly mounting from above

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-arrows-.
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1. Removing and installing engine 17

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unbolt gearbox side of assembly mounting from above

-arrows-.

Note

♦ To remove securing bolts use a stepladder - VAS 5085- .

♦ When lifted out, the engine/gearbox assembly must be care‐ n AG. Volkswagen AG do
fully guided to prevent damage to the bodywork. lkswage es n
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Secure engine to engine and gearbox support - VAS 6095- to

ce
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carry out repairs.

un

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– Unbolt gearbox.
rm

ab
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– Secure engine on engine and gearbox support - VAS 6095- .
ot

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1.2 Installing engine (Golf Plus, Eos, Scir‐

spec
es, in part or in w

occo, Golf, Touran, Golf Cabriolet)

t to the co

satelettronica
Installation is carried out in the reverse order. When installing,
note the following:

rrectness of i
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Caution

nform
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Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

n in
r
te o

vated charcoal filter system, coolant and refrigerant, brake

thi
s
fluid and vacuum) and electrical wiring in their original po‐
iva

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sitions.
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clearance to all moving or hot components.
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– Check clutch release bearing for wear and renew if necessary.
AG.

– Lightly lubricate clutch release bearing, release bearing guide

sleeve and splines on input shaft with grease for clutch plate
splines - G 000 100- .
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
– When swinging engine/gearbox assembly in, ensure that there
is clearance between drive shafts.
Align engine mountings as follows:

18 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ Ensure that edges of support arm on gearbox assembly
mounting -2- and gearbox support -1- are parallel.
– Install pendulum support.

satelettronica
Note

Specified torques for assembly mountings ⇒ page 64 .

– Install drive shafts ⇒ Running gear, axles, steering; Rep.

nAG. Volgr.
kswagen AG
wage drive
40 ; Repairing drive shafts; Removing and Vinstalling
does
olks not
gu
shafts. se
d by ara
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or
– Install air conditioning system compressor
au
th ⇒ Heating, air con‐ or
ac
ditioning system; Rep. gr. 87 . s s

ce
le
un

– Install poly V-belt. ⇒ page 75 pt

an
d
itte

y li
rm

– Electrical connections and routing ⇒ Electrical system; Rep. ab

pe

ility
gr. 97
ot

wit
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– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐

h re
hole

box 02S; Rep. gr. 30 ; Repairing clutch mechanism .

spec
es, in part or in w

– Install selector mechanism ⇒ 6-speed manual gearbox 02S;

t to the co

Rep. gr. 34 ; Repairing selector mechanism .

– Install noise insulation.
rrectness of i

Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf,
l purpos

Touran, Tiguan, Golf Cabriolet). ⇒ page 185

Draining and filling with coolant (Polo). ⇒ page 189
nform
ercia

– Install air filter ⇒ page 342 .

m

a
com

tio

– Install battery and battery carrier ⇒ Electrical system; Rep. gr.

n in
r

27 ; Removing and installing battery .

te o

thi
s
iva

do

– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

r
rp

cum

necting and reconnecting battery .

fo

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

1. Removing and installing engine 19

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push engine cover panel down at points -1- in direction of

-arrow- until it engages.
– Connect Vehicle diagnosis, testing and information system -
VAS 5051B- .
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided Functions”.
– Carry out vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
ded fault finding”.
– End the vehicle system test so that any entries stored in the
event memory during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Perform road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.

1.3 Removing engine (Tiguan)

swa
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Special tools and workshop tho eo
equipment required au ra
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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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Cop py
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rig ht
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Prote AG.

♦ Engine support - T40075 A- with adapters /4, /5, /6

♦ Torque wrench - V.A.G 1331-

20 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Engine and gearbox support - VAS 6095-
♦ Drip tray for workshop hoist - VAS 6208-

Note

The engine support - T40075- can continue to be used if conver‐

ted as described in the respective work sequence.

Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill a hole with a 13.0 mm bit.
– Identify engine support with an -A- behind tool designation.

satelettronica
AG. Volkswagen AG d
agen oes
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urposes, in part or in wh

t to the co
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f inform
mer

atio
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c

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1. Removing and installing engine 21

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

satelettronica
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♦ Hose clamp uth pliers - VAS 6340-
o
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♦ Stepladder - VAS 5085-
ce
le
un

pt
an
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♦ Torque wrench - V.A.G 1332-

itte

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erm

ab

♦ Guide pins - T10093-

ility
ot p

wit
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h re
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Note
spec
urposes, in part or in wh

t to the co

The battery earth must be disconnected for the remaining proce‐

dure. Therefore, first check whether a coded radio is fitted. Then
obtain anti-theft coding first if necessary.
rrectness o
cial p

f inform
mer

atio
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n
c

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22
co Vo
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Rep. gr.10 - Removing and installing engine
cted agen
Prote AG.
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

– Unbolt heat shield over turbocharger -arrows-.

– Remove air filter ⇒ page 342 .
– Open and close expansion tank cap to release pressure in
cooling system. n AG. Volkswagen AG age does
ksw not
– Drain coolant
by ⇒ page 185 .
Vol gu
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s c ce
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nl

pt
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Pull coolant hoses off engine with hose clip pliers - VAS 6340- .
itte

y li
erm

ab
ility
ot p

– Release hose guides -arrows- and remove coolant hose -1-

wit
, is n

from coolant reservoir.

h re
hole

spec

– Remove hose -2- from activated charcoal filter system sole‐

es, in part or in w

t to the co

noid valve 1 - N80- to activated charcoal filter.

WARNING
rrectness of i
l purpos

Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
nform
ercia

lease pressure by carefully pulling hose off connection.

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ion
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or

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ate

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Cop py
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Prote AG.

1. Removing and installing engine 23

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 7 .
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier; Service po‐
sition .
The engine is removed downwards together with the gearbox.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Remove battery and battery tray. ⇒ Electrical system; Rep.
gr. 27 ; Removing and installing battery .

satelettronica
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
n AG. Volkswagen A
– Pull off or disconnect all otheroelectrical
lksw
age connections Gas
donec‐
es n
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essary from engine and lay d b to side.
y V ua
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– Pull vacuum and breather
ut
ho hoses off engine. or
a ac
ss
– Pull connectors off thermal switch and radiator fan.
ce
e
nl

pt
du

an

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

itte

y li

screen wiper system; Removing and installing wiper arms .

erm

ab
ility
ot p

– Remove plenum chamber cover: ⇒ General body repairs, ex‐

wit
, is n

terior; Rep. gr. 64 ; Removing and installing plenum chamber

h re

cover
hole

spec
es, in part or in w

– Remove engine control unit - J623- . ⇒ page 373

t to the co

– Open all line guide fasteners -arrows-.

rrectness of i

– Remove wiring from engine control unit.

l purpos

– Secure lines/wiring to engine with a cable tie.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

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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.

24 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove wiring for Lambda probe after catalytic converter -

G130- and for alternator from cable guides -arrows-.
– Disconnect connector for Lambda probe after catalytic con‐
verter - G130- .

– Remove Lambda probe

agen
AGafter
. Volkscatalytic
wagen AG converter - G130- -1-.
do w es n
olks o
– Open hose
d b clip -3- and remove charge air pipe
yV t gu
ar-2-.
a
e nte
ris
– Unbolt
ut exhaust pipe from catalytic converter -arrows-.
ho eo
ra
a c
ss

ce
e
nl

pt
du

an
itte

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erm

ab

satelettronica
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co

– If fitted, unscrew bolts -arrows- and remove bracket -1-.

Vehicles with all-wheel drive
rrectness of i

– Remove both drive shafts ⇒ Repairing drive shafts; Rep. gr.

l purpos

40 ; Removing and installing drive shafts .

nf
ercia

orm
m

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or c

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op py
– Remove securing bolts -1- and -2- for exhaust pipe mounting.
. C rig
ht ht
rig by
py
– Remove exhaust pipe mounting downwards.
co Vo
by lksw
cted agen
Prote AG.

1. Removing and installing engine 25

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
n AG. Volkswagen AG do
– Loosen securing nuts of clamping sleeve -arrows- and slide it lkswage es n
forwards on exhaust pipe -1-. d byV
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ab
ility
ot p

wit
is n

h re
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spec
urposes, in part or in wh

t to the co
– Unscrew nuts -arrows- and pull exhaust pipe backwards.

rrectne
– Push exhaust pipe backwards out of mounting -1-.
– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐

ss
shaft and final drive; Rep. gr. 39 ; Removing and installing

o
cial p

f i
propshaft .

nform
mer

– Push propshaft aside.

atio
om

satelettronica
n
– Lower subframe ⇒ Subframe, anti-roll bar, suspension links;
c

i
or

n thi
Rep. gr. 40 ; Lowering subframe .
te

sd
iva

o
r

– Remove exhaust pipe forwards.

p

cum
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fo

en
ng

– Remove gearbox carrier from bevel box ⇒ 6-speed manual

t.
yi Co
op
gearbox 0A6; Rep. gr. 34 ; Removing and installing bevel box . C py
t. rig
gh ht
yri by
Vehicles with front-wheel drive cop Vo
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cted agen
Prote AG.
– Unbolt exhaust pipe together with flexible joint -arrows-.

– Loosen securing bolts of clamp -arrows- and pull exhaust pipe

to rear.
Continued for all vehicles

26 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Disconnect pendulum support -arrows-.

– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 0A6; Rep. gr. 34 ; Repairing selector mechanism .

– Remove hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed

manual gearbox 0A6; Rep. gr. 30 ; Assembly overview AG. Volkswagen AG d
agen - hy‐ oes
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draulic system . by Vol not
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Do not depress clutch pedal.

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erm

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ot p

– Remove poly V-belt. ⇒ page 78

wit
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h re
– Remove air conditioner compressor ⇒ Heating, air condition‐
hole

ing system; Rep. gr. 87 .

spec
es, in part or in w

t to the co
Note

rrectness of i
The air conditioning system lines must not be opened.
l purpos

– Secure air conditioner compressor to lock carrier.

nf
ercia

– Ensure that lines are not kinked.

orm
m

atio
m

Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐
o

n in
c

quired to lower engine with gearbox.

or

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– Screw adapter T40075A /4 into the crankcase to stop.

– Position the engine support - T40075A- with adapters -/5- and
-/6- on crankcase.

1. Removing and installing engine 27

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
en AG. V
olkswa-geEdition
n AG 02.2019
ag does
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y Vol gu
– Secure engine support - T40075A- hand-tight to crankcase sed b ara
nte
using bolt -1-. ho
ri eo
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ab
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ility
ot

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Tighten all bolts on engine support - T40075A- to 20 Nm.
l purpos
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .

nform
mercia

a
com

tion in
r
te o

thi

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s
iva

do
r
rp

cum
fo

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Cop py
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co
– Unbolt engine side of assembly mounting from above
by lksw
cted agen
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-arrows-.
AG.

– Unbolt gearbox side of assembly mounting from above

-arrows-.

Note

♦ To remove securing bolts use a stepladder - VAS 5085- .

♦ When lifted out, the engine/gearbox assembly must be care‐
fully guided to prevent damage to the bodywork.

– Carefully lower engine and gearbox.

Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
– Unbolt gearbox.
– Secure engine on engine and gearbox support - VAS 6095- .

1.4 Installing engine (Tiguan)

Installation is carried out in the reverse order. When installing,
note the following:

28 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Caution

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.

– Check clutch release bearing for wear and renew if necessary.

– Lightly lubricate clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease for clutch plate
splines - G 000 100- .
. Volkswage
– Check whether dowel sleevesksfor wagaligning
en AG enginenand
AG dogearbox
es n
are fitted in cylinder blockbyand
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– Hook intermediate tplate
ho
r
onto sealing flange and slide onto tee

satelettronica
or
dowel sleeves -arrows-.
ss
au ac

ce
le

Align engine mountings as follows:

un

pt
an
d
itte

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rm

ab
pe

ility
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h re
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spec
es, in part or in w

t to the co
rrectness of i
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nform
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tion in
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te o

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t.
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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.

1. Removing and installing engine 29

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ Ensure that edges of support arm on gearbox assembly
mounting -1- and gearbox support -2- are parallel.
– Install exhaust pipe.
Vehicles with all-wheel drive
– Install gearbox carrier for bevel box ⇒ 6-speed manual gear‐
box 0A6; Rep. gr. 34 ; Removing and installing bevel box .

Note

First tighten securing nuts hand-tight.

– Install exhaust pipe mounting and tighten securing bolts -1-

and -2- to 25 Nm.

satelettronica
Specified torques for exhaust pipe ⇒ page 418 .
– Install subframe ⇒ Subframe, anti-roll bar, suspension links;
Rep. gr. 40 ; Removing and installing subframe .
– Install propshaft ⇒ Propshaft and rear final drive; Rep. gr. 39 ;
Removing and installing propshaft .
Continued for all vehicles
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts.
– Attach selector mechanism ⇒ 6-speed manual gearbox 0A6;
Rep. gr. 34 ; Repairing selector mechanism .
G. Volkswagen AG d
– Install hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed ksw
agen
A
oes
not
manual gearbox 0A6; Rep. gr. 30 ; Assembly overview - hy‐ y Vol gu
b ara
draulic system . ris
ed nte
tho eo
– Install pendulum support. s au ra
c
s
ce
le
un

pt
an
d
itte

Note y li
rm

ab
pe

ility
Specified torques for engine/gearbox assembly mountings
ot

wit
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⇒ page 65
h re
hole

spec
es, in part or in w

– Install air conditioning system compressor ⇒ Heating, air con‐

t to the co

ditioning system; Rep. gr. 87 .

– Install poly V-belt. ⇒ page 78
rrectness of i

– Electrical connections and routing ⇒ Electrical system; Rep.

gr. 97
l purpos

– Fill with coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Ti‐
nform

guan, Golf Cabriolet). ⇒ page 185

mercia

– Install air filter ⇒ page 342 .

a
com

tion in

– Install battery and battery carrier ⇒ Electrical system; Rep. gr.

r
te o

thi

27 ; Removing and installing battery .

s
iva

do
r
rp

– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

um
fo

necting and reconnecting battery .

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
30
agen
Prote AG.
Rep. gr.10 - Removing and installing engine
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push engine cover panel down at points -1- in direction of

-arrow- until it engages.
– Connect Vehicle diagnosis, testing and information system -
VAS 5051B- .
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided Functions”.
– Carry out vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
ded fault finding”.
– End the vehicle system test so that any entries stored in the
event memory during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Perform road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.

1.5 Removing engine (Polo)

satelettronica
Note

The engine is removed downwards together with the gearbox.

AG. Volkswagen AG d
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aut ra
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nl

pt
du

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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

nf
ercia

orm
m

atio
om

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or c

thi
te

sd
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t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.

1. Removing and installing engine 31

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
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un

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an
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itte

y li
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ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

♦ Engine support - T10416- with adapters /1, /2, /3

♦ Torque wrench - V.A.G 1331-
rrectne

♦ Engine and gearbox jack - V.A.G 1383 A-

s

♦ Engine and gearbox support - VAS 6095-

s o
cial p

f i

♦ Drip tray for workshop hoist - VAS 6208-

nform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

en
ng

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

32 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

n AG. Volkswagen AG do
wage es n

satelettronica
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un

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an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

♦ Hose clamp pliers - VAS 6340-

inform
mer

♦ Stepladder - VAS 5085-

atio
m

♦ Torque wrench (40 … 200 Nm) - V.A.G. 1332-

o

n
c

i
or

n thi
te

sd
iva

o
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Note
p

cum
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en
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t.
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The battery earth must be disconnected for the remaining proce‐
Cop py
dure. Therefore, first check whether a coded radio is fitted. Then
t. rig
gh ht
yri
obtain anti-theft coding first if necessary.
p by
co Vo
by lksw
cted agen
Prote AG.

1. Removing and installing engine 33

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

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
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ab
ility
ot p

– Unbolt heat shield over turbocharger -arrows-.

wit
, is n

h re
– Pull hose -1- off at camshaft housing.
hole

spec
es, in part or in w

t to the co
rrectness of i

satelettronica
l purpos

nform
mercia

at
om

ion
– Open spring-type clip -2- and pull intake hose off.
c

in t
or

his
e

– Pull intake hose out of intake connection.

at

do
priv

cum
or

– Unscrew securing bolt and pull air filter housing -4- upwards.
f

en
ng

t.
yi Co
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐ Cop py
necting and reconnecting battery . ht. rig
rig ht
py by
co Vo
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
by lksw
cted agen
Prote
27 ; Battery; Removing and installing battery .
AG.

– Remove noise insulation securing bolts -arrows-.

– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Open and close expansion tank cap to release pressure in
cooling system.
– Drain coolant ⇒ page 185 .
– Observe rules for cleanliness ⇒ page 7 .

WARNING

Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.

34 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
– Pull coolant hoses off at heat exchanger behind intake mani‐
fold.
AG. Volkswagen AG d
agen
– Pull off connector -1-. Volksw
oes
not
gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
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– Pull vacuum hose -2- off at vacuum pump for brakes - V192-

h re
hole

-3-.

spec
es, in part or in w

RHD only

t to the co
– Additionally pull vacuum hose off at brake servo.
Continued for all vehicles

rrectness of i
– Secure vacuum hose to engine with cable tie.
l purpos

satelettronica
– Pull off connector -1-.

nform
mercia

at
om

ion
c

in t
or

his
– Pull coolant hoses -2- off coolant expansion tank.
ate

do
priv

c
– Unscrew securing bolts -3- and pull coolant reservoir upwards.

um
for

en
ng

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

– Release coolant hoses -arrows- at gearbox side and pull them

off.
– Pull coolant hoses off at radiator and remove completely.
– Remove engine control unit ⇒ page 373 .
– Remove wiring harness from wiring guides and secure to en‐
gine with cable ties.
– Remove main fuse box in engine compartment ⇒ Electrical
system; Rep. gr. 97 ; Removing and installing main fuse box
in engine compartment .
– Secure main fuse box to side of body with cable ties.
– Remove selector lever cable ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable .

1. Removing and installing engine 35

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing nuts on turbocharger -arrows-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Remove charge air hose -arrow-. auth or
ac
ss
– Remove air conditioner compressor ⇒ Heating, air condition‐

ce
le
un

pt
ing; Rep. gr. 87

an
d
itte

y li
erm

ab
ility
ot p

Note

wit
is n

h re
ole,

The air conditioning system lines must not be opened.

spec

satelettronica
urposes, in part or in wh

t to the co
– Secure air conditioner compressor to lock carrier.
– Ensure that lines are not kinked.

rrectne
– Disconnect connector -3- for Lambda probe after catalytic
converter - G130- .

ss o
cial p

f
– Also disconnect all further connectors at gearbox support.

inform
mer

– Unscrew securing bolts -1- for charge air pipe.

atio
om

n
– Unscrew securing bolts -4- and remove bracket -5-.
c

i
or

n thi
te

– Pull upper charge air hose off turbocharger.

sd
iva

o
pr

cum
r

– Remove charge air pipe downwards.

fo

en
ng

t.
yi Co
– Press front exhaust pipe support rings off pins. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

36 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Loosen securing bolts of clamp -arrows- and slide to rear.

– Remove catalytic converter
AG. Volkwith
swagfront
en AG exhaust pipe down‐
agen does
wards. Volksw not
g
y ua
db ran
– Remove
or poly V-belt ⇒ page 75 .
ise tee
h
ut or
– Allsscable
a
ties that are opened or cut through when theac engine
is removed must be renewed/replaced in the same position

ce
le
un

pt
when the engine is installed.

an
d
itte

y li
erm

– Disconnect all electrical wiring from gearbox, alternator and

ab
ility
starter and lay to side.
ot p

wit
is n

– Pull off or disconnect all other electrical connections as nec‐

h re
ole,

essary from engine and lay to side.

spec
urposes, in part or in wh

– Pull vacuum and breather hoses off engine.

t to the co
– Pull connectors off thermal switch and radiator fan.

rrectne
– Remove right and left drive shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts; Removing and
installing drive shafts .

ss o
cial p

f inform
Caution

satelettronica
mer

atio
m

Bolt -1- must not be loosened.

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r

– Remove pendulum support securing bolts -arrows-.

fo

en
ng

t.
yi Co
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
Cop py
. rig
40 ; Removing and installing subframe .
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Engine support - T10416- with adapters -/1-, -/2- and -/3- is re‐
quired to lower engine with gearbox.

1. Removing and installing engine 37

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw adapter - T10416/1- to stop into crankcase.

– Position the engine support - T10416- with adapters -/2- and
-/3- on crankcase.
– Secure engine support - T10416- hand-tight to crankcase us‐
ing a bolt -1-.

n AG. Volkswagen AG
– Tighten all bolts on engine
olks
wagesupport - T10416-doto 20
es n
o Nm.
yV t gu
db ara
ir se nte
ho eo
Note aut ra
c
ss

ce
e
nl

Adjuster nut -2- sets correct angle between pin on engine support

pt
du

an
- T10416- and engine and gearbox jack - V.A.G 1383 A- .
itte

y li
erm

ab
ility
ot p

satelettronica
– Position engine and gearbox jack - V.A.G 1383 A- on engine

wit
, is n

support - T10416- .

h re
hole

spec
– Lift engine and gearbox slightly using engine and gearbox jack
es, in part or in w

- V.A.G 1383 A- . t to the co

Note
rrectness of i
l purpos

To remove securing bolts use a stepladder - VAS 5085- .

– Unbolt earth wire -1-.

nf
ercia

orm
m

atio
m

Caution
o

n in
or c

thi
te

Nut -2- must not be loosened.

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op py
– Unscrew securing bolts -arrows- for engine mounting. t. C rig
gh ht
pyri by
– Remove complete engine mounting.
co Vo
by lksw
cted agen
Prote AG.

38 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolts -arrows- at gearbox mounting.

Note

When lowering engine, guide it carefully to prevent damage.

AG. Volkswagen A
n G do
wage es n
Volks ot g
– Carefully lower engine and gearbox. ed
by ua
ran
oris tee
Secure engine to engine and gearbox
au
th support - VAS 6095- to or
ac
carry out repairs. ss

ce
e
nl

pt
– Unbolt gearbox.
du

an
itte

y li
erm

– Secure engine on engine and gearbox support - VAS 6095- .

ab
ility
ot p

wit
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1.6 Installing engine (Polo)

h re
hole

spec
Installation is carried out in the reverse order. When installing,
es, in part or in w

t to the co
note the following:

Caution

rrectness of i

satelettronica
l purpos

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:

nf
ercia

♦ Route all the various lines, e.g. for fuel, coolant, refriger‐

or
ant, vacuum and electrical wiring, in their original posi‐

m
m

atio
tions.
om

n in
or c

♦ To avoid damaging lines, make sure there is sufficient

thi
te

clearance to all moving or hot components.

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
– Check whether dowel sleeves for aligning engine and gearbox Cop py
are fitted in cylinder block and install if necessary.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Removing and installing engine 39

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
– Bolt on gearbox.
Specified torques for gearbox: ⇒ Rep. gr. 34 ; Removing and
installing gearbox
– Rock engine to align engine mountings stress-free.

Note

Specified torques for engine/gearbox assembly mountings

⇒ page 64

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

40 ; Removing and installing subframe .
– Install pendulum support.
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .

satelettronica
– Install selector lever cable: ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable
– Install air conditioning system compressor ⇒ Heating, air con‐
ditioning system; Rep. gr. 87 . swa
gen AG
. Volkswagen AG
does
k not
Vol gu
– Install poly V-belt ⇒ page 75 . ed by ara
nte
is
or eo
– Electrical connections andau routing: ⇒ Electrical system; Rep.
th ra
gr. 97 . ss c
ce
e
nl

pt

– Install noise insulation beneath engine.

du

an
itte

y li
erm

– Fill with coolant (Polo). ⇒ page 189

ab
ility
ot p

– Install air filter ⇒ page 343 .

wit
, is n

h re

– Install battery and battery carrier ⇒ Electrical system; Rep. gr.

hole

spec

27 ; Removing and installing battery .

es, in part or in w

t to the co

– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

necting and reconnecting battery .
rrectness of i

– Connect ⇒ Vehicle diagnostic tester.

l purpos

– Erase learnt values and adapt engine control unit to throttle

valve module “Guided functions”.
nf
ercia

– Carry out vehicle system test.

orm
m

– End the vehicle system test so that any entries stored in the
atio
m

event memory during assembly can be deleted automatically.

o

n in
or c

thi
e

Observe applicable safety precautions during road test.

t

sd
iva

o
r
rp

cu

– Perform road test.

o

m
f

en
ng

t.
yi
– Then carry out vehicle system test again and rectify any faults
Co
op py
which may have occurred.
t. C rig
gh ht
pyri by
Vo
co lksw
by
1.7 Removing engine (Sharan)
cted agen
Prote AG.

40 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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
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
rrectness of i

satelettronica
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

♦ Engine support - T40075 A- with adapters /4, /5, /6

♦ Torque wrench - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine and gearbox support - VAS 6095-
♦ Drip tray for workshop hoist - VAS 6208-

Note

The engine support - T40075- can continue to be used if conver‐

ted as described in the respective work sequence.

1. Removing and installing engine 41

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill hole through the material with 13.0 mm bit.
– Identify engine support with an -A- behind tool designation.

satelettronica
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
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

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ Hose clamp pliers - VAS 6340-
cted agen
Prote AG.

♦ Stepladder - VAS 5085-

♦ Torque wrench - V.A.G 1332-
♦ Guide pins - T10093-

42 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

The battery earth must be disconnected for the remaining proce‐

dure. Check whether a coded radio is fitted. Then obtain anti-theft
coding first if necessary.

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

– Unbolt heat shield over turbocharger -arrows-.

satelettronica
– Remove air filter ⇒ page 342 .
– Open and close expansion tank cap to release pressure in
cooling system.
– Drain coolant ⇒ page 193 .

Note

Pull coolant hoses off engine with hose clip pliers - VAS 6340- .
n AG. Volkswagen A G do
wage es n
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by ua
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oris tee
th or
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nl

pt
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ility
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spec
es, in part or in w

t to the co
rrectness of i
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at
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ion
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or

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ate

do
priv

cum
for

en
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t.
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rig ht
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cted agen
Prote AG.

1. Removing and installing engine 43

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull coolant hoses -arrows- off coolant expansion tank.

WARNING

Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.

– Disconnect the fuel supply line -1- and line from activated
charcoal filter system solenoid valve 1 - N80- -2- on the clutch.

Note

Press in securing ring to release fuel and breather lines.

– Seal lines so that no dirt is able to enter fuel system.

– Observe rules for cleanliness ⇒ page 7 .
– Remove engine splash guard at bottom.

satelettronica
– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
The engine is removed downwards together with the gearbox.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery . AG. Volkswagen A gen G do
swa es n
– All cable ties which are opened or cut throughby
Vol when engine is
k ot g
ua
removed must be replaced in the same ris position when engine
ed ran
tee
is installed. ut
ho or
sa ac
s
– Disconnect all electrical wiring from gearbox, alternator and
ce
e
nl

starter and lay to side.

pt
du

an
itte

y li

– Pull off or disconnect all other electrical connections as nec‐

erm

ab

essary from engine and lay to side.

ility
ot p

wit
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– Pull vacuum and breather hoses off engine.

h re
hole

spec

– Remove plenum chamber bulkhead ⇒ General body repairs;

es, in part or in w

Rep. gr. 50 ; Body - front, plenum chamber bulkhead .

t to the co

– Remove engine control unit - J623- ⇒ page 373 .

rrectness of i

– Open all line guide fasteners -arrows-.

l purpos

– Remove wiring from engine control unit.

– Secure lines/wiring to engine with a cable tie.
nform
mercia

at
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ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

44
Prote AG.
Rep. gr.10 - Removing and installing engine
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
n AG. Volkswagen A
– Remove wiringolks
for
wagLambda
e
probe after
G do
ecatalytic
s no converter -
G130- and
d byfor alternator from cable guidest -arrows-.
V gu
ar
e an
ris te
– Disconnect
tho connector for Lambda probe after catalytic
eo
r a con‐
au
verter
ss - G130- . 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
– Remove Lambda probe after catalytic converter - G130- -1-.

rrectness of i
– Open hose clip -3- and remove charge air pipe -2-.
l purpos

– Unbolt exhaust pipe from catalytic converter -arrows-.

nf
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m

atio
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satelettronica
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or c

thi
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sd
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– If fitted, unscrew bolts -arrows- and remove bracket -1-.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Loosen securing nuts of clamping sleeve -arrows- and slide it

forwards on exhaust pipe -1-.

1. Removing and installing engine 45

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew nuts -arrows- and pull exhaust pipe backwards.

– Push exhaust pipe backwards out of mounting -1-.
– Remove exhaust pipe.

– Disconnect pendulum support -arrows-.

Vehicles with manual gearbox:
– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 0BB; Rep. gr. 34 ; Repairing selector mechanism .

satelettronica
– Remove hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed
manual gearbox 0BB; Rep. gr. 30 ; Assembly overview - hy‐
draulic system .

Caution
AG. Volkswagen AG d
Do not operate clutch pedalolany
ksw more.
agen oes
not
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rise nte
ho eo
Vehicles with duals ut
aclutch gearbox: ra
s c
ce

– Remove selector mechanism from gearbox ⇒ 6-speed dual

e
nl

pt
du

clutch gearbox 02E; Rep. gr. 34 .

an
itte

y li
erm

ab

Continued for all vehicles:

ility
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wit

– Remove poly V-belt ⇒ page 75 .

, is n

h re
hole

– Remove air conditioner compressor ⇒ Heating, air condition‐

spec

ing system; Rep. gr. 87 .

es, in part or in w

t to the co

Note
rrectness of i

The air conditioning system lines must not be opened.

l purpos

– Secure AC compressor to lock carrier.

nf
ercia

or

– Make sure that lines are not kinked.

m
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
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f

en
ng

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

46 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Disconnect coolant pipe -1- from the cylinder block.

– Remove right drive shaft; unbolt left drive shaft at gearbox,
raise and secure ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .

Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐
quired to lower engine with gearbox.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– Screw adapter T40075A /4 into the crankcase
orise
to stop. nte
eo
h
ut ra
– Position engine support - T40075A-
ss a
with adapters -/5- and c
-/6- on crankcase.

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

– Secure engine support - T40075A- hand-tight to crankcase

l purpos

using bolt -1-.

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
o
by c lksw
cted agen
Prote AG.

1. Removing and installing engine 47

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Tighten all bolts on the engine support - T40075A- to 20 Nm.

– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
– Unbolt engine side tofho assembly mounting from above
r eo
-arrows-. s au ra
c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
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h re
hole

satelettronica
spec
es, in part or in w

t to the co
rrectness of i
– Unbolt gearbox side of assembly mounting from above
l purpos

-arrows-. nform
ercia

Note
m

at
om

ion

♦ To remove securing bolts use a stepladder - VAS 5085- .

c

in t
or

his
te

♦ When lifted out, the engine/gearbox assembly must be care‐

a

do
riv

fully guided to prevent damage to the bodywork.

p

cum
for

en
ng

t.
yi Co
– Carefully lower engine and gearbox. Cop py
t. rig
gh ht
yri
Secure engine to engine and gearbox support - VAS 6095- to
p by
co Vo
by lksw
carry out repairs. Prote
cted AG.
agen

– Unbolt gearbox.
– Secure engine on engine and gearbox support - VAS 6095- .

1.8 Installing engine (Sharan)

Repairing the clutch:
♦ Vehicles with manual gearbox ⇒ 6-speed manual gearbox
0BB; Rep. gr. 30 .
♦ Vehicles with dual clutch gearbox ⇒ 6-speed dual clutch gear‐
box 02E; Rep. gr. 30 .
Installation is carried out in the reverse order. When installing,
note the following:

48 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Caution

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.

Vehicles with manual gearbox:

– Check clutch release bearing for wear and renew if necessary.
– Lightly lubricate clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease for clutch plate
splines - G 000 100- .
Continued for all vehicles:

satelettronica
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-. G. Volkswagen AG do nA
es n wage
Vehicles with manual gearbox:
yV
olks ot g
ua
b
ed ran
– Fix hydraulic clutch
thoris
slave cylinder hose: ⇒ 6-speed manual tee
gearbox 0BB; au Rep. gr. 30 ; Assembly overview - hydraulic or a
ss c
system .
ce
e
nl

pt
du

– Install gearbox selector mechanism and adjust if necessary ⇒

an
itte

y li

6-speed manual gearbox 0BB; Rep. gr. 34 .

erm

ab
ility
ot p

Vehicles with dual clutch gearbox:

wit
, is n

h re

– Install gearbox selector lever cable and adjust if necessary ⇒

hole

spec

6-speed dual clutch gearbox 02E; Rep. gr. 34 .

es, in part or in w

t to the co

Continued for all vehicles:

Align the engine mountings as follows:
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.

1. Removing and installing engine 49

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
en AG . Volkswagen AG
♦ Ensure that edges of support arm -1- and gearbox wagbracket does
-2- are parallel. Volks not
gu
by ara
ed nte
ris
– Install the exhaust pipe. tho eo
s au ra
c
– Install drive shafts ⇒ Running gear,
s axles, steering; Rep. gr.

ce
40 ; Repairing drive shafts; Removing and installing drive e
nl

pt
du

an
shafts.
itte

y li
erm

ab
– Install the pendulum support.

ility
ot p

wit
, is n

h re
hole

Note

spec
es, in part or in w

t to the co
Specified torques for assembly mountings ⇒ page 67 .

– Install air conditioning system compressor ⇒ Heating, air con‐

rrectness of i
ditioning system; Rep. gr. 87 .
l purpos

satelettronica
– Install poly V-belt ⇒ page 75 .
– Electrical connections and routing ⇒ Electrical system; Rep.

nform
ercia

gr. 97
m

at
om

– Add coolant ⇒ page 193 .

ion
c

in t
or

– Install air filter ⇒ page 342 .

his
ate

do
riv

– Install battery and battery tray ⇒ Electrical system; Rep. gr.

p

cum
or

27 ; Removing and installing battery .

f

en
ng

t.
yi Co
op
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐ C py
ht. rig
necting and reconnecting battery . rig ht
py by
co Vo
by lksw
cted agen
– Push engine cover panel down at points -1- in direction of
Prote AG.

-arrow- until it engages.

– Connect vehicle diagnosis and service information system -
VAS 5051B- .
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided Functions”.
– Perform vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
ded fault finding”.
– Finish vehicle system test so that any event entries stored
during assembly can be cleared automatically.
Note safety precautions applicable to a road test.
– Perform road test.
– Then carry out vehicle system test again and rectify any faults
which have occurred.

1.9 Removing engine (Passat, Passat CC)

50 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
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
un

pt
an
d
itte

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erm

ab
ility
ot p

♦ Engine support - T40075 A- with adapters /4, /5, /6

wit
is n

h re

♦ Torque wrench - V.A.G 1331-

ole,

spec
urposes, in part or in wh

♦ Engine and gearbox jack - V.A.G 1383 A-

t to the co

♦ Engine and gearbox support - VAS 6095-

♦ Drip tray for workshop hoist - VAS 6208-
rrectnes

Note
s o
cial p

f inform

The engine support - T40075- can continue to be used if conver‐

mer

ted as described in the respective work sequence.

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
Prote AG.

1. Removing and installing engine 51

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill hole through the material with 13.0 mm bit.
– Identify engine support with an -A- behind tool designation.

satelettronica
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
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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cu
o

m
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en
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t.
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Cop py
♦ Hose clamp pliers - VAS 6340- ht. rig
rig ht
py by
o Vo
♦ Stepladder - VAS 5085- by c lksw
cted agen
Prote AG.
♦ Torque wrench - V.A.G 1332-
♦ Guide pins - T10093-

52 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Caution

Proceed very carefully to prevent unnecessary dismantling or

further damage.

Note

♦ The battery earth must be disconnected for the remaining pro‐

cedure. Check whether a coded radio is fitted. Then obtain
anti-theft coding first if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.

Caution

satelettronica
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all hoses, pipes and cables so that they are in their
original positions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.

– Remove noise insulation ⇒ Generalenbody AG. Vorepairs,

lkswagen exterior;
AG do
Rep. gr. 50 ; Body - front, noise
olkswinsulation
ag . es n
ot V gu
by ara
– Lift engine cover paneloriat
se points -1- and pull it forwards in di‐
d
nte
rection of -arrow-. auth eo
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
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
co lksw
by
cted agen
Prote AG.

1. Removing and installing engine 53

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unbolt heat shield over turbocharger -arrows-.

– Remove air filter ⇒ page 342 .

WARNING

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 and close expansion tank cap to release pressure in

cooling system.
– Drain coolant ⇒ page 198 .

– Release retaining clip -arrow-.

– Pull off coolant hose -1- from radiator.
AG. Volkswagen AG d
agen oes
olksw not
V

satelettronica
by gu
d ara
Note orise nte
eo
th
au ra
s c
Pull coolant hoses off engine with hose clip pliers - VAS 6340- . s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

– Pull coolant hoses -arrows- off coolant expansion tank. t to the co

WARNING
rrectne

Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
ss

the connection before loosening hose connections. Then re‐

o
cial p

lease pressure by carefully pulling hose off connection.

inform
mer

atio
om

– Disconnect the fuel supply line -1- and line from activated
n
c

i
or

charcoal filter system solenoid valve 1 - N80- -2- on the clutch.

thi
te

sd
iva

o
pr

cum
r
fo

Note
en
ng

t.
yi Co
Cop py
t.
Press in securing ring to release fuel and breather lines.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release connector -2- and pull off.
– Unclip line from bracket -1-.
– Remove bracket -1- with fuel quality sender - G446- , un‐
screwing bolts -arrows- to do so.
– Release fuel lines on fuel quality sender - G446- and pull off
– Seal lines so that no dirt is able to enter fuel system.
– Observe rules for cleanliness ⇒ page 7 .
– Remove engine control unit - J623- ⇒ page 373 .

54 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger,
gen AG
supercharger)
. Volkswagen AG - Edition 02.2019
d wa oes
olks not
yV gu
– Open all line guide fasteners -arrows-. ed
b ara
nte
ris
ho eo
– Remove wiring from engine control unit. au
t ra
c
ss
– Secure lines/wiring to engine with a cable tie.

ce
e
nl

pt
du

an
itte
– Remove noise insulation ⇒ General body repairs, exterior;

y li
erm

ab
Rep. gr. 50 ; Body - front, noise insulation .

ility
ot p

wit
– Remove front left and right wheel housing liners ⇒ General

, is n

h re
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing

hole
and installing front wheel housing liner .

spec
es, in part or in w

t to the co
The engine is removed downwards together with the gearbox.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery

rrectness of i
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
l purpos

27 ; Battery; Removing and installing battery .

– All cable ties which are opened or cut through when engine is

nform
ercia

removed must be replaced in the same position when engine

m

is installed.

at
om

ion
c

– Disconnect all electrical wiring from gearbox, alternator and

in t
or

starter and lay to side.

his
e

satelettronica
at

do
priv

c
– Pull off or disconnect all other electrical connections as nec‐

um
for

essary from engine and lay to side.

en
ng

t.
yi Co
op
– Pull vacuum and breather hoses off engine.
C py
t. rig
gh ht
yri by
Vehicles with push-fit charge air hoses cop Vo
by lksw
cted agen
Prote AG.

– Release securing clip on right of charge air cooler in direction

of -arrow- and pull off hose -arrow-.
– Release and pull off charge air hose in same way on left-hand
side.

Vehicles with screw-type hose clips on charge air hoses

– Loosen screw-type hose clip -arrow-.
– Pull off charge air hose -1- on left of charge air cooler -2-.
– Loosen screw-type hose clip on right-hand side as well and
pull off charge air hose.
Continued for all vehicles

1. Removing and installing engine 55

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove wiring for Lambda probe after catalytic converter -

G130- and for alternator from cable guides -arrows-.
– Disconnect connector for Lambda probe after catalytic con‐ wagen AG. Volkswagen AG does
verter - G130- . olks not
yV gu b ara
ed nte
oris e
th 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
– Remove Lambda probe after catalytic converter - G130- -1-.
es, in part or in w

t to the co
– Open hose clip -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from catalytic converter -arrows-.

rrectness of i
l purpos

Caution

Risk of damage to flexible joint.

satelettronica
nform
ercia

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

m

at
om

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

in t
or

his
te

♦ Do not damage wire mesh on decoupling element.

a

do
priv

cum
for

en
ng

t.
yi Co
op py
– Release connectors -1- and pull off. t. C rig
gh ht
pyri by
– Unclip bracket -2- on subframe for electric wire to oil level and
o Vo
by c lksw
cted
oil temperature sender - G266- .
agen
Prote AG.

Vehicles with engine preheating element - Z97-

– Unclip locking mechanism -arrow-.
– Pull off wiring -1- on engine preheating element - Z97- -2-.

56 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unclip wire -1- to engine preheater heater element - Z97- on

charge air pipe -2- -arrow-.

Continued for all vehicles

– Disconnect pendulum support -arrows-.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
– Unscrew nuts -arrows orise A- on exhaust pipe -1-. nte
eo
th
u ra
– Push front exhaust
ss a
pipe -2- backwards out of mounting c
-arrows B -.
ce
le
un

pt
an
d

– Remove front exhaust pipe forwards.

itte

y li
erm

ab

Vehicles with manual gearbox

ility
ot p

wit
is n

– Unbolt selector mechanism from gearbox: ⇒ Rep. gr. 34 ;

h re
ole,

Repairing selector mechanism

spec
urposes, in part or in wh

– Remove slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ;

t to the co

Repairing clutch mechanism

rrectne

Note
ss

Do not depress clutch pedal.

o
cial p

f inform

– Remove right drive shaft; unbolt left drive shaft at gearbox,

mer

atio

raise and secure ⇒ Running gear, axles, steering; Rep. gr.

om

40 ; Repairing drive shafts; Removing and installing drive

n
c

i
or

shafts .
thi
te

sd
va

Vehicles with an automatic gearbox

i

o
pr

cum
r
fo

en
ng

– Remove selector lever cable ⇒ Rep. gr. 34 ; Removing and

t.
yi Co
installing selector lever cable . Cop py
t. rig
gh ht
yri
– Remove drive shafts ⇒ Running gear, axles, steering; Rep. p by
co Vo
gr. 40 ; Repairing drive shafts; Removing and installing drive
by lksw
cted agen
Prote
shafts .
AG.

1. Removing and installing engine 57

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Vehicles with auxiliary heater

– Disconnect coolant pipes -1- from cylinder block and remove.

Continued for all vehicles

– Undo and remove bolts -arrows- of cowling.
– Release connectors -1- and pull off.
– Remove cowling downwards.
Vehicles with air conditioning system
– Remove poly V-belt ⇒ page 75 .

satelettronica
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87

Note

The air conditioning system lines must not be opened.

– Secure air conditioner compressor to lock carrier. AG. Volkswagen AG d

agen oes
olksw not
V gu
– Make sure lines are not kinked. ed by ara
nte
ris
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Continued for all vehicles: aut ra
c
ss

ce
e
nl

– Unscrew bolts -arrows-. pt

du

an
itte

– Remove bracket -1-. y li

erm

ab
ility
ot p

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform

Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐
ercia

quired to lower engine with gearbox.

m

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ion
c

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or

his
ate

do
priv

cum
for

en
ng

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

58 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw adapter T40075A /4 into the crankcase to stop.

– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.

– Secure engine support - T40075A- hand-tight to crankcase

using bolt -1-.

satelettronica
– Tighten all bolts on the engine support - T40075A- to 20 Nm.
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- . agen
AG. Volkswagen AG d
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rise nte
Note utho eo
ra
s a c
s

ce
e

♦ To remove securing bolts of assembly mountings, use a step‐

nl

pt
du

ladder - VAS 5085- .

an
itte

y li
erm

ab
♦ Take different mountings of gearbox into account.

ility
ot p

wit
, is n

h re
hole

spec
– Unbolt engine side of assembly mounting from above
es, in part or in w

-arrows-.

t to the co
rrectness of i
l purpos

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

1. Removing and installing engine 59

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Assembly mountings on the gearbox side with 2 bolts at gearbox

– Unbolt gearbox side of assembly mounting from above
-arrows-.

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

ce
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nl

pt
du

an
itte

y li
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ab
Assembly mountings on the gearbox side with 3 bolts at gearbox

ility
ot p

– Unbolt gearbox side of assembly mounting from above

wit
, is n

h re
-arrows-.
hole

spec
es, in part or in w

t to the co
Note

When lifted out, the engine/gearbox assembly must be carefully

rrectness of i

satelettronica
guided to prevent damage to the bodywork.
l purpos

– Carefully lower engine and gearbox.

nf
ercia

Secure engine to engine and gearbox support - VAS 6095- to

orm
carry out repairs.
m

atio
om

– Unbolt gearbox.

n in
or c

thi
e

– Secure engine on engine and gearbox support - VAS 6095- .

t

sd
iva

o
r
rp

cu
o

m
f

1.10 Installing engine (Passat, Passat CC)

en
ng

t.
yi Co
Cop py
t. rig
Install in reverse order of removal. When doing this, observe the yri
gh by
ht
following: cop Vo
by lksw
cted agen
Prote AG.

Caution

When performing any repair work, especially in the engine

compartment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure clearance between lines and moving or hot com‐
ponents.

Vehicles with manual gearbox

– Check clutch release bearing for wear and renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100.
Continued for all vehicles
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.

60 Rep. gr.10 - Removing and installing engine

 agen G olksw
Eos 2006 ➤ , Golf 2009sw➤ ag,enGolf Cabriolet A2012
AG. V does➤ , Golf Plus 2005 ➤ , ...
olk not
4-cylinder direct-injection engine (1.4 dl,byEA 111, turbocharger, supercharger)
V gu
a - Edition 02.2019
e ran
ris tee
– Hook intermediate plate onto sealinguthoflange and slide onto or
a ac
dowel sleeves -arrows-. ss

ce
le
un

pt
– Bolt on gearbox.

an
d
itte

y li
erm

ab
Align engine mountings as follows

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
♦ There must be a distance -a- of at least 10 mm between engine

ss
support and longitudinal member (right side).

o
cial p

f in
♦ The side surface of the engine support -2- should be located

form
mer

parallel to the support arm -1-.

atio
om

n
c

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or

n thi
te

sd
iva

o
pr

satelettronica
um
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fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
Align gearbox mountings as follows in the case of a gearbox
brackets with 2 bolts on the gearbox
♦ Ensure that edges of support arm -2- and gearbox bracket
-1- are parallel.

1. Removing and installing engine 61

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Align gearbox mounting as follows if gearbox bracket is secured

to gearbox by three bolts.
♦ Ensure that edges of support arm -2- and gearbox bracket
-1- are parallel.
– Install the pendulum support.

Note

Specified torques for assembly mountings ⇒ page 67 .

Vehicles with manual gearbox

– Install slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ; Re‐
pairing clutch mechanism .
– Mount selector mechanism: ⇒ Rep. gr. 34 ; Repairing selector
mechanism .
Vehicles with an automatic gearbox
– Install selector lever cable: ⇒ Automatic gearbox 09M; Rep.
gr. 34 ; Removing and installing selector lever cable

satelettronica
Vehicles with air conditioning system
– Install air conditioner compressor: ⇒ Heating, air conditioning
system; Rep. gr. 87 .
– Install poly V-belt ⇒ page 75 .
Continued for all vehicles
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
– Install catalytic converter and exhaust pipe.
Specified torques for exhaust system ⇒ page 422
Vehicles with screw-type hose clips on charge air hoses agen
AG. Volkswagen AG d
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Caution horise nte
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ut ra
s a c
The screw-type clips on the charge air pipes must be tightened s
ce
le

to 5.5 Nm. If the torque is too low or too high, the charge air
un

pt
an
d

hose may slip off the charge air pipe during vehicle operation.
itte

y li
erm

ab
ility
ot p

wit
is n

Vehicles with push-fit charge air hoses

h re
ole,

spec
urposes, in part or in wh

Note
t to the co

Note installation of charge air hoses.

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.
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Cop py
t. rig
gh ht
yri by

62
cop Vo
by lksw
Rep. gr.10 - Removing and installing engine Prote
cted AG.
agen
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– If oil seal is renewed, place seal in groove of charge air hose.

Ensure that seal is correctly seated around groove and is not
twisted.
– Coat sealing surface and oil seal with oil. AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Bring retaining clip to release position e d -1-.
b ara
nte
ris
ho eo
– Push charge air hose into couplingaut as far as stop. ra
c
ss
– Bring retaining clip to locking position -2- and then press

ce
le
un

pt
charge air hose again.

an
d
itte

y li
rm

ab
– Pull on hose to ensure that plug-in connector is properly seat‐
pe

ility
ed and engaged.
ot

wit
, is n

h re
Continued for all vehicles
hole

spec
– Install noise insulation or skid plate ⇒ General body repairs,
es, in part or in w

exterior; Rep. gr. 50 ; Removing and installing noise insulation

t to the co
or skid plate .
– Electrical connections and routing ⇒ Electrical system; Rep.

rrectness of i
gr. 97 .
l purpos

– Add coolant ⇒ page 198 .

satelettronica
– Install air filter ⇒ page 342 .

nform
ercia

– Install battery and battery tray ⇒ Electrical system; Rep. gr.

m

a
27 ; Removing and installing battery .
com

tion in
r
te o

– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

thi
s
necting and reconnecting battery .
iva

do
r
rp

cum
fo

en
g

– Push engine cover panel down at points -1- in direction of

n

t.
yi Co
-arrow- until it engages. Cop py
ht. rig
rig ht
– Connect vehicle diagnostic tester . py by
co Vo
by lksw
cted agen
– Erase learnt values and adapt engine control unit to throttle Prote AG.
valve module ⇒ Vehicle diagnostic tester “Guided functions”.
– Perform vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
ded fault finding”.
– Finish vehicle system test so that any event entries stored
during assembly can be cleared automatically.
Note safety precautions applicable to a road test.
– Perform road test.
– Then carry out vehicle system test again and rectify any faults
which have occurred.

1. Removing and installing engine 63

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings (Touran, Golf
Plus, Eos, Scirocco, Golf, Golf Cabriolet)”, page 64
⇒ “2.2 Assembly overview - assembly mountings (Tiguan)”, page
65
⇒ “2.3 Assembly overview - assembly mountings (Polo)”,
page 66
⇒ “2.4 Assembly overview - assembly mountings (Sharan)”, page
67
⇒ “2.5 Assembly overview - assembly mountings (Passat, Passat
CC)”, page 67

2.1 Assembly overview - assembly mount‐

ings (Touran, Golf Plus, Eos, Scirocco,
Golf, Golf Cabriolet)

Note

satelettronica
AG. Volkswagen AG d
agen oes
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The securing bolts for the assemblyby
Vol
mountings are stretch bolts not
gu
and must be renewed. rised ara
nte
ho eo
aut ra
s c
Engine mounting s
ce
le
un

pt

A 1) = 20 Nm + 90° (1/4 turn) further

an
d
itte

y li
rm

ab

B 1) = 40 Nm + 90° (1/4 turn) further

pe

ility
ot

wit
, is n

C 1) = 60 Nm + 90° (1/4 turn) further

h re
hole

spec

1) Renew
es, in part or in w

t to the co
rrectness of i
l purpos

Gearbox mounting
nform
ercia

A 1) = 40 Nm + 90° (1/4 turn) further

m

a
com

B 1) = 60 Nm + 90° (1/4 turn) further

ion in
r
te o

thi

1) Renew
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.

64 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Pendulum support
A 1) = property class 8.8 = 40 Nm + 90° (1/4 turn) further
A 1) = property class 10.9 = 50 Nm + 90° (1/4 turn) further
B 1) = 100 Nm + 90° (1/4 turn) further
1) Renew

2.2 Assembly overview - assembly mount‐

ings (Tiguan)

Note

Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.

satelettronica
Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further

B 1) = 40 Nm + 90° (1/4 turn) further

C 1) = 60 Nm + 90° (1/4 turn) further

1) Renew
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
Gearbox mounting

ce
le
un

pt
an
d
itte

A 1) = 60 Nm + 90° (1/4 turn) further

y li
rm

ab
pe

ility
B 1) = 40 Nm + 90° (1/4 turn) further
ot

wit
, is n

h re
1) Renew
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Pendulum support
nform
ercia

A Bolt M10 1) = 50 Nm + 90° (1/4 turn) further

m

a
com

tion in

A Bolt M12 1) = 60 Nm + 90° (1/4 turn) further

r
te o

thi
s
iva

B Bolt M10 1) = 50 Nm + 90° (1/4 turn) further

do
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rp

cum
fo

en
g

B Bolt M12 1) = 60 Nm + 90° (1/4 turn) further

n

t.
yi Co
Cop py
t. rig
C 1) = 100 Nm + 90° (1/4 turn) further gh ht
pyri by
Vo
co lksw
by
1) Renew
cted agen
Prote AG.

2. Assembly mountings 65
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.3 Assembly overview - assembly mount‐

ings (Polo)

Note

Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.

Caution

Nut -arrow- must not be loosened.

Engine mounting
A = 20 Nm + turn 90° further
B = 30 Nm + turn 90° further
AG. Volkswagen AG d
agen oes
ksw not

satelettronica
Vol
by gu
d ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
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itte

y li
erm

ab
ility
ot p

wit
is n

Gearbox mounting

h re
ole,

A = 40 Nm + turn 90° further

spec
urposes, in part or in wh

t to the co
B = 50 Nm + turn 90° further
C = 50 Nm + turn 90° further

rrectne
Caution

ss o
Bolt -arrow- must not be loosened.
cial p

f inform
mer

atio
om

n
c

i
or

Pendulum support
thi
te

sd
iva

A = 30 Nm + turn 90° further

o
pr

cum
r
fo

en
ng

B = 40 Nm + turn 90° further

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

66 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.4 Assembly overview - assembly mount‐

ings (Sharan)

Note

Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.

Engine mounting wage

n AG. Volkswagen AG do
es n
olks ot g
yV
A 1) = 20 Nm + 90° (1/4 turn) furtherd b ua
ran
ir se tee
tho
or
B 1) = 40 Nm + 90° (1/4 turn)
ss
au
further ac

ce
le

C 1) = 60 Nm + 90° (1/4 turn) further

un

pt
an
d
itte

y li
erm

1)

ab
Renew

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

satelettronica
t to the co
Gearbox mounting

rrectne
A 1) = 60 Nm + 90° (1/4 turn) further

B 1) = 40 Nm + 90° (1/4 turn) further

ss o
cial p

f i
1)

n
Renew

form
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

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ng

t.
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op py
Pendulum support
t. C rig
gh ht
pyri by
Vo
o
A Bolt M10 1) = 50 Nm + 90° (1/4 turn) further
c by lksw
cted agen
Prote AG.

A Bolt M12 1) = 60 Nm + 90° (1/4 turn) further

B Bolt M10 1) = 50 Nm + 90° (1/4 turn) further

B Bolt M12 1) = 60 Nm + 90° (1/4 turn) further

C 1) = 100 Nm + 90° (1/4 turn) further

1) Renew

2.5 Assembly overview - assembly mount‐

ings (Passat, Passat CC)

Note

Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.

2. Assembly mountings 67
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further

B 1) = 40 Nm + 90° (1/4 turn) further

C 1) = 60 Nm + 90° (1/4 turn) further

1) Renew
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Assembly mountings with 2 bolts on gearbox

ce
e
nl

pt
du

an
A 1) = 40 Nm + 90° further
itte

y li
erm

ab
ility
B 1) = 60 Nm + 90° further
ot p

wit
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1)

h re
Renew
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

Assembly mountings with 3 bolts on gearbox nform

ercia

A 1) = 60 Nm + 90° (1/4 turn) further

m

at
om

io

B 1) = 40 Nm + 90° (1/4 turn) further

n
c

in t
or

his
te

1)
a

Renew
do
priv

cum
for

en
ng

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

Pendulum support
A Bolt M10 1) = 50 Nm + 90° (1/4 turn) further

A Bolt M12 1) = 60 Nm + 90° (1/4 turn) further

B Bolt M10 1) = 50 Nm + 90° (1/4 turn) further

B Bolt M12 1) = 60 Nm + 90° (1/4 turn) further

C Bolt M10 1) = 100 Nm + 90° (1/4 turn) further

1) Renew

68 Rep. gr.10 - Removing and installing engine

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

13 – Crankshaft group
1 Cylinder block (pulley end)

Note

♦ If metal shavings or larger quantities of metal particles or other

deposits (caused for example, by partial seizure of the conrod
bearings) are found in the engine oil when making repairs,
clean the oil passages thoroughly and renew the oil filter in
order to prevent further damage from occurring later.
♦ Oil all bearing and running surfaces before assembly.

Note

Secure engine on engine and gearbox support - VAS 6095- to

carry out repairs.

satelettronica
⇒ “1.1 Assembly overview - poly V-belt drive”, page 71
⇒ “1.2 Assembly overview - cylinder block, belt pulley end”, page
73
⇒ “1.3 Removing and installing poly V-belt (Golf Plus, Eos, Scir‐
occo, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cab‐
riolet)”, page 75
⇒ “1.4 Removing and installing poly V-belt (Tiguan)”, page 78 AG. Volkswagen AG d
agen oes
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⇒ “1.5 Removing and installing bracket for ancillaries”, d by Vo gu
ara
page 80 orise nte
eo
th
u ra
⇒ “1.6 Renewing crankshaft oil seal - pulley end”, spage
sa 81 c

ce
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nl

⇒ “1.7 Removing and installing crankshaft pulley”, page 83

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Part II ⇒ page 73

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1. Cylinder block (pulley end) 69

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

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70 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.1 Assembly overview - poly V-belt drive

1 - 40 Nm + 1/4 turn (90°) fur‐

ther
❑ To loosen and tighten
securing bolt, counter‐
hold supercharger shaft
with 16 mm spanner.
❑ Renew
2 - Belt pulley
❑ For supercharger
3 - 23 Nm
4 - Tensioning element
❑ For supercharger poly
V-belt
❑ Relieve tension using
16 mm spanner.
❑ Lock with locking pin -

satelettronica
T10060 A- .
5 - 8 Nm
6 - Coolant pump with magnet‐
ic clutch for supercharger -
N421-
❑ Removing and installing
(Golf, Golf Plus, Eos,
Polo, Tiguan, Touran,
Scirocco, Golf Cabrio‐
let) ⇒ page 214
❑ Removing and installing AG. Volkswagen AG d
(Sharan) ⇒ page 225 agen oes
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❑ Removing and installing ise
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(Passat, Passat CC) thor eo
⇒ page 242 ss au ra
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❑ Removing and installing
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coolant pump belt pulley

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(Golf, Golf Plus, Eos, Polo, Tiguan, Touran, Scirocco, Golf Cabriolet) ⇒ page 218
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❑ Removing and installing coolant pump belt pulley (Sharan) ⇒ page 230
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❑ Removing and installing coolant pump belt pulley (Passat, Passat CC) ⇒ page 236
h re
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spec

7 - 23 Nm
es, in part or in w

t to the co

8 - Tensioning element
❑ For poly V-belt.
❑ Release tension using open-end spanner 16 mm - T10447-
rrectness of i

❑ Lock with locking pin - T10060 A- .

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Note
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♦ Vehicles with a manual gearbox:

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idler roller installed instead of

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tensioning element.
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bolt: 40 Nm.
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1. Cylinder block (pulley end) 71

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

9 - 23 Nm
10 - Alternator
11 - Belt pulley
❑ For crankshaft
❑ With diamond coated washer
❑ Observe note on diamond coated washers ⇒ page 82 .
❑ Contact surfaces must be free of oil and grease.
12 - Securing bolt
❑ Removing and installing crankshaft pulley ⇒ page 83
❑ Renew
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.
❑ Secure belt pulley against turning with counterhold - 3415- .
❑ Turning further can be done in several stages.
❑ The turning further angle can be measured with a commercial protractor.
13 - 40 Nm + 1/4 turn (90°) further

satelettronica
❑ Removing and installing with vehicle raised
❑ Renew
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15 - 23 Nm orise nte
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❑ For poly V-belt.

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❑ Relieve tension with spanner.

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❑ Lock with 4 mm Allen key.

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17 - Poly V-belt

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❑ Mark direction of rotation before removing.

spec
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t to the co
Caution
When installing poly V-
belt, observe direction of rrectness of i
rotation and make sure it
l purpos

is properly seated on pul‐

leys and tensioning ele‐
ments.
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❑ Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Sharan, Passat, Passat CC,
o

n in
c

Golf Cabriolet) ⇒ page 75

or

thi
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❑ Removing and installing poly V-belt (Tiguan) ⇒ page 78

iva

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18 - Poly V-belt
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❑ For supercharger
Co
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❑ Mark direction of rotation before removing. gh ht
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Caution
When installing poly V-
belt, observe direction of
rotation and make sure it
is properly seated on pul‐
leys and tensioning ele‐
ments.

72 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.2 Assembly overview - cylinder block, belt pulley end

1 - Cylinder head with cam‐

shaft housing
❑ Removing and installing
⇒ page 116
❑ Do not rework sealing
surface.
❑ With integrated cam‐
shaft bearings.
❑ Remove sealant resi‐
due.
❑ When installing, insert
vertically from above so
that dowel pins fit into
holes in cylinder head
2 - Cylinder block
❑ Dismantling and assem‐
bling cylinder block wage
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⇒ page 87 . yV
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rods ⇒ page 101 ss

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3 - Ancillary bracket

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❑ For tensioning element
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❑ Removing and installing
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⇒ page 80
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4 - Cover
5 - Sprocket

rrectness of i
❑ For oil pump drive and
timing chain.
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❑ Contact surfaces must

be free of oil and grease.

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6 - 20 Nm + 1/4 turn (90°) further

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❑ Renew tion in
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7 - Sprocket
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❑ Lock chain sprocket using counterhold - T10172- .

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8 - Drive chain
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❑ Before removing, mark direction of rotation (installation position). t. C rig
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9 - 25 Nm
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10 - Locating pin for chain tensioner
❑ Specified torque: 8 Nm
11 - Chain tensioner with tensioning rail
❑ For oil pump drive.
❑ Specified torque: 8 Nm
12 - Spring
13 - Sump
❑ Removing and installing ⇒ page 171
❑ Clean sealing surface before fitting.

1. Cylinder block (pulley end) 73

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
❑ Install with silicone sealant - D 176 600 A1- .
14 - 13 Nm
15 - Piston
❑ For drive chain tensioner
16 - Compression spring
17 - Chain tensioner
18 - 9 Nm
19 - Valve timing housing
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❑ Additionally install edwith
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❑ To facilitate aguidance
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on installation, screw two “M6x80” studs e o into camshaft housing and cylinder block.
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❑ To guide valve
s timing housing, secure sump in position with two bolts.

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20 - 10 Nm

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21 - Belt pulley

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❑ With diamond coated washer

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❑ Observe note on diamond coated washers ⇒ page 82 .

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❑ Note tightening sequence ⇒ page 83 .
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t to the co
❑ Contact surfaces must be free of oil and grease.
❑ Secure belt pulley against turning with counterhold - 3415- .
❑ Removing and installing ⇒ page 83
22 - Securing bolt rrectness of i
l purpos

❑ Removing and installing crankshaft pulley ⇒ page 83

nform
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❑ Renew
❑ Contact surface for securing bolt must be free of oil and grease.
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❑ Oil threads before inserting.

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❑ Secure belt pulley against turning with counterhold - 3415- .

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❑ The turning further angle can be measured with a commercial protractor.

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23 - Bearing bush
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❑ Contact surfaces must be free of oil and grease.
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24 - O-ring
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❑ Renew
Prote AG.

25 - 50 Nm
26 - Seal
27 - 40 Nm + 1/4 turn (90°) further
❑ Lock sprockets using counterhold - T10172- .
❑ Bolt with left-hand thread.
❑ Renew
28 - 50 Nm + 1/4 turn (90°) further
❑ Renew
29 - Tensioning rail
30 - Camshaft adjuster
❑ Removing and installing ⇒ page 145
❑ Must not be dismantled.
31 - Timing chain
❑ Removing and installing ⇒ page 159

74 Rep. gr.13 - Crankshaft group

 AG. Volkswagen AG d
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4-cylinder direct-injection engine (1.4
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32 - Sprocket

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❑ Removing and installing ⇒ page 159

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❑ For exhaust camshaft

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❑ Lock sprockets using counterhold -T10172- .

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33 - Slide rail

es, in part or in w
❑ For timing chain

t to the co
34 - Guide pin
❑ Specified torque: 20 Nm

rrectness of i
35 - Bearing bush
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1.3 Removing and installing poly V-belt

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t
(Golf Plus, Eos, Scirocco, Golf, Touran,

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Polo, Sharan, Passat, Passat CC, Golf

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Special tools and workshop equipment required

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♦ Locking pin - T10060 A-
ht rig
rig ht
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♦ 16 mm open-end spanner - T10447- (not shown)

♦ 4 mm Allen key
Removing

Note

The belt drive can be fitted with a tensioning element and an idler
roller or with two tensioning elements.

– Remove noise insulation.

– Mark direction of rotation of poly V-belt.

1. Cylinder block (pulley end) 75

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Polo only
– Press filler neck for windscreen washer fluid out of bracket in
-direction of arrow-.
Sharan only
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– Open retaining clip of refrigerant line -arrow-.
hole

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es, in part or in w

Vehicles with two tensioning elements

t to the co
rrectness of i

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tion in
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– To slacken poly V-belt, swivel tensioning element in direction

do
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rp

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of -arrow- from above using 16 mm open-end spanner -

um
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T10447- .

en
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t.
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– Lock tensioning element using locking pin - T10060 A- .
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ht ht
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Continued for all vehicles
co Vo
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Prote AG.

76 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– To slacken poly V-belt, swing tensioning element in direction

of -arrow- from below using 16 mm open-end spanner.
– Lock tensioning element with a 4 mm Allen key -1-.
– Remove poly V-belt -2-.
Installing

Caution

Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
When installing poly V-belt, observe
AG. Volkswagendirection
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agenseated on pulleys
make sure it is properly and
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– Fit poly V-belt first over crankshaft pulley. Finally, push belt

ce
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onto tensioning roller.

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Further assembly is basically a reverse of the dismantling se‐
rm

ab
quence.
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After completing repairs:

h re
hole

spec
– Start engine, and check if belt runs properly.
es, in part or in w

t to the co
1.3.1 Poly V-belt routing rrectness of i

Belt drive with air conditioner compressor

1 - Pulley - cooling system pump
l purpos

2 - Crankshaft pulley
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3 - Tensioning pulley
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4 - Tensioning roller or idler roller

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5 - Alternator pulley
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6 - Air conditioner compressor pulley

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7 - Poly V-belt
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t.
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Belt drive for supercharger
co Vo
by lksw
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Prote AG.

Note

♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .

1 - Supercharger pulley
2 - Tensioning pulley
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt

1. Cylinder block (pulley end) 77

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.4 Removing and installing poly V-belt (Ti‐

guan) swagen AG. Volkswagen AG does
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Special tools and by
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se ri nte
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♦ Locking pin
au - T10060 A-
t ra
c
ss

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spec
es, in part or in w

t to the co
rrectness of i
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♦ 16 mm open-end spanner - T10447- (not shown)

♦ 4 mm Allen key

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Removing
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Note
s
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Two tensioning elements must be slackened to remove poly V-

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t.
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belt.
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– Drain coolant; to do this, pull hose -2- off.
op Vo
by c lksw
cted agen
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Item -1- can be disregarded.
AG.

– Release retaining clip and pull right connection (as seen in

direction of travel) off radiator.
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Mark direction of rotation of poly V-belt.

– To slacken poly V-belt, swivel tensioning element in direction

of -arrow- from above using 16 mm open-end spanner -
T10447- .
– Lock tensioning element using locking pin - T10060 A- .

78 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– To slacken poly V-belt, swing tensioning element in direction

of -arrow- from below using 16 mm open-end spanner.
– Lock tensioning element with a 4 mm Allen key -1-.
– Remove poly V-belt -2-.
Installing

Caution

Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
When installing poly V-belt, observe direction of rotation and
make sure it is properly seated on pulleys and tensioning ele‐
ments.

olksw
– Fit poly V-belt first over crankshaftswpulley.
agen
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push dbelt
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Further assembly is basically
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ri e or
quence. sa
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s

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Add coolant ⇒ page 185 .

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After completing repairs:
rm

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– Start engine, and check if belt runs properly.
ot

wit
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1.4.1 Poly V-belt routing

spec
es, in part or in w

t to the co
Belt drive with air conditioner compressor
1 - Pulley - cooling system pump
2 - Crankshaft pulley rrectness of i
l purpos

3 - Tensioning pulley
4 - Tensioning pulley
nform
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5 - Alternator pulley
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6 - Air conditioner compressor pulley

n in
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thi

7 - Poly V-belt
s
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en
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Belt drive for supercharger

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

♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .

1 - Supercharger pulley
2 - Tensioning pulley
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt

1. Cylinder block (pulley end) 79

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.5 Removing and installing bracket for an‐

cillaries
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
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Removing
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Tiguan

spec

satelettronica
es, in part or in w

– Depending on vehicle equipment, remove noise insulation or

t to the co
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .

rrectness of i
Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat,
Passat CC, Golf Cabriolet
l purpos

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front, noise insulation .

nf
ercia

orm
Continued for all vehicles
m

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om

n in
– Remove poly V-belt (Tiguan) ⇒ page 78 .
or c

thi
te

– Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran,

sd
iva

o
r

Polo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75

rp

cu
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f

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ng

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐

t.
yi Co
op
ing and installing alternator . C py
t. rig
gh ht
yri by
– Remove air conditioner compressor ⇒ Heating, air condition‐ cop Vo
by lksw
ing; Rep. gr. 87 cted agen
Prote AG.

Note

The air conditioning system lines must not be opened.

– Secure air conditioner compressor to lock carrier.

– Ensure that lines are not kinked.
– Unscrew securing bolts -1- and remove bracket.
Installing
– Fit ancillary bracket to cylinder block.

80 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Tighten securing bolts -1- to 25 Nm.

Specified torque for tensioning element ⇒ Item 13 (page 72)
Further assembly is basically a reverse of the dismantling se‐
quence.

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1.6 Renewing crankshaft oil seal - pulley end
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Special tools and workshop
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equipment required

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urposes, in part or in wh

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♦ Seal puller - 3203-

♦ Torque wrench - V.A.G 1332-
♦ Assembly sleeve - T10117/2-
♦ Assembly tool - T10053-

1. Cylinder block (pulley end) 81

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
Tiguan
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat,
Passat CC, Golf Cabriolet
– Remove noise insulation.
Continued for all vehicles
– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
– Remove poly V-belt (Tiguan) ⇒ page 78 .
– Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran,
Polo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .
– Removing and installing crankshaft pulley ⇒ page 83 .
– Unscrew inner part of oil seal extractor - 3203- 3 turns (approx.

satelettronica
5 mm) from the outer part and lock in position with the knurled
n AG. Volkswagen AG do
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– Lubricate threaded head of oil seal extractor,ris place it in posi‐
ed nte
tion and, exerting firm pressure, screw itutinto oil seal as far as
ho eo
ra
possible. ss
a c

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– Loosen knurled screw and turn inner part against crankshaft

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an
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until the oil seal is pulled out.

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erm

ab
– Remove bearing bush from crankshaft journal and clean con‐

ility
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tact surfaces of crankshaft sprocket and bearing bush.

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Installing

spec
urposes, in part or in wh

t to the co
Note

♦ From model year 2009, a diamond coated washer is installed. rrectne

The washer prevent the crankshaft from being turned when
the securing bolt is tightened.
ss o
cial p

♦ Install a diamond coated washer -7- when a washer was not

inform

fitted as original equipment ⇒ Electronic Parts Catalogue “ET‐

mer

KA”.
atio
om

♦ The washer is fitted -7- between the bearing bush -5- and the
c

i
or

crankshaft sprocket.
thi
te

sd
iva

♦ Note that all contact surfaces from the securing bolt to the
pr

cum
r
fo

crankshaft sprocket must be free of oil and grease.

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82 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Clean sealing surfaces carefully. They must be free of oil and

grease.
1 - Securing bolt
2 - Crankshaft belt pulley
3 - Diamond coated washer (clipped onto crankshaft belt pulley)
4 - Crankshaft oil seal
5 - Bearing bush
6 - O-ring
7 - Diamond coated washer . Volkswagen AG
gen AG does
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– Push bearing bush onto ycrankshaft
Volk journal. not
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– Fit sleeve -T10117/2-
aut
h
onto bush and slide oil seal onto bush. ra
ss c
– Remove sleeve -T10117/2- from bush.

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, is n

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es, in part or in w

t to the co
rrectness of i
l purpos

– Using assembly tool - T10053- , drive in oil seal into valve tim‐
ing housing as far as it will go with even blows of hammer.
nf
ercia

Further assembly is basically a reverse of the dismantling se‐

or

quence.
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1.7 Removing and installing crankshaft pulley

1. Cylinder block (pulley end) 83

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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ss c

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ility
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spec
es, in part or in w

t to the co
rrectness of i
♦ Torque wrench - V.A.G 1601-
l purpos

♦ Counterhold tool - 3415-

nf
ercia

♦ Pin - 3415/1- (not illustrated) orm

m

atio

♦ Locating bolt - T10340-

om

n in
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♦ Torque wrench - V.A.G 1331-

or

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cted agen
Prote AG.

84 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Dial gauge - VAS 6079-

♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170
A-

Note

If the dial gauge adapter - T10170 A- is used, the ball head does
not need to be unscrewed from the dial gauge - VAS 6079- . The
ball head is fitted onto the flat side of the rod.

Removing
– Removing poly V-belt (Tiguan) ⇒ page 78 .
– Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran,
Polo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .
Only Tiguan with all-wheel drive
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
drive shafts .

satelettronica
Continued for all vehicles

– Loosen pulley securing bolt. Hold pulley

agen
AG. Vowith
lkswacounterhold
gen AG
does -
3415- and -3415/1- . V olksw not
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db ran
Installing rise tee
tho or
au
– Tighten pulley hand-tight
ss using a new securing bolt. ac
ce
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nl

pt
du

an
itte

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ab
ility
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wit
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hole

spec
es, in part or in w

t to the co

– Turn crankshaft in direction of engine rotation to TDC for No.

1 cylinder.
rrectness of i
l purpos

nf
ercia

orm
m

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thi
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1. Cylinder block (pulley end) 85

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew plug from crankcase.

– Screw locking pin - T10340- to stop into crankcase.
– Tighten locking pin - T10340- to 30 Nm.

AG. Volkswagen AG d
agen oes
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Locking pin - T10340- locks crankshaft in direction of engine ro‐
erm

ab
tation.

ility
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wit
, is n

h re
hole

Note

spec
es, in part or in w

t to the co
♦ Note that all contact surfaces from the securing bolt to the
crankshaft sprocket must be free of oil and grease.

satelettronica
♦ Always use a new bolt.

rrectness of i
l purpos

Specified torque: 150 Nm + 1/2 turn (180°) further.

Hold pulley with counterhold - 3415- and -3415/1- .

nform
mercia

at
om

– Unscrew locking pin - T10340- from crankcase.

ion
c

in t
or

– Screw plug into crankcase.

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ate

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Specified torque: 30 Nm
– Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Po‐
lo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .
– Install poly V-belt (Tiguan) ⇒ page 78 .
Further assembly is basically a reverse of the dismantling se‐
quence.

86 Rep. gr.13 - Crankshaft group

 . Volkswagen AG
gen AG does
swa
Eos 2006 ➤ , Golf 2009 ➤ , Golf y V Cabriolet 2012 ➤ , Golf Plus 2005
olk not
gu ➤ , ...
b ara
4-cylinder direct-injection engine (1.4 l, EA 111,risturbocharger, supercharger) - Edition 02.2019
ed
nte
ho eo
aut ra
ss c
2 Cylinder block, gearbox end

ce
le
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pt
an
d
itte

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⇒ “2.1 Assembly overview - cylinder block, gearbox end”,

erm

ab
page 87

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wit
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⇒ “2.2 Removing and installing sealing flange on gearbox side”,

h re
ole,
page 89

spec
urposes, in part or in wh
2.1 Assembly overview - cylinder block,

t to the co
gearbox end

rrectne
Note

ss o
cial p
Repairing clutch ⇒ Repairing clutch; Rep. gr. 30 ; Removing and

f in
installing clutch .

form
mer

atio
om

n
c

i
or

n
1 - Securing bolt

thi
te

sd
va

❑ Removing and installing

i

o
pr

cum
crankshaft pulley
r
fo

satelettronica
en
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⇒ page 83
t.
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op
❑ Renew
C py
ht. rig
rig ht
❑ Contact surface for se‐
py by
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curing bolt must be free Prote
cted AG.
agen
of oil and grease.
❑ Oil threads before in‐
serting.
❑ Secure belt pulley
against turning with
counterhold - 3415- .
❑ The turning further an‐
gle can be measured
with a commercial pro‐
tractor.
2 - Belt pulley
❑ With diamond coated
washer
❑ Contact surfaces must
be free of oil and grease.
❑ Secure against turning
with counterhold - 3415-
when removing and in‐
stalling
❑ Remove poly V-belt (Ti‐
guan) ⇒ page 78 .
❑ Remove poly V-belt
(Golf Plus, Eos, Sciroc‐
co, Golf, Touran, Polo,
Sharan, Passat, Passat
CC, Golf Cabriolet)
⇒ page 75
3 - Seal
❑ Renew
4 - Bearing bush
❑ Contact surfaces must be free of oil and grease.
5 - O-ring
❑ Renew

2. Cylinder block, gearbox end 87

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

6 - Cylinder block
❑ Removing and installing ⇒ page 116
7 - 60 Nm + 1/4 turn (90°) further
❑ Renew
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold - T10044- .
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage when assembling.
10 - 12 Nm
❑ Renew
11 - Sealing flange with sender wheel and oil seal
❑ Removing and installing engine speed sender AG-. VG28-
olkswa(not
gen Ashown) ⇒ page 431 .
agen G do
es n
❑ Specified torque for engine speedysender olksw - G28- : 5 Nm. ot gu
V
db ar
❑ Renew sealing flange complete orise with oil seal and sender wheel only. ante
eo
h
❑ Renewing crankshaft sealing ut flange - flywheel end ⇒ page 89 . ra
sa

satelettronica
c s

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e
nl

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ility
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es, in part or in w

t to the co
rrectness of i
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Prote AG.

88 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
AG. Volkswagen n AG do
wage es n
olks ot g
2.2 Removing and installing sealing flange on gearbox side
V
by ua
ed ran
oris tee
th or
au ac
ss
Special tools and workshop

ce
e
nl
equipment required

pt
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erm

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ility
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spec
es, in part or in w

t to the co
rrectness of i
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orm
m

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satelettronica
thi
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sd
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♦ Assembly tool - T10134-

♦ Torque wrench - V.A.G 1331-
♦ Tool insert 24 mm - V.A.G 1332/11-
♦ 3 hexagon bolts M6 x 35 mm
♦ Feeler gauge
♦ Depth gauge

2.2.1 Pressing sealing flange with sender

wheel off crankshaft

Note

♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.

2. Cylinder block, gearbox end 89

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Procedure
– Remove flywheel or drive plate ⇒ Item 8 (page 88) .
– Set engine to TDC No. 1 cylinder ⇒ page 143 .
– Remove sump ⇒ page 171 .
– Remove engine speed sender - G28- -arrow-.
– Unscrew sealing flange securing bolts.

Note

Sealing flange and sender wheel are pressedAG. Voff

olksthe
wagcrankshaft
en AG
agen
together with 3 M6 × 35 mm bolts.
V olksw
does
not
y gu
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tho eo
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c
ss

ce
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pt
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d
itte

y li
– Screw three M6×35 mm bolts into threaded holes -arrows- of
erm

ab
sealing flange.

ility
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satelettronica
wit
is n

– Screw bolts alternately (max. 1/2 turn (180°) for each bolt) into

h re
ole,

sealing flange and press sealing flange together with sender

spec
urposes, in part or in wh

wheel off crankshaft.

t to the co
rrectness o
cial p

f inform
mer

2.2.2 Pressing sealing flange with sender

atio
om

n
c

wheel onto crankshaft

i
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Note
en
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t.
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♦ The sealing flange with a PTFE seal is equipped with a sealing
t. rig
gh ht
yri
lip support ring. This support ring serves as a fitting sleeve and
p by
o Vo
by c lksw
must not be removed prior to installation. Prote
cted AG.
agen

♦ Do not separate or turn the sealing flange and sender wheel

after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.

90 Rep. gr.13 - Crankshaft group

 n AEos
G. Vo2006
lkswage➤
n A,GGolf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
wage do
4-cylinderVdirect-injection
olks engine (1.4el,s nEA
ot g 111, turbocharger, supercharger) - Edition 02.2019
y ua
db ran
rise tee
Assembly thotool - T10134- or
s au ac
A - Clamping surface
s

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nl

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B - Hexagon nut

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C - Assembly housing

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D - Locating pin
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hole

E - Hexagon socket head bolt

spec
es, in part or in w

F - Guide pin for diesel engines (black knob)

t to the co
G - Guide pin for petrol engines (red knob)

rrectness of i
2.2.3 A - Assemble seal with sender wheel on
l purpos

assembly tool - T10134- .

nf
ercia

o
– Screw in hexagon nut -B- to just before clamping surface -A-

rm
m

of threaded spindle.

atio
om

n in
or c

thi
te

sd
iva

satelettronica
o
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pyri by
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by
cted agen
Prote AG.

– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards so that it lies on hex‐
agon nut -B- -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.

– Remove securing clip -arrow- from new sealing flange.

Note

Do not remove the sender wheel from the sealing flange or turn
it.

2. Cylinder block, gearbox end 91

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
– Push sealing lip support ring -A- downwards
s in direction of ar‐
s c
row until it lies on flat surface.

ce
le
un

pt
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d
itte

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erm

ab
ility
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wit
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ole,

spec
urposes, in part or in wh

satelettronica
t to the co
rrectnes
– Upper edge of sender wheel and front edge of sealing flange

s o
cial p

must align -arrows-.

f inform
mer

atio
om

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en
ng

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– Place sealing flange with front side on assembly tool - T10134-

so that locating pin -B- can be inserted in sender wheel hole
-A-.

Note

Ensure sealing flange lies flat on assembly tool.

92 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- so that locating pin cannot
slide out of sender wheel hole whilst tightening the three
knurled screws -A-.

Note

When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.

2.2.4 B - Fitting assembly tool - T10134- with

sealing flange to crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.
– Screw hexagon nut -B- to end of threaded spindle.

satelettronica
– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing on sump side of crankcase
sealing surface.

AG. Volkswagen AG d
agen oes
olksw not
– Secure assembly tool - T10134- d by Vto crankshaft flange using gu
ara
hexagon socket head boltsor-A-.
ise nte
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aut ra
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ce
e

Note
nl

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Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
ab
ility

prox. 5 full turns).

ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– To guide sealing flange, screw 2 M6 × 35 mm bolts -A- into

rrectness of i

cylinder block.
l purpos

nf
ercia

orm
m

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py by
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by lksw
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Prote AG.

2. Cylinder block, gearbox end 93

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.2.5 C - Screwing assembly tool - T10134- on

crankshaft flange G. Volkswage
nA n AG d
wage oe
– Push assembly housing yV
ol-C-
ks by hand in direction of sarrow
not
gu until
sealing lip supportisering
d b -B- contacts crankshaft flange -A-. ara
n r tee
ho
– Push guide pin sa
ut for petrol engines (red knob) -F- into hole in or a
c
crankshaft. This ensures that the sender wheel reaches its fi‐
s

ce
e

nal installation position.

nl

pt
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erm

ab
ility
Note
ot p

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The guide pin for diesel engines (black knob) -D- must not be
hole

spec
inserted in threaded hole of crankshaft.
es, in part or in w

t to the co
– Hand-tighten both hexagon socket head bolts of assembly
tool.

rrectness of i
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.
l purpos

2.2.6 D - Pressing sender wheel onto crank‐

satelettronica
nform
ercia

shaft flange using assembly tool -

m

at
om

io
T10134-
n
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in t
or

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– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐

a

do
riv

ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G

p

cum
or

1332/11- .
f

en
ng

t.
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Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.

2.2.7 E - Checking sender wheel installation

position on crankshaft

Special tools and workshop equipment required

♦ Ruler - T40100-

94 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw hexagon nut -E- to end of threaded spindle.

– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Unscrew the two hexagon socket-head bolts on the assembly
device again.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.

– The sender wheel is exactly in the installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.

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– Set vernier gauge on crankshaft flange.
, is n

h re
hole

– Measure distance -a- between crankshaft flange and sender

spec
wheel.
es, in part or in w

t to the co
Note
rrectness of i
If the engine and gearbox support - VAS 6095- does not provide
l purpos

the necessary space, the ruler - T40100- should be placed on the

crankshaft flange and the distance determined with a feeler
nform
ercia

gauge.
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om

If dimension -a- is too small:

on
c

in t
or

– Re-press sender wheel ⇒ page 96 .

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ate

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If dimension -a- is attained:

p

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for

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ng

t.
– Tighten new securing bolts for sealing flange to 15 Nm using op
yi Co
alternate and diagonal sequence.
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– Install engine speed sender - G28- -arrow- and tighten secur‐ Prote
cted AG.
agen
ing bolt to 5 Nm.
– Install sump ⇒ page 171 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to
60 Nm +1/4 turn (90°).

2. Cylinder block, gearbox end 95

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4-cylinder direct-injection engine hor (1.4 l, EA 111, turbocharger, supercharger)
is tee - Edition 02.2019
ut or
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ss
2.2.8 f) Re-pressing sender wheel

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– Secure assembly tool - T10134- to crankshaft flange using

y li
erm

ab
hexagon socket head bolts -A-.

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– Hand tighten both hexagon socket head bolts.

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– Push assembly tool - T10134- by hand to sealing flange. hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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– Screw hexagon nut -E- onto threaded spindle by hand until it

m

at
lies on assembly housing -C-.
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– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐

ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again ⇒ page 94 .
If dimension -a- is still too small:
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 94 .

96 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 97
⇒ “3.2 Pulling needle bearing out of and driving into crankshaft”,
page 98
⇒ “3.3 Crankshaft dimensions”, page 100

3.1 Assembly overview - crankshaft

For assembly work, secure engine in engine and gearbox bracket
- VAS 6095- .

1 - 50 Nm + 1/4 turn (90°) fur‐

ther
❑ Only tighten to 50 Nm
when measuring crank‐
shaft radial clearance.
Do not turn further.
2 - Bearing cap

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❑ Do not interchange gen AG. Volkswagen AG d
bearing caps (mark Vol
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not
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❑ Bearing ut cap 3 with re‐
ho eo
ra
cesses
ss a for thrust wash‐ c
ers
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❑ Bearing shell retaining

an
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lugs in cylinder block

erm

ab

and bearing caps must

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align.
wit
is n

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3 - Crankshaft
spec
urposes, in part or in wh

❑ Axial play, new: 0.07…

t to the co

0.24 mm
❑ Wear limit: 0.26 mm
rrectne

Check radial clearance with

Plastigage
ss

❑ New: 0.03 … 0.05 mm

o
cial p

f i

❑ Wear limit: 0.13 mm

nform
mer

❑ Do not rotate crankshaft

atio
m

when checking radial

o

n
c

clearance
i
or

n thi
e

❑ Pulling needle bearing

t

sd
iva

out of and driving into

pr

cum
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fo

crankshaft
en
ng

t.
⇒ page 98 .
yi Co
Cop py
❑ Crankshaft dimensions ht. rig
rig ht
⇒ page 100 .
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4 - Sealing flange with sender wheel and oil seal
Prote AG.

❑ With engine speed sender - G28- (not illustrated).

❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 89 .
5 - 12 Nm
❑ Renew
6 - Thrust washers
❑ For bearing cap 3

3. Crankshaft 97
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
❑ Note fixing arrangement
7 - Bearing shell
❑ In cylinder block
8 - Sprocket wage
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❑ Removing and installing ⇒ page 159 d by V ua
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❑ For oil pump drive and timing chain.
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❑ Contact surfaces must be free sof
s oil and grease.

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9 - Bearing shell nl

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❑ In bearing cap.
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❑ Do not interchange used bearing shells (mark).
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hole

spec
3.2 Pulling needle bearing out of and driving
es, in part or in w

t to the co
into crankshaft
Only vehicles with a dual clutch gearbox

rrectness of i
Special tools and workshop equipment required
l purpos

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♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-

nform
mercia

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♦ Internal puller - VAS 251 635-

♦ Drift - VW 207 C-

98 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Installing

Note

The needle bearing must always be renewed after the gearbox

has been separated from the engine.

Condition:
• The front edges of the inner puller must be free of chips.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.

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Installing

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– Clean bearing seat in crankshaft and apply as thin coating of
d
itte

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grease.
erm

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– Drive needle bearing into crankshaft to installation depth using

wit
is n

drift - VW 207 C- .

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spec
urposes, in part or in wh

t to the co
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mer

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3. Crankshaft 99
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Installation depth: dimension -a- = 2.0 mm AG. Volkswagen AG d

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If the needle bearing is inadvertently driven in too far, it must be

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pt
renewed because it will be damaged when it is pulled out again.

du

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erm

ab
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐

ility
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box; Installing gearbox .

wit
, is n

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es, in part or in w

t to the co
rrectness of i
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3.3 Crankshaft dimensions

m

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Honing Crankshaft Conrod

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dimension in mm main journal ∅ journal ∅

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Basic dimension -0.022 -0.022

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54.00 47.80
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-0.037 -0.037
AG.

Stage II --- -0.022

47.30
-0.037

100 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 101
⇒ “4.2 Checking piston”, page 103
⇒ “4.3 Checking cylinder bores”, page 104
⇒ “4.4 Separating new conrod”, page 104
⇒ “4.5 Removing and installing pistons”, page 104
⇒ “4.6 Removing and installing oil spray jets”, page 105

4.1 Assembly overview - pistons and con‐

rods

Note

Oil all bearing and running surfaces before assembly.

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❑ If difficult to remove, ss a ra
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heat piston to 60°C.

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❑ Remove and install us‐

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ing drift - 10 - 14- .
erm

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3 - Piston

wit
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❑ Checking ⇒ page 103

h re
ole,

spec
❑ Mark installation posi‐
urposes, in part or in wh

tion and cylinder num‐

t to the co
ber.

rrectne
Caution
Arrow on piston crown

s
points to belt pulley end.

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cial p

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❑ Install using piston ring
mer

clamp.
atio
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n
c

4 - Compression rings
or

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sd

❑ Offset gaps by 120°

iva

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pr

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❑ Remove and install

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compression rings with

t.
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piston ring pliers. Cop py
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❑ “TOP” faces towards
ht
pyri by
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piston crown.
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❑ Checking ring gap
⇒ page 103 .
❑ Checking ring-to-groove
clearance ⇒ page 103 .
5 - Oil scraper rings
❑ Carefully remove and
install 3-part oil scraper
rings by hand.
❑ Checking ring gap ⇒ page 103 .
❑ Ring-to-groove clearance not measurable.

4. Pistons and conrods 101

 AG. Volkswagen AG d
agen oes
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Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf bPlus y V 2005 ➤ , ...
ol not
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4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger,
orise supercharger) - Edition 02.2019 nte
h eo
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6 - Conrod bolt ss

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❑ M7×0.75: 20 Nm + 1/4 turn (90°) further.

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❑ M8×1: 30 Nm + 1/4 turn (90°) further.

erm

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❑ Renew

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❑ Oil threads and contact surface

hole

spec
❑ To measure radial clearance, tighten to corresponding specified torque but not further.

es, in part or in w

t to the co
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod.

rrectness of i
❑ Markings -A-: mark with cylinder number

l purpos
❑ Markings -B-: mark paired conrods and conrod bearing caps
8 - Bearing shell

nform
ercia
❑ Do not interchange used bearing shells.
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❑ Insert bearing shells centrally.

n
c

in t
or

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Checking radial clearance with Plastigage:

at

do
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c
❑ New: 0.020…0.060 mm

um
for

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en
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❑ Wear limit: 0.090 mm

n

t.
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op py
❑ Do not rotate crankshaft when checking radial clearance.
t. C rig
gh ht
pyri by
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9 - 27 Nm
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❑ Opening pressure of pressure relief valve: 1.8…2.2 bar
AG.

10 - Oil spray jet

❑ For piston cooling.
11 - Connecting rod
❑ Renew as set only.
❑ Markings -A-: mark with cylinder number
❑ Markings -B-: mark paired conrods and conrod bearing caps
❑ Separating new conrod ⇒ page 104 .

Caution
The conrod must be re‐
installed in exactly the
same position as it was
previously installed.
If new conrods are fitted,
then the choice of posi‐
tion is arbitrary.

❑ Guided axially by piston.

102 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

4.2 Checking piston

Special tools and workshop equipment required
♦ External micrometer 75 - 100 mm - VAS 6071-
Checking piston
– Measure pistons approx 12 mm from the lower edge of skirt,
at 90° to the piston pin axis. Difference between actual and
nominal diameter max. 0.04 mm.
Piston ∅
Basic dimension mm 76.4601)
• 1) Measure approx. 12 mm from bottom of piston skirt

Checking piston ring gap

– Push ring squarely from above down into cylinder bore to ap‐
prox. 15 mm from bottom end of cylinder.
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Piston ring New Wear
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dimensions in mm ol not

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1st compression ring 0.20 … 0.40
tho 1.0 eo
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2nd compression ring 0.40 …ss 0.60 1.0 c

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nl

Oil scraper ring 0.20 … 0.80 ---1)

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erm

1)No

ab
wear limit details

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Checking ring-to-groove clearance

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hole

spec
Clean annular groove before check.
es, in part or in w

t to the co
Piston ring New Wear limit
dimensions in mm

rrectness of i
1st compression ring 0.04 … 0.08 0.15
2nd compression ring 0.02 … 0.06 0.15
l purpos

Oil scraper ring Cannot be measured

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rig ht
py by
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4. Pistons and conrods 103

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

4.3 Checking cylinder bores

Special tools and workshop equipment required
♦ Cylinder gauge - VAS 6078-
Checking cylinder bores
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Deviations compared with
nominal diameter max. 0.08 mm.
Cylinder bore ∅
Basic dimension mm 76.51

Note

Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.

satelettronica
4.4 Separating new conrod
On a new conrod, it is possible thatenthe
AG.breaking
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fully separated. If the conrodobearing
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hand, proceed as follows:ed by
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or
– Mark cylinder allocation
au
th of conrod ⇒ Item 11 (page 102) . eo
ra
ss c
– Gently clamp conrod, as shown in illustration, in a vice with
ce
e
nl

pt

soft aluminium jaws.

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erm

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ility
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Note
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♦ To prevent damage to the conrod, only clamp conrod in lightly.

spec
es, in part or in w

♦ Conrod is clamped below the dashed line.

t to the co

– Unscrew the two bolts -arrows- approx. 5 turns.

rrectness of i
l purpos

– Using a plastic hammer, carefully knock against conrod bear‐

nform
ercia

ing cap in -direction of arrow- until it is loose.

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Prote AG.

4.5 Removing and installing pistons

Special tools and workshop equipment required

104 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Drift - VW 222 A-

♦ Piston ring clamp, commercially available

Removing
– Remove cylinder head ⇒ page 116 .
– Remove sump ⇒ page 171 .
– Mark piston installation position and corresponding cylinder
number ⇒ Item 3 (page 101) .

satelettronica
– Mark installation position and matching of cylinder and conrod
bearing cap to conrod ⇒ Item 7 (page 102) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards. AG. Volkswagen A n G do
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Note oris tee
th or
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ss
If the piston pin is difficult to move, heat the piston to approx. 60°

ce
le

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un

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rm

ab
– Remove retaining ring from piston pin eye.
pe

ility
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wit
– Drive out piston pin using drift - VW 222 A- .
, is n

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hole

Installing
spec
es, in part or in w

Install in reverse order of removal, observing the following: t to the co

Note
rrectness of i
l purpos

Renew bolts that are tightened with turning further angle.

nform
ercia

– Oil running surfaces of bearing shells.

m

– Install piston with commercially available piston ring clamp,

com

tio

noting installation position ⇒ Item 3 (page 101) .

n in
r
te o

thi

– Install conrod bearing cap, observing installation position

s
iva

do

⇒ Item 7 (page 102) .

r
rp

cum
fo

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– Install cylinder head ⇒ page 116 .

n

t.
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Cop py
– Install sump ⇒ page 171 .
t. rig
gh ht
pyri by
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Specified torques
c by lksw
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Prote AG.
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 101

4.6 Removing and installing oil spray jets

Special tools and workshop equipment required
♦ Torx bit - T10545-

4. Pistons and conrods 105

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
– Remove noise insulation ⇒ General body repairs, exterior; wage
n AG. Volkswagen AG do
es n
s
Rep. gr. 66 ; Noise insulation; Assembly overview y V - noise in‐
o lk ot g
ua
sulation . ir se
d b ran
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– Remove front right wheel housing liner ⇒ au General body re‐ ac
ss
pairs; Rep. gr. 66 ; Wheel housing liner; Removing and

ce
e
nl
installing front wheel housing liner .

pt
du

an
itte

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– Remove sump ⇒ page 171 .
erm

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ility
– Remove oil pump ⇒ page 175 . ot p

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
♦ The crank web of the respective cylinder must be positioned
so that the socket - T10545- can be inserted in the pressure

rrectness of i
relief valve as close to vertical as possible.
♦ Furthermore, the corners of the socket - T10545- and of the
l purpos

pressure relief valve must engage well.

nform
ercia

– Turn crankshaft via vibration damper securing bolt in direction

satelettronica
m

of engine rotation until the respective bolt is accessible.

at
om

ion
c

– Unscrew pressure relief valve -1- using Torx bit T40 -

in t
or

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T10545- .
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– Remove oil spray jets -2-.

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for

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ng

t.
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Installing
Co
Cop py
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pyri by
Caution
co Vo
by lksw
cted agen
Prote AG.

Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Check clearance of oil jets after reinstallation of pistons.
♦ Bent oil spray jets must be renewed.

1- Pressure relief valve - 27 Nm

2- Oil spray jet
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
– Install oil pump ⇒ page 175 .
– Install sump ⇒ page 171 .
– Install front right wheel housing liner ⇒ General body repairs;
Rep. gr. 66 ; Wheel housing liner; Removing and installing
front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .

106 Rep. gr.13 - Crankshaft group

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

15 – Cylinder head, valve gear

1 Cylinder head
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♦ When installing anss exchange cylinder head, oil all contact sur‐
a ac
faces between the support elements, roller rocker arms and

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le
un

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the cams before installing the camshaft housing.

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♦ Do not remove the plastic packing pieces for protecting the
erm

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ility
open valves until immediately before fitting cylinder head.
ot p

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is n

♦ If the cylinder head is renewed, all the coolant in the system

h re
ole,

must also be renewed.

spec
urposes, in part or in wh

♦ Oil all bearing and running surfaces before assembly.

t to the co
♦ Dismantling and assembling intake manifold ⇒ page 344

rrectne
⇒ “1.1 Assembly overview - cylinder head”, page 107

satelettronica
s
⇒ “1.2 Removing and installing camshaft housing”, page 110

s o
cial p

f
⇒ “1.3 Removing and installing cylinder head”, page 116

inform
mer

⇒ “1.4 Checking compression”, page 118

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om

n
1.1 Assembly overview - cylinder head
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1. Cylinder head 107

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - 20 Nm
2 - High-pressure pump
❑ For fuel supply.
❑ With fuel pressure regu‐
lating valve - N276- .
❑ Removing and installing
⇒ page 369
3 - Wiring guide
❑ Bolt to camshaft hous‐
ing with 8 Nm torque.
4 - To air filter
5 - 10 Nm
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6 - Hall sender - G40- olksw
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❑ With O-ring rised
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❑ Renew O-ring if dam‐ aut ra
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aged. ss

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7 - Stud, 6 Nm

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8 - 10 Nm + 1/4 turn (90°) fur‐

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ther

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❑ Renew
ole,

spec
❑ Tighten from inside out‐
urposes, in part or in wh

wards.

t to the co
9 - Camshaft case

rrectne
Note

s
The strainer for oil circuit must be

s o
installed in cylinder head.
cial p

f inform
mer

❑ Removing and installing

atio
m

⇒ page 110
o

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c

i
❑ Remove sealant residue.
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❑ Carefully clean sealing surfaces. They must be oil and grease free.
iv

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❑ Before installing, coat with sealant - D 154 103 A1- .

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❑ When installing, carefully fit onto dowel pins.
Co
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10 - 20 Nm rig ht
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11 - Lifting eye cted agen
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12 - Exhaust turbocharger
13 - Oil pressure switch - F1- , 20 Nm
❑ Checking ⇒ page 178
❑ If seal is leaking, nip open and renew.
14 - Cylinder head gasket
❑ Renew
❑ Metal gasket.
❑ After renewing, renew entire coolant.
15 - Cylinder head

Note

The strainer for oil circuit must be

installed in cylinder head.

108 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
❑ Removing and installing ⇒ page 116
❑ Check for distortion ⇒ page 109 .
❑ Sealing surfaces to camshaft housing must be oil and grease free.
❑ After renewing, renew entire coolant.
16 - Guide pin
❑ Specified torque: 20 Nm
17 - Dowel pin
18 - Oil strainer
❑ Inserted into cylinder head
❑ Renew
19 - Support element
❑ Do not interchange
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface
20 - Roller rocker fingers
❑ Check roller bearing for ease of movement.

satelettronica
❑ Oil contact surface
❑ When installing, secure to supporting element using securing clip.
21 - Seal

Note

Note the different sealing types

when removing and installing the
camshaft housing ⇒ page 110 . agen
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❑ Renew ised b ara
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❑ Qty. 4 aut
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❑ Inserted into cylinder head. s
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22 - Cylinder head bolt an

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❑ Renew ab
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❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 116 .
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23 - Roller tappet
hole

spec

❑ Lightly coat contact surface with engine oil.

es, in part or in w

t to the co

24 - O-ring
❑ Renew
rrectness of i

❑ Moisten with oil before inserting.

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Checking cylinder head for distortion

nf
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or

Check with straightedge 500 mm - VAS 6075- and feeler gauge.

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Max. permissible distortion: 0.05 mm

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1. Cylinder head 109

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.2 Removing and installing camshaft housing

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
y V gu
b

satelettronica
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es, in part or in w

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♦ Dial gauge - VAS 6079-

o

his
ate

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♦ Puller - T10094 A-
p

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for

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♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170

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♦ Camshaft clamp - T10171 B- (use new version) p by
co Vo
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♦ Counterhold tool - T10172- Prote AG.

♦ Adapter - T10172/1-
♦ Pin - T40011-

110 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Spark plug socket - 3122 B-

♦ Torque wrench - V.A.G 1331-
♦ Sealant - D 154 103 A1- agen
AG. Volkswagen AG d
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ole,

1.2.1 Removing

spec
urposes, in part or in wh

t to the co
Note

rrectne
♦ The camshafts are mounted in the camshaft housing on this
engine. Before removing camshaft housing, first remove valve

s
timing housing.
s o
cial p

♦ Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf, f inform
mer

Polo, Sharan, Golf Cabriolet) ⇒ page 128 .

atio
m

♦ Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .

o

n
c

i
or

n thi
e

♦ Remove valve timing housing (Passat, Passat CC)

t

sd
va

⇒ page 138 .
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♦ The camshaft housing sealing surface cannot be reworked.

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ng

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Cop py
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– First check whether a coded radio is fitted. If so, obtain anti- rig ht
py by
theft code.
co Vo
by lksw
cted agen
Prote AG.
– With ignition switched off, disconnect battery earth strap.
– Remove air filter (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan,
Passat, Passat CC, Golf Cabriolet) ⇒ page 342 .
– Drain coolant ⇒ page 185 .
– Drain coolant (Sharan) ⇒ page 193 .
– Drain coolant (Passat, Passat CC) ⇒ page 198 .
– Remove coolant hoses and line/wiring guides.
– Remove turbocharger ⇒ page 282 .
– Remove regulating flap control unit ⇒ page 349 .
– Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf,
Polo, Sharan, Golf Cabriolet) ⇒ page 128 .
– Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .

1. Cylinder head 111

 AG. Volkswagen AG d
agen oes
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Eos 2006 ➤ , Golf 2009by➤ V , Golf Cabriolet 2012 ➤ , Golf
ol not
gPlus
ua 2005 ➤ , ...
d
4-cylinder direct-injection
rise engine (1.4 l, EA 111, turbocharger, ran
tesupercharger) - Edition 02.2019
tho eo
au ra
c
– Remove valve timings housing (Passat, Passat CC)
s

ce
e
⇒ page 138

nl

pt
du

an
itte

y li
– Turn crankshaft to TDC for No. 1 cylinder. Then turn crank‐ erm

ab
shaft 45° in engine direction and remove camshaft timing

ility
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sprockets with timing chain ⇒ page 145 .

wit
, is n

h re
– Unbolt camshaft sealing covers.
hole

spec
– Pull connectors off fuel pressure sender for low-pressure -
es, in part or in w

t to the co
G410- and off high-pressure pump.
– Unscrew earth cable from camshaft housing.

rrectness of i
– Remove ignition coils. Use puller -T10094 A- for this purpose
⇒ page 429 .
l purpos

– Remove cable guide with wiring harness from camshaft hous‐

ing.

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– Release connector -2- and pull off.
m

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Note
t

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Disregard item -1-.
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WARNING
op Vo
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Prote AG.
Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.

– Pull connector and fuel supply line -arrows- off high-pressure

pump.

– Remove wiring guide -2- and remove connector -4- from Hall
sender - G40- .

Note

Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.

– Loosen union nuts -3- and -1- of high-pressure line.

– Pull out oil dipstick.
– Loosen camshaft housing bolts from outside to inside, alter‐
nately and diagonally and remove.
– Carefully lift camshaft housing off.

112 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EAen111,
AG. Vturbocharger,
olkswagen AG supercharger) - Edition 02.2019
ag does
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1.2.2 Installing by ara
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Condition au ra
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• The pistons cannot be positioned at TDC.

un

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ab
ility
Note
ot p

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is n

h re
The strainer for oil circuit must be installed in cylinder head.
ole,

spec
urposes, in part or in wh

t to the co
– Remove sealant residues from cylinder head and camshaft
housing with a rotating brush, e.g. a hand drill with a plastic
brush (wear eye protection).

rrectne
– Clean sealing surfaces carefully. They must be free of oil and
grease.

ss o
– Also prevent dirt and residual sealant from entering cylinder
cial p

f i
head.

nform
mer

atio
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Caution
o

n
c

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or

n thi

satelettronica
te

Before using camshaft clamp - T10171 B- you must check that

sd
iva

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the pins on the tool project by at least 7 mm.

p

cum
r
fo

en
ng

If this is not the case, the camshaft clamp is defective and must
t.
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op
be renewed. C py
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Do not use any kind of hammer to position the camshaft clamp.
op Vo
by c lksw
cted agen
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– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 B- can be inserted into holes in camshaft to stop.
– Screw in an M6 bolt hand-tight to secure camshaft clamp -
T10171 B- , but do not tighten.

Note

Camshaft housings with different sealing variants in area of spark

plug recess have been fitted.

Sealing on cylinder head with no sealing ring in area of spark plug

recess

Caution

No sealant is applied in area of the oil strainer -1-.

1. Cylinder head 113

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Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤y V,oGolf Plus 2005 ➤ , ...
lks ot g
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4-cylinder direct-injection engine (1.4 l, EA 111, ir se turbocharger, supercharger) - Edition 02.2019
d ran
tee
tho
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– Apply thin, even coat of sealant on clean camshaft
ss housing
sealing surface. See hatched area in illustration.

ce
e
nl

pt
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an
itte

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erm

ab
Note

ility
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Sealant cannot be applied too thickly; otherwise excess sealant

hole
can enter oil channels and cause damage to engine.

spec
es, in part or in w

t to the co
Sealing on cylinder head with sealing ring in area of spark plug
recess

rrectness of i
– Place new seals into grooves in cylinder head. l purpos

Caution

nform
ercia

No sealant is applied in area of the oil strainer -1-.

m

at
om

ion
c

in t
or

his
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– Apply thin, even coat of sealant on clean camshaft housing

a

do
riv

sealing surface. See hatched area in illustration.

p

cum
or

satelettronica
f

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g

– Do not apply sealant in area of -arrows-.

n

t.
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Cop py
.
Sealing on cylinder head with machined chamfer in area of spark
t rig
gh ht
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plug recess cop Vo
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cted agen
Prote AG.

Caution

No sealant is applied in area of the oil strainer -1-.

– Apply thin, even coat of sealant - D 154 103 A1- on clean

camshaft housing sealing surface. See hatched area in illus‐
tration.
– Apply sealant -D 176 600 A1- to the chamfer -arrows- of cyl‐
inder head.
The sealant bead must be 2 mm thick.

Note

Sealant cannot be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.

Caution

Ensure that all roller rocker fingers contact valve stem ends
-1- correctly and that they are clipped into their respective sup‐
port elements -2-.
Proceed with extreme caution when fitting the camshaft hous‐
ing onto the cylinder head in order to prevent the roller rocker
fingers from sliding down!

114 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– When fitting camshaft housing onto cylinder head, first fit cam‐
shaft housing at angle shown in illustration onto dowel pins
-arrows-.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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ce
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un

– Then, carefully lower camshaft housing in

pt
an
d

-direction of arrow- towards cylinder head.

itte

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rm

ab
pe

ility
ot

wit
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Note

h re
hole

spec
Ensure that no oil residue can drip onto sealing surfaces.
es, in part or in w

t to the co
– Evenly tighten new camshaft housing securing bolts from in‐
side to outside alternately and diagonally.
rrectness of i

Ensure that camshaft housing is not canted. Specified torque

l purpos

10 Nm + 1/4 turn (90°) further.

nform
ercia

Note
m

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com

tion in

After installing the camshaft housing, wait about 30 minutes for

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te o

thi

the sealant to dry.

s
iva

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– Adjust valve timing ⇒ page 145 .

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ng

t.
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Further assembly is basically a reverse of the dismantling se‐ Cop py
ht. rig
quence. During this procedure, observe the following: rig ht
py by
co Vo
by lksw
♦ Install valve timing housing (Eos, Golf Plus, Scirocco, Golf, Prote
cted AG.
agen
Polo, Sharan, Golf Cabriolet) ⇒ page 128
♦ Installing valve timing housing (Tiguan, Touran) ⇒ page 132
♦ Installing valve timing housing (Passat, Passat CC)
⇒ page 138
♦ Install regulating flap control unit ⇒ page 349 .
♦ Install turbocharger ⇒ page 282 .
♦ Install crankshaft belt pulley ⇒ page 83 .
♦ Attaching fuel lines ⇒ page 369

1. Cylinder head 115

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.3 Removing and installing cylinder head

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

satelettronica
rrectness of i
l purpos

nf
ercia

orm
m

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n in
or c

thi
te

sd
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Cop py
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gh ht
pyri by
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♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8- (Golf Plus, Eos)
♦ Adapter - 10 - 222 A /22- (Tiguan)
♦ Bracket - T10358-
♦ Torque wrench - V.A.G 1332-
♦ Torque wrench - V.A.G 1331-

1.3.1 Removing
Remove following components:
♦ Removing and installing valve timing housing (Eos, Golf Plus,
Golf, Scirocco, Polo, Sharan, Golf Cabriolet) ⇒ page 128
♦ Removing and installing valve timing housing (Tiguan, Tour‐
an) ⇒ page 132
♦ Remove valve timing housing (Passat, Passat CC)
⇒ page 138
♦ Remove thermostat housing from cylinder head.

116 Rep. gr.15 - Cylinder head, valve gear

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by V Eos 2006 ➤ , Golf 2009 ➤ ,t gGolf ua Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
d ran
ir se
4-cylinderth direct-injection engine (1.4 l, EA 111, turbocharger,
o tee
or supercharger) - Edition 02.2019
au ac
ss
♦ Remove timing chain ⇒ page 159

ce
e
nl

pt
du

an
♦ Remove turbocharger ⇒ page 282 . itte

y li
erm

ab
♦ Remove regulating flap control unit - J808- and throttle valve

ility
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module - J338- ⇒ page 349 .

wit
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h re
♦ Removing intake manifold ⇒ page 344 .
hole

spec
es, in part or in w

– Unscrew securing bolt for gearbox and attach bracket -

t to the co
T10358- as shown.
– Attach hooks of support bracket - 10 - 222 A- to bracket -

rrectness of i
T10358- as shown.
l purpos

– Turn spindle until the hooks are lightly tensioned.

nform
mercia

at
om

ion
c

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or

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ate

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– Unhook hook -1- from left lifting eye and push spindle onto left

en
ng

t.

satelettronica
yi
side of support bracket - 10 - 222 A- .
Co
Cop py
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gh
Removing and installing camshaft housing ⇒ page 110 .
ht
pyri by
Vo
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– Remove roller rocker fingers together with support elements
cted agen
Prote AG.
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.

– Loosen cylinder head bolts in sequence given and then re‐

move completely.
– Carefully remove cylinder head.

1.3.2 Installing
Condition
• The pistons cannot be positioned at TDC.

Note

♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
♦ The strainer for oil circuit must be installed in cylinder head.

1. Cylinder head 117

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall
wage
n AGand
. Volkspiston.
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– Now carefully clean sealingedsurfaces
by of cylinder head and cyl‐ ara
nte
inder block. Ensure thereby
thoris
that surfaces are not scored or eo
scratched (if abrasive
s aupaper is used, grade must not be less ra
c
than 100). s

ce
e
nl

pt
du

– Carefully remove metal particles, emery residue and cloths.

an
itte

y li
erm

ab
– Set No. 1 cylinder piston to top dead centre and then turn

ility
ot p

crankshaft back slightly.

wit
, is n

h re
– Fit new cylinder head gasket. Inscription (Part No.) must be
hole

spec
readable.
es, in part or in w

t to the co
– Fit cylinder head. When doing this, observe centring pins in
cylinder block.
– Insert new cylinder head bolts and tighten hand-tight.

rrectness of i
– Tighten cylinder head in sequence as follows:
l purpos

Specified torque/turning further angle

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Stage Specified torque

rm

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m

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1 30 Nm
o

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or c

2 Turn 90° further with rigid span‐

thi
e

ner
t

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3 Turn 90° further with rigid span‐
o

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ner
t.
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4 Turn 90° further with rigid span‐
C py
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ner
ht
pyri by
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cted agen
– Install supporting elements in cylinder head and fit respective Prote AG.
roller rocker finger onto respective valve stem end or support‐
ing element.
– Install camshaft housing.
Removing and installing camshaft housing ⇒ page 110 .
– Adjust valve timing ⇒ page 145 .
Further assembly is basically a reverse of the dismantling se‐
quence.

1.4 Checking compression

118 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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

ce
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un

pt
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♦ Spark plug socket - 3122 B-

h re
hole

spec
♦ Torque wrench - V.A.G 1331-
es, in part or in w

t to the co
♦ Compression tester - V.A.G 1763-
♦ Puller - T10094 A-
rrectness of i
Test conditions
l purpos

• The engine oil temperature must be at least 30 °C.

Procedure
nform
ercia

– Remove engine cover panel.

m

a
com

tion in

– Remove ignition coils. Use puller - T10094 A- for this purpose.

r
te o

thi
s
iva

– Screw out spark plugs with spark plug socket - 3122 B-

do
r

⇒ page 429 .
rp

cum
fo

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ng

t.
– Remove fuse for fuel pump control unit voltage supply from
yi Co
op
fuse holder beneath left dash panel ⇒ Current flow diagrams,
C py
t. rig
gh
Electrical fault finding and Fitting locations.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Cylinder head 119

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

Removing fuse interrupts voltage supply for fuel pump control

unit.

– Check compression using compression tester - V.A.G 1763- ,

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .

Note

Using compression tester: ⇒ Operating instructions .

– Operate starter until tester shows no further pressure in‐

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10.0 … 15.0 7.0 max. 3.0
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– Insert spark plugs using spark plug socket - 3122 B- and tight‐
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spec
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– Read event memory, rectify any faults and then clear event
memory: ⇒ Vehicle diagnostic tester “Guided Fault Finding”.

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The readiness code must be generated if the event memory has
been cleared.
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120 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2 Valve gear
⇒ “2.1 Assembly overview - valve gear”, page 121
⇒ “2.2 Measuring axial clearance of camshaft”, page 123
⇒ “2.3 Reworking valve seats”, page 123
⇒ “2.4 Checking valve guides”, page 125
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❑ Must not be dismantled.
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❑ Removing and installing
⇒ page 145

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3 - Camshaft sprocket
❑ Note position when in‐
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stalling timing chain.

4 - O-ring

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❑ Renew if damaged
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❑ Before installing, coat
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❑ Renew
❑ Tighten from inside out‐
wards.
8 - Camshaft case
❑ Removing and installing
⇒ page 110
❑ Remove sealant resi‐
due.
❑ Before installing, coat
with sealant - D 154 103
A1- .
❑ When installing, carefully fit onto dowel pins from above.
9 - 10 Nm
10 - Cap
❑ For inlet camshaft
❑ For exhaust camshaft
11 - Roller rocker fingers
❑ Check roller bearing.
❑ Oil contact surface
❑ When installing, secure to supporting element using securing clip.

2. Valve gear 121

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

12 - Valve cotters
13 - Valve stem seal
❑ Renew
14 - Support element
❑ Check oil spray holes.
❑ With hydraulic valve clearance compensation.
❑ Do not interchange
❑ Before installing, check camshaft axial clearance ⇒ page 123 .
❑ Oil contact surface
15 - Valve guide
❑ Checking ⇒ page 125
16 - Valve springs
❑ To remove and install with cylinder head removed, use valve spring tool - 3362- .
❑ With cylinder head installed ⇒ page 125 .
17 - Cylinder head
❑ Removing and installing ⇒wpage agen 116
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❑ Do not rework; only lapping-in is permitted.

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❑ Checking axial clearance ⇒ page 123 .

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❑ Coat with oil before inserting (also axial bearing shoulder).

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20 - Guide bush
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21 - Inlet camshaft
❑ With cam for high-pressure pump
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❑ Before removing, remove and renew bucket tappet for high-pressure pump.
❑ Do not interchange with exhaust camshaft.
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❑ Checking axial clearance ⇒ page 123 .

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❑ Coat with oil before inserting (also axial bearing shoulder).

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Note

When the sealing surface has been reworked, the valves must be
set deeper by the same amount (valve seat inserts reworked) or
valves will contact pistons. When doing this, ensure that the per‐
missible minimum dimension is maintained ⇒ page 123 .

122 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.2 Measuring axial clearance of camshaft

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

♦ Dial gauge
Perform measurements with camshaft housing removed and cap
fitted.

satelettronica
Checking camshaft axial clearance
Wear limit: max. 0.40 mm

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∅a mm 29.5 26.0
∅b mm 5.973 5.953
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c mm 100.9 100.5
α ∠° 45 45
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Special tools and workshop equipment required

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♦ Depth gauge
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2. Valve gear 123

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 125 .
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.

The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.

Note

satelettronica
If the valve is to be renewed as part of a repair, use a new valve
for the calculation.
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– Measure distance between end of valvebstem yV
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Minimum dimension: inlet valve 7.6 mm, exhaust valve 7.6 mm

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Minimum dimension 7.6 mm

=max. perm. rework dimension1) 0.4 mm
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1) The max. permissible reworking dimension is shown as dimension “b” in the

illustrations for reworking valve seats.
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a = ∅ 28.7 mm
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a = 25.0 mm ∅
b = max. permissible reworking dimension1
c = approx.1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
3) Calculating max. permissible reworking dimension ⇒ page 123 .

124 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.4 Checking valve guides

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

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– Insert new valve into guide. The end of the valve stem must

y li
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be flush with the guide. On account of differing stem diame‐
pe

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ters, only use inlet valve in inlet guide and exhaust valve in
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exhaust guide.

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– Determine rock by moving valve in direction of -arrow-.

spec
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Wear limit: 0.8 mm
If the amount of sideways play is exceeded:

rrectness of i
– Renew cylinder head.
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2.5 Removing and installing valve stem

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Special tools and workshop equipment required

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♦ Spark plug socket - 3122B-

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2. Valve gear 125

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Valve stem pliers - VAS 6770-

♦ Valve spring tool - 3362- with thrust piece - 3362/1-

satelettronica
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♦ Valve stem seal fitting tool - 3365-
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♦ Pressure hose - VW 653/3-

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Removing

2.5.1 Removing
(With cylinder head installed)
Removing and installing valve timing housing (Eos, Golf Plus,
Golf, Scirocco, Polo, Sharan, Golf Cabriolet) ⇒ page 128

126 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing and installing valve timing housing (Tiguan, Touran)

⇒ page 132
Remove valve timing housing (Passat, Passat CC) ⇒ page 138
– Remove camshaft housing ⇒ page 110 .
– Remove roller rocker fingers and place onto a clean surface.
When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Attach valve spring tool - 3362- with thrust piece - 3362/1- .
– Screw pressure hose - VW 653/3- into spark plug thread.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals using valve stem pliers - VAS 6770- .
AG. Volkswagen AG d
agen oes
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satelettronica
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2.5.2 Installing

rrectness of i
– Place plastic sleeve supplied on respective valve stem. This
will prevent damage to new valve stem seal.
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– Place new valve stem seal in valve stem seal fitting tool -
3365- .
nform
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– Oil valve stem seal sealing lip and press carefully onto the
m

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valve guide.
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– Install camshaft housing ⇒ page 113 .

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– Adjust valve timing ⇒ page 145 .

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Further assembly is basically a reverse of the dismantling se‐

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cted AG.
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♦ Removing and installing valve timing housing (Tiguan, Tour‐

an) ⇒ page 132
♦ Remove valve timing housing (Passat, Passat CC)
⇒ page 138
♦ Install fuel lines ⇒ page 369

2. Valve gear 127

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3 Cover for timing chain

⇒ “3.1 Removing and installing valve timing housing (Eos, Golf
Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet)”, page 128
⇒ “3.2 Removing and installing valve timing housing (Touran, Ti‐
guan)”, page 132
⇒ “3.3 Removing and installing valve timing housing (Passat CC,
Passat)”, page 138

3.1 Removing and installing valve timing housing (Eos, Golf Plus, Scirocco,
Golf, Polo, Sharan, Golf Cabriolet)

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
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♦ Support - 10-222A-
♦ Adapter - 10 - 222 A /8-
♦ Counterhold tool - 3415-
♦ Pin - 3415/1-
♦ Torque wrench - V.A.G 1331-

128 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

♦ Silicone adhesive sealant - D 176 501 A1-

3.1.1 Removing
– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
– Remove noise insulation.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .

satelettronica
– Mark the direction of rotation of the poly V-belt and remove
belt ⇒ page 75 .
– Turn crankshaft in direction of engine rotation to TDC for no.
1 cylinder ⇒ page 143 .
– Drain coolant ⇒ page 185 .
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– Remove coolant pump ⇒ page 214
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– Remove banjo bolt from isoiled supply
b pipe to turbocharger. ara
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– Remove air conditioner
aut
compressor from bracket with refrig‐ ra
c
ss
erant lines still connected ⇒ Heating, air conditioning; Rep.
ce
le

gr. 87 .
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– Remove bracket for tensioning element and air conditioner

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compressor.
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– Remove alternator.
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spec
es, in part or in w

t to the co

– Install support device - 10 - 222 A- with adapter - 10 - 222 A /

8- as shown and hook into lifting eye.
rrectness of i

– Position adapter - 10 - 222 A /8- on vehicle front end

-arrows- as shown.
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3. Cover for timing chain 129

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Install support device - 10 - 222 A- with adapter - 10 - 222 A /

8- as shown and hook into lifting eye.

– Take up weight of engine and remove securing bolts

-arrows-.
– Remove sump ⇒ page 171 .

satelettronica
– Now remove pulley securing bolt. Hold pulley with counterhold
- 3415- and -3415/1- . wagen AG. Volkswagen AG doe
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– Remove Allen head bolts for valve timing housing and hexa‐
gon bolts indicated by -arrows-.
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– Remove valve timing housing.

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Note that crankshaft bearing bush remains in sealing flange.

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130 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.1.2 Installing

Note

♦ From model year 2009, a diamond coated washer is installed.

The washer prevent the crankshaft from being turned when
the securing bolt is tightened.
♦ Install a diamond coated washer -7- when a washer was not
fitted as original equipment ⇒ Electronic Parts Catalogue “ET‐
KA”.
♦ The washer is fitted -7- between the bearing bush -5- and the
crankshaft sprocket.
♦ Note that all contact surfaces from the securing bolt to the
crankshaft sprocket must be free of oil and grease.

– Clean sealing surfaces carefully. They must be free of oil and

grease.
1 - Securing bolt

satelettronica
2 - Crankshaft belt pulley
3 - Diamond coated washer (clipped onto crankshaft belt pulley)
4 - Crankshaft oil seal
5 - Bearing bush
6 - O-ring agen
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♦ Timing housing is still sealed to engine with a gasket and ad‐

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ditionally with silicone adhesive sealant - D 176 501 A1- .
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♦ Silicone adhesive sealant - D 176 501 A1- prevents leaks be‐

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tween timing housing and joints -1- and -2-.

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♦ Sealant spots must have a diameter of 10 mm and a thickness
es, in part or in w

of approx. 1 mm.
t to the co
♦ Do not apply sealant until directly before the valve timing
housing is fitted.
rrectness of i
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3. Cover for timing chain 131

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Apply silicone adhesive sealant - D 176 501 A1- to joints be‐

tween camshaft housing and cylinder head -1- and between
cylinder head and cylinder block -2-.
– Fit new gasket onto dowel pins. n AG. Volkswagen AG do
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– Fit valve timing housing with crankshaft
ss
a bearing bush simul‐ ac
taneously onto studs, dowel pins and crankshaft journal.

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– Tighten valve timing housing securing bolts evenly and diag‐
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Specified torque:
hole

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es, in part or in w

M6 bolt to 10 Nm

t to the co
M10 bolt to 50 Nm
Eos, Golf Plus, Scirocco, Golf, Golf Cabriolet, Sharan

rrectness of i
Align engine mountings as follows:
l purpos

satelettronica
♦ There must be a distance -a- of at least 10 mm between engine

nform
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support and longitudinal member (right side).

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♦ The side surface of the engine support -2- should be located
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– Rock engine to align engine mountings stress-free.

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t.
yi Co
Install crankshaft belt pulley ⇒ page 83 . t. Cop py
rig
gh ht
yri
Further assembly is basically a reverse of the dismantling se‐ p by
co Vo
quence.
by lksw
cted agen
Prote AG.

3.2 Removing and installing valve timing housing (Touran, Tiguan)

132 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
n AG. Volkswagen AG do
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o ot g
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♦ Support - 10 - 222 A-
spec
urposes, in part or in wh

♦ Adapter - 10 - 222 A /22-

t to the co

♦ Counterhold tool - 3415-

rrectne

♦ Pin - 3415/1-
♦ Torque wrench - V.A.G 1331-
ss 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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Cover for timing chain 133

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Adapter - 10 - 222 A /26- (for Touran)

♦ Adapter - 10-222A/30- (for Touran)
♦ Hook - 10 - 222 A /10- (for Touran)
♦ Shackle - 10 - 222 A /12- (for Touran)
AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1332- ksw
agen oes
not
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♦ Silicone adhesive sealant - D 176 501 A1- ise
d b ara
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Note

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itte

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♦ The Touran has different versions of the front end.
erm

ab
ility
ot p

♦ The shape of the headlights is a distinguishing characteristic.

wit
, is n

h re
♦ Determine which version of the front end is at hand and use
hole

the correct adapters accordingly.

spec
es, in part or in w

t to the co
Vehicles ► 11.06

rrectness of i
Small headlights -arrow 1-: adapter - 10-222A/22- .

satelettronica
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Vehicles from 12.06 ► 05.10

Large headlights with curve -arrows 2-: adapter - 10-222A/26- .

nform
ercia

Vehicles 06.10 ►
m

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c

in t
or

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ate

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priv

cum
for

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ng

t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Large headlights without curve -arrow 3-: adapter - 10-222A/30- .

134 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.2.1 Removing
– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Mark direction of rotation of poly V-belt and remove it (Tiguan)
⇒ page 78 .
– Mark direction of rotation of poly V-belt and remove it (Touran)
⇒ page 75 .
– Turn crankshaft in direction of engine rotation to TDC for no.
1 cylinder ⇒ page 143 .
– Drain coolant ⇒ page 185 .
– Remove coolant pump ⇒ page 214 .

satelettronica
– Remove banjo bolt from oil supply pipe to turbocharger.
– Remove ancillary bracket ⇒ page 80 .
Tiguan

– Support bracket - 10 - 222 A- with adapter - 10 - 222 A /22-

Touran

Note

Observe distinguishing characteristics of the front end agen

AG. Volkswagen AG d
oes
⇒ page 134 . yV
olksw not
gu
d b ara
ise nte
or eo
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aut ra
ss c

ce
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nl

pt
du

an
itte

y li
– Fit engine support bracket - 10-222A- with adapter - 10 - 222
erm

ab
ility
A /26- and take up weight of engine in installation position.
ot p

wit
, is n

h re
hole

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

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

3. Cover for timing chain 135

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Take up weight of engine and remove securing bolts

-arrows-.
– Remove sump ⇒ page 171 .

– Now remove pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .

satelettronica
– Remove Allen head bolt for control housing and hexagon bolts
indicated by -arrows-.
– Remove valve timing housing.
AG. Volkswagen AG d
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Note that crankshaft bearings bush remains in sealing flange.
s a c
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un

pt
an
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itte

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rm

ab
pe

ility
ot

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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
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rp

cum
fo

en
ng

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

136 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.2.2 Installing

Note

♦ From model year 2009, a diamond coated washer is installed.

The washer prevent the crankshaft from being turned when
the securing bolt is tightened.
♦ Install a diamond coated washer -7- when a washer was not
fitted as original equipment ⇒ Electronic Parts Catalogue ag“ET‐
en AG. V
olkswagen AG
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♦ The washer is fitted -7- between the bearing
tho bush -5- and the
ris nte
e or
crankshaft sprocket. au ac
ss

ce
♦ Note that all contact surfaces from the securing bolt to the le
un

pt
crankshaft sprocket must be free of oil and grease.

an
d
itte

y li
erm

ab
ility
– Clean sealing surfaces carefully. They must be free of oil and
ot p

wit
grease.
is n

h re
ole,

1 - Securing bolt

spec
urposes, in part or in wh

satelettronica
2 - Crankshaft belt pulley

t to the co
3 - Diamond coated washer (clipped onto crankshaft belt pulley)

rrectne
4 - Crankshaft oil seal
5 - Bearing bush

ss o
6 - O-ring
cial p

f inform
7 - Diamond coated washer
mer

atio
om

n
c

i
or

n
Note

thi
te

sd
iva

o
pr

c
♦ Timing housing is still sealed to engine with a gasket and ad‐

um
r
fo

en
ditionally with silicone adhesive sealant - D 176 501 A1- .
ng

t.
yi Co
op py
♦ Silicone adhesive sealant - D 176 501 A1- prevents leaks be‐
t. C rig
gh ht
tween timing housing and joints -1- and -2-. pyri by
Vo
co lksw
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cted agen
♦ Sealant spots must have a diameter of 10 mm and a thickness Prote AG.
of approx. 1 mm.
♦ Do not apply sealant until directly before the valve timing
housing is fitted.

3. Cover for timing chain 137

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ o,lkGolf Plus 2005 ➤ , ...
. V swagen AG
4-cylinder direct-injection engine (1.4 l, lEAw gen AG
a111, turbocharger, supercharger)
does - Edition 02.2019
k
os n ot g
yV ua
edb ran
– Apply silicone adhesive sealant - D 176 ho
ris 501 A1- to joints be‐ tee
tween camshaft housing and cylinder aut head -1- and between or
ac
cylinder head and cylinder block s-2-.
s

ce
e
nl

pt
du
– Fit new gasket onto dowel pins.

an
itte

y li
erm

ab
– When fitting, install two “M6x80” studs into cylinder head and

ility
ot p
cylinder block as a guide.

wit
, is n

h re
– Fit valve timing housing with crankshaft bearing bush simul‐
hole

taneously onto studs, dowel pins and crankshaft journal.

spec
es, in part or in w

– Tighten valve timing housing securing bolts evenly and diag‐

t to the co
onally.
Ensure that valve timing housing is not canted.

rrectness of i
Specified torque:
l purpos

M6 bolt to 10 Nm

nform
ercia

M10 bolt to 50 Nm
m

at
Align engine mountings as follows:
om

ion
c

in t
or

♦ There must be a distance -a- of at least 10 mm between engine

his
ate

satelettronica
do
riv

support and longitudinal member (right side).

p

cum
for

♦ The side surface of the engine support -2- should be located

en
ng

t.
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parallel to the support arm -1-.
Co
Cop py
t. rig
gh
Install crankshaft belt pulley ⇒ page 83 .
ht
pyri by
Vo
o
by c lksw
cted
Further assembly is basically a reverse of the dismantling se‐
agen
Prote AG.
quence.

3.3 Removing and installing valve timing housing (Passat CC, Passat)

138 Rep. gr.15 - Cylinder head, valve gear

 n AG. Volkswagen AG do
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Vol 2006 ➤ , Golf 2009es➤ not, Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
gu
by
4-cylinder direct-injection
rise
d engine (1.4 l, EA 111, turbocharger,
ara
nte supercharger) - Edition 02.2019
tho eo
au r ac
Special toolsss and workshop
equipment required

ce
le
un

pt
an
d
itte

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rm

ab
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

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

satelettronica
en
ng

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

♦ Support - 10-222A-
♦ Adapter - 10 - 222 A /22-
♦ Counterhold tool - 3415-
♦ Pin - 3415/1-
♦ Torque wrench (5 … 50 Nm) - V.A.G. 1331-
♦ Torque wrench (40 to 200 Nm) - V.A.G. 1332-
♦ Sealant - D 176 501 A1-
Removing

3. Cover for timing chain 139

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
– Remove crankcase breather on union of valve timing housing.
– Remove noise insulation or skid plate ⇒ General body repairs,
exterior; Rep. gr. 50 ; Removing and installing noise insulation
or skid plate .
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Mark direction of rotation of poly V-belt and remove it
⇒ page 75 .
– Drain coolant
⇒ “1.8 Draining and filling coolant (Passat, Passat CC)”, page
198 .
– Remove coolant pump
⇒ “2.10 Removing and installing coolant pump (Passat, Passat
CC)”, page 242 .
– Turn crankshaft in engine direction of rotation to TDC for No.
1 cylinder ⇒ page 143 .

satelettronica
– Unscrew banjo bolt of turbocharger oil supply pipe on valve
timing housing ⇒ Item 16 (page 282) .
– Remove bracket for ancillaries ⇒ page 80 .

– Position support bracket - 10 - 222 A- with adapter - 10 - 222

A /8- and hook - 10 - 222gA
en /10-
AG. Vas
olksshown ind illustration.
wagen AG
wa oes
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– Fit adapter - 10 d-b222
y V A /8- behind bolts -arrow 1- tand
gu
ara
-arrow 2-. ori se nte
e th or
s au ac
s
WARNING
ce
e
nl

pt
du

an
itte

y li

Do not position adapter - 10 - 222 A /8- on edges of wing.

erm

ab
ility
ot p

The wing will otherwise be damaged.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Take up weight of engine and remove securing bolts

nform
ercia

-arrows-.
m

at

– Remove sump ⇒ page 171 .

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.

140 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Undo bolt for poly V-belt. Hold pulley with counterhold - 3415-
and -3415/1- .

– Undo socket bolts of valve timing

gen AG
.housing.
Volkswagen AG
d wa oes
olks not
– Undo the marked socket
db
y V bolts -arrows-. gu
ara
e nte
ris
– Remove valveuthtiming
o housing. eo
ra
a c
ss

ce
le
un

pt
Note

an
d
itte

y li
erm

ab

satelettronica
Note that crankshaft bearing bush remains in sealing flange.

ility
ot p

wit
is n

h re
Installing
ole,

spec
urposes, in part or in wh

Install in reverse order of removal. During this procedure, observe

t to the co
the following:

Note rrectnes

Note that belt pulley contact surfaces, securing bolt, bearing bush
s o

and crankshaft sprocket must be free of oil and grease.

cial p

f inform
mer

Clean sealing surfaces carefully.

atio
om

The sealing surfaces must be free of oil and grease.

c

i
or

n thi
te

sd
iva

o
pr

cum

Note
r
fo

en
ng

t.
yi Co
op
♦ The valve timing housing is still sealed to the engine with a
C py
ht. rig
seal and also sealant D 176 501 A1. rig ht
py by
co Vo
by lksw
♦ The sealant D 176 501 A1 is used to prevent leaks between
cted agen
Prote AG.
the valve timing housing and the joints -1- and -2-.
♦ Sealant spots must have a diameter of 10 mm and a thickness
of approx. 1 mm.
♦ Do not apply sealant until directly before the valve timing
housing is fitted.

3. Cover for timing chain 141

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
n AG. Volkswagen AG do
wage e
– Apply sealant D 176 501 A1 toy the Vol joints camshaft housing/ ot gu
ks sn
cylinder head -1- and cylinder
ise
d b head/cylinder block -2-. ara
n r tee
ho
– Place new seal onto dowel
sa
ut pins. or
ac
s
– Screw two -M6x80- studs into cylinder head and cylinder block

ce
e
nl

pt
du
to improve guidance.

an
itte

y li
erm

ab
– Fit timing housing with crankshaft bearing bush simultaneous‐

ility
ot p

ly onto studs, dowel pins and crankshaft journal.

wit
, is n

h re
– Tighten valve timing housing securing bolts evenly and diag‐
hole

onally.

spec
es, in part or in w

t to the co
Ensure that timing housing is not canted.
Specified torque

rrectness of i
M6 bolt to 10 Nm
l purpos

M8 bolt to 20 Nm
M10 bolt to 50 Nm

nform
ercia

Align engine mountings as follows:

m

at
om

ion
c

♦ There must be a distance -a- of at least 10 mm between engine

satelettronica
in t
or

his
e

support and longitudinal member (right side).

at

do
priv

c
♦ The side surface of the engine support -2- should be located

um
for

parallel to the support arm -1-.

en
ng

t.
yi Co
op py
Engine mounting specified torque ⇒ page 67 t. C rig
gh ht
pyri by
Install crankshaft belt pulley ⇒ page 83 .
o Vo
by c lksw
cted agen
Prote AG.
Install poly V-belt ⇒ page 75 .

142 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

4 Chain drive
⇒ “4.1 Checking valve timing”, page 143
⇒ “4.2 Adjusting valve timing”,gpage
en AG. 145
Volkswagen AG
d wa oes
olks not
⇒ “4.3 Checking timing
d b chain”, page 152
yV gu
ara
e nte
ris
⇒ “4.4 Removing thoand installing timing chain and chain drive fore or
au
oil pump”, page
ss 159 ac

ce
le
un

4.1 Checking valve timing

pt
an
d
itte

y li
erm

ab
ility
ot p

Special tools and workshop

wit
is n

equipment required

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

satelettronica
ss 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
Prote AG.

♦ Spark plug socket - 3122 B-

♦ Torque wrench - V.A.G 1331-
♦ Dial gauge - VAS 6079-
♦ Puller - T10094 A-
♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170
A- (observe note ⇒ page 144 ).
♦ Camshaft clamp - T10171 B- (use new version)

4. Chain drive 143

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

The mounting points for securing the camshaft clamp were modi‐
fied. A new special tool designated camshaft clamp - T10171 B-
has been introduced.

Test sequence
– Remove lower part of front right wheel housing liner ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Remove air filter ⇒ page 342 .
– Remove spark plug from No. 1 cylinder. To do this, use puller
- T10094 A- and spark plug socket and extension - 3122 B-
⇒ page 429 .
– Release connector -2- and pull off.

Note

satelettronica
Disregard item -1-.

– Then remove bolts for both camshaft covers -3-.

n AG. Volkswagen AG do
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ss
– Unclip engine pre-wiring harness -1-.

ce
e
nl

pt
du

an
– Pull coolant pipe -2- and engine pre-wiring harness -1- away
itte

y li
from cylinder head.
erm

ab
ility
ot p

– Remove both bolts -3- from cylinder head.

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
If the dial gauge adapter - T10170 A- is used, the ball head does
not need to be unscrewed from the dial gauge - VAS 6079- . The

rrectness of i
ball head is fitted onto the flat side of the rod.
l purpos

– Screw dial gauge adapter - T10170- into spark plug hole to

nf
ercia

stop.
orm
m

– Insert dial gauge - VAS 6079- with extension from dial gauge
atio
m

adapter - T10170- to stop and lock using lock nut -arrow-.

o

n in
or c

thi
e

– Turn crankshaft in direction of engine rotation, to TDC for No.

t

sd
iva

1 cylinder. Note position of small needle on dial gauge.

o
r
rp

cu
o

m
f

en
ng

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

144 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

The bores -arrows- in the camshafts must be as illustrated. If

necessary, turn crankshaft one turn (360°) further.

Note

♦ If crankshaft is turned 0.01 mm passed TDC, turn crankshaft

two full turns in engine direction of rotation to set crankshaft at
TDC for No. 1 cylinder.
♦ Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.

Caution

Before using camshaft clamp - T10171 B- you must check that

the pins on the tool project by at least 7 mm.
If this is not the case, the camshaft clamp is defective and must
be renewed.
Do not use any kind of hammer to position the camshaft clamp.

satelettronica
– Insert camshaft clamp - T10171 B- to stop in camshaft open‐
ings.
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
tion “TOP” -arrow 3- must be readable
AG. Volkfrom
swageabove.
nA gen G do
swa es
If camshaft clamp - T10171
by
Vol B- cannot be inserted intootcamshaft
k n
gu
openings to stop, then
rise timing is incorrect and must be readjusted
d ara
nte
⇒ page 145 . ut ho eo
r
sa ac
Timing is OKs if camshaft clamp - T10171 B- can be fitted into
ce
le

camshaft openings to stop.

un

pt
an
d
itte

y li

Further assembly is basically a reverse of the dismantling se‐

rm

ab

quence. During this procedure, observe the following:

pe

ility
ot

wit
, is n

♦ Renew oil seals for camshaft sealing cover and oil them before
h re

fitting.
hole

spec
es, in part or in w

t to the co

4.2 Adjusting valve timing

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
co lksw
by
cted agen
Prote AG.

4. Chain drive 145

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
♦ Dial gauge - VAS 6079- ss c
ce
e
nl

pt
du

♦ Puller - T10094 A-
an
itte

y li
erm

♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170

ab
ility

A- (observe note ⇒ page 148 ).

ot p

wit
, is n

♦ Camshaft clamp - T10171 B- (use new version)

h re
hole

spec

♦ Counterhold tool - T10172-

es, in part or in w

t to the co

♦ Pin - T40011-
rrectness of i
l purpos

nf
ercia

orm
m

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or c

thi
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Cop py
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Prote
146
AG.
Rep. gr.15 - Cylinder head, valve gear
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

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AG. Volkswagen AG d
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♦ Torque wrench - V.A.G 1601-
rrectne

♦ Counterhold tool - 3415-

ss

♦ Locating bolt - T10340-

o
cial p

f in

♦ Torque wrench - V.A.G 1331-

form
mer

atio

♦ Spark plug socket - 3122 B-

om

n
c

Procedure
or

n thi
te

sd
a

– Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf,

iv

o
pr

Polo, Sharan, Golf Cabriolet) ⇒ page 128 .

um
r
fo

en
ng

t.
yi
– Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .
Co
Cop py
ht. rig
– Remove valve timing housing (Passat, Passat CC)
rig ht
py by
o Vo
⇒ page 138 by c lksw
cted agen
Prote AG.

4. Chain drive 147

 AG. Volkswagen AG d
agen oes
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Eos 2006 ➤ , Golf 2009 by V ➤ , Golf Cabriolet 2012 ➤ , Golf
ol
gu Plus 2005 ➤ , ...
ara
d
4-cylinder direct-injection
orise engine (1.4 l, EA 111, turbocharger, nte supercharger)
eo
- Edition 02.2019
th
au ra
s c
– To turn crankshaft,s reinstall bearing bush, crankshaft pulley

ce
le
-2- and crankshaft bolt -3- and securely tighten crankshaft bolt

un

pt
an
d
(use counterhold - 3415- ).
itte

y li
rm

ab
– Remove spark plug from No. 1 cylinder. To do this, use puller
pe

ility
- T10094 A- and spark plug socket and extension - 3122 B-
ot

wit
, is n

⇒ page 429 .

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Release connector -2- and pull off.

nform
mercia

Note

a
com

tion in
r
te o

Disregard item -1-.

thi
s
iva

do
r
rp

cum
– Then remove bolts for both camshaft covers -3-.
fo

en

satelettronica
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.

– Unclip engine pre-wiring harness -1-.

– Pull coolant pipe -2- and engine pre-wiring harness -1- away
from cylinder head.
– Remove both bolts -3- from cylinder head.

Note

If the dial gauge adapter - T10170 A- is used, the ball head does
not need to be unscrewed from the dial gauge - VAS 6079- . The
ball head is fitted onto the flat side of the rod.

– Screw dial gauge adapter - T10170- into spark plug hole to

stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC for No.
1 cylinder. Note position of small needle on dial gauge.
– Then turn crankshaft 2 revolutions in engine direction of rota‐
tion.

148 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Press tensioning rail -1- in direction of -arrow-, and lock piston

with locking pin - T40011- .

– Mark direction of rotation of timing chain -3- using coloured felt

tip marker pen.

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Caution olkswage es n
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Camshaft adjuster tho centre bolt -2- has a left-hand thread. tee
or
au ac
ss

ce
e

satelettronica
nl

pt
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
du

an
itte

with timing chain -3-. Counterhold using counterhold -

y li
erm

ab
T10172- .

ility
ot p

– Install camshaft adjuster -1- again.

wit
, is n

h re
hole

– Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt

spec
-4- to 50 Nm (use counterhold - T10172- ).
es, in part or in w

t to the co
Caution rrectness of i

Before using camshaft clamp - T10171 B- you must check that

l purpos

the pins on the tool project by at least 7 mm.

If this is not the case, the camshaft clamp is defective and must
nf
ercia

be renewed.
orm
m

Do not use any kind of hammer to position the camshaft clamp.

atio
om

n in
or c

thi
te

sd
iva

– Turn inlet and exhaust camshafts until camshaft clamp -

r
rp

cu
o

T10171 B- can be inserted into holes in camshaft to stop.

f

en
ng

t.
yi Co
op
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐ C py
t. rig
tion “TOP” -arrow 3- must be readable from above.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note

Do not push camshafts axially whilst turning.

4. Chain drive 149

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw M6 bolt hand-tight into corresponding bore -arrows- (do

not tighten) to secure camshaft clamp - T10171 B- .

Note

Note that there are different securing points for the camshaft
clamp - T10171 B- .

– Remove camshaft sprocket bolts. It is absolutely necessary to

use counterhold - T10172- for this.

Note

Do not use camshaft clamp - T10171 B- as a counterhold.

– Remove one camshaft sprocket. agen

AG. Volkswagen AG d
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Caution horis nte
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satelettronica
If the camshaft adjuster has been removed, the guide sleeve

ce
le
un

must seat in the camshaft when installing!

pt
an
d
itte

y li
erm

ab
ility
ot p

– Place timing chain over camshaft sprockets, observing chain

wit
is n

direction of rotation, and install camshaft sprocket again.

h re
ole,

spec
– Tighten camshaft bolts until camshaft sprockets can still just
urposes, in part or in wh

be turned on camshafts.

t to the co
– Tension timing chain by removing locking pin - T40011- .

– Turn crankshaft in direction of engine rotation to TDC No. 1 rrectne

cylinder. Permissible deviation from TDC No. 1 cylinder:
s

±0.01 mm.
s o
cial p

f inform
mer

Note
atio
om

n
c

If crankshaft is turned more than 0.01 mm past TDC, turn crank‐

i
or

n thi

shaft two full turns in direction of engine rotation to set crankshaft

te

sd
va

at TDC for No. 1 cylinder.

i

o
pr

cum
r
fo

en
ng

t.
yi
Only Tiguan with all-wheel drive
Co
Cop py
t. rig
– Remove right drive shaft ⇒ Running gear, axles, steering;
gh ht
pyri by
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
o Vo
by c lksw
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drive shafts .
agen
Prote AG.

Continued for all vehicles

– Unscrew plug -arrow- from crankcase.

– Screw locking pin - T10340- to stop into crankcase.
– Tighten locking pin - T10340- to 30 Nm.

150 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.

– Hold camshaft sprockets -1- and -5- in this position with coun‐
terhold - T10172- and tighten bolt -2- (left-hand thread) to
40 Nm and bolt -4- to 50 Nm.

Note

Crankshaft cannot move, and timing chain -3- must remain ten‐
sioned on both sides when tightening camshaft bolts.

satelettronica
– Remove camshaft clamp - T10171 B- .

– Unscrew locking pin - T10340- from crankcase.

– Rotate crankshaft two full turns in direction of engine rotation
AG. Volkswagen AG d
to TDC No. 1 cylinder. Permissible deviation
kswagen from TDC No. 1oes n
cylinder: ± 0.01 mm. Vol ot g
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oris tee
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Caution au ac
ss
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nl

pt
du

Before using camshaft clamp - T10171 B- you must check that

an
itte

the pins on the tool project by at least 7 mm.

y li
erm

ab
ility

If this is not the case, the camshaft clamp is defective and must
ot p

wit

be renewed.
, is n

h re
hole

Do not use any kind of hammer to position the camshaft clamp.

spec
es, in part or in w

t to the co

– Insert camshaft clamp - T10171 B- to stop in camshaft open‐

rrectness of i

ings.
l purpos

If camshaft clamp - T10171 B- cannot be fitted:

– Repeat adjustment.
nf
ercia

If camshaft clamp - T10171 B- can be inserted:

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

4. Chain drive 151

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw locking pin - T10340- to stop into crankcase.

– Tighten locking pin - T10340- to 30 Nm.

– Remove camshaft clamp - T10171 B- , hold camshaft sprock‐

ets with counterhold - T10172- and tighten boltsAG. Volkswagen AG d
swagen -2- (left-hand oes
k not
thread) and -4- 1/4 turn (90°) furtherbywith
Vol a rigid wrench. gu
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Note ss

ce
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nl

pt
du

an
♦ Camshaft adjuster centre bolt -2- has a left-hand thread.
itte

y li

satelettronica
erm

ab
♦ Camshaft sprockets cannot move on camshaft whilst tighten‐

ility
ot p

ing.

wit
, is n

h re
hole

Further assembly is basically a reverse of the dismantling se‐

spec
es, in part or in w

quence. During this procedure, observe the following:

t to the co
Note

rrectness of i
The locking pin - T10340- remains in the crankcase until the
l purpos

crankshaft pulley is installed.

nform
ercia

4.3 Checking timing chain

m

at
om

ion
c

Special tools and workshop equipment required

in t
or

his
ate

♦ Torque wrench - VAS 6583-

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.

152 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Tester for checking elongation of chain links - T10550-

AG. Volkswagen AG d
agen oes
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♦ Camshaft clamp - T10550/1- s

ce
le
un

pt
♦ Indicator - T10550/2-

an
d
itte

y li
rm

ab
♦ Scale sleeve - T10550/3-
pe

ility
ot

wit
• The engine oil temperature must be at least 40°C ⇒ Vehicle
, is n

h re
diagnostic tester.
hole

spec
• The engine must necessarily not be at »TDC« position.
es, in part or in w

satelettronica
t to the co
– Remove right front wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres .

rrectness of i
– Remove noise insulation ⇒ Body, front; Rep. gr. 50 ; Noise
insulation; Assembly overview - noise insulation .
l purpos

– Remove front right wheel housing liner: ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
nform
ercia

housing liner .
m

a
com

– Remove poly V-belt ⇒ page 69 .

ion in
r
te o

– Drain coolant ⇒ page 185 .

thi
s
iva

do
r

Vehicles with condensate trap on charge air pipe

rp

cum
fo

en
g

– Open clamps -arrows-.

n

t.
yi Co
Cop py
– Pull coolant hoses -1- off charge air pipe -2-, and clamp them
ht. rig
rig ht
by
off using hose clips up to 40 mm - 3093- . copy Vo
by lksw
cted agen
Prote AG.

Vehicles with engine preheating element - Z97-

– Unclip wire -1- to engine preheater heater element - Z97- on
charge air pipe -2- -arrow-.

4. Chain drive 153

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Vehicles with auxiliary/supplementary heater:

– Open hose clips, and pull coolant hoses off coolant pipes -1-.
– Remove auxiliary/supplementary heater with exhaust pipe
and coolant hoses still connected ⇒ Auxiliary heater, supple‐
mentary heater; Rep. gr. 82 ; auxiliary/supplementary heater;
Removing and installing auxiliary/supplementary heater .

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se
Continued for all vehicles:
tho tee
or
au ac
– Pull off securing clip on charge air cooler in ss

ce
e

-direction of arrow-.
nl

pt
du

an
itte

y li
– Pull charge air hose -arrow- off charge air cooler.
erm

ab
ility
ot p

wit
, is n

h re
hole

satelettronica
spec
es, in part or in w

t to the co
rrectness of i
– Remove securing bolt -arrow- for charge air pipe -1-.
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Release and pull off connector -1- on oil level and oil temper‐
AG.

ature sender - G266- .

– Unclip bracket -2- on subframe for electric wire to oil level and
oil temperature sender - G266- .

154 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolt -arrow- for charge air pipe -1-.

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

ce
e
nl

pt
du

an
itte
– Lift off engine cover at points -1- and pull it forwards in direction

y li
erm

ab
of -arrow-.

ility
ot p

wit
– Remove air filter housing ⇒ page 342 .
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nform
ercia

– Pull off fuel supply line -1- and line leading to activated char‐
m

at
coal filter -2- by pressing release tabs.
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
o
by c lksw
cted agen
Prote AG.

– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.

4. Chain drive 155

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew hose clip -1- on charge air pipe.

– Open hose retainer -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3- and pull off con‐
nector from charge air pressure sender - G31- with intake air
temperature sender 2 - G299- .
– Remove bracket -4-.

– To do this, unscrew bolts -arrows-.

– Remove bracket -1-.

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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s a ac
– Unscrew bolts -arrows- and remove scharge pressure sender -

ce
le

G31- -1-.
un

pt
an
d
itte

y li
– Remove charge air pipe downwards.
rm

ab
pe

ility
– Release connector -2- and pull off.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Disregard item -1-.

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.

156 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove bolts for both camshaft covers -3-.

– Unclip wiring harness -1-.
– Pull coolant pipe -2- and wiring harness -1- away from cylinder
head.
– Lever both camshaft covers -3- out of cylinder head.

– The hole in the left exhaust camshaft -left arrow- mustgben AG. Volkswagen AG do
positioned as shown in the illustration. lkswa e es n
Vo ot gu
y
db ara
– If necessary, turn crankshaft in direction of
or engine rotation.
ise nte
eo
th
au ra
c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab

satelettronica
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Insert camshaft clamp - T10550/1- to stop in camshaft open‐
ings.

rrectness of i
– The locking pin -arrow A- must engage in hole -arrow B- in
l purpos

exhaust camshaft.
– Inscription “TOP” must be readable from above.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
op
– Bolt on camshaft clamp - T10550/1- hand-tight.
C py
t. rig
gh ht
yri by
– Use one bolt of the camshaft covers for this purpose -arrow-. cop Vo
by lksw
cted agen
Prote AG.

4. Chain drive 157

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw indicator - T10550/2- into hole in sump.

– Align centring point vertically so that the tip faces upwards.
– Tighten centring point with knurled nut.

– Position scale sleeve - T10550/3- on belt pulley. agen

AG. Volkswagen AG d
oes
olksw not
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d
Caution orise nte
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h
aut ra
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There is a risk of injury caused by trapping fingers. s

ce
e
nl

pt
du

The scale sleeve - T10550/3- is equipped with magnets.

an
itte

y li
erm

ab
Proceed with great care when joining the components.

satelettronica
ility
ot p

wit
Note that the components are drawn together quickly by the
, is n

h re
magnetic force.
hole

spec
es, in part or in w

t to the co
– Align scale sleeve - T10550/3- with indicator - T10550/2- as
shown in illustration.

rrectness of i
– Apply torque wrench - VAS 6583- with a suitable socket to
l purpos

crankshaft bolt.
– Push torque wrench - VAS 6583- clockwise and maintain a

nf
ercia

torque of 40 Nm on it.

orm
m

atio
– Set scale sleeve - T10550/3- and indicator - T10550/2- to »0«.
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

158 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Switch setting of torque wrench - VAS 6583- , and push it

slowly anti-clockwise.
– Maintain a torque of 40 Nm on torque wrench - VAS 6583- .
. Volkswagen AG
wa gen AG does
– Read value on the Vscale.
olks not
gu
y
db ar
– If the chain skips
ris during
e
the test, renew timing chain antee
⇒ page 159 uth.o or
a ac
ss
– If the chain skips, it can be heard and felt clearly.

ce
le
un

pt
an
d

Evaluation of the test

itte

y li
erm

ab
– If a chain elongation of up to 28° has been determined during

ility
ot p

the test, the timing chain is OK.

wit
is n

h re
ole,

– If a chain elongation of 29° and more has been determined,

spec
the timing chain is not OK and must be renewed
urposes, in part or in wh

⇒ page 159 .

t to the co
Assemble in reverse order of dismantling. During this procedure,
observe the following:

rrectnes
Note

s o

satelettronica
cial p

f inform
♦ The scale sleeve - T10550/3- is equipped with magnets.
mer

atio
♦ Do not use any levers for removing the scale sleeve -
om

n
T10550/3- from the belt pulley!
c

i
or

n thi
te

sd
va

– Turn scale sleeve - T10550/3- towards right by approx. 45° so

i

o
pr

cum
r

that indicator - T10550/2- is not positioned within range of

fo

en
ng

scale.
t.
yi Co
Cop py
.
– Grasp behind scale sleeve - T10550/3- with both hands.
t rig
gh ht
pyri by
Vo
co
– Press thumbs against bolt of belt pulley, and pull off scale
by lksw
cted agen
Prote
sleeve - T10550/3- .
AG.

– Renew oil seals for camshaft sealing cover and oil them before
fitting.
– Add coolant ⇒ page 185 .
Specified torques
♦ ⇒ “1 Air filter”, page 340
♦ ⇒ “2.1 Assembly overview - valve gear”, page 121
♦ ⇒ “3 Charge air system”, page 319
♦ ⇒ “2.1 Assembly overview - supercharger”, page 297
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 71
♦ ⇒ Body, front; Rep. gr. 50 ; Noise insulation, Assembly over‐
view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres

4.4 Removing and installing timing chain and chain drive for oil pump

4. Chain drive 159

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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♦ Dial gauge - VAS 6079-
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♦ Puller - T10094 A-
♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170
A- (observe note ⇒ page 162 ).
♦ Camshaft clamp - T10171 B- (use new version)
♦ Counterhold tool - T10172-
♦ Pin - T40011-

160 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Spark plug socket - 3122 B-

♦ Counter-hold tool - 3415-
♦ Torque wrench - V.A.G 1331-
Removing

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– Lift engine cover panel at points -1- and pull it forwards in di‐

pt
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rection of -arrow-.

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ab
pe

– Remove air filter (Golf, Golf Plus, Eos, Scirocco, Touran, Ti‐

ility
ot

guan, Sharan, Passat, Passat CC, Golf Cabriolet)

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h re
⇒ page 342 .
hole

spec
– Drain coolant (Golf, Golf Plus, Eos, Scirocco, Touran, Tiguan,
es, in part or in w

Golf Cabriolet) ⇒ page 185 .

t to the co

satelettronica
– Drain coolant (Sharan) ⇒ page 193 .

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– Drain coolant (Passat, Passat CC) ⇒ page 198 .
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nform
– Remove coolant hoses and line/wiring guides -arrows-.
mercia

– Unscrew securing bolts of camshaft cover -1-.

a
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tion in

– Remove spark plug from No. 1 cylinder. To do this, use puller

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te o

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- T10094 A- and spark plug socket and extension - 3122 B-

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⇒ page 429 .
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– Release connector -2- and pull off.

Note

Disregard item -1-.

– Then remove bolts for both camshaft covers -3-.

4. Chain drive 161

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unclip engine pre-wiring harness -1-.

– Pull coolant pipe -2- and engine pre-wiring harness -1- away
from cylinder head.
– Lever off both camshaft covers -3- from cylinder head.

Note

If the dial gauge adapter - T10170 A- is used, the ball head does
not need to be unscrewed from the dial gauge - VAS 6079- . The
ball head is fitted onto the flat side of the rod.
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– Screw dial gauge adapter - T10170- into spark plugd holeby
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– Insert dial gauge - VAS 6079- as far as stopssand lock it in po‐
a c
sition with lock nut -arrow-.

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– Turn crankshaft in direction of engine rotation, to TDC No. 1

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cylinder. Note position of small needle on dial gauge.

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The bores -arrows- in the camshafts must be as illustrated. If

rrectne
necessary, turn crankshaft one turn (360°) further.

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Note

inform
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♦ If crankshaft is turned 0.01 mm past TDC, turn crankshaft two

atio
m

full turns in direction of engine rotation to set crankshaft in di‐

o

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rection of engine rotation at TDC for No. 1 cylinder.

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♦ Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.

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Before using camshaft clamp - T10171 B- you must check that Prote
cted AG.
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the pins on the tool project by at least 7 mm.
If this is not the case, the camshaft clamp is defective and must
be renewed.
Do not use any kind of hammer to position the camshaft clamp.

– Insert camshaft clamp - T10171 B- to stop in camshaft open‐

ings.
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
tion “TOP” -arrow 3- must be readable from above.

162 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Screw an M6 bolt hand-tight into corresponding bore

-arrows- (but do not tighten) to secure camshaft clamp -
T10171 B- .

Note

Note that there are different securing points for the camshaft
clamp - T10171 B- .

Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf, Po‐
lo, Sharan, Golf Cabriolet) ⇒ page 128 .
Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .
Remove valve timing housing (Passat, Passat CC) ⇒ page 138

– Pull cover -1- off sprocket for oil pump.

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– Press tensioning rail in -direction of arrow- by hand and lock
piston of chain tensioner with locking pin - T40011- .
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– Mark direction of rotation of timing chain -3- using coloured felt

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Caution cted agen
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Camshaft adjuster securing bolt -2- has a left-hand thread.

– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .

4. Chain drive 163

 AG. Volkswagen AG d
agen oes
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Eos 2006 ➤ , Golf 2009 by
V ➤ , Golf Cabriolet 2012 ➤ , Golf
ol not
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d ara
4-cylinder direct-injection
orise engine (1.4 l, EA 111, turbocharger, nte supercharger) - Edition 02.2019
h eo
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– Hold oil pump sprocket
ss
with counterhold - T10172- and loosen

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securing bolt -1-.

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– Use a screwdriver on bolt -2- to release tensioning spring -1-

then remove tensioning spring -1-.

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– Unscrew securing bolt -3- and remove chain tensioner.
m

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– Mark direction of rotation of oil pump drive chain -2- using felt-

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tip marker.

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– Unscrew securing bolt for sprocket -1- and remove sprockets

-1- and -3- together with drive chain for oil pump -2-.
Installing
• The crankshaft must be positioned at TDC No. 1 cylinder.

– Push sprocket -1- in -direction of arrow- onto crankshaft jour‐

nal as far as the stop.

Caution

Cast lug -2- on sprocket -1- must seat in groove -3- on crank‐
shaft journal.

164 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Mark position of sprocket and crankshaft to cylinder block us‐

ing a felt-tip marker.

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– Place oil pump drive chain -3- onto sprocket -1- while posi‐ , is n

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tioning sprocket -2- on oil pump drive shaft.
hole

spec
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t to the co
Note

♦ Note running direction mark on oil pump drive chain.

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♦ Oil pump drive sprocket only fits on oil pump drive shaft in one
l purpos

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position -arrow-.

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– Hold oil pump drive sprocket with counterhold - T10172- .

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– Tighten new securing bolt -1- to 20 Nm + 1/4 turn (90°) further.

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– Position chain tensioner on oil pump drive chain and tighten

securing bolt -3- to 8 Nm.
– Lever tensioning spring -1- onto bolt -2- using a screwdriver.

Note

♦ Note marks -arrows-.

♦ The crankshaft must remain stationary.

– Tighten sprocket -3- hand-tight with new securing bolt.

4. Chain drive 165

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Place timing chain -1- on crankshaft sprocket -4-, exhaust

camshaft sprocket -3-, and tighten camshaft adjuster -2- hand-
tight using a new securing bolt.

Note

♦ Note running direction mark on timing chain -1-.

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Timing chain must lie on guide rail -1- and crankshaft sprocket

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– Install chain tensioner -1- and tighten securing bolts -2- to
cial p

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9 Nm.

form
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atio
– Tension timing chain by pulling locking pin - T40011- from
om

chain tensioner.

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– Check marks on crankshaft sprocket and cylinder block; they

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must align.

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– Tighten securing bolt -2- to 40 Nm and bolt -4- to 50 Nm (use

counterhold -T10172- ).

Note

♦ Securing bolts -2- and -4- are only tightened 90° further once
timing has been checked.
♦ The camshaft adjuster securing bolt -2- has a left-hand thread.

166 Rep. gr.15 - Cylinder head, valve gear

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew bolt -arrow- and remove camshaft clamp - T10171

B- from camshaft housing.
– Check valve timing ⇒ page 143
If valve timing is OK:

– Hold camshaft sprockets with counterhold - T10172- and tight‐

en securing bolts -2- (left-hand thread) and -4- 1/4 turn (90°)
further with a rigid wrench.

Note

Camshaft adjuster securing bolt -2- has a left-hand

gen AG
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Camshaft sprockets cannot move on camshaft whilst tightening.

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– Install oil pump wheel cover -1-.
ot p

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Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf, Po‐

h re
hole

lo, Sharan, Golf Cabriolet) ⇒ page 128 .

spec
es, in part or in w

Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .

Remove valve timing housing (Passat, Passat CC) ⇒ page 138 t to the co
rrectness of i
– Install crankshaft pulley ⇒ page 83 .
l purpos

– Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Po‐
lo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .
nf
ercia

– Install poly V-belt (Tiguan) ⇒ page 78 .

orm
m

atio
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– Push engine cover panel down at points -1- in direction of

n in
or c

-arrow- until it engages.

thi
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Further assembly is basically a reverse of the dismantling se‐

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4. Chain drive 167

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

17 – Lubrication
1 Sump, oil pump

Note

♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the conrod bear‐
ings are damaged. To prevent this from causing further
damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renewing oil filter
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 171 .

⇒ “1.1 Engine oil:”, page 168

⇒ “1.2 Assembly overview - sump, oil pump”, page 168

satelettronica
⇒ “1.3 Removing and installing oil sump”, page 171
⇒ “1.4 Removing and installing oil pump”, page 175

1.1 Engine oil:

agen
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Oil capacities (Tiguan, Sharan)

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Engine oil specifications

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⇒ Maintenance ; Booklet ; Service tables

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es, in part or in w

Changing engine oil: “Engine oil: Drain or extract”

t to the co

⇒ Maintenance ; Booklet ; Service tables

1.2 Assembly overview - sump, oil pump

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168 Rep. gr.17 - Lubrication

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 171 .
2 - Engine oil cooler

Note

♦ To remove:
♦ Drain coolant ⇒ page 180 .
♦ Remove coolant pipe
⇒ Item 4 (page 169) .
♦ Remove engine oil cooler.
♦ Install in reverse order of remov‐
al.

3 - O-ring
❑ Renew

satelettronica
4 - Coolant pipe
❑ For engine oil cooler
❑ Specified torque, brack‐
et to crankcase: 20 Nm.
5 - 8 Nm
6 - Cap
❑ Renew seal if damaged.
7 - Seal
❑ Renew if damaged
8 - Oil filter, 20 Nm
❑ Loosen with oil filter tool gen AG. Volkswagen AG d
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❑ Observe fittingris instructions on oil filter
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9 - Valve timing housing
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❑ Additionally install with silicone adhesive sealant - D 176 501 A1- .

itte

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Removing and installing valve timing housing (Eos, Golf Plus, Golf, Scirocco, Polo, Sharan, Golf Cabriolet)
ility
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⇒ page 128
wit
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h re
hole

Removing and installing valve timing housing (Tiguan, Touran) ⇒ page 132
spec
es, in part or in w

Remove valve timing housing (Passat, Passat CC) ⇒ page 138

t to the co

❑ When installing, install two -M6x80- studs in cylinder block and camshaft housing as a guide.
❑ To guide valve timing housing, secure sump in position with two bolts.
rrectness of i

10 - 10 Nm
l purpos

11 - Securing bolt
nform
ercia

❑ Removing and installing crankshaft pulley ⇒ page 83

m

❑ Renew
at
om

ion

❑ Contact surface for securing bolt must be free of oil and grease.
c

in t
or

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e

❑ Oil threads before inserting.

at

do
riv

❑ Secure belt pulley against turning with counterhold - 3415- .

p

cum
for

en
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❑ The turning further angle can be measured with a commercial protractor.

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169
by lksw
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1. Sump, oil pump
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

12 - Belt pulley
❑ With diamond coated washer
❑ Observe note on diamond coated washers ⇒ page 82 .
❑ Contact surfaces of pulley must be free of oil and grease.
❑ Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat
CC, Golf Cabriolet) ⇒ page 75
❑ Removing and installing poly V-belt (Tiguan) ⇒ page 78
❑ Secure belt pulley against turning with counterhold - 3415- .
13 - Seal
❑ Renew
14 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
15 - Seal
❑ Renew if damaged
16 - Sprocket
❑ Removing and installing ⇒ page 159
❑ For oil pump drive.

satelettronica
17 - 20 Nm + 1/4 turn (90°) further
❑ Renew
18 - Sprocket
❑ Removing and installing ⇒ page 159
❑ For oil pump.
❑ Lock with counterhold - T10172- . AG. Volkswagen AG d
agen oes
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19 - Drive chain byV
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❑ Removing and installing ⇒ page 159orise nte
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❑ For oil pump. ss a ra
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❑ Before removing, mark direction of rotation (installation position).
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20 - 10 Nm
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21 - Oil level and oil temperature sender - G266-

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❑ Renew if damaged
h re
hole

❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
spec
es, in part or in w

22 - Oil drain plug, 30 Nm

t to the co

❑ With captive seal

❑ Renew
rrectness of i

23 - 13 Nm
l purpos

❑ Loosen and tighten flywheel end bolts only with long-reach Allen key - T10058- .
24 - 40 Nm
nf
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25 - Sump
m

atio
om

❑ Removing and installing ⇒ page 171

n in
or c

thi

❑ Clean sealing surface before fitting.

te

sd
iva

❑ Install with silicone sealant - D 176 600 A1- .

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Prote AG.

170 Rep. gr.17 - Lubrication

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

26 - 14 Nm + 1/4 turn (90°) further

27 - Oil pump

Caution
The oil supply line must
be renewed on the tur‐
bocharger if a new oil
pump or oil suction pipe
is fitted.

❑ with oil suction pipe

❑ Specified torque oil suction pipe: 9 Nm
28 - 2 Nm + 1/4 turn (90°) further
29 - Oil separator
AG. Volkswagen AG d
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Markings on rioils dipstick
ed
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1 - Max.ss mark

satelettronica
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2 - Min. mark
un

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a - Area above hatched field up to max. mark: Do not top up with
rm

ab
engine oil!
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b - Oil level within hatched zone: engine oil can be added

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hole

c - Area from min. mark up to hatched field: top up with max. 0.5 l
spec

of engine oil!
es, in part or in w

t to the co
rrectness of i

1.3 Removing and installing oil sump

l purpos

Special tools and workshop equipment required

nform
ercia

♦ Torx bit - T10058-

m

a
com

tion in
r
te o

thi
s
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1. Sump, oil pump 171

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

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♦ Wedge - T10383/2-
erm

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ility
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spec
es, in part or in w

t to the co

satelettronica
rrectness of i
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nform
mercia

at
♦ Cutting tool - T10561-
om

ion
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or

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ate

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♦ Hand drill with plastic brush

♦ Scraper
♦ Safety glasses
♦ Silicone sealant ⇒ Electronic Parts Catalogue
Removing
– Remove noise insulation.
Polo
– Remove catalytic converter with front silencer ⇒ page 424 .
Continued for all vehicles
– Remove front right wheel housing liners ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - front wheel housing liner .
– Unbolt front exhaust pipe ⇒ page 416 .

172 Rep. gr.17 - Lubrication

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull 3-pin connector off oil level and oil temperature sender -
G266- -1-.
– Drain engine oil ⇒ Maintenance ; Booklet 36.1 .

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– Unbolt sump sealed with liquid gasket.

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– On the gearbox side, two screws may not be immediately ac‐
rm

ab
cessible. If the screw heads cannot be reached with a bit -
pe

ility
T10058- , turn the crankshaft in the engine direction until the
ot

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screws are accessible. The flywheel is provided with recesses.

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es, in part or in w

Note

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♦ The sump is sealed with liquid sealant ⇒ Electronic Parts

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Catalogue .
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♦ When hardened, the sealant has a high adhesive strength.

♦ Two bolts must be loosened but not removed to secure the

nform
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sump from falling after seal has been cut.

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– Cut through seal between oil sump -4- and engine -1-.
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– Use cutting tool - T10561- to do this.
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1. Sump, oil pump 173

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Drive in cutting tool - T10561- -3- using a hammer as far as it AG. Volkswagen AG d
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– Do not cutting tool - T10561- sideways. ut or
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– Do not lever with cutting tool - T10561- .

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– Perform procedure at other points as described until sump is

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detached.

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Note

spec
urposes, in part or in wh

t to the co
When the seal has been broken, a sucking noise will be heard as
the sump detaches.

rrectne
– Use wedge - T10383/2- to further loosen detached positions.
– Using a plastic hammer carefully drive in wedge.

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– Drive in wedge - T10383/2- only to same depth as sealing

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– Release sump carefully from adhesive.
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– Remove bolts which are still holding sump.

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– Remove sump.
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– Remove sealant residue from cylinder block with a flat scraper.

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– Remove sealant residue on sump with a rotating brush, e.g.
ht
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an electric drill with plastic brush attachment (wear eye pro‐
o
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– Clean sealing surfaces. They must be free of oil and grease.

Installing

Note

♦ Check the expiry date of the sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted into the cylinder block flange at two
positions as guides.

174 Rep. gr.17 - Lubrication

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

nozzle).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ 2…3 mm thick
♦ Run bead along inner side of bolt holes -arrows-.

Note

The sealing compound bead cannot be thicker, or excessive seal‐

ing compound will enter the sump and may block the oil suction
pipe strainer.
AG. Volkswagen AG d
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– Install sump immediately and tighten all sump bolts lightly.
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– Tighten oil sump bolts to 13 Nm. auth eo
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Specified torque for oil pan securing bolts to gearbox: 40 Nm

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Note

satelettronica
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Let sealing compound dry for approx. 30 minutes after installing

h re
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oil sump. Only then fill with engine oil.

spec
urposes, in part or in wh

t to the co
Further assembly is basically a reverse of the dismantling se‐
quence.

rrectne
1.4 Removing and installing oil pump

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Caution

inform
mer

The oil supply line must be renewed on the turbocharger if a

atio
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new oil pump or oil suction pipe is fitted.

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Special tools and workshop equipment required

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♦ Counterhold tool - T10172-

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Removing
– Remove sump ⇒ page 171 .

1. Sump, oil pump 175

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull cover -1- off sprocket for oil pump.

– Hold oil pump sprocket with counterhold - T10172- .

– Loosen sprocket securing bolt.

Note

Do not remove bolt completely.

satelettronica
– Press chain tensioner in direction of -arrow- with a screwdriv‐
er.
– Remove sprocket securing bolt.
– Take sprocket off oil pump and out of chain.

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– Loosen oil pump securing bolts -arrows- and remove them.

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– Remove oil pump from cylinder block.

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Installing
hole

spec
es, in part or in w

t to the co

Caution

The oil supply line must be renewed on the turbocharger if a

rrectness of i

new oil pump or oil suction pipe is fitted.

l purpos

– Install oil pump and tighten securing bolts to 14 Nm + 1/4 turn

nf
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(90°) further.
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Specified torque oil suction pipe: 9 Nm

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by
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Prote AG.

176 Rep. gr.17 - Lubrication

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Press chain tensioner in direction of -arrow- with a screwdriv‐

er.
– Insert sprocket in chain and fit sprocket onto oil pump shaft.

– Observe installation position of sprocket on oil pump shaft

-arrows-.
– Screw in sprocket securing bolt.
– Hold sprocket with counterhold - T10172- .

satelettronica
– Position torque wrench - V.A.G 1331- as shown.
AG. Vo wagen AG d lks
– Tighten securing bolt to 20 Nm a+g1e/n4 turn (90°) further.
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spec
urposes, in part or in wh

– Install cover -1-.

t to the co

– Install sump ⇒ page 171 .

rrectness o
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1. Sump, oil pump 177

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2 Oil filter, oil pressure switch

2.1 Checking oil pressure and oil pressure switch

Special tools and workshop

equipment required

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♦ Oil pressure tester - V.A.G 1342-

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♦ Voltage tester - V.A.G 1527B-

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ercia

♦ Adapter set - V.A.G 1594C-

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♦ 10 mm jointed spanner - T40175-

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ate

Note
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Functional check and repair of the optical and acoustic oil pres‐
n

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Test sequence
AG.

The oil pressure switch is located on the gearbox side beneath

the two camshaft covers.

178 Rep. gr.17 - Lubrication

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull connector off oil pressure switch - F1- -arrow-.

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

– Remove oil pressure switch - F1- using 24 mm jointed spanner

t to the co
- T40175- and screw switch into oil pressure tester - V.A.G
1342- .
– Screw tester into cylinder head in place of oil pressure switch.

rrectne
– Connect brown wire of tester to earth (-).

ss
– Connect voltage tester - V.A.G 1527B- to battery positive (+)

o
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f i
and oil pressure switch using cable from auxiliary measuring

satelettronica
form
set - V.A.G 1594C- .
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– If LED lights up, replace pressure switch - F1- .

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If LED does not light up:
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– Start engine and increase speed slowly. At 0.3…0.7 bar the

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LED must light up, otherwise renew oil pressure switch.

en
ng

t.
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op
– Increase engine speed further. At 2,000 rpm and an oil tem‐
C py
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gh
perature of 80°C the oil pressure should be at least 2.0 bar.
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At higher engine speed, oil pressure must remain below or at 7.0
cted agen
Prote AG.
bar.
Specified torque for oil pressure switch: 20 Nm

2. Oil filter, oil pressure switch 179

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

19 – Cooling
1 Cooling system/coolant

Caution

♦ Observe the following points during all installation work, in

particular in the engine compartment, due to the space
limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.

satelettronica
Note

♦ Cooling system is pressurised when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.
♦ Hose clip pliers - VAS 6340- or spring-type clip pliers - VAS
5024A- are recommended for use in installing spring-type
clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe agen
AG. Volkswagen AG d
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Test for leaks in cooling system using cooling system tester
aut - ra
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V.A.G 1274 B- and adapter for cooling system tester -s V.A.G
s

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le

1274/8- and adapter for cooling system tester - V.A.G 1274/9- .

un

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⇒ “3.1 Assembly overview - radiator/radiator fan (Eos, Golf Plus, y li

erm

ab
Scirocco, Golf, Touran, Golf Cabriolet)”, page 256 ility
ot p

wit
⇒ “1.1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco,
is n

h re

Golf, Touran, Polo, Golf Cabriolet)”, page 181

ole,

spec
urposes, in part or in wh

⇒ “1.2 Schematic diagram for coolant hoses (Tiguan)”,

t to the co

page 182
⇒ “1.3 Schematic diagram for coolant hoses (Sharan)”,
page 183
rrectne

⇒ “1.4 Coolant hose schematic diagram (Passat, Passat CC)”,

s

page 184
s o
cial p

f i

⇒ “1.5 Draining and filling with coolant (Golf Plus, Eos, Scirocco,
nform

Golf, Touran, Tiguan, Golf Cabriolet)”, page 185

mer

atio
m

⇒ “1.6 Draining and filling coolant (Polo)”, page 189

o

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c

i
or

n thi

⇒ “1.7 Draining and filling coolant (Sharan)”, page 193

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⇒ “1.8 Draining and filling coolant (Passat, Passat CC)”,

p

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page 198
en
ng

t.
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op
⇒ “1.9 Checking cooling system for leaks (Polo, Touran, Golf Plus,
C py
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Eos, Scirocco, Golf, Golf Cabriolet)”, page 204 rig ht
py by
co Vo
by lksw
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Prote AG.

180 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
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⇒ “1.10 Checking cooling system for leaks (Sharan,Vol Tiguan)”, ot g
by ua
page 206 ris
ed ran
tee
tho or
⇒ “1.11 Checking cooling system for leaks
au (Passat, Passat CC)”, ac
ss
page 208

ce
e
nl

pt
du
1.1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran,

an
itte

y li
erm

ab
Polo, Golf Cabriolet)

ility
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1 - Expansion tank hole

spec
es, in part or in w

2 - Coolant pump

t to the co
3 - Intake manifold
4 - Cylinder head and cylinder

rrectness of i
block
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❑ If renewed, refill system

with fresh coolant.

nform
ercia

5 - Heat exchanger for heater

m

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6 - Thermostat housing

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satelettronica
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7 - Radiator/cooler

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8 - Engine oil cooler

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9 - Coolant circulation pump -

n

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V50- C py
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❑ Removing and installing yri
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⇒ page 223
c by lksw
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Prote AG.
10 - Exhaust turbocharger
❑ Removing and installing
⇒ page 282
11 - Circulation pump - V55-
❑ Optional equipment
12 - Auxiliary heater
❑ Optional equipment

1. Cooling system/coolant 181

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.2 Schematic diagram for coolant hoses (Tiguan)

1 - Expansion tank
2 - Intake manifold
3 - Heat exchanger for heater
4 - Thermostat housing
5 - Engine oil cooler
6 - Radiator/cooler
7 - Coolant circulation pump -
V50-
❑ Removing and installing
⇒ page 223
8 - Exhaust turbocharger
❑ Removing and installing
⇒ page 282
9 - Cylinder head and cylinder

satelettronica
block
❑ If renewed, refill system
with fresh coolant.
10 - Auxiliary heater
❑ Optional equipment

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es, in part or in w

t to the co
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nf
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orm
m

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Prote AG.

182 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.3 Schematic diagram for coolant hoses (Sharan)

1 - Expansion tank
2 - Intake manifold
3 - Heat exchanger for heater
4 - Gear oil cooler
❑ Only vehicles with a du‐
al clutch gearbox
5 - Thermostat housing
6 - Radiator/cooler
7 - Engine oil cooler
8 - Coolant circulation pump -
V50-
❑ Removing and installing
⇒ page 234
9 - Exhaust turbocharger

satelettronica
10 - Cylinder head and cylinder
block
❑ If renewed, refill system
with fresh coolant.
AG. Volkswagen AG d
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11 - Coolant pump olksw not
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es, in part or in w

t to the co
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m

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Cop py
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Prote AG.

1. Cooling system/coolant 183

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.4 Coolant hose schematic diagram (Passat, Passat CC)

1 - Expansion tank
❑ Check cooling system
for leaks using cooling
system tester - V.A.G
1274 B- and adapter for
cooling system tester -
V.A.G 1274/8- agen
AG. Volkswagen AG d
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2 - Intake manifold d by ara
rise nte
❑ Removing and installing utho eo
ra
⇒ page 344 ss a c

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nl
3 - Charge air pipe with con‐

pt
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an
densate trap
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ab
❑ Assembly overview

ility
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⇒ page 322

wit
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4 - Heat exchanger for heater
hole

spec
5 - Gear oil cooler
es, in part or in w

t to the co

satelettronica
❑ Only vehicles with a du‐
al clutch gearbox

rrectness of i
6 - Engine preheating element
- Z97-
l purpos

❑ Removing and installing

⇒ page 253

nf
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o
7 - Thermostat

rm
m

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❑ Assembly overview
o

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c

⇒ page 211
or

thi
te

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8 - Radiator/cooler
iv

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❑ Removing and installing
o

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f

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⇒ page 267
t.
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Cop py
9 - Engine oil cooler
t. rig
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❑ Assembly overview
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cted
⇒ page 213
agen
Prote AG.

10 - Coolant circulation pump -

V50-
❑ Removing and installing ⇒ page 249
11 - Exhaust turbocharger
❑ Removing and installing ⇒ page 282
12 - Cylinder head and cylinder block
❑ If renewed, refill system with fresh coolant.
13 - Coolant pump
❑ Removing and installing ⇒ page 242
14 - Auxiliary heater
❑ Optional equipment

184 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.5 Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf, Touran,
Tiguan, Golf Cabriolet)

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
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es, in part or in w

t to the co
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l purpos

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m

♦ Refractometer - T10007 A-
atio
om

n in
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♦ Hose clamp pliers - VAS 6340-

or

thi
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sd
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♦ Coolant system charge unit - VAS 6096-

iv

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Draining
f

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t.
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WARNING
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Hot steam may escape when expansion tank is opened. Wear
Prote AG.

protective goggles and clothing to avoid eye injuries and scald‐

ing. Cover cap with a cloth and carefully open.

– Open filler cap on coolant expansion tank.

Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet
– Remove noise insulation.

1. Cooling system/coolant 185

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull off retaining clip -arrow- and remove coolant hose from
radiator.
Tiguan
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .

– Detach spring-type clip and pull off coolant hose -2-.

Disregard item -1-.
Continued for all vehicles

Note

satelettronica
Please observe disposal instructions!

Filling

Caution

Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.

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

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

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rrectness of i
l purpos

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ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
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cu
o

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f

en
ng

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

186 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐

satelettronica
ical climates.
♦ Use ONLY refractometer - T10007A- for determining current
anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible gonly
en AGif
. Vcli‐
olkswagen AG
does
matic conditions require stronger frost protection.
olkswItamay, how‐ not
yV
ever, be increased only to a maximum ofse-48°C.
d b Otherwise, gu
ara
the cooling effect will be impaired. thori nte
eo
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♦ Do not reduce the coolant concentration
ss by adding water even c

ce
le

in warmer seasons and in warmer countries. Frost protection

un

pt
must be guaranteed down to at least -25°C.
an
d
itte

y li
rm

ab
♦ Read off anti-freeze figures for respective replenished coolant
pe

ility
additives.
ot

wit
, is n

♦ The temperature read off the refractometer - T10007A- corre‐ h re

hole

spec
sponds the »ice flocculation point«. Flakes of ice may start
es, in part or in w

forming in the coolant at this temperature.

t to the co

♦ Never reuse old coolant.

♦ Use only a water/coolant additive mixture as a slip agent for
rrectness of i

coolant hoses.
l purpos

Recommended mixing ratios (use only distilled water for mixing):

nform
ercia

Frost Anti-freeze Coolant ad‐ Distilled wa‐

m

protection to proportion ditive 4) ter 4)

a
com

tion in

-25°C 40% 2.25 l 3.35 l

r
te o

thi

-36°C 50% 2.8 l 2.8 l

s
iva

do
r
rp

4) The quantity of coolant can vary depending upon vehicle equipment.

um
fo

en
ng

t.
Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Cooling system/coolant 187

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Press connection against radiator and slide retaining clip

-arrow- into groove.
– Install noise insulation.
Tiguan

– Push coolant hose -2- together with spring-type clip onto con‐
nection.
Disregard item -1-.
– Depending on vehicle equipment, install noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate . olksw
AG. V agen AG
agen does
Continued for all vehicles lksw not

satelettronica
o
yV gu
db ara
With cooling system charge unit - VAS 6096- rise nte
tho eo
au ra
– Fill coolant circuit using cooling system
ss charge unit - c
VAS 6096- ⇒ Operating instructions for cooling system charge

ce
e
nl

pt
du

unit VAS 6096 .

an
itte

y li
erm

ab
Without cooling system charge unit - VAS 6096-

ility
ot p

wit
, is n

– Fill with coolant up to max. mark on expansion tank.

h re
hole

spec
With or without cooling system charge unit - VAS 6096-
es, in part or in w

t to the co
– Fit expansion tank cap.
– Turn off heater controls.
Vehicles with no auxiliary heater rrectness of i
l purpos

– Start engine and maintain an engine speed of about 2,000 rpm

for about 3 minutes.
nf
ercia

– Run engine until radiator fan - V7- cuts in.

rm
m

atio
m

Vehicles with auxiliary heater

o

n in
or c

thi
te

sd
a

Caution
iv

o
r
rp

cu
o

m
f

en

The auxiliary heater must only be switched on when the coolant

ng

t.
yi Co
circuit is filled, described as follows: t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

188 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
n AG. Volkswagen AG do
– Connect vehicle diagnostic, testing and information system
olks
wage- es n
ot g
VAS 5051B- as follows: db
y V ua
ran
e
ris tee
– Push diagnosis cable connector onto diagnosis
tho connection in or
au
driver footwell. ss ac

ce
e
nl
– Start engine and maintain an engine speed of about 2,000 rpm

pt
du

an
for about 3 minutes.

itte

y li
erm

ab
– Press buttons on display for “Vehicle self-diagnosis”, “18 -

ility
ot p
Auxiliary/supplementary heater” and “03 - Final control diag‐

wit
, is n
nosis” one after the other.

h re
hole

spec
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- . es, in part or in w

t to the co
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed of approx. 2,000

rrectness of i
rpm for about 1 minute.
l purpos

– Run engine until radiator fan - V7- cuts in.

Continued for all vehicles

nf
ercia

orm
m

atio
WARNING
om

satelettronica
n in
or c

thi
Hot steam may escape when expansion tank is opened. Wear
te

sd
iva

protective goggles and clothing to avoid eye injuries and scald‐

o
r
rp

cu
ing. Cover cap with a cloth and carefully open.
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
– Check coolant level and top up as needed. When the engine rig ht
py by
Vo
is at normal operating temperature, the coolant level must be
co lksw
by
cted agen
on the max. mark and between the min. and max. marks when Prote AG.
the engine is cold.

1.6 Draining and filling coolant (Polo)

1. Cooling system/coolant 189

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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

satelettronica
an
d
itte

y li
erm

ab
ility
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

♦ Refractometer - T10007 A-
te

sd
iva

o
pr

♦ Hose clamp pliers - VAS 6340-

um
r
fo

en
ng

t.
♦ Coolant system charge unit - VAS 6096-
yi Co
Cop py
t. rig
Draining
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING

Hot steam may escape when expansion tank is opened. Wear

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.

– Open filler cap on coolant expansion tank.

– Remove noise insulation.
– Pull coolant hose from bottom of radiator.

Note

Observe environmental regulations for disposal.

190 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Filling

Caution

Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.

satelettronica
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
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

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.

1. Cooling system/coolant 191

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
♦ The water used for mixing has a major
s au influence on the effec‐ ra
c
tiveness of the coolant. Because the water quality differs from s

ce
e
country to country and even from region to region, the quality

nl

pt
du

an
of the water to be used in the cooling system has been speci‐

itte

y li
fied by Volkswagen. Distilled water fulfils all requirements.
erm

ab
ility
Therefore, always use only distilled water when mixing coolant
ot p

for topping up or renewing coolant.

wit
, is n

h re
hole

♦ Use only coolant additives which conform with the ⇒ Elec‐

spec
tronic parts catalogue (ETKA) . Other coolant additives may
es, in part or in w

t to the co
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.

rrectness of i
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
l purpos

the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.

nf
ercia

o
♦ Because of its high boiling point, the coolant improves engine

rm
m

atio
reliability under heavy loads, particularly in countries with trop‐
m

satelettronica
o

ical climates.

n in
or c

thi
e

♦ Use ONLY refractometer - T10007A- for determining current

t

sd
iva

anti-freeze value.

o
r
rp

cu
o

m
f

en
ng

♦ Frost protection must be guaranteed down to -25°C as a min‐

t.
yi Co
imum and, in countries with arctic conditions, down to approx. Cop py
. rig
-36°C. Increasing the frost protection is permissible only if cli‐
ht ht
rig by
py
matic conditions require stronger frost protection. It may, how‐ co Vo
by lksw
ever, be increased only to a maximum of -48°C. Otherwise, cted agen
Prote AG.
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant at this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.

Recommended mixing ratios (use only distilled water for mixing):

Frost Anti-freeze Coolant ad‐ Distilled wa‐
protection to proportion ditive 5) ter 4)
-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l
5) The quantity of coolant can vary depending upon vehicle equipment.

Polo
– Connect coolant hose to bottom of radiator.
– Install noise insulation.
With cooling system charge unit - VAS 6096-
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .

192 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Without cooling system charge unit - VAS 6096-

– Fill with coolant up to max. mark on expansion tank.

With or without cooling system charge unit - VAS 6096-
– Fit expansion tank cap.
– Turn off heater controls.
Vehicles with no auxiliary heater
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Run engine until radiator fan - V7- cuts in.
Vehicles with auxiliary heater

Caution agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
The auxiliary heater must only beoswitched
ris
ed
on when the coolant nte
circuit is filled, described as follows:
aut
h eo
ra
ss c

ce
e

satelettronica
nl

pt
du

an
itte

y li
– Connect vehicle diagnostic, testing and information system -
erm

ab
VAS 5051B- as follows:

ility
ot p

wit
– Push diagnosis cable connector onto diagnosis connection in
, is n

h re
driver footwell.
hole

spec
– Start engine and maintain an engine speed of about 2,000 rpm
es, in part or in w

t to the co
for about 3 minutes.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary/supplementary heater” and “03 - Final control diag‐

rrectness of i
nosis” one after the other.
l purpos

– Press right arrow button on display up to final control diagnosis

for heater coolant shut-off valve - N279- . nform
ercia

– Initiate final control diagnosis for heater coolant shut-off valve

m

- N279- . Continue to maintain engine speed of approx. 2,000

at
om

io

rpm for about 1 minute.

n
c

in t
or

his
e

– Run engine until radiator fan - V7- cuts in.

at

do
priv

Continued for all vehicles

um
for

en
ng

t.
yi Co
op py
WARNING
. C rig
ht ht
rig by
copy Vo
by lksw
Hot steam may escape when expansion tank is opened. Wear Prote
cted AG.
agen
protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.

– Check coolant level and top up as needed. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark and between the min. and max. marks when
the engine is cold.

1.7 Draining and filling coolant (Sharan)

1. Cooling system/coolant 193

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen

satelettronica
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
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness

♦ Refractometer - T10007 A-
o
cial p

f inform

♦ Hose clamp pliers - VAS 6340-

mer

atio

♦ Coolant system charge unit - VAS 6096-

om

n
c

i
or

Draining
thi
te

sd
iva

o
pr

cum
r

WARNING
fo

en
ng

t.
yi Co
op py
Hot steam may escape when expansion tank is opened. Wear t. C rig
gh ht
protective goggles and clothing to avoid eye injuries and scald‐ yri
p by
o Vo
ing. Cover cap with a cloth and carefully open.
by c lksw
cted agen
Prote AG.

– Open filler cap on coolant expansion tank.

– Remove engine splash guard.

194 Rep. gr.19 - Cooling

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ed ra
Eos 2006 hor ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤nt,eeGolf Plus 2005 ➤ , ...
is
t or
4-cylinder direct-injections aengine
u (1.4 l, EA 111, turbocharger, supercharger) ac - Edition 02.2019
s

ce
e
nl
– Release spring-type clip unit and pull coolant hose off -2-.

pt
du

an
itte

y li
Disregard item -1-.

erm

ab
ility
ot p

wit
, is n

h re
Note

hole

spec
es, in part or in w
Please observe disposal instructions!

t to the co
Filling

rrectness of i
Caution
l purpos

Use only distilled water for mixing coolant additives. The use

nform
ercia

of distilled water ensures optimum protection against corro‐

sion.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
op

satelettronica
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Cooling system/coolant 195

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐

satelettronica
ical climates.
♦ Use ONLY refractometer - T10007A- for determining current
anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protectiongen AG
. Volkswagen AG
does
swa
must be guaranteed down to at least -25°C. yV
olk not
gu b ara
ed
♦ Read off anti-freeze figures for respective replenished
tho
ris coolant nte
e
additives. au
or
ac
ss
♦ The temperature read off the refractometer - T10007A- corre‐
ce
e
nl

pt
du

sponds the »ice flocculation point«. Flakes of ice may start

an
itte

y li

forming in the coolant at this temperature.

erm

ab
ility
ot p

♦ Never reuse old coolant.

wit
, is n

h re

♦ Use only a water/coolant additive mixture as a slip agent for

hole

coolant hoses.
spec
es, in part or in w

t to the co

Recommended mixing ratios (use only distilled water for mixing):

Frost Anti-freeze Coolant ad‐ Distilled wa‐
rrectness of i

protection to proportion ditive 6) ter 6)

l purpos

-25°C 40% 2.25 l 3.35 l

-36°C 50% 2.8 l 2.8 l
nf
ercia

6) The quantity of coolant can vary depending upon vehicle equipment.

rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

196 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push coolant hose -2- together with spring-type clip onto con‐
nection.
Disregard item -1-.
– Install engine splash guard.
With cooling system charge unit - VAS 6096-
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
Without cooling system charge unit - VAS 6096-

– Fill with coolant up to max. mark on expansion tank.

With or without cooling system charge unit - VAS 6096-
– Fit expansion tank cap.
– Turn off heater controls.
Vehicles with no auxiliary heater
– Start engine and maintain an engine speed of about 2,000 rpm

satelettronica
for about 3 minutes.
– Run engine until radiator fan - V7- cuts in.
Vehicles with auxiliary heater
AG. Volkswagen AG d
agen oes
lksw not
Caution d byV
o gu
ara
ise nte
or eo
th
Do not switch auxiliary heater on until the scooling
au circuit has ra
c
been filled as subsequently described. s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Cooling system/coolant 197

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Connect vehicle diagnosis, testing and information system -

VAS 5051B- as follows:
– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Start engine and maintain engine speed at approx. 2,000 rpm
for approx. 3 minutes.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary heater” and “03 - Final control diagnosis” one after
the other.
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- .
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed at approx. 2,000
rpm for about 1 minute.
– Run engine until radiator fan - V7- cuts in.
Continued for all vehicles

WARNING
n AG. Volkswagen AG do

satelettronica
lkswage es n
Vo ot g
Hot steam may escape when expansionedtank by is opened. Wear ua
ran
protective goggles and clothing to avoidhor eye injuries and scald‐
is tee
ing. Cover cap with a cloth and carefully
aut
open. or
ac
ss

ce
le
un

pt
an
d

– Check coolant level and top up as needed. When the engine

itte

y li
erm

is at normal operating temperature, the coolant level must be

ab
ility
on the max. mark and between the min. and max. marks when
ot p

wit
the engine is cold.
is n

h re
ole,

spec
1.8 Draining and filling coolant (Passat,
urposes, in part or in wh

t to the co
Passat CC)
rrectne

Caution
s

Use only distilled water for mixing coolant additives. The use
s o

of distilled water ensures optimum protection against corro‐

cial p

f in

sion.
form
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
Prote AG.

198 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
♦ Refractometer - T10007 A- s
ce
e
nl

pt
du

♦ Hose clamp pliers - VAS 6340-

an
itte

y li
erm

ab

♦ Coolant system charge unit - VAS 6096-

ility
ot p

Draining
wit
, is n

h re
hole

spec

WARNING
es, in part or in w

t to the co

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

Danger of scalding by steam and hot coolant.
rrectness of i

Cover filler cap on expansion tank with a cloth and open care‐
l purpos

fully to release pressure.

nform
mercia

at
om

WARNING
ion
c

in t
or

his
e

Hot steam may escape when expansion tank is opened. Wear

at

do
riv

protective goggles and clothing to avoid eye injuries and scald‐

p

cum
or

ing. Cover cap with a cloth and carefully open.

f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
199
AG.
1. Cooling system/coolant
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Open filler cap on coolant expansion tank.

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front, noise insulation .
– Pull out retaining clip -arrow- and pull off coolant hose from
radiator.

olkswagen AG
Continued for vehicles with engine preheater heater aelement
gen AG
.V
- does
ksw
Z97- by
Vol not
gu
d ara
se nte
– Loosen spring-type clips -arrows-. thori eo
au ra

satelettronica
c
– Pull off coolant hoses -2- on engine
ss preheater heater element

ce
le

- Z97- -1-.
un

pt
an
d
itte

y li
– Allow remaining coolant to drain out.
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Continued for vehicles with condensate trap

rrectne
– Open spring-type clips -arrows-.
– Pull off coolant hose -1- and charge air pipe -2-.
ss o
cial p

– Allow remaining coolant to drain out.

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

200 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Vehicles with auxiliary heater

– Open clips and pull auxiliary heater - - coolant hoses off cool‐
ant pipes -1-.
– Allow remaining coolant to drain out.

Note

Please observe disposal instructions! AG. Volkswagen AG d

agen oes
olksw not
y V gu
b
Filling rise
d ara
nte
tho eo
au ra
s c
Caution s

ce
e
nl

pt
du

an
itte

Use only distilled water for mixing coolant additives. The use

y li
erm

ab
of distilled water ensures optimum protection against corro‐

ility
ot p

sion.

wit
, is n

h re
hole

spec
es, in part or in w

satelettronica
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
Vo
co lksw
by
cted agen
Prote AG.

1. Cooling system/coolant 201

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐

satelettronica
ical climates.
♦ Use ONLY refractometer - T10007A- for determining current
anti-freeze value. AG. Volkswagen AG d
agen oes
ksw
Frost protection must be guaranteed down to -25°C as a min‐by V l not
♦ o gu
ara
imum and, in countries with arctic conditions, down to approx. rise
d
nte
-36°C. Increasing the frost protection is permissible only ut if cli‐
ho eo
ra
matic conditions require stronger frost protection. It may, how‐
s a c
s
ever, be increased only to a maximum of -48°C. Otherwise,

ce
e
nl

pt
du

the cooling effect will be impaired.

an
itte

y li
erm

♦ Do not reduce the coolant concentration by adding water even

ab
ility
in warmer seasons and in warmer countries. Frost protection
ot p

wit
must be guaranteed down to at least -25°C.
, is n

h re
hole

♦ Read off anti-freeze figures for respective replenished coolant

spec
additives.
es, in part or in w

t to the co
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant at this temperature.

rrectness of i
♦ Never reuse old coolant.
l purpos

♦ Use only a water/coolant additive mixture as a slip agent for

coolant hoses.
nform
mercia

at
om

Recommended mixing ratios (use only distilled water for mixing):

ion
c

in t
or

Frost Anti-freeze Coolant ad‐ Distilled wa‐

his
ate

protection to proportion ditive 7) ter 7)

do
priv

cum
or

-25°C 40% 2.25 l 3.35 l

f

en
ng

t.
-36°C 50% 2.8 l 2.8 l
yi Co
Cop py
t. rig
gh ht
7) The quantity of coolant can vary depending upon vehicle equipment. copyri by
Vo
by lksw
cted agen
Prote AG.

202 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Press connection against radiator and slide retaining

agen
Aclip
G. Volkswagen AG d
oes
-arrow- into groove. V olksw not
g by ua
ed ran
– Secure spring-type clips using hose clip
ho
ris pliers - VAS 6340- or tee
spring-type clip pliers - VAS 5024A-
a .
ut or
ac
ss
– When installing coolant hoses, route stress-free so that they

ce
e
nl

pt
du
do not come into contact with other components (observe

an
itte

y li
markings on coolant connection and hose).

erm

ab
ility
ot p
– Install noise insulation ⇒ General body repairs, exterior; Rep.

wit
gr. 50 ; Body - front, noise insulation . , is n

h re
hole

With cooling system charge unit - VAS 6096-

spec
es, in part or in w

– Fill coolant circuit using cooling system charge unit -

t to the co
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .

rrectness of i
Without cooling system charge unit - VAS 6096-
l purpos

– Fill with coolant up to max. mark on expansion tank.

nf
ercia

With or without cooling system charge unit - VAS 6096-

orm
m

atio
– Fit expansion tank cap.
m

satelettronica
o

n in
c

– Switch off heater controls.

or

thi
te

sd
iva

Vehicles with auxiliary heater

o
r
rp

cu
o

m
f

– Start engine and keep engine speed at approx. 2000 rpm for

en
ng

t.
yi
about 3 minutes.
Co
Cop py
t. rig
gh
– Run engine until radiator fan - V7- cuts in.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution

The auxiliary heater must only be switched on when the coolant

circuit is filled, described as follows:

1. Cooling system/coolant 203

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Connect vehicle diagnosis, testing and information system -

VAS 5051B- as follows:
– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Start engine and keep engine speed at approx. 2000 rpm for
about 3 minutes.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary heater” and “03 - Final control diagnosis” one after
the other.
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- .
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed at approx. 2,000
rpm for about 1 minute.
– Run engine until radiator fan - V7- cuts in.
Continued for all vehicles

WARNING

satelettronica
Hot steam may escape when expansion tank is opened. Wear
protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.

– Check coolant level and top up as needed. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark and between the min. and max. marks when
the engine is cold.

1.9 Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Scirocco,
Golf, Golf Cabriolet)
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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
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
co lksw
by
cted agen
204
Prote AG.
Rep. gr.19 - Cooling
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
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
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
♦ Cooling system tester - V.A.G 1274 B-
urposes, in part or in wh

t to the co
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-
rrectne

Test conditions
• Engine at operating temperature.
ss o
cial p

Test sequence
inform
mer

atio
m

WARNING
o

n
c

i
or

n thi
e

Hot steam may escape when expansion tank is opened. Place

t

sd
va

cloth over cap and open with caution.

i

o
pr

cum
r
fo

en
ng

t.
yi Co
op py
– Open cap on coolant expansion tank. t. C rig
gh ht
pyri by
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
o Vo
by c lksw
cted
expansion tank.
agen
Prote AG.

– Clamp connector - V.A.G 1274 B/1- into adapter for cooling

system tester - V.A.G 1274/8- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.

1. Cooling system/coolant 205

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Use hand pump on tester to create a pressure of about 1.0 bar.

• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.

Note

A pressure drop of 0.2 bar within 10 minutes is caused by the

coolant cooling down. The colder the engine, the lower the pres‐
sure loss. If necessary, repeat the check
agen
AG. Vowhile the
lkswage engine
n AG do is cold.
ksw es n
Vol ot g
d by ua
ran
e
ris tee
WARNING
au
tho or
ac
ss

ce
e

Risk of scalding! Before disconnecting cooling system tester -

nl

pt
du

V.A.G 1274 B- from connecting hose or connector - V.A.G

an
itte

y li
1274 B/1- , always relieve existing pressure. To do this, press
erm

ab
pressure relief valve on cooling system tester - V.A.G 1274 B-

ility
ot p

until pressure gauge displays value of »0«.

wit
, is n

h re
hole

spec
es, in part or in w

If pressure drops by more than 0.2 bar:

satelettronica
t to the co
– Find leaks and rectify.
Check pressure relief valve in cap.

rrectness of i
– Screw cap into adapter for cooling system tester - V.A.G
l purpos

1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
nf
ercia

system tester - V.A.G 1274/9- .

rm
m

atio
m

– Join connection piece - V.A.G 1274 B/1- to cooling system

o

n in
c

tester - V.A.G 1274 B- using connecting hose supplied.

or

thi
te

sd
a

– Use hand pump on cooling system tester to create a pressure

iv

o
r
rp

of max. 1.4 bar.

cu
o

m
f

en
ng

t.
The pressure relief valve must still remain closed.
yi Co
Cop py
t. rig
If the pressure relief valve opens prematurely: gh ht
pyri by
Vo
o
by c lksw
– Renew sealing cap. Prote
cted AG.
agen

– Increase pressure to over 1.4 bar.

The pressure relief valve must open.
If the pressure relief valve does not open:
– Renew sealing cap.

1.10 Checking cooling system for leaks (Sharan, Tiguan)

206 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

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
c

satelettronica
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
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

♦ Cooling system tester - V.A.G 1274 B-

n in
or c

thi
e

♦ Adapter for cooling system tester - V.A.G 1274/8-

t

sd
iva

o
r
rp

cu

♦ Adapter for cooling system tester - V.A.G 1274/9-

o

m
f

en
ng

t.
yi
Test conditions
Co
Cop py
t. rig
gh
• Engine at operating temperature.
ht
pyri by
Vo
co lksw
by
Test sequence
cted agen
Prote AG.

WARNING

Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.

– Open filler cap on coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.

1. Cooling system/coolant 207

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Generate about 1.0 bar pressure using hand pump of tester.

WARNING

Risk of scalding! Before disconnecting cooling system tester -

V.A.G 1274 B- from connecting hose or connector - V.A.G
1274 B/1- , always relieve existing pressure. To do this, press
pressure relief valve on cooling system tester - V.A.G 1274 B-
until pressure gauge displays value of »0«.

If the pressure drops:

– Find leaks and rectify.
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Join connection piece - V.A.G 1274 B/1- to cooling system

satelettronica
tester - V.A.G 1274 B- using connecting hose supplied.
– Build up pressure to maximum 1.6 bar using hand pump on
cooling system tester.
The pressure relief valve must still remain closed.
If the pressure relief valve opens prematurely:
– Renew cap.
– Increase pressure to over 1.6 bar.
The pressure relief valve must open. n AG. Volkswagen AG do
lkswage es n
If the pressure relief valve does not open: d byV
o ot g
ua
ran
ir se tee
– Renew cap. utho
or
a ac
ss
1.11 Checking cooling system for leaks (Passat, Passat CC)
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

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.

208 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
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
hole

spec
es, in part or in w

♦ Cooling system tester - V.A.G 1274 B-

t to the co
♦ Adapter for cooling system tester - V.A.G 1274/8-
rrectness of i
♦ Adapter for cooling system tester - V.A.G 1274/9-
l purpos

Test conditions
• Engine at operating temperature.
nform
ercia

Test sequence
m

at
om

ion
c

WARNING
in t
or

his
ate

do
riv

Hot steam may escape when expansion tank is opened. Place

p

cum
or

cloth over cap and open with caution.

f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
– Open filler cap on coolant expansion tank. py by
co Vo
by lksw
cted agen
– Screw adapter for cooling system tester - V.A.G 1274/8- into Prote AG.
coolant expansion tank.
– Screw connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.

1. Cooling system/coolant 209

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Generate about 1.0 bar pressure using hand pump of tester.

WARNING

Risk of scalding! Before the cooling system tester - V.A.G 1274

B- is disconnected from the connecting hose or the connector
- V.A.G 1274 B/1- it is essential that the pressure is first re‐
lieved. To do this, press pressure relief valve on cooling system
tester - V.A.G 1274 B- until pressure gauge displays value of
»0«.

If the pressure drops:

– Find leaks and rectify.
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .

satelettronica
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.
– Build up pressure to maximum 1.4 bar using hand pump on
cooling system tester.
The pressure relief valve must still remain closed.
If the pressure relief valve opens prematurely:
– Renew cap.
– Increase pressure to over 1.4 bar.
The pressure relief valve must open. AG. Volkswagen AG d
agen oes
ksw not
If the pressure relief valve does not open: byV
ol
gu
ara
ed
is nte
– Renew cap. hor eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

210 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - thermostat”, page 211
⇒ “2.2 Assembly overview - thermostat (Passat, Passat CC)”,
page 213
⇒ “2.3 Removing and installing coolant pump (Polo, Touran, Golf
Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)”, page 214
⇒ “2.4 Removing and installing coolant pump belt pulley (Polo,
Touran, Golf Plus, Eos, Tiguan, Scirocco,AG. Volkswagen AG d
swagen Golf, Golf Cabriolet)”,
oes
page 218 by Vol
k not
gu
a d ran
se
⇒ “2.5 Removing and installing
ho
ri coolant circulation pump V50 (Po‐ tee
ut or
lo, Touran, Golf Plus,
ss Eos,
a Tiguan, Scirocco, Golf, Golf Cabrio‐ ac
let)”, page 223

ce
le
un

pt
an
⇒ “2.6 Removing and installing coolant pump (Sharan)”,
d
itte

y li
page 225
rm

ab
pe

ility
⇒ “2.7 Removing and installing coolant pump belt pulley (Shar‐
ot

wit
, is n

an)”, page 230

h re

satelettronica
hole

spec
⇒ “2.8 Removing and installing coolant circulation pump V50
es, in part or in w

(Sharan)”, page 234

t to the co
⇒ “2.9 Removing and installing coolant pump belt pulley (Passat,
Passat CC)”, page 236

rrectness of i
⇒ “2.10 Removing and installing coolant pump (Passat, Passat
l purpos

CC)”, page 242

⇒ “2.11 Removing and installing coolant circulation pump V50
nform
ercia

(Passat, Passat CC)”, page 249

m

⇒ “2.12 Assembly overview - heater element for engine preheater

a
com

tio

Z97 (Passat, Passat CC)”, page 251

n in
r
te o

thi

⇒ “2.13 Removing and installing heater element for engine pre‐

s
iva

do

heater Z97 (Passat, Passat CC)”, page 253

r
rp

cum
fo

en
g

2.1 Assembly overview - thermostat

n

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

2. Coolant pump, regulation of cooling system 211

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - Union
2 - O-ring
❑ Renew
3 - Compression spring
4 - Plunger
❑ Do not cant when instal‐
ling
5 - Thermostat 2
❑ Starts to open at 96 °C
6 - Radiator outlet coolant -
G62-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
7 - Retaining clip
❑ Check for firm seating
8 - Thermostat housing

satelettronica
❑ Specified torque: 10 Nm
9 - Seal
❑ Renew
10 - Thermostat 1
❑ Starts to open at 80 °C
11 - To expansion tank
❑ Coolant hose schematic AG. Volkswagen AG d
diagram (Golf Plus, Eos, agen oes
olksw not
Scirocco, Golf, Touran, byV gu
ara
ed
Polo, Golf Cabriolet) horis nte
eo
⇒ page 181 s aut ra
c
s
❑ Coolant hose schematic
ce
e
nl

pt

diagram (Tiguan)
du

an
itte

⇒ page 182
y li
erm

ab
ility

12 - Union
ot p

wit
, is n

13 - Coolant pipe
h re
hole

spec

❑ To remove, remove thermostat housing ⇒ Item 8 (page 212) .

es, in part or in w

❑ To remove, remove supercharger ⇒ page 299 .

t to the co

❑ Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet)
⇒ page 181
rrectness of i

❑ Coolant hose schematic diagram (Tiguan) ⇒ page 182

l purpos

14 - Coolant pipe
❑ To remove, remove thermostat housing ⇒ Item 8 (page 212) .
nform
ercia

❑ To remove, remove supercharger ⇒ page 299 .

m

at

❑ Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet)
om

io

⇒ page 181
n
c

in t
or

his
e

❑ Coolant hose schematic diagram (Tiguan) ⇒ page 182

at

do
priv

15 - 5 Nm
um
for

en
ng

t.
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16 - From bottom of radiator.
Co
Cop py
.
❑ Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet)
ht rig
rig ht
by
⇒ page 181 copy Vo
by lksw
cted agen
❑ Coolant hose schematic diagram (Tiguan) ⇒ page 182 Prote AG.

212 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

17 - To top of radiator
❑ Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet)
⇒ page 181
❑ Coolant hose schematic diagram (Tiguan) ⇒ page 182

2.2 Assembly overview - thermostat (Passat, Passat CC)

. Volkswagen AG
gen AG
Components onkengine does
swa ol not
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1 - Coolant
ut
ho pump eo
ra
a c
❑ss Removing and installing

ce
e

⇒ page 242
nl

pt
du

an
itte

y li
2 - Bolt
erm

ab
❑ 8 Nm

ility
ot p

wit
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❑ Qty. 3

h re
hole

3 - Engine preheating element

spec
es, in part or in w

- Z97-

t to the co

satelettronica
❑ Removing and installing
⇒ page 253

rrectness of i
4 - Bolt
l purpos

❑ 10 Nm
5 - Bolt
nform
ercia

❑ 10 Nm
m

❑ Qty. 3
at
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ion
c

6 - Charge air pipe with con‐

in t
or

his
e

densate trap
at

do
riv

❑ Assembly overview
p

cum
or

⇒ page 322
f

en
ng

t.
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op
7 - Engine
C py
t. rig
gh ht
yri by
8 - Bolt cop Vo
by lksw
cted agen
❑ 10 Nm Prote AG.

9 - Coolant circulation pump -

V50-
❑ Removing and installing
⇒ page 249
10 - Bolt
❑ 5 Nm
❑ Qty. 4
11 - Thermostat
❑ Assembly overview ⇒ page 211
12 - Bolt
❑ 8 Nm
❑ Qty. 5
13 - Oil cooler

2. Coolant pump, regulation of cooling system 213

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.3 Removing and installing coolant pump

(Polo, Touran, Golf Plus, Eos, Tiguan,
Scirocco, Golf, Golf Cabriolet)

Note

Coolant pump seal is bonded in position. If the seal is damaged,

the coolant pump must be renewed.

Special tools and workshop

equipment required

satelettronica
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
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm

♦ Refractometer - T10007 A-
m

atio
om

n in

♦ Hose clamp pliers - VAS 6340-

or c

thi
te

♦ Coolant system charge unit - VAS 6096-

sd
iva

o
r
rp

cu

♦ Torque wrench - V.A.G 1331- (not illustrated)

o

m
f

en
ng

t.
yi Co
♦ 16 mm open-end spanner - T10241- (not shown) ht. Cop py
rig
rig ht
♦ Bit - T10451- (not shown) py by
co Vo
by lksw
cted agen
Prote AG.

214 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
– Drain coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan,
Golf Cabriolet) ⇒ page 185 .
– Drain coolant (Polo) ⇒ page 189 .
– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.

– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove

satelettronica
pressure pipe.

– Unscrew hose clip -1- on charge air pipe.

– Open hose clip -2- and pull out hose.
AG. Volkswagen AG d
agen oes
– Unscrew securing bolt for charge air
Vol pipe -3-.
ksw not
gu
y
db ara
Polo rise nte
tho eo
au ra
– Remove engine mounting
ss ⇒ page 66 . c
ce
e
nl

Continued for all vehicles

pt
du

an
itte

y li

– Remove bracket -4-.

erm

ab
ility
ot p

wit
, is n

h re
hole

spec

– To do so, remove bolts -arrows-.

es, in part or in w

t to the co

– Remove bracket -1-.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
215
agen
Prote AG.
2. Coolant pump, regulation of cooling system
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
Removing poly V-belt (Tiguan) ⇒ page 78 .
Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo,
Golf Cabriolet) ⇒ page 75 .

AG. Volkswagen AG d
agen oes
o lksw not
yV gu
– Push securing clip at charge air cooler in direction
ed b of -arrow- ara
nte
is
and pull hose -arrow- off. hor eo
aut ra
ss c

ce
e
nl

Note

pt
du

an
itte

y li
erm

ab
Charge air hoses with screw-type clips are also installed.

ility
ot p

wit
, is n

satelettronica
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Remove securing bolt -arrow- for charge air pipe -1-.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
– Unscrew securing bolt for charge air pipe -arrow- and remove
by lksw
cted agen
charge air pipe -1- downwards.
Prote AG.

Only vehicles with auxiliary heater

– Remove coolant hoses for auxiliary heater.
Continued for all vehicles

216 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Carefully press locking lugs on noise insulation housing for

supercharger -arrows- outwards.
– Pull off front housing with noise insulation.
– Remove charge air pipe downwards.
Tiguan with four-wheel drive
– Remove front exhaust pipe ⇒ page 402 .

Note

The front exhaust pipe is only unbolted at the attaching points and
placed down on the subframe.

– Release tension from supercharger poly V-belt by swinging

tensioning element using open-end spanner, 16 mm -
T10241- .
– Lock tensioning element using locking pin - T10060 A- .

AG. Volkswagen AG d

satelettronica
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

– Unscrew securing bolts -arrows- for tensioning element and

wit
remove tensioning element.
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

– Hold supercharger shaft with 16 mm spanner -1-.

n
c

i
or

n thi
e

– Remove securing bolt -2- for pulley and remove pulley and
t

sd
iva

supercharger poly V-belt -3-.

pr

cum
r
fo

en
ng

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

2. Coolant pump, regulation of cooling system 217

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Loosen bolts for coolant pump with magnetic clutch for super‐
charger - N421- -arrows- with the bit - T10451- .
– Remove coolant pump with magnetic clutch for supercharger
- N421- from cylinder block.
AG. Volkswagen AG d
Installing lksw
agen oes
not
Vo gu
d by ara
ise nte
or eo
Note auth
ra
ss c

ce
e

Coolant pump seal is bonded in position. If the seal is damaged,

nl

pt
du

an
the coolant pump must be renewed.
itte

y li
erm

ab
ility
ot p

Installation is carried out in the reverse order. When installing,

wit
, is n

note the following:

h re
hole

spec
– Insert coolant pump with magnetic clutch for supercharger -
es, in part or in w

N421- into cylinder block.

t to the co
– Tighten securing bolts to 8 Nm.
– Place poly v-belt on the magnetic clutch for supercharger -

rrectness of i
N421- .
l purpos

satelettronica
– Bolt on supercharger pulley with poly-v-belt and new securing
bolt.

nf
ercia

Specified torques: orm

m

atio
om

n in
c

Caution
or

thi
te

sd
iva

The screw-type clips on the charge air pipes must be tightened

o
r
rp

cu
o

to 5.5 Nm. If the torque is too low or too high, the charge air
m
f

en
ng

t.
hose may slip off the charge air pipe during vehicle operation. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
by c
Assembly overview - part I, belt drive ⇒ page 71 .
lksw
cted agen
Prote AG.
Assembly overview - supercharger ⇒ page 297
Assembly overview - charge air system (Golf Plus, Eos, Scirocco,
Golf, Touran, Tiguan, Golf Cabriolet) ⇒ page 320
Assembly overview - charge air system (Polo) ⇒ page 321
Install poly V-belt (Tiguan) ⇒ page 78 .
Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet,
Touran, Polo) ⇒ page 75
Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf,
Golf Cabriolet, Touran, Tiguan) ⇒ page 185
Draining and filling with coolant (Polo) ⇒ page 189

2.4 Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus,
Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)

218 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
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

♦ Socket XZN 10 - T10154-

hole

spec

♦ Hose clamp pliers - VAS 6340-

es, in part or in w

t to the co

♦ Torque wrench - V.A.G 1331-

Removing
rrectness of i

Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo

l purpos

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front, noise insulation .
nform
ercia

Tiguan
m

at
om

io

– Depending on vehicle equipment, remove noise insulation or

n
c

in t
or

skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐

his
ate

moving and installing noise insulation or skid plate .

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.

2. Coolant pump, regulation of cooling system 219

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Continued for all vehicles

– Pull retaining clip in direction of -arrow- and pull out charge air
hose -1- from charge air pipe.

Note

Charge air hoses with screw-type clips are also installed.

– Unscrew securing bolt for charge air pipe -arrow-.

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

satelettronica
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

– Remove securing bolt -arrow- for charge air pipe -1-.

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
g

– Release and pull off connector -1- on oil level and oil temper‐
n

t.
yi Co
op
ature sender - G266- . C py
t. rig
gh ht
yri
– Unclip bracket -2- for electric wire to oil level and oil tempera‐
p by
o Vo
by c lksw
ture sender - G266- . Prote
cted AG.
agen

Only vehicles with auxiliary heater

– Remove coolant hoses for auxiliary heater.
Continued for all vehicles

220 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Carefully press locking tabs on noise insulation housing for

supercharger -arrows- outwards.
– Pull off housing with noise insulation and place to one side.

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Detach fuel supply line -1- and line leading to activated char‐ s ce
e
nl

coal filter -2- by pressing the release tabs.

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

– Pull off hose -1- from pressure pipe.

nform
ercia

– Unscrew securing bolts -2- from pressure pipe and remove

pressure pipe.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

2. Coolant pump, regulation of cooling system 221

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew hose clip -1- on charge air pipe.

– Open hose clip -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3-.
– Remove bracket -4-.

AG. Volkswagen AG d
agen oes
olksw not
– To do so, remove bolts -arrows-.
d by
V gu
ara
ise nte
r
– Remove bracket -1-. utho eo
ra
s a c
s

ce
le
un

pt
Note

an
d
itte

y li
rm

ab
pe

Charge air pressure sender - G31- with intake air temperature

ility
ot

sender 2 - G299- is installed on rear of charge air pipe.

wit
, is n

satelettronica
h re
hole

spec
es, in part or in w

t to the co
– Unscrew bolts -arrows- and remove charge pressure sender -

rrectness of i
G31- -1-.
l purpos

– Remove charge air pipe downwards. 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
– Loosen securing bolts -1- for coolant pump pulley.
o Vo
by c lksw
cted agen
Prote AG.

WARNING

As the poly V-belt is still tensioned, the pulley securing bolts

must not yet be removed.

– Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cab‐
riolet, Touran, Polo) ⇒ page 75 .
– Remove poly V-belt (Tiguan) ⇒ page 78 .

222 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolts -1- and pull pulley from coolant pump.
Installing

– Position pulley on coolant pump and tighten securing bolts

-1- hand-tight.
– Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cab‐
riolet, Touran, Polo) ⇒ page 75 .
– Install poly V-belt (Tiguan) ⇒ page 78 .
– Tighten securing bolts to 24 Nm.

satelettronica
Further installation is carried out in reverse order of removal.
When installing, note the following:
Specified torques:
Assembly overview - charge air system ⇒ page 320
Assembly overview - intake manifold ⇒ page 344 .

– Push engine cover panel down at points -1- in direction of

-arrow- until it engages.

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

pt
an
d
itte

y li
erm

ab

2.5 Removing and installing coolant circulation pump - V50- (Polo, Touran, Golf
ility
ot p

wit
is n

Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)

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
ht. rig
rig ht
py by
co Vo
by lksw

223
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
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

♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
nf
ercia

or

♦ Torque wrench - V.A.G 1331-

m
m

atio
om

n in
c

♦ Hose clamps to 40 mm - 3093-

or

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

Removing
Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front, noise insulation .

224 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Tiguan
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
Continued for all vehicles
– Seal coolant hoses with hose clamps up to 40 mm - 3093- .
– Remove spring-type clips -arrows- and pull coolant hoses off.
– Pull connector -1- off and remove securing bolt -2-.
– Remove coolant circulation pump - V50- -3-.
Installing
Volkswa
Installation is carried out in the reverse aorder.
gen AG When installing,
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does
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note the following: by Vol not
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a d ran
se
Specified torque for securing
tho bolt: 10 Nm.
ri tee
or
au ac
– Check coolant level;ssreplenish as necessary (Golf Plus, Eos,

ce
e

Scirocco, Golf, Golf Cabriolet, Touran, Tiguan) ⇒ page 185 .

nl

pt
du

an
itte

y li
– Check coolant level; replenish as necessary (Polo)
erm

ab

satelettronica
⇒ page 189 .

ility
ot p

wit
, is n

h re
2.6 Removing and installing coolant pump
hole

spec
(Sharan)
es, in part or in w

t to the co
Note

rrectness of i
Coolant pump seal is bonded in position. If the seal is damaged,
l purpos

the coolant pump must be renewed.

nform
mercia

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c

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or

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2. Coolant pump, regulation of cooling system 225

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lk s ot g
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4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger,
ir se
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tho eo
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equipment required

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es, in part or in w

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en
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t.
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♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-
♦ Bit - T10451- (not shown)
Removing
– Drain coolant ⇒ page 193 .
– Disconnect the fuel supply line -1- and line from activated
charcoal filter system solenoid valve 1 - N80- -2- on the clutch.

Note

Press in securing ring to release fuel and breather lines.

– Seal lines so that no dirt is able to enter fuel system.

– Observe rules for cleanliness ⇒ page 7 .

226 Rep. gr.19 - Cooling

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agen oes
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tee 2005 ➤ , ...
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4-cylinder direct-injection engineau(1.4
th l, EA 111, turbocharger, supercharger) - Edition or
ac 02.2019
ss

ce
le
– Pull off hose -1- from pressure pipe.

un

pt
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– Unscrew securing bolts -2- from pressure pipe and remove

erm

ab
pressure pipe.

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urposes, in part or in wh

t to the co
rrectness o
cial p

f
– Unscrew hose clip -1- on charge air pipe.

inform
mer

– Open hose clip -2- and pull out hose.

atio
om

n
– Unscrew securing bolt for charge air pipe -3-.
c

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n thi
te

– Remove bracket -4-.

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t.
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Cop py
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rig ht
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– To do so, remove bolts -arrows-.

– Remove bracket -1-.

– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
Remove poly V-belt ⇒ page 75 .

2. Coolant pump, regulation of cooling system 227

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push securing clip at charge air cooler in direction of -arrow-

and pull hose -arrow- off.

– Remove securing bolt -arrow- for charge air pipe -1-.

Only vehicles with auxiliary heater
– Remove coolant hoses for auxiliary heater.
Continued for all vehicles

satelettronica
– Carefully press locking lugs on noise insulation housing for
supercharger -arrows- outwards. G. Volkswagen nA AG do
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– Pull off front housing with noise insulation.
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pe

ility
ot

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h re
hole

spec
es, in part or in w

– Unscrew the securing bolt for charge air pipe -arrows- and re‐
t to the co

move charge air pipe -1- downwards.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
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228 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Release tension from supercharger poly V-belt by swinging

tensioning element using open-end spanner, 16 mm -
T10241- .
– Lock tensioning element using locking pin - T10060 A- .

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agen oes
– Unscrew securing bolts -arrows- for tensioning
Vol
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satelettronica
wit
, is n

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spec
es, in part or in w

t to the co
– Hold supercharger shaft with 16 mm spanner -1-.

rrectness of i
– Remove securing bolt -2- for pulley and remove pulley and
l purpos

supercharger poly V-belt -3-.

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2. Coolant pump, regulation of cooling system 229

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Loosen bolts for coolant pump with magnetic clutch for super‐
charger - N421- -arrows- with the bit - T10451- .
– Remove coolant pump with magnetic clutch for supercharger
- N421- from cylinder block.
Installing

Note

Coolant pump seal is bonded in position. If the seal is damaged,

the coolant pump must be renewed.

Installation is carried out in the reverse order. When installing,

note the following:
– Insert coolant pump with magnetic clutch for supercharger -
N421- into cylinder block.
– Tighten securing bolts to 8 Nm.
– Place poly v-belt on the magnetic clutch for supercharger -
N421- .

satelettronica
– Bolt on supercharger pulley with poly-v-belt and new securing
bolt.
Specified torques:
Assembly overview - part I, belt drive ⇒ page 71 .
Assembly overview - supercharger ⇒ page 297 .
Assembly overview - charge air system ⇒ page 320 .
Install poly V-belt ⇒ page 75 .
– Add coolant ⇒ page 193 .

2.7 Removing and installing coolant pump does belt pulley (Sharan)
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Prote AG.

230 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
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♦ Socket XZN 10 - T10154- s aut ra
c
s
♦ Hose clamp pliers - VAS 6340-
ce
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un

pt
an
d
itte

♦ Torque wrench - V.A.G 1331-

y li
erm

ab
ility

Removing
ot p

wit
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– Remove engine splash guard at bottom.

h re
ole,

spec

– Pull retaining clip in direction of -arrow- and pull charge air

urposes, in part or in wh

hose -1- out of charge air pipe.

t to the co
rrectness o
cial p

f inform
mer

atio
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n
c

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231
by lksw
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Prote 2. Coolant pump, regulation of cooling system
AG.
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew the securing bolt for charge air pipe -arrow-.

– Remove securing bolt -arrow- for charge air pipe -1-.

satelettronica
AG. Volkswagen AG d
agen oes
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– Lift engine cover panel at points -1- and pull it forwards in di‐
pt
du

an

rection of -arrow-.
itte

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ility
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spec
es, in part or in w

t to the co
rrectness of i
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– Disconnect the fuel supply line -1- and line from activated
nf
ercia

charcoal filter system solenoid valve 1 - N80- -2- on the clutch.

rm
m

atio
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n in
or c

Note
thi
te

sd
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rp

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Press in securing ring to release fuel and breather lines.

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t.
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op
– Seal lines so that no dirt is able to enter fuel system.
C py
t. rig
gh ht
yri by
– Observe rules for cleanliness ⇒ page 7 . cop Vo
by lksw
cted agen
Prote AG.

232 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.

– Unscrew hose clip -1- at charge air pipe.

– Open hose clip -2- unit and pull hose off.
– Unscrew securing bolt for charge air pipe -3- and pull connec‐
tor off charge air pressure sender - G31- with intake air tem‐
perature sender 2 - G299- .
– Remove holder -4-.

satelettronica
– Unscrew bolts -arrows- and remove charge pressure sender -
G31- -1-.

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Charge air pressure sender - G31- twith
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ss
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itte

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ility
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wit
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– Loosen securing bolts -1- for coolant pump pulley.

hole

spec
es, in part or in w

t to the co

WARNING

As the poly V-belt is still tensioned, the pulley securing bolts

rrectness of i

must not yet be removed.

l purpos

– Remove poly V-belt ⇒ page 75 .

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.

2. Coolant pump, regulation of cooling system 233

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolts -1- and pull pulley from coolant pump.
Installing

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pt
– Position pulley on coolant pump and tighten securing bolts

du

an
itte
-1- hand-tight.

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erm

ab
ility
– Install poly V-belt ⇒ page 75 .
ot p

wit
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– Tighten securing bolt to 24 Nm.

h re
hole

spec
Further installation is carried out in reverse order of removal.
es, in part or in w

When installing, note the following:

t to the co

satelettronica
Specified torques:

rrectness of i
Assembly overview - charge air system ⇒ page 320
l purpos

Assembly overview - intake manifold ⇒ page 344 .

nf
ercia

– Push engine cover panel down at points -1- in direction of

or
-arrow- until it engages.

m
m

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or c

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t.
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2.8 Removing and installing coolant circulation pump - V50- (Sharan)

234 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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

♦ Refractometer - T10007 A-
l purpos

♦ Hose clamp pliers - VAS 6340-

nform
ercia

♦ Torque wrench - V.A.G 1331-

m

at
om

io

♦ Hose clamps to 40 mm - 3093-

n
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
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pyri by
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Prote AG.

Removing
– Remove engine splash guard at bottom.
– Seal coolant hoses with hose clamps up to 40 mm - 3093- .

2. Coolant pump, regulation of cooling system 235

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove spring-type clips -arrow- and pull coolant hoses off.

– Pull connector -1- off and remove securing bolt -2-.
– Remove continued coolant circulation pump - V50- .
Installing
Installation is carried out in the reverse order. When installing,
note the following:
AG. Volkswagen AG d
Specified torque for securing bolt: 10 Nm. agen oes
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– Check coolant level; replenish as necessary
rise
d
(Sharan) nte
⇒ page 193 . autho eo
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ce
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un

pt
2.9 Removing and installing coolant pump belt pulley (Passat, Passat CC)

an
d
itte

y li
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ab
pe

ility
ot

Special tools and workshop

wit
, is n

equipment required

h re
hole

spec
es, in part or in w

t to the co

satelettronica
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.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.

♦ Socket XZN 10 - T10154-

♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-

236 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Hose clamps to 40 mm - 3093-

Removing

WARNING

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

Danger of scalding by steam and hot coolant.

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

– Remove noise insulation ⇒ General body repairs, exterior; G. Volkswagen

Rep. gr. 50 ; Body - front, noise insulation . lksw
agen
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– Pull retaining clip in direction of -arrow- and pull eout
d b charge air ran
ris tee
hose -1- from charge air pipe. ut
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Note

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Charge air hoses with screw-type clips are also installed

ility
ot p

⇒ page 335 .

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Unscrew securing bolt for charge air pipe -arrow-.
ss o
cial p

f inform
mer

atio
om

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c

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or

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te

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2. Coolant pump, regulation of cooling system 237

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove securing bolt -arrow- for charge air pipe -1-.

– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
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– Unclip bracket -2- on subframe for electric wire to oil level
ksw
and
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oil temperature sender - G266- . by
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an
d
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ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

Vehicles with condensate trap on charge air pipe

t to the co
– Clamp off coolant hoses -1- using hose clamps, up to 40 mm in
diameter - 3093- .

rrectne
– Open clamps -arrows-.
– Pull off coolant hoses -1- on charge air pipe -2-.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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Vehicles with engine preheater heater element - Z97-

fo

en
ng

t.
yi Co
– Unclip wire -1- to engine preheater heater element - Z97- on t. Cop py
charge air pipe -2- -arrow-.
rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

238 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Vehicles with auxiliary heater

– Seal coolant hoses to auxiliary heater - Z- with hose clamps
up to 40 mm - 3093- .
– Drain coolant ⇒ page 198 .
– Pull coolant hoses for auxiliary heater - Z- off coolant pipes
-1-.

Continued for all vehicles

– Carefully press locking tabs on noise insulation housing for
supercharger -arrows- outwards.
– Pull off housing with noise insulation and place to one side.

Note

satelettronica
Housing with noise insulation remains in vehicle.

n AG. Volkswagen AG do
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– Lift off engine cover at points -1- and pull it forwards in direction
byV ua
ed ran
of -arrow-. oris tee
th or
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ss

ce
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un

pt
an
d
itte

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ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Pull off fuel supply line -1- and line leading to activated char‐

rrectne
coal filter -2- by pressing release tabs.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
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
gh ht
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Vo
co lksw
by
cted agen
Prote AG.

2. Coolant pump, regulation of cooling system 239

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.

– Unscrew hose clip -1- on charge air pipe.

– Open hose retainer -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3- and pull off con‐
nector from charge air pressure sender - G31- with intake air
temperature sender 2 - G299- .
– Remove bracket -4-.

satelettronica
AG. Volkswagen AG d
agen oes
lksw not
– To do this, unscrew by bolts -arrows-.
Vo gu
ara
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– Remove bracket
ut
hor
-1-. eo
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pt
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ab
pe

ility
ot

wit
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h re
hole

spec
es, in part or in w

t to the co

– Unscrew bolts -arrows- and remove charge pressure sender -

rrectness of i

G31- -1-.
l purpos

– Remove charge air pipe downwards.

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
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by c lksw
cted agen
Prote AG.

240 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Loosen securing bolts -1- for coolant pump belt pulley.

WARNING

As the poly V-belt is still tensioned, the pulley securing bolts

must not yet be removed.

– Remove poly V-belt ⇒ page 75 .

– Unscrew securing bolts -1- and pull off belt pulley from coolant
pump.
Installing
Install in reverse order of removal. When doing this, observe the
following: . Volkswag n AG en AG
wage does
Volks not
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ed

satelettronica
ris nte
tho eo
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c
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nl

pt
du

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itte

y li
erm

ab
– Position belt pulley on coolant pump and tighten securing bolts ility
ot p

wit
-1- by hand.
, is n

h re
hole

– Install poly V-belt ⇒ page 75 .

spec
es, in part or in w

– Tighten securing bolts -1-.

t to the co

Vehicles with screw-type hose clips on charge air hoses

rrectness of i

Caution
l purpos

The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
nf
ercia

hose may slip off the charge air pipe during vehicle operation.
rm
m

atio
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Vehicles with push-fit charge air hoses

thi
te

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Note
t.
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Note installation of charge air hoses. rig ht
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cted agen
Prote AG.

2. Coolant pump, regulation of cooling system 241

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– If oil seal is renewed, place seal in groove of charge air hose.

Ensure that seal is correctly seated around groove and is not
twisted.
– Coat sealing surface and oil seal with oil.
– Bring retaining clip to release position -1-.
– Push charge air hose into coupling as far as stop.
– Bring retaining clip to locking position -2- and then press
charge air hose again.
– Pull on hose to ensure that plug-in connector is properly seat‐
ed and engaged.
Vehicles with condensate trap on charge air pipe
– Check coolant level and top up if necessary ⇒ page 198 .
Vehicles with auxiliary heater
– Add coolant ⇒ page 198 .
Continued for all vehicles
Assembly overview - charge air system ⇒ page 322

satelettronica
Assembly overview - intake manifold ⇒ page 344 .

– Push down engine cover panel at points -1- in direction of

-arrow- until engine cover panel engages.

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Specified torque ir se
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tee
tho
u or
Components ss
a Specified torque ac
ce
e

Securing bolts for charge air pipe 10 Nm

nl

pt
du

an
itte

Screw-type hose clips on charge air pipes 5.5 Nm

y li
erm

ab

Belt pulley to coolant pump 20 Nm

ility
ot p

wit
, is n

h re
hole

spec

2.10 Removing and installing coolant pump (Passat, Passat CC)

es, in part or in w

t to the co

Note
rrectness of i
l purpos

Coolant pump seal is bonded in position. If the seal is damaged, the coolant pump must be renewed.
nf
ercia

orm
m

atio
om

n in
or c

thi
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sd
iva

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rp

cu
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f

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

242
co Vo
by lksw
Rep. gr.19 - Cooling cted agen
Prote AG.
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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

♦ Refractometer - T10007 A-
t to the co
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-
rrectness of i

♦ 16 mm open-end spanner - T10241- (not shown)

l purpos

♦ Bit - T10451- (not shown)

nform
ercia

♦ 16 mm open-end spanner - T10241- (not shown)

m

at
om

io

♦ Locking pin - T10060 A-

n
c

in t
or

his
ate

do
priv

cum
for

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ng

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

2. Coolant pump, regulation of cooling system 243

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front, noise insulation .
– Drain coolant ⇒ page 198 .
– Pull retaining clip in direction of -arrow- and pull out charge air
hose -1- from charge air pipe.

Note

Charge air hoses with screw-type clips are also installed

⇒ page 335 .
AG. Volkswagen AG d
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aut ra
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nl

pt
du

– Unscrew securing bolt for charge air pipe -arrow-.

an
itte

y li
erm

ab
ility

satelettronica
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

– Remove securing bolt -arrow- for charge air pipe -1-.

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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rp

cu
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f

en
ng

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

– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– Unclip bracket -2- for electric wire to oil level and oil tempera‐
ture sender - G266- .

244 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Vehicles with condensate trap on charge air pipe

– Open clamps -arrows-.
– Pull off coolant hoses -1- on charge air pipe -2-.

Vehicles with engine preheater heater element - Z97-

– Unclip wire -1- to engine preheater heater element - Z97- on
charge air pipe -2- -arrow-.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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Vehicles with auxiliary heater
ce
le
un

pt
an
d

– Pull coolant hoses for auxiliary heater - Z- off coolant pipes

itte

y li
erm

-1-. ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o

Continued for all vehicles

cial p

f inform

– Carefully press locking tabs on noise insulation housing for

mer

atio

supercharger -arrows- outwards.

om

n
c

– Pull off housing with noise insulation and place to one side.
or

n thi
te

sd
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pr

cum
r
fo

Note
en
ng

t.
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op py
Housing with noise insulation remains in vehicle.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

2. Coolant pump, regulation of cooling system 245

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Lift off engine cover at points -1- and pull it forwards in direction
of -arrow-.

– Pull off fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing release tabs.

AG. Volkswagen AG d
agen oes
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satelettronica
ol not
byV gu
ara
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ce
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pt
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– Pull off hose -1- from pressure pipe.
erm

ab
ility
ot p

– Unscrew securing bolts -2- from pressure pipe and remove

wit
is n

pressure pipe.

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

– Unscrew hose clip -1- on charge air pipe.

atio
om

n
c

– Open hose retainer -2- and pull out hose.

i
or

n thi
te

sd
a

– Unscrew securing bolt for charge air pipe -3- and pull off con‐
iv

o
pr

nector from charge air pressure sender - G31- with intake air
um
r
fo

temperature sender 2 - G299- .

en
ng

t.
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op
– Remove bracket -4-.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

246 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– To do this, unscrew bolts -arrows-.

– Remove bracket -1-.

– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
– Remove charge air pipe downwards.

satelettronica
– Release tension from supercharger poly V-belt by swinging
tensioning element using open-end spanner, 16 mm -
T10241- . wage
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Vol t
– Use the lockingedpin
by - T10060 A- to lock the tensioning
gu
aelement
ran
in place. thoris tee
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

– Unscrew securing bolts -arrows- for tensioning element and

t to the co

remove tensioning element.

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Coolant pump, regulation of cooling system 247

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Hold supercharger shaft with AF 16 spanner -1-.

– Remove securing bolt -2- for belt pulley and remove belt pulley
and supercharger poly V-beltge-3-.
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Vol gu
d by ara
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ris
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au ra
c
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nl

pt
du

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ab
ility
ot p

wit
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hole

spec
– Loosen bolts -arrows- of coolant pump using socket -
es, in part or in w

T10451- .

t to the co
– Remove coolant pump with magnetic clutch for supercharger
- N421- from cylinder block.

rrectness of i
Installing
l purpos

Install in reverse order of removal. When doing this, observe the

following:

satelettronica
nf
ercia

orm
m

atio
Note
om

n in
or c

thi
e

Coolant pump seal is bonded in position. If the seal is damaged,

t

sd
iva

the coolant pump must be renewed.

o
r
rp

cu
o

m
f

en
ng

t.
yi
– Insert coolant pump with magnetic clutch for supercharger -
Co
op py
N421- into cylinder block. t. C rig
gh ht
pyri by
Vo
– Tighten bolts.
o
by c lksw
cted agen
Prote AG.
– Place poly v-belt on the magnetic clutch for supercharger -
N421- .
– Bolt on supercharger pulley with poly-v-belt and new securing
bolt.
Vehicles with screw-type hose clips on charge air hoses

Caution

The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.

Vehicles with push-fit charge air hoses

Note

Note installation of charge air hoses.

248 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– If oil seal is renewed, place seal in groove of charge air hose.

Ensure that seal is correctly seated around groove and is not
twisted.
– Coat sealing surface and oil seal with oil.
– Bring retaining clip to release position -1-.
– Push charge air hose into coupling as far as stop.
– Bring retaining clip to locking position -2- and then press
charge air hose again.
– Pull on hose to ensure that plug-in connector is properly seat‐
ed and engaged.
Continued for all vehicles
Assembly overview - part I, belt drive ⇒ page 71 .
Assembly overview - supercharger ⇒ page 297
Assembly overview - charge air system ⇒ page 322
Install poly V-belt ⇒ page 75 .
Fill with coolant ⇒ page 198

satelettronica
Specified torque
Component Specified torque
Coolant pump to engine 8 Nm
Belt pulley to coolant pump 24 Nm
Belt pulley for supercharger 40 Nm + 90°
Securing bolts for charge air pipe 5 Nm
Screw-type hose clips on charge pressure pipes 5.5 Nm
. Volkswage AG
Belt drive wagen AG ⇒ pagen71 does
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Charge air system ed b ⇒ page 322 ara
nte
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Compressor auth ⇒ page 297 eo
ra
ss c

ce
e
nl

pt
du

an
itte

y li
2.11 Removing and installing coolant circulation pump - V50- (Passat, Passat
erm

ab
ility
CC)
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

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.

2. Coolant pump, regulation of cooling system 249

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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
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

satelettronica
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
co lksw
by
cted agen
Prote AG.

♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-

♦ Hose clamps to 40 mm - 3093-

250 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing

WARNING

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.

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front, noise insulation .
– Seal coolant hoses for coolant circulation pump - V50- using
hose clips up to 40 mm - 3093- .
– Release spring-type clips -arrows- and pull off coolant hoses.
– Pull off connector -1- and unscrew securing bolt -2-.
– Remove coolant circulation pump - V50- -3-.
AG. Volkswagen AG d
Installing agen oes

satelettronica
o lksw not
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Install in reverse order of removal. rWhen
ised doing this, observe the ara
nte
following: ut
ho eo
ra
s a c
– Check coolant level and top up if necessary ⇒ page 198 . s

ce
e
nl

pt
du

an
itte

y li
Specified torque
erm

ab
ility
ot p

Component Specified torque

wit
, is n

h re
Securing bolt 10 Nm
hole

spec
es, in part or in w

t to the co
2.12 Assembly overview - heater element for engine preheater - Z97- (Passat,
rrectness of i
Passat CC)
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

2. Coolant pump, regulation of cooling system 251

 AG. Volkswagen AG d
agen oes
olksw no
Eos 2006 ➤ , Golfd b2009
yV ➤ , Golf Cabriolet 2012 ➤ ,t gGolf
ua Plus 2005 ➤ , ...
ran
e
4-cylinder direct-injection
thoris engine (1.4 l, EA 111, turbocharger,
tee
or
supercharger) - Edition 02.2019
au ac
ss
1 - Bolt

ce
e
nl

pt
du
❑ 10 Nm

an
itte

y li
erm

ab
2 - Bracket

ility
ot p

❑ Note installation posi‐

wit
, is n

tion ⇒ page 253

h re
hole

spec
3 - Clip
es, in part or in w

t to the co
4 - Connection for coolant hose
❑ To engine

rrectness of i
❑ Connection diagram for
coolant hoses
l purpos

⇒ page 184
5 - Connection for coolant hose

nf
ercia

o
❑ To thermostat housing.

rm
m

atio
❑ Connection diagram for
om

n in
coolant hoses
or c

thi
⇒ page 184
te

sd
iva

o
r

6 - Engine preheating element

rp

cu
o

m
- Z97-
f

en
ng

satelettronica
t.
yi Co
❑ Removing and installing Cop py
t. rig
⇒ page 253 opyri
gh by
Vo
ht
by c lksw
7 - Bracket Prote
cted AG.
agen

❑ Comprises upper and

lower part
❑ For engaging wiring har‐
ness in radiator grille
8 - Connecting cable
❑ 220 V
9 - Air intake grille
❑ Right side

252 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.13 Removing and installing heater element for engine preheater - Z97- (Pas‐
sat, Passat CC)

Special tools and workshop

equipment required

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

satelettronica
ise 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
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do

♦ Refractometer - T10007 A-
r
rp

cum
fo

en
g

♦ Hose clamp pliers - VAS 6340-

n

t.
yi Co
Cop py
♦ Torque wrench - V.A.G 1331-
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
♦ Hose clamps to 40 mm - 3093-
agen
Prote AG.

2. Coolant pump, regulation of cooling system 253

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing

WARNING

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.
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
– Remove noise insulation ⇒ Generalrisbody ed b
repairs, exterior; ara
nte
Rep. gr. 50 ; Body - front, noise insulation
utho . eo
ra
s a c
– Unclip locking mechanism -arrow-.
s

ce
le
un

pt
– Pull off wiring -1- on engine preheating element - Z97- -2-.

an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

satelettronica
t to the co
rrectness
– Clamp off coolant hoses -2- using hose clamps, up to 40 mm in

o
cial p

f i
diameter - 3093- .

nform
mer

– Loosen spring-type clips -arrows-.

atio
om

n
– Pull off coolant hoses -2- from engine preheater heater ele‐
c

i
or

n thi
ment - Z97- -1-.
te

sd
iva

o
r

– Allow remaining coolant to drain out.

p

cum
r
fo

en
ng

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

– Unscrew bolt -arrow A- and remove engine preheater heater

element - Z97- -1- with bracket.
– Open clip, and detach engine preheating element - Z97- from
bracket.
Installing
Install in reverse order of removal. When doing this, observe the
following:

254 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Installation position of engine preheater heater element - Z97-

Observe anti-twist device -arrow-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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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
– Fit bracket of engine preheater heater element - Z97- -1- with
hole

spec
lug in guide -arrow B-.
es, in part or in w

t to the co
– Tighten bolt -arrow A-.
– Check coolant level and top up if necessary ⇒ page 198 .

rrectness of i
l purpos

satelettronica
nform
mercia

at
om

ion
c

in t
or

his
ate

Specified torque

do
priv

cum
for

Component Specified torque

en
ng

t.
yi Co
op
Bracket to engine 10 Nm
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Coolant pump, regulation of cooling system 255

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3 Radiator, radiator fan

⇒ “3.2 Assembly overview - parts of cooling system, body side
(Tiguan)”, page 258
⇒ “3.3 Assembly overview - radiator/radiator fan (Polo)”,
page 260
⇒ “3.4 Assembly overview - radiator/radiator fan (Sharan)”, page
261 gen AG
. Volkswagen AG
a does
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⇒ “3.5 Assembly overview d- bradiator/radiator
yV
o
fan (Passat, Passat
ot g
ua
CC)”, page 262 orise ran
te
h eo
ut ra
⇒ “3.6 Removing and
ss installing radiator fan V7 and radiator fan 2
a c
V177 (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet)”,

ce
e
nl

pt
page 263
du

an
itte

y li
⇒ “3.7 Removing and installing radiator fan V7 and radiator fan 2
erm

ab
ility
V177 (Polo)”, page 264
ot p

wit
, is n

⇒ “3.8 Removing and installing radiator, radiator fan V7 and ra‐

h re
hole

diator fan 2 V177 (Sharan)”, page 265

spec
es, in part or in w

⇒ “3.9 Removing and installing radiator (Passat, Passat CC)”,

t to the co

satelettronica
page 267
⇒ “3.10 Removing and installing fan cowling (Passat, Passat

rrectness of i
CC)”, page 270
l purpos

⇒ “3.11 Removing and installing radiator fan V7 and radiator fan

2 V177 (Passat, Passat CC)”, page 271
nf
ercia

⇒ “3.12 Removing and installing radiator (Golf Plus, Eos, Sciroc‐ orm
co, Golf, Touran, Golf Cabriolet)”, page 272
m

atio
om

⇒ “3.13 Removing and installing radiator and radiator fan V7 (Ti‐

n in
or c

guan)”, page 273

thi
te

sd
iva

⇒ “3.14 Removing and installing radiator with charge air cooler

r
rp

cu
o

(Polo)”, page 275

f

en
ng

t.
yi Co
op
3.1 Assembly overview - radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf,
C py
t. rig
gh ht
yri
Touran, Golf Cabriolet)
p by
co Vo
by lksw
cted agen
Prote AG.

256 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - Radiator/cooler
❑ Removing and installing
⇒ page 272
❑ After renewing, renew
entire coolant.
2 - O-ring
❑ Renew if damagedn AG. Volkswagen A
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3 - Upper coolant by
Vohose
lk ot g
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❑ To hconnection
ris on cylin‐ tee
derut ohead. or
a ac
ss
❑ Connection diagram for

ce
le
un

coolant hoses

pt
an
d
itte

⇒ page 181

y li
erm

ab
4 - Expansion tank

ility
ot p

wit
is n

❑ Check cooling system

h re
for leaks using cooling
ole,

spec
system tester - V.A.G
urposes, in part or in wh

1274 B- and adapter for

t to the co
cooling system tester -

satelettronica
V.A.G 1274/8-

rrectne
5 - Connector
6 - Cap
❑ Check using cooling ss o
cial p

f i
system tester - V.A.G
nform

1274 B- and adapter for

mer

atio

cooling system tester -

om

V.A.G 1274/9-
n
c

i
or

n thi

❑ The pressure relief

te

sd
va

valve must open at a

i

o
pr

pressure of 1.4…1.6 bar

um
r
fo

en
ng

t.
yi
7 - 5 Nm
Co
Cop py
t. rig
gh
8 - Plastic inserts
ht
pyri by
Vo
co lksw
by
❑ For securing bolts. Prote
cted AG.
agen

9 - Bracket
10 - Cowling
11 - 5 Nm
12 - Radiator fan 2 - V177-
13 - Connector
14 - Radiator fan - V7-
❑ With radiator fan control unit - J293-
15 - Bracket
❑ For connector.
16 - Lower coolant hose
❑ To connection for thermostat.
17 - Retaining clip
18 - Radiator outlet coolant temperature sender - G83-
19 - 5 Nm

3. Radiator, radiator fan 257

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.2 Assembly overview - parts of cooling system, body side (Tiguan)

1 - Radiator/cooler
❑ Removing and installing
⇒ page 273
❑ After renewing, renew
entire coolant.
2 - O-ring agen
AG. Volkswagen AG d
oes
lksw not
❑ Renew if damaged d byV
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ara
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r
3 - Union ut
ho eo
ra
a
❑ To remove, pull out re‐ ss c

ce
le

taining clip.
un

pt
an
d
itte

4 - Spring-type clip

y li
erm

ab
❑ Remove and install with

ility
ot p

hose clip pliers - VAS

wit
is n

6340- .

h re
ole,

spec
5 - Coolant hose
urposes, in part or in wh

t to the co

satelettronica
❑ Connection diagram for
coolant hoses
⇒ page 181

rrectne
6 - Upper coolant hose
❑ To connection on cylin‐

ss
der head.

o
cial p

f in
❑ Connection diagram for

form
mer

coolant hoses

atio
⇒ page 182
om

n
c

i
or

n
7 - Expansion tank thi
te

sd
va

❑ Check cooling system

i

o
pr

for leaks using cooling

um
r
fo

en
ng

system tester - V.A.G

t.
yi Co
1274 B- and adapter for Cop py
. rig
cooling system tester -
ht ht
rig by
py
V.A.G 1274/8- co Vo
by lksw
cted agen
Prote
8 - Connector
AG.

9 - Cap
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
❑ The pressure relief valve must open at a pressure of 1.4…1.6 bar
10 - 5 Nm
11 - Plastic inserts
❑ For securing bolts.
12 - Bracket
13 - 5 Nm
14 - Cowling with radiator fan - V7-
❑ With radiator fan control unit - J293-

Note

The radiator fan - V7- and the cowl‐

ing may only be renewed complete.

258 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

WARNING
Heat shields must be in‐
stalled to prevent dam‐
age to radiator fan due to
heat radiated by exhaust
system.

❑ Specified torque for heat shields: 3 Nm.

15 - Bracket
❑ For connector.
16 - Connector
17 - Retaining clip
18 - Lower coolant hose
❑ To connection for thermostat.
❑ Connection diagram for coolant hoses ⇒ page 181
19 - Hose guide

satelettronica
Volkswagen AG
20 - Radiator outlet coolant temperature sender - G83-
swa
gen AG
.
does
olk not
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21 - Lower coolant hose edb ara
nte
ris
❑ To connection for thermostat. tho eo
s au ra
c
❑ Connection diagram for coolant shoses ⇒ page 181

ce
e
nl

pt
du

22 - Union

an
itte

y li
❑ To remove, pull out retaining clip.
erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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

3. Radiator, radiator fan 259

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.3 Assembly overview - radiator/radiator fan (Polo)

1 - Radiator/cooler
❑ Removing and installing
⇒ page 275
❑ After renewing, renew
entire coolant n AG. Volkswagen AG do
swage es n
⇒ page 189 byV
olk ot g
ua
d ran
ir se
2 - Spring-type clip tho tee
or
au ac
3 - Coolant hose ss

ce
le
❑ To expansion tank un

pt
an
d
itte

y li
4 - Spring-type clip
erm

ab
ility
ot p

5 - Cap

wit
is n

h re
❑ Check using cooling
ole,

system tester - V.A.G

spec
urposes, in part or in wh

1274 B- and adapter for

t to the co
cooling system tester -
V.A.G 1274/9-

satelettronica
❑ The pressure relief

rrectne
valve must open at a
pressure of 1.4…1.6 bar

ss o
6 - Expansion tank
cial p

f in
❑ Check cooling system

form
mer

for leaks using cooling

atio
m

system tester - V.A.G

o

n
c

1274 B- and adapter for

i
or

n thi
cooling system tester -
te

sd
va

V.A.G 1274/8-
i

o
pr

cum
r
fo

7 - 5 Nm

en
ng

t.
yi Co
op
8 - Connector
C py
t. rig
gh ht
yri by
9 - Plastic inserts cop Vo
by lksw
cted agen
❑ For securing bolts.
Prote AG.

10 - Bracket
11 - Cowling
12 - 5 Nm
13 - Radiator fan 2 - V177-
14 - Connector
15 - Bracket
❑ For connector.
16 - Radiator fan - V7-
❑ With radiator fan control unit - J293-
17 - Charge air cooler
18 - Spring-type clip
19 - Lower coolant hose
❑ To connection for thermostat.
20 - Radiator outlet coolant temperature sender - G83-

260 Rep. gr.19 - Cooling

 AG. Volkswagen AG d
agen oes
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aut Eos 2006 ➤ , Golf 2009 ➤ , Golf oCabriolet
2012 ➤ , Golf Plus 2005 ➤ , ...
ra
c
s
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
s

ce
e
nl

pt
du

an
3.4 itte Assembly overview - radiator/radiator fan (Sharan)

y li
erm

ab
ility
ot p

wit
, is n

1 - Coolant hose

h re
hole

❑ To top of expansion tank

spec
es, in part or in w

❑ Connection diagram for

t to the co
coolant hoses
⇒ page 183

rrectness of i
2 - Coolant hose
l purpos

❑ To bottom of expansion
tank
❑ Connection diagram for

nf
ercia

o
coolant hoses

rm
m

⇒ page 183

atio
om

n in
c

3 - Clip
or

thi
te

sd
a

4 - Connector
iv

o
r
rp

cu
o

m
5 - Cap
f

en
ng

t.
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❑ Check using cooling t. Cop py
system tester - V.A.G
rig

satelettronica
gh ht
yri by
1274 B- and adapter for op Vo
by c lksw
cooling system tester - cted agen
Prote AG.
V.A.G 1274/9-
❑ Pressure relief valve
must open at between
1.4 and 1.6 bar
6 - 5 Nm
7 - Expansion tank
❑ Check cooling system
for leaks using cooling
system tester - V.A.G
1274 B- and adapter for
cooling system tester -
V.A.G 1274/8-
8 - Coolant hose
❑ Connection diagram for
coolant hoses
⇒ page 183
9 - Radiator/cooler
❑ Removing and installing ⇒ page 265
❑ After renewing, renew entire coolant.
10 - Cowling
❑ with radiator fan - V7- and radiator fan 2 - V177-
11 - 5 Nm
12 - Connector
13 - Upper coolant hose
❑ Connection diagram for coolant hoses ⇒ page 183

3. Radiator, radiator fan 261

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.5 Assembly overview - radiator/radiator fan (Passat, Passat CC)

1 - Coolant hose
❑ To bottom of expansion
tank
❑ Connection diagram for
coolant hoses n AG. Volkswagen AG do
swage es n
⇒ page 184 byV
olk ot g
ua
d ran
ir se
2 - Coolant hose tho tee
or
au ac
❑ To top of expansion tank ss

ce
e

❑ Connection diagram for

nl

pt
du

an
coolant hoses
itte

y li
⇒ page 184
erm

ab
ility
ot p

3 - Clip

wit
, is n

h re
❑ To fit spring-type clips,
hole

hose clip pliers - VAS

spec
es, in part or in w

6340- or spring-type clip

t to the co
pliers - VAS 5024A- are
recommended

satelettronica
4 - Connector

rrectness of i
❑ For coolant shortage in‐
l purpos

dicator sender - G32- .

5 - Cap

nform
ercia

❑ Check using cooling

m

at
system tester - V.A.G
om

io
1274 B- and adapter for

n
c

in t
or

cooling system tester -

his
ate

V.A.G 1274/9- do
priv

cum

❑ Pressure relief valve

for

en
g

must open at between

n

t.
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op
1.4 and 1.6 bar C py
t. rig
gh ht
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6 - Bolt
p by
co Vo
by lksw
cted
❑ 5 Nm
agen
Prote AG.

❑ Qty. 2
7 - Expansion tank
❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling
system tester - V.A.G 1274/8-
8 - Cowling
❑ Removing and installing ⇒ page 270
❑ with radiator fan - V7- and radiator fan 2 - V177-
9 - Bolt
❑ 5 Nm
❑ Qty. 4
10 - Radiator fan - V7-
❑ Removing and installing ⇒ page 271
11 - Radiator fan 2 - V177-
❑ Removing and installing ⇒ page 271
12 - Lower coolant hose
❑ Connection diagram for coolant hoses ⇒ page 184
13 - Upper coolant hose
❑ Connection diagram for coolant hoses ⇒ page 184

262 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

14 - Nut
❑ 10 Nm
❑ Qty. 6
15 - Radiator/cooler
❑ Removing and installing ⇒ page 267
❑ After renewing, renew entire coolant.

3.6 Removing and installing radiator fan -

V7- and radiator fan 2 - V177- (Eos, Golf
Plus, Scirocco, Golf, Touran, Golf Cab‐
riolet)
Removing radiator fan
– Remove engine cover.
– Remove upper securing bolts of cowling -arrows-.
– Remove noise insulation ⇒ General body repairs, exterior;

satelettronica
Rep. gr. 50 ; Body - front; Noise insulation .

– Separate connector -1- and unscrew lower cowling securing

bolts -arrows-. gen AG
. Volkswagen AG
d a oes
lksw not
– Remove cowling downwards.
db
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ris
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c
ss
ce
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un

pt
an
d
itte

y li
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ab
pe

ility
ot

wit
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h re
hole

spec
es, in part or in w

t to the co

– Separate electrical connector -1- and free wiring.

– Unscrew nuts -arrows- and remove fan.
rrectness of i

Installing radiator fan

l purpos

Installation is carried out in the reverse order. When installing,

note the following:
nform
ercia

Specified torques:
m

a
com

Component Nm
ion in
r
te o

Radiator fan to cowling 10

thi
s
iva

do

Cowling to radiator 5
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.

3. Radiator, radiator fan 263

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.7 Removing and installing radiator fan -

V7- and radiator fan 2 - V177- (Polo)
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front, noise insulation .
– Disconnect electrical connector -arrow-.

– Pull connector -arrow- from radiator outlet coolant temperature

satelettronica
AG. Volkswagen AG d
sender - G83- . agen oes
olksw not
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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
hole

spec
es, in part or in w

t to the co
– Pull off intake hose -1-.
– Unscrew securing bolts -arrows- and remove intake cowl.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op
– Press both radiator latches in -direction of arrow-. C py
ht. rig
rig ht
by
– Carefully remove cowling -1- downwards together with radia‐ copy Vo
by lksw
tor fans. cted agen
Prote AG.

264 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Disconnect electrical connector -1-.

Depending on which radiator fan is to be removed.
– Unclip line from line guide and unscrew securing nuts
-arrows-.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Specified torques
Component Nm
Radiator fan to air scoop 5

3.8 Removing and installing radiator, radiator fan - V7- and radiator fan 2 -
V177- (Sharan)

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-

3. Radiator, radiator fan 265

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
– Remove engine splash guard at bottom.
– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
– Push securing clip at charge air cooler in direction of -arrow-
and pull hose -arrow- off.
– Also remove second hose from charge air cooler.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Disconnect connector
orise -1-. nte
th eo

satelettronica
u ra
– Drain coolant.
ss a Pull off hose -2-. 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
rrectness of i

– Release retaining clip and pull connection -arrow- off radiator.

l purpos

– Pull the connection from bottom of radiator.

– Unclip coolant hose from cowling.
nform
ercia

– Bring lock carrier into service position ⇒ General body repairs,

m

a
com

exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐

ion in

sition .
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
– Unscrew securing bolts -arrows- and remove cowling upwards cted agen
Prote AG.
together with the radiator fans.

266 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Disconnect electrical connector -1- and lay lines aside.

– Unscrew nuts -arrows- and remove fan.

– Unscrew the securing bolt -arrow-.

satelettronica
– Unscrew bolts -arrows- and remove radiator downwards.
n AG. Volkswagen AG do
lkswage es n
Note byV
o ot g
ua
d ran
ir se tee
o
To prevents adamage to condenser or to refrigerant lines andorho‐
th
u ac
ses, ensure that lines and hoses are not stretched, kinked or bent.
s
ce
le
un

pt
an
d
itte

– Unbolt retaining clamps for refrigerant lines.

y li
rm

ab
pe

ility

– Unbolt condenser from radiator and secure to lock carrier.

ot

wit
, is n

Installing
h re
hole

spec

Installation is carried out in the reverse order. When installing,

es, in part or in w

note the following:

t to the co

Filling with new coolant ⇒ page 193 .

– Electrical connections and routing ⇒ Current flow diagrams,
rrectness of i

Electrical fault finding and Fitting locations.

l purpos

Specified torques:
nform
ercia

Component Nm
m

Radiator fan to cowling 10

a
com

tion in

Cowling to radiator 5
r
te o

thi

Radiator to charge air cooler 5

s
iva

do
r
rp

cum
fo

en
g

3.9 Removing and installing radiator (Passat, Passat CC)

n

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

3. Radiator, radiator fan 267

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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

satelettronica
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
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi

♦ Refractometer - T10007 A-
s
iva

do
r

♦ Hose clamp pliers - VAS 6340-

rp

cum
fo

en
ng

♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-

t.
yi Co
Cop py
. rig
Removing
t
gh ht
pyri by
Vo
co
– Remove noise insulation or skid plate ⇒ General body repairs,
by lksw
cted agen
Prote
exterior; Rep. gr. 50 ; Removing and installing noise insulation
AG.

or skid plate .
– Drain coolant ⇒ page 198 .

268 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection enginew(1.4
agen l, EA 111, turbocharger,
AG. Volkswagen AG d
oe supercharger) - Edition 02.2019
ks s no
Vol t gu
by ara
Vehicles with push-fit chargeriairse hoses
d
nte
tho eo
– Release securing clipss aon
u
right of charge air cooler in direction ra
c
of -arrow- and pull off hose -arrow-.

ce
le
un

pt
an
– Release and pull off charge air hose in same way on left-hand

d
itte

y li
side.
rm

ab
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

Vehicles with screw-type hose clips on charge air hoses

– Loosen screw-type hose clip -arrow-.

nform
ercia

– Pull off charge air hose -1- on left of charge air cooler -2-.
m

a
com

tio
– Loosen screw-type hose clip on right-hand side as well and

n in
r
te o

pull off charge air hose.

thi

satelettronica
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.

Continued for all vehicles

– Remove air filter ⇒ page 342 .
– Release retaining clip -arrow-.
– Pull off coolant hose -1- from top of radiator.

– Undo and remove bolts -arrows- of cowling.

– Release connectors -1- and pull off.
– Remove cowling downwards.

3. Radiator, radiator fan 269

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew bolts -arrows-.

– Remove radiator -1- downwards.
Installing
Install in reverse order of removal. When doing this, observe the
following:
Vehicles with screw-type hose clips on charge air hoses
AG. Volkswagen AG d
Caution agen oes
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The screw-type clips on the charge air pipes must bethotightened
ris
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to 5.5 Nm. If the torque is too low or too high, the
s au charge air ra
c
hose may slip off the charge air pipe during vehicle operation.
s

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Vehicles with push-fit charge air hoses
pe

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Note
hole

spec
es, in part or in w

Note installation of charge air hoses.

t to the co

satelettronica
rrectness of i
– If oil seal is renewed, place seal in groove of charge air hose.
Ensure that seal is correctly seated around groove and is not
l purpos

twisted.
– Coat sealing surface and oil seal with oil.

nform
ercia

– Bring retaining clip to release position -1-.

m

a
com

tio
– Push charge air hose into coupling as far as stop.

n in
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te o

thi
– Bring retaining clip to locking position -2- and then press

s
iva

do
charge air hose again.
r
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cum
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– Pull on hose to ensure that plug-in connector is properly seat‐

en
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t.
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Continued for all vehicles
rig by
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– Fill with coolant ⇒ page 198 .
agen
Prote AG.

– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.

Specified torque
Component Nm
Radiator to charge air cooler 5
Cowling to radiator 5
Screw-type hose clips on charge air pipes 5.5 Nm

3.10 Removing and installing fan cowling

(Passat, Passat CC)
Removing
– Remove noise insulation or skid plate ⇒ General body repairs,
exterior; Rep. gr. 50 ; Removing and installing noise insulation
or skid plate .

270 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Undo and remove bolts -arrows- of cowling.

– Release connectors -1- and pull off.
– Remove cowling with radiator fan - V7- and radiator fan 2 -
V177- downwards.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.

Specified torque
Component Specified torque
Cowling to radiator 5 Nm

AG. Volkswagen AG d
agen oes
ksw
3.11 Removing and installing radiator fan -
by Vol not
gu

satelettronica
d ara

utV7- and radiator fan 2 - V177- (Passat,

horise nte
eo
ra
ss a
Passat CC) c
ce
e
nl

pt
du

Removing radiator fan

an
itte

y li
erm

– Remove noise insulation or skid plate ⇒ General body repairs,

ab
ility

exterior; Rep. gr. 50 ; Removing and installing noise insulation

ot p

wit

or skid plate .
, is n

h re
hole

– Undo and remove bolts -arrows- of cowling.

spec
es, in part or in w

– Release connectors -1- and pull off.

t to the co

– Remove cowling downwards.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
riv

– Uncover cables -1-.

p

cum
for

en

– Unscrew nuts -arrows- and remove fan.

ng

t.
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op py
Installing radiator fan t. C rig
gh ht
pyri by
Vo
Install in reverse order of removal. When doing this, observe the
co lksw
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cted agen
following: Prote AG.

– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.

Specified torque
Component Specified torque
Radiator fan to cowling 10 Nm
Cowling to radiator 5 Nm

3. Radiator, radiator fan 271

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.12 Removing and installing radiator (Golf Plus, nEos, Scirocco, Golf, Touran,
AG. Volkswagen AG d
Golf Cabriolet) yV
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th or
Special tools and workshop au ac
ss
equipment required

ce
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nf
ercia

orm
m

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n in
or c

thi
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sd
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t.
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Cop py
t. rig
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Prote AG.

♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-
Removing
– Remove air filter ⇒ page 342 .
– Drain coolant ⇒ page 185 .
– Pull coolant hoses off radiator.
– Pull connectors off thermal switch and radiator fan.
– Remove cowling together with radiator fans downwards
⇒ page 263 .
– Remove radiator securing bolts and remove radiator with fan
downwards.

272 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Note

To prevent damage to condenser or to refrigerant lines and ho‐

ses, ensure that lines and hoses are not stretched, kinked or bent.

– Unbolt retaining clamps for refrigerant lines.

– Unbolt condenser from radiator and secure to lock carrier.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Filling with new coolant ⇒ page 185 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.

3.13 Removing and installing radiator and radiator fan - V7- (Tiguan)

Special tools and workshop

satelettronica
equipment required

n AG. Volkswagen AG do
lkswage es n
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byV ua
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ir se tee
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a ac
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nl

pt
du

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ab
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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
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ion
c

in t
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ate

do
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♦ Refractometer - T10007 A-
p

cum
for

en
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♦ Hose clamp pliers - VAS 6340-

n

t.
yi Co
Cop py
♦ Torque wrench - V.A.G 1331-
t. rig
gh ht
pyri by
Vo
co lksw
by

273
cted agen
Prote AG.
3. Radiator, radiator fan
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing
wage
liner
n AG..Volkswagen AG do
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Vol t
– Remove bracket
ed -1- by unscrewing securing bolts -arrows-.
by gu
ara
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
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
– Push securing clip at charge air cooler in direction of -arrow-
and pull hose -arrow- off.
l purpos

– Also remove second hose from charge air cooler.

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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t.
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Cop py
t. rig
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– Disconnect connector -1-.
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– Drain coolant; to do this, pull hose -2- off.

– Release retaining clip and pull connection -arrow- off radiator.

– Also pull off connection at bottom of radiator.

274 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
AG. Volkswagen AG d
agen oes
– Unscrew securing bolts -arrows- and remove cowling upwards
olks
w not
yV gu
together with radiator fan - V7- . se
d b ara
nte
ri
ho eo
aut ra
ss c
Note

ce
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nl

pt
du

an
itte
♦ The radiator fan - V7- and the cowling may only be renewed

y li
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ab
complete.

ility
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wit
♦ To remove and install radiator, lock carrier only has to be

, is n

h re
moved to service position.

hole

spec
es, in part or in w
– Bring lock carrier into service position ⇒ General body repairs,

t to the co
exterior; Rep. gr. 50 ; Body - front; Lock carrier; Service po‐
sition .

rrectness of i
– Remove securing bolt -arrow-.
l purpos

nform
mercia

at
om

ion
c

satelettronica
in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Unscrew bolts -arrows- and remove radiator downwards.
Prote AG.

Installing
Installation is carried out in the reverse order. When installing,
note the following:
Filling with new coolant ⇒ page 185 .
Specified torques:
Component Nm
Cowling to radiator 5
Radiator to charge air cooler 5

3.14 Removing and installing radiator with

charge air cooler (Polo)

Caution

The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.

Note

♦ Radiator and charge air cooler are separate components.

♦ Radiator is mounted onto charge air cooler.
♦ Radiator and charge air cooler are removed and installed to‐
gether.

3. Radiator, radiator fan 275

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Assembly overview - parts of cooling system, body side

⇒ page 260 .
Special tools and workshop equipment required
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
Removing
– Drain coolant (Polo) ⇒ page 189 .
– Pull upper coolant hose off radiator.
– Removing cowling with both radiator fans ⇒ page 264 .
– Remove both charge air hoses.
– Disconnect electrical connector -arrow-.

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

– Pull connector -arrow- from radiator outlet coolant temperature

pt
du

an

sender - G83- .
itte

y li
erm

ab

– Bring lock carrier into service position ⇒ General body repairs,

ility
ot p

exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐

wit
, is n

sition .
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove securing bolts -arrows-.

nf
ercia

orm

– Lift radiator out of lower mountings and press it back slightly.

m

atio
om

n in

– Remove side radiator mounting.

or c

thi
te

– Unscrew securing bolt on side for AC compressor lines.

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

276 Rep. gr.19 - Cooling

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove securing bolts of condenser -arrows-.

– Secure condenser to lock carrier using cable ties.
– Remove radiator and charge air cooler downwards.

– Pull radiator -1- in -direction of arrow- out of lateral charge air

cooler -2- mounting brackets.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Filling with new coolant
⇒ “1.6 Draining and filling coolant (Polo)”, page 189 .

satelettronica
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Specified torques
Component Nm
Radiator mounting to lock carrier 5
Bracket for air conditioner compressor lines to 5
radiator
n AG. Volkswagen AG do
Radiator to condenser wage es n 5
olks ot
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rise nte
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au ra
c
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ce
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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

his
ate

do
priv

cum
for

en
ng

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

3. Radiator, radiator fan 277

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

21 – Turbocharging/supercharging agen
AG. Volkswagen AG d
oes
olksw not
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1 Exhaust turbocharger d b ara
rise nte
tho eo
au ra
ss c

ce
e
Note

nl

pt
du

an
itte

y li
erm
♦ Secure all hose connections with hose clips which conform to

ab
ility
production standard.

ot p

wit
, is n
♦ Hose connections and hoses for charge air system must be

h re
free of oil and grease before assembly. The seal and sealing hole

spec
surface must be oiled lightly only for plug-in connectors
es, in part or in w

t to the co
⇒ page 323 .
♦ Charge air system must be free of leaks.

rrectness of i
♦ Renew self-locking nuts.
l purpos

♦ It is recommended that spring-type clips should be installed

using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- .

nform
ercia

satelettronica
♦ Fill turbocharger with engine oil at oil supply line connection.
m

at
om

ion
♦ After installing turbocharger, run engine for about 1 minute at
c

in t
or

idling speed and do not rev up immediately. This ensures that

his
ate

the turbocharger is fully primed with oil.

do
priv

cum
for

en
ng

⇒ “1.1 Assembly overview - turbocharger”, page 278

t.
yi Co
Cop py
t. rig
⇒ “1.2 Removing and installing turbocharger”, page 282 opyri
gh by
Vo
ht
c lksw
⇒ “1.3 Checking vacuum unit for turbocharger”, page 287
by
cted agen
Prote AG.

⇒ “1.4 Removing and installing vacuum unit for turbocharger”,

page 289
⇒ “1.5 Adjusting vacuum unit for turbocharger”, page 291

1.1 Assembly overview - turbocharger

278 Rep. gr.21 - Turbocharging/supercharging

 n AG. Volkswagen AG do
lkswage es n
Vo ot g
Eos e2006
d by ➤ , Golf 2009 ➤ , Golf Cabriolet ua 2012 ➤ , Golf Plus 2005 ➤ , ...
ran
ir s
4-cylinder direct-injection
tho engine (1.4 l, EA 111, turbocharger, supercharger)
tee
or - Edition 02.2019
au ac
ss

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
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.

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

Part I

1. Exhaust turbocharger 279

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - Charge pressure control

solenoid valve - N75-
2 - 10 Nm
3 - 7 Nm
4 - Turbocharger air recircula‐ AG. Volkswagen AG d
tion valve - N249- lksw
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not
o
❑ To remove, pressure byV gu
ara
ed
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pipe must be removed horis
eo
⇒ page 284 . aut ra
ss c

ce
le
5 - O-ring un

pt
an
d
❑ Renew if damaged
itte

y li
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ab
6 - Exhaust turbocharger

ility
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wit
❑ Removing and installing
is n

h re
⇒ page 282
ole,

spec
urposes, in part or in wh

❑ Checking turbocharger
vacuum unit

t to the co
⇒ page 287 .
❑ Removing and installing

rrectne

satelettronica
vacuum unit for turbo‐
charger ⇒ page 289 .

s
❑ Adjusting vacuum unit

s o
for turbocharger
cial p

f in
⇒ page 291 .

form
mer

atio
7 - Connection hose
om

n
c

i
8 - Connection hose
or

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t.
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Cop py
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rig ht
py by
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Prote AG.

Part II

280 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - 8 Nm
2 - Coolant pipe
3 - O-ring
❑ Renew
4 - Exhaust turbocharger
❑ Specified torque for cat‐
alytic converter studs:
20 Nm
❑ Removing and installing
⇒ page 282
❑ Checking turbocharger
vacuum unit
⇒ page 287 .
❑ Removing and installing
vacuum unit for turbo‐
charger ⇒ page 289 .
❑ Adjusting vacuum unit
for turbocharger
⇒ page 291 .

satelettronica
5 - Seal
n AG. Volkswagen AG do
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6- Bracket oris tee
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Notes
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♦ Retainer is discontinued.
itte

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♦ The retainer is not reinstalled in

ility
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cases of repair.
wit
is n

h re
ole,

spec

7 - Bracket
urposes, in part or in wh

t to the co

Note

♦ Retainer is discontinued.
rrectne

♦ The retainer is not reinstalled in

cases of repair.
ss o
cial p

f in

8 - 25 Nm
form
mer

❑ Renew studs and fastening nuts.

atio
om

n
c

Screw the studs into cylinder head until they project only 25 mm.
i
or

n thi
te

sd
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Coat studs with high-temperature paste.

i

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en
ng

Observe tightening sequence: items -A- to -I-.

t.
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Cop py
t. rig
9 - Coolant pipe gh ht
pyri by
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10 - Seal Prote
cted AG.
agen

❑ Renew
11 - 8 Nm
12 - Oil return pipe
❑ To remove, catalytic converter needs to be removed ⇒ page 416 .
13 - Seal
❑ Renew

1. Exhaust turbocharger 281

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

14 - Banjo bolt, 20 Nm
❑ Secured to valve timing housing.
15 - Oil supply pipe

Caution
Oil supply line must be
renewed when installing
a new turbocharger.

16 - Banjo bolt, 30 Nm

1.2 Removing and installing turbocharger

Special tools and workshop equipment required
♦ Hose clamp pliers - VAS 6340-

satelettronica
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
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

♦ Torque wrench - V.A.G 1331-

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
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cum
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fo

en
ng

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

282 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing

Caution

If a mechanical fault is found on the turbocharger, e.g. a de‐

stroyed compressor impeller, just renewing the turbocharger is
not enough.
To prevent this from causing further damage, perform the fol‐
lowing repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing
AGand
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swagen Aair cooler
for foreign objects. swagen G do
es n
olk o t gu
V
by ara
If foreign objects are found
ris in the charge air system, the charg‐
ed nte
ed air routing must abeut cleaned and the charge air cooler must
ho eo
ra
be renewed, if necessary.
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
Note
ot p

satelettronica
wit
, is n

h re
The battery earth must be disconnected for the remaining proce‐
hole

spec
dure. Therefore, first check whether a coded radio is fitted. Then
es, in part or in w

obtain anti-theft coding first if necessary.

t to the co
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

rrectness of i
necting and reconnecting battery .
– Lift engine cover panel at points -1- and pull it forwards in di‐
l purpos

rection of -arrow-. nf
ercia

orm
m

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om

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or c

thi
te

sd
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t.
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Cop py
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gh ht
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co lksw
by
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Prote AG.

1. Exhaust turbocharger 283

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unbolt heat shield over turbocharger -arrows-.

olkswagen AG
en AG. V
– Open and close expansion tank cap to release pressure in olkswag does
not
cooling system. ed
by
V gu
ara
ris nte
– Drain coolant (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet,
au
tho eo
ra
Touran, Tiguan) ⇒ page 185 . ss c

ce
le
un
– Drain coolant (Polo) ⇒ page 189 .

pt
an
d
itte

y li
– Drain coolant (Sharan) ⇒ page 193 .

erm

ab
ility
ot p
– Drain coolant (Passat, Passat CC) ⇒ page 198 .

wit
is n

h re
– Depending on vehicle equipment, remove noise insulation or

ole,

spec
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate . urposes, in part or in wh

t to the co
– Remove radiator fan - V7- together with cowling ⇒ page 256 .
Continued for all vehicles

rrectness
Note

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Pull coolant hoses off engine with hose clip pliers - VAS 6340- .
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– Observe rules for cleanliness ⇒ page 7 .

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– Pull off connecting hoses -1- and coolant hoses -3-.
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– Unscrew bracket -2- and securing nuts -4- from turbocharger.

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– Unscrew securing bolt -2- and remove upper coolant pipe.

Note

The lower coolant pipe can only be removed following the removal
of the catalytic converter.

– Unscrew bolts -1- and remove pressure pipe

.
Passat, Passat CC
– Remove cowling ⇒ page 270 .
– Remove catalytic converter ⇒ page 425 .

Continued for all vehicles

284 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove wiring for Lambda probe after catalytic converter -

G130- and for alternator from cable guides -arrows-.
– Pull connector off Lambda probe after catalytic converter -
G130- and remove.

– Open hose clip -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from catalytic converter -arrows-.

satelettronica
– Unbolt exhaust pipe to rear silencer -arrows-.

Note

In the Polo, the catalytic converter is removed together with the

front exhaust pipe.

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– Loosen securing bolts of clamp -arrows- and pull exhaust pipe
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to rear.
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– Also pull out exhaust pipe together with flexible joint.

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– Remove catalytic converter together with charge air pipe

wit
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downwards.
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hole

spec

Removing poly V-belt (Tiguan) ⇒ page 78 .

es, in part or in w

t to the co

Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabrio‐
let, Touran, Polo, Sharan, Passat, Passat CC) ⇒ page 75 .
rrectness of i
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285
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agen 1. Exhaust turbocharger
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolts for tensioning element -arrows- and

remove it.
– Remove upper alternator bolt and swing alternator out for‐
wards.
– Unscrew securing bolt -arrow- for oil return pipe -2- from tur‐
bocharger.

– Pull oil return pipe downwards.

– Unbolt charge air hose -1- from turbocharger.
– Unscrew banjo bolts of oil supply pipe -arrows- from turbo‐
charger and valve timing housing.

satelettronica
– Remove oil supply pipe.
– Unscrew all securing nuts from exhaust manifold -1-.
– Pull exhaust manifold out upwardsenwith
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manifold.
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es, in part or in w

Oil supply line must be renewed when installing a new turbo‐

t to the co

charger.
rrectness of i

Installation is carried out in the reverse order. When installing,

l purpos

note the following:

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286 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Renew studs and fastening nuts.

♦ Screw the studs into cylinder head until they project only
25 mm.
♦ Coat studs with high-temperature paste.
♦ Observe tightening sequence and specified torques: items
-A- to -I- ⇒ page 278 .
♦ Renew seals, gaskets and self-locking nuts.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Secure all hose connections with hose clips which conform to
production standard.
♦ Install exhaust system and align it free of stress.
♦ When installing air pipes with plug-in connector, ensure that
securing clip -arrow- audibly engages into retaining lug -A-.

satelettronica
Fitting hose connections with plug-in connectors ⇒ page 323
Specified torques:

Caution

The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.

Assembly overview - turbocharger ⇒ page 278 .

Assembly overview - charge air system (Eos, Golf Plus, Golf, Golf
Volkswagen AG
Cabriolet, Touran, Scirocco, Tiguan, Sharan)
swagen A⇒
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Assembly overview - charge airsesystem
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Assembly overview - chargeau air system (Passat, Passat CC)
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⇒ page 322 ss
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⇒ page 396
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installing alternator .
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urposes, in part or in wh

– Push engine cover panel down at points -1- in direction of

-arrow- until it engages.
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1.3 Checking vacuum unit for turbocharger

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287
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1. Exhaust turbocharger
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Hand operated vacuum pump - VAS 6213-

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– Check retaining clip -1- is seated correctly on vacuum unit
linkage.

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Securing nut -2- must be locked with sealing paint.
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– Fit hose -2- onto vacuum unit connection.

– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
stop in direction of -arrow-.

288 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Operate hand vacuum pump - VAS 6213- until a pressure of

700 mbar is displayed on pressure gauge.
Linkage of vacuum unit -1- must move in direction of -arrow-.
If pressure of 700 mbar is displayed:
Vacuum unit is OK.
If pressure drops abruptly:
– Renew vacuum unit ⇒ page 282 .

1.4 Removing and installing vacuum unit for

turbocharger
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

satelettronica
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Removing
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– Release vacuum hose on vacuum reservoir -arrow- and pull it

off.
– Lift engine cover panel at points -1- and pull it forwards in di‐
rrectness of i

rection of -arrow-.
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– Unbolt heat shield over turbocharger -arrows-.
op Vo
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Prote AG.

1. Exhaust turbocharger 289

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 AG➤ , l...
. Vo kswagen AG
agen does
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger,
Volkswsupercharger) - Edition 02.2019
not
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– Pull hose -1- from pressure pipe and unscrew securingutbolts
ho or
-2- for pressure pipe. ss a ac

ce
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– Remove pressure pipe.

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es, in part or in w

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– Pull hose -arrow- from vacuum unit. l purpos
– Remove sealing paint from securing nut -2-.

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– Pull off retaining clip -1- and loosen securing nut -2- on vacuum
unit linkage.
– Unscrew knurled nut from vacuum unit stud.

– Unscrew securing bolts -arrows- for vacuum unit and remove

vacuum unit from turbocharger.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
♦ Linkage must be adjusted after installing vacuum unit
⇒ page 291 .
♦ Specified torque for vacuum unit to turbocharger: 10 Nm
♦ Renew seals, gaskets and self-locking nuts.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Secure all hose connections with hose clips which conform to
production standard.

290 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.5 Adjusting vacuum unit for turbocharger

Note

The vacuum unit must be adjusted only if the linkage has been
loosened.

Special tools and workshop

equipment required

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es, in part or in w

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♦ Pressure regulating valve - VAS 6342-

♦ Dial gauge set, 4-part - VAS 6341-
♦ Hand operated vacuum pump - VAS 6213-
♦ Turbocharger tester - V.A.G 1397A-
♦ Universal dial gauge holder - VW 387-
♦ Dial gauge extension, 30 mm - VAS 6341/3- (not shown)
♦ Flat pickup - VAS 6341/4- (not shown)

1. Exhaust turbocharger 291

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Procedure
– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

AG. Volkswagen AG d
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d b ara
rise nte
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nl

pt
du

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ab
– Unbolt heat shield over turbocharger -arrows-.

ility
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– Open and close expansion tank cap to release pressure in
, is n

h re
cooling system.
hole

spec
– Now drain coolant.
es, in part or in w

t to the co

satelettronica
Note

rrectness of i
Pull coolant hoses off engine with hose clip pliers - VAS 6340- .
l purpos

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– Pull off connecting hoses -1- and coolant hoses -3-.
om

n in
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– Remove bolts and securing nuts -4- from turbocharger.

thi
te

sd
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t.
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Cop py
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pyri by
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by
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– Unscrew securing bolt -2- and remove upper coolant pipe.

Note

The lower coolant pipe can only be removed following the removal
of the catalytic converter.

– Unscrew bolts -1- and remove pressure pipe.

– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove wiring for Lambda probe after catalytic converter -
G130- and for alternator from cable guides -arrows-.

292 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
. Volkswagen AG
4-cylinder direct-injection engine (1.4 l, EA 111,kturbocharger,
swa
gen AG supercharger)
does
n
- Edition 02.2019
ol ot g
yV ua
db ran
– Pull connector off Lambda probe after catalytic
ris
e
converter - tee
ho
G130- and remove. aut or
ac
ss

ce
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nl

pt
du

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itte

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erm

ab
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Open hose clip -3- and remove charge air pipe -2-.
l purpos

– Unbolt exhaust pipe from catalytic converter -arrows-.

– Remove catalytic converter downwards.

nf
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m

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Note

n in
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satelettronica
In the Polo, the catalytic converter is removed together with the
iv

o
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cu
front exhaust pipe.
o

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f

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t.
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op
– Pull hose -arrow- from vacuum unit on turbocharger.
C py
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Checking vacuum unit adjustment ⇒ page 287 . co Vo
by lksw
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Continuation if the vacuum unit has been renewed or the linkage
loosened
– Remove sealing paint from lock nut -2-.

– Pull off retaining clip -1- and loosen lock nut -2- on vacuum
unit linkage.

– Pre-adjust bypass flap -2- on vacuum unit linkage -1- via

knurled screw, so that bypass flap can just be turned by hand.
– Turn knurled nut -1- 2 turns further.
– Tighten lock nut hand-tight.

1. Exhaust turbocharger 293

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Connect hand vacuum pump - VAS 6213- , turbocharger tester

- V.A.G 1397A- to connection -II- and pressure control valve -
VAS 6342- as shown in illustration.
– Close pressure control valve - VAS 6342- at lever -2-.
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
pressure gauge in direction of -arrow-.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position -II-.

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es, in part or in w

t to the co
rrectness of i
l purpos

nf
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t.
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by
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Prote AG.

294 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Secure universal dial gauge bracket - VW 387- to turbocharg‐

er.

Note

The dial gauge linkage and the vacuum unit linkage must align.

– Secure dial gauge - VAS 6341/1- with dial gauge extension,

30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to uni‐
versal dial gauge bracket - VW 387- .
– With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm
preload.
– Operate hand vacuum pump - VAS 6213- until a pressure of
800 mbar is displayed on turbocharger tester - V.A.G 1397A- .
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 0 mbar.
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Note ho
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This procedure is intended to prevent the vacuum unit bypass flap

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or linkage from jamming.

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Note

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The values in mm refer to the read value (includes 1 mm preten‐
urposes, in part or in wh

sion).

t to the co
– Vent system via pressure control valve - VAS 6342- so that

rrectne
pressure reading drops to 0 mbar.
– Set dial gauge - VAS 6341/1- to 0. ss o
cial p

f inform

Note
mer

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♦ The following measurements must be performed in continuous

o

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sequence. Do not allow the pressure to drop to 0 between

thi
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♦ Do not knock against linkage throughout the entire measure‐

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ment procedure.
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tester - V.A.G 1397A- indicates 500 +/- 5 mbar.
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– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 800 +/- 5 mbar.
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 500 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5.5 +/- 0.25 mm.

1. Exhaust turbocharger 295

 agen AG olksw
Eos 2006 ➤ , Golf 2009 ➤ , Golf wageCabriolet 2012 ➤ d, oGolf
n AG. V
es n Plus 2005 ➤ , ...
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4-cylinder direct-injection
d byengine (1.4 l, EA 111, turbocharger,
V ot g
ua supercharger) - Edition 02.2019
e ran
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– Correct setting if the result
utho (average) is not 5.5 +/- 0.25 mm, or
a ac
tighten lock nut hand-tight
ss and repeat measurement.

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nl

pt
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– If the result (mean value) is 5.5 +/- 0.25 mm, tighten the lock

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itte

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nut to 9 Nm and secure with sealing paint. erm

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– Secure retaining clip to vacuum unit linkage.

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Installation is carried out in the reverse order. When installing,
hole

note the following:

spec
es, in part or in w

t to the co
♦ Renew seals, gaskets and self-locking nuts.
♦ Hose connections and hoses for charge air system must be

rrectness of i
free of oil and grease before assembly.
l purpos

♦ Secure all hose connections with hose clips which conform to

production standard.

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♦ If renewed, place seal in groove of charge air hose. Ensure

or
seal is correctly seated in groove.

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♦ Lightly moisten seal with engine oil.

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♦ Bring retaining clip to release position -arrow-.

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♦ When installing air pipes with plug-in connector, ensure that
o

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securing clip -arrow- audibly engages into retaining lug -A-.

t.
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Cop py
t. rig
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Caution p by
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by lksw
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Prote AG.
The screw-type clips on the charge air pipes must be tightened
to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.

Assembly overview - turbocharger ⇒ page 278 .

Assembly overview - charge air system ⇒ page 319
Removing and installing parts of exhaust system ⇒ page 396

296 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2 Compressor
⇒ “2.1 Assembly overview - supercharger”, page 297
⇒ “2.2 Removing and installing supercharger”, page 299
⇒ “2.3 Removing and installing supercharger (Tiguan with four-
wheel drive)”, page 307
⇒ “2.4 Removing and installing drive unit seal for supercharger”,
page 315

2.1 Assembly overview - supercharger

1 - Housing with noise insula‐ n AG. Volkswagen A

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❑ For noise insulation.
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❑ For intake air.

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3 - Intake hose
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rm

ab
❑ Secure with spring-type
pe

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clips
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4 - 7 Nm
hole

spec
❑ Self-tapping bolt
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t to the co
❑ Securing bolt must only
be tightened with a nut
runner if nut runner rrectness of i
speed is max. 500 rpm
and a max. specified tor‐
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que of 7 Nm is set.
5 - 7 Nm
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❑ Renew
AG.

8 - Pressure pipe
9 - Noise insulation
10 - Housing
❑ For noise insulation.
11 - Noise insulation
❑ For charge air.
❑ With seal
❑ Renew seal between supercharger and noise insulation.
12 - Belt pulley
❑ For supercharger

2. Compressor 297
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

13 - 8 Nm
14 - Coolant pump with magnetic clutch for supercharger - N421-
15 - Poly V-belt
❑ For supercharger

Caution
When installing poly V-
belt, observe direction of AG. Volkswagen AG d
agen oes
ksw
rotation and make sure it by
Vol not
gu
ara
is properly seated on pul‐ rised
nte
leys and tensioning ele‐ ut
ho eo
ra
ment. ss a c

ce
e
nl

pt
du

an
16 - 23 Nm itte

y li
erm

ab
ility
17 - Tensioning element
ot p

wit
, is n

❑ For supercharger poly V-belt.

h re
hole

❑ Relieve tension using 16 mm open-end spanner - T10241- .

spec
es, in part or in w

❑ Lock with locking pin - T10060 A- .

t to the co

satelettronica
18 - 40 Nm + 1/4 turn (90°) further

rrectness of i
❑ To loosen and tighten securing bolt, counterhold supercharger shaft with spanner.
❑ Renew
l purpos

19 - Compressor

nform
ercia

❑ Removing and installing (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC)
⇒ page 299
m

at
om

i
❑ Removing and installing (Tiguan with four-wheel drive) ⇒ page 307 .

on
c

in t
r

❑ Removing and installing drive unit seal for supercharger ⇒ page 315
o

his
ate

❑ Repair kit for supercharger ⇒ Electronic parts catalogue (ETKA)

do
priv

cum
for

20 - 25 Nm

en
ng

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

298 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.2 Removing and installing supercharger

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

satelettronica
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

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
♦ Pliers for spring-type clips - VAS 5024A- pyri by
Vo
co lksw
by
cted agen
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331- Prote AG.

♦ Guide pin - T10341-

♦ Locking pin - T10060 A-
Removing
– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

2. Compressor 299
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Detach spring-type clip from intake hose -arrow-.

– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.

satelettronica
– Pull off hose -1- from pressure pipe.
– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.

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

pt
an
d
itte

– Unscrew hose clip -1- on charge air pipe.

y li
rm

ab
pe

ility

– Open hose clip -2- and pull out hose.

ot

wit
, is n

– Unscrew securing bolt for charge air pipe -3-.

h re
hole

spec

– Remove bracket -4-.

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

300 Rep. gr.21 - Turbocharging/supercharging

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ed ran
Eos 2006 ➤ , Golf 2009 hor ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005
is tee ➤ , ...
t or
4-cylinder direct-injection engine (1.4 l,s aEA
u 111, turbocharger, supercharger) - Edition 02.2019 ac
s

ce
le
un
– To do so, remove bolts -arrows-.

pt
an
d
itte

y li
– Remove bracket -1-.

rm

ab
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

nform
ercia

– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
m

a
com

tio
– Remove front right wheel housing liner ⇒ General body re‐

n in
r

pairs; Rep. gr. 66 ; Wheel housing liner; Removing and

te o

thi
installing front wheel housing liner .

s
iva

do
r
rp

cum
Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabrio‐
fo

en
g

let, Touran, Polo, Sharan, Passat, Passat CC) ⇒ page 75

n

t.
yi Co
op

satelettronica
C py
– Remove right drive shaft ⇒ Running gear, axles, steering;
t. rig
gh ht
yri
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
p by
co Vo
by lksw
drive shafts . Prote
cted AG.
agen

Passat, Passat CC
– Remove front exhaust pipe ⇒ page 405 .
Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo, Shar‐
an
– Remove Lambda probe after catalytic converter - G130- -1-.

– Unbolt exhaust pipe from catalytic converter -arrows-.

– Unbolt exhaust pipe to front silencer -arrows-.

Note

In the Polo, the catalytic converter is removed together with the

front exhaust pipe.

2. Compressor 301
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Loosen securing bolts of clamp -arrows- and pull exhaust pipe

to rear.
– Also pull out exhaust pipe together with flexible joint.

AG. Volkswagen AG d
agen oes
olksw not
Continued for all vehicles
d by V gu
ara
rise nte
o
– Push securingaut clip at charge air cooler in direction of -arrow-
h eo
ra
and pull hose
ss -arrow- off. c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

satelettronica
h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
Vehicles with condensate trap on charge air pipe
– Clamp off coolant hoses -1- with hose clips up to 40 mm -
s

3093- .
s o
cial p

f in

– Open clamps -arrows-.

form
mer

– Pull off coolant hoses -1- on charge air pipe -2-.

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
Continued for all vehicles
co lksw
by
cted agen
Prote AG.
– Remove securing bolt -arrow- for charge air pipe -1-.

302 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove securing bolt -arrow- from charge air pipe -1-.

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

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
– Opens clips for hose guides -2- and push hoses to one side.
ole,

spec
urposes, in part or in wh

t to the co
rrectness

satelettronica
o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
a

– Carefully press locking lugs on noise insulation housing

iv

o
pr

-arrows- outwards.
um
r
fo

en
ng

t.
– Pull off front housing with noise insulation.
yi Co
Cop py
ht. rig
– Remove charge air pipe downwards. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Release tension from supercharger poly V-belt by swinging

tensioning element using open-end spanner, 16 mm -
T10241- .
– Lock tensioning element using locking pin - T10060 A- .

2. Compressor 303
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolts -arrows- for tensioning element and

remove tensioning element.
– Hold supercharger shaft with 16 mm spanner -1-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Remove securing bolt -2- for ris pulley and remove pulley and
ed
nte
supercharger poly V-beltuth-3-.
o eo
ra
s a c
s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re

satelettronica
hole

spec
es, in part or in w

t to the co
rrectness of i
– Unscrew securing bolts -1- for supercharger and remove su‐
percharger together with intake noise insulation.
l purpos

Removing noise insulation for charge air:

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
– Pull noise insulation for charge air -2- together with pressure cted agen
Prote AG.
pipe in direction of -arrow-.
Installing

Note

♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 297) .

♦ Before installing, lightly moisten O-rings with engine oil.
♦ The pressure pipe can only be pushed in one position into the
intake silencer for charge air (note locating element).

304 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push noise insulation for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
– Press intake silencer for charge air -2- against crankcase to
allow both dowel sleeves -3- to sit in holes.

– Turn guide pins - T10341- hand-tight to stop in both lower

threaded holes.
– Renew oil seal -1- and ensure it is correctly seated in the
groove.
– Push supercharger together with intake silencer onto guide
pins - T10341- and tighten upper securing bolts hand-tight.
– Remove guide pins - T10341- .

satelettronica
– Tighten lower securing bolts hand-tight.
AG. Volkswagen AG d
w agen oes
– Tighten securing bolts -1- evenly
yV
in
olksdiagonal sequence. not
gu
b ara
ed nte
oris eo
th
au ra
Specified torque: 25 Nm ss c

ce
e
nl

pt
– Install supercharger belt pulley with poly V-belt positioned
du

an
itte

-3-.
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

Specified torque for new securing bolt -2-: 40 Nm + 1/4 turn (90°)
further.
nf
ercia

orm

– Hold supercharger shaft with 16 mm spanner -1-.

m

atio
om

n in

– Install tensioner.
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

2. Compressor 305
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Tighten bolts -arrows- to 23 Nm.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Hold tensioning element using 16 mm open-end spanner
aut - ra
c
T10241- and pull out locking pin - T10060 A- . ss

ce
e
nl

pt
– Position housing with noise insulation onto supercharger. du

an
itte

y li
erm

ab
ility
ot p

Note

wit
, is n

h re
hole

Ensure correct position of noise insulation in housing.

spec

satelettronica
es, in part or in w

t to the co
rrectness of i
l purpos

– Press housing together with noise insulation against super‐

charger until locking lugs -arrows- click into place.

nf
ercia

Perform further installation in reverse order, paying attention to

orm
the following:
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

306 Rep. gr.21 - Turbocharging/supercharging

 . Volkswagen AG
gen AG d
Eos
olks 2006 ➤ , Golf 2009 ➤ , sGolf
wa oe
not Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
yV gu
4-cylinder direct-injection
ised b engine (1.4 l, EA 111, turbocharger,
ara
n supercharger) - Edition 02.2019
r tee
ho
ut or
♦ Renew seals,ss gaskets
a
and self-locking nuts. ac

ce
le
un
♦ Hose connections and hoses for charge air system must be

pt
an
d
free of oil and grease before assembly. itte

y li
erm

ab
♦ Secure all hose connections with hose clips which conform to

ility
ot p

production standard.

wit
is n

h re
ole,

♦ Install exhaust system and align it free of stress.

spec
urposes, in part or in wh

♦ When installing air pipes with plug-in connector, ensure that

t to the co
securing clip -arrow- audibly engages into retaining lug -A-.
Installing hose connections with plug-in connectors

rrectne
⇒ page 323 .
Specified torques:

ss o
cial p

f in
Caution

form
mer

atio
m

The screw-type clips on the charge air pipes must be tightened

o

n
c

to 5.5 Nm. If the torque is too low or too high, the charge air

i
or

n thi
hose may slip off the charge air pipe during vehicle operation.
te

sd
iva

o
pr

cum
r
fo

satelettronica
en
ng

Assembly overview - charge air system ⇒ page 319

t.
yi Co
Cop py
t. rig
Assembly overview - catalytic converter and add-on parts yri
gh by
ht
⇒ page 396
op Vo
by c lksw
cted agen
Prote AG.
– Push engine cover panel down at points -1- in direction of
-arrow- until it engages.
– Fit vacuum hose onto connection -arrow-.
Vehicles with condensate trap on charge air pipe
– Check coolant level and top up if necessary ⇒ page 198 .

2.3 Removing and installing supercharger (Tiguan with four-wheel drive)

2. Compressor 307
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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

pt
du

an
itte

y li
erm

ab
ility
ot p

♦ Hose clamp pliers - VAS 6340-

wit
, is n

h re

♦ Torque wrench - V.A.G 1331-

hole

spec

♦ Guide pin - T10341-

es, in part or in w

t to the co

♦ Locking pin - T10060 A-

Removing
rrectness of i

– Pull vacuum hose off engine cover panel.

l purpos

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

308 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Detach spring-type clip from intake hose -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Separate fuel supply line -1- and line to activated charcoal filter
s

ce
le

-2-. Press release tabs to do this.

un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

satelettronica
t to the co
rrectness

– Pull off hose -1- from pressure pipe.

o
cial p

f inform

– Unscrew securing bolts -2- from pressure pipe and remove

mer

pressure pipe.
atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

– Unscrew hose clip -1- on charge air pipe.

– Open hose clip -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3-.
– Remove bracket -4-.

2. Compressor 309
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabrioletgen AG 2012 ➤ , nGolf
. Volkswage AG Plus 2005 ➤ , ...
does
swa
4-cylinder direct-injection engine
y V (1.4 l, EA 111, turbocharger, tsupercharger)
olk no
gu - Edition 02.2019
b ara
ed nte
ris
– To do so, remove bolts -arrows-.
au
tho e or
ac
ss
– Remove bracket -1-.

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
– Unscrew bolts -arrows- and remove charge pressure sender -
l purpos

G31- -1-.

nform
ercia

– Depending on vehicle equipment, remove noise insulation or

skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
m

at
moving and installing noise insulation or skid plate .
om

ion
c

in t
r

Remove poly V-belt (Tiguan) ⇒ page 78 .

o

his
ate

do
riv

– Remove right drive shaft ⇒ Running gear, axles, steering;

satelettronica
p

cum
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
for

en
g

drive shafts .
n

t.
yi Co
Cop py
– Remove Lambda probe after catalytic converter - G130- -1-. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unbolt exhaust pipe from catalytic converter -arrows-.

– Loosen securing nuts of clamping sleeve -arrows- and slide it

forwards on exhaust pipe -1-.

310 Rep. gr.21 - Turbocharging/supercharging

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
h
Eos
aut 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012o➤ r a , Golf Plus 2005 ➤ , ...
c
s
4-cylinder direct-injection
s engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

ce
e
nl

pt
du

an
itte
– Unscrew nuts -arrows- and pull exhaust pipe backwards.

y li
erm

ab
– Push exhaust pipe backwards out of mounting -1-.

ility
ot p

wit
, is n
– Lower subframe ⇒ Subframe, anti-roll bar, suspension links;

h re
Rep. gr. 40 ; Lowering subframe . hole

spec
es, in part or in w

– Remove exhaust pipe forwards.

t to the co
– Remove bevel box ⇒ 6-speed manual gearbox 0A6; Rep. gr.
34 ; Removing and installing bevel box .

rrectness of i
l purpos

nform
ercia

– Push securing clip at charge air cooler in direction of -arrow-

m

at
and pull hose -arrow- off.
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig

satelettronica
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove securing bolt -arrow- for charge air pipe -1-.

– Unscrew securing bolt for charge air pipe -arrow-.

2. Compressor 311
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Opens clips for hose guides -2- and push ehoses

n AG. Voto
lksone
wageside.
n AG
ag does
ksw not
– Carefully press locking lugs on noise Vol insulation housing gu
by ara
-arrows- outwards. ris
ed
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
hole

spec
es, in part or in w

t to the co
– Pull off front housing with noise insulation.
– Remove charge air pipe downwards.

rrectness of i
l purpos

nf
ercia

orm
m

atio

satelettronica
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op
– Slacken supercharger poly V-belt by swinging tensioning ele‐ C py
t. rig
ment in direction of -arrow- with 16 mm spanner.
gh ht
pyri by
Vo
co lksw
by
– Lock tensioning element using locking pin - T10060 A- . cted agen
Prote AG.

– Unscrew securing bolts -arrows- for tensioning element and

remove tensioning element.
– Hold supercharger shaft with 16 mm spanner -1-.

312 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger,
wage supercharger)
n AG. Volkswagen AG
doe - Edition 02.2019
ks s no
Vol t gu
by ara
– Remove securing bolt -2- for pulley and remove
ris
ed
pulley and nte
supercharger poly V-belt -3-. autho eo
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
– Unscrew securing bolts -1- for supercharger and remove su‐
percharger together with intake silencer.
l purpos

Removing intake silencer for charge air:

nf
ercia

orm
m

atio
om

n in
or c

thi
te

satelettronica
sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Pull intake silencer for charge air -2- together with pressure cted agen
Prote AG.
pipe in direction of -arrow-.
Installing

Note

♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 297) .

♦ Before installing, lightly moisten O-rings with engine oil.
♦ The pressure pipe can only be pushed in one position into the
intake silencer for charge air (note locating element).

– Push noise insulation for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
– Press intake silencer for charge air -2- against crankcase to
allow both dowel sleeves -3- to sit in holes.

2. Compressor 313
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Turn guide pins - T10341- hand-tight to stop in both lower

threaded holes.
– Renew oil seal -1- and ensure it is correctly seated in the
groove.
– Push supercharger together with intake silencer onto guide
pins - T10341- and tighten upper securing bolts hand-tight.
– Remove guide pins - T10341- . agen
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oes
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V
– Tighten lower securing bolts d b hand-tight.
y gu
ara
rise nte
o
– Tighten securing bolts
aut evenly and diagonally.
h eo
ra
ss c

ce
le
un

pt
an
d

Specified torque: 25 Nm
itte

y li
rm

ab
– Position housing with noise insulation onto supercharger.
pe

ility
ot

wit
, is n

h re
hole

Note

spec
es, in part or in w

t to the co
Ensure correct position of noise insulation in housing.

satelettronica
rrectness of i
l purpos

nform
ercia

– Press housing together with noise insulation against super‐

m

a
charger until locking lugs -arrows- click into place.
com

tion in
Perform further installation in reverse order, paying attention to
r
te o

thi

the following:
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.

314 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Renew securing bolt for supercharger pulley. Specified torque

40 Nm + 1/4 turn (90°) further.
♦ Renew seals, gaskets and self-locking nuts.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Secure all hose connections with hose clips which conform to
production standard.
♦ Install exhaust system and align it free of stress.
♦ When installing air pipes with plug-in connector, ensure that
securing clip -arrow- audibly engages into retaining lug -A-.
Fitting hose connections with plug-in connectors ⇒ page 323
Specified torques:
Assembly overview - charge air system (Eos, Golf Plus, Golf, Golf
Cabriolet, Touran, Scirocco, Tiguan, Sharan) ⇒ page 320
Assembly overview - charge air system (Polo) ⇒ page 321
Assembly overview - catalytic converter and add-on parts
⇒ page 418

satelettronica
– Push engine cover panel down at points -1- in direction of
-arrow- until it engages.

n AG. Volkswagen AG do
lkswage es n
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ss
2.4 Removing and installing drive unit seal
ce
le
un

pt
an
d

for supercharger
itte

y li
rm

ab
pe

ility

Special tools and workshop equipment required

ot

wit
, is n

♦ Gearbox support - T10108-

h re
hole

spec

♦ Assembly tool - T10208-

es, in part or in w

t to the co

♦ Extractor hook - T20143-

♦ Repair kit for supercharger ⇒ Electronic parts catalogue (ET‐
rrectness of i

KA)
l purpos

Note
nform
ercia

All components in the repair kit must be used!

m

a
com

tion in

Removing
r
te o

thi
s
iva

– Remove supercharger ⇒ page 297

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.

2. Compressor 315
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Secure compressor on the gearbox support - T10108- with 2

bolts-arrow-.

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

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

– Pry off the circlip -1- with a slot-head screwdriver -2-.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

– Pull out the seal -1- with the puller hooks - T20143/1- .
o
r
rp

cu
o

m
f

en
ng

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

– Put together assembly cone -T10208/5- and assembly sleeve

-T10208/4- .
– Slide the new seal -1- onto the assembly sleeve in the
-arrow direction- -T10208/5- -T10208/4- via the assembly
cone.

316 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull down the assembly cone - T10208/5- from the assembly

sleeve in the -arrow direction- -T10208/4- .

– Slide the assembly sleeve - T10208/4- onto the compressor

shaft.

satelettronica
– Using the thrust piece - T10208/2- , press in the seal via the
assembly sleeve - T10208/4- up to the stop.

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

pt
an
d

– Press in the new circlip -1- up to the stop also using the as‐
itte

y li

sembly tool - T10208/2- .

erm

ab
ility
ot p

Changing the compressor fluid

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
o
by c lksw
cted agen
Prote
317
AG.
2. Compressor
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Undo the securing bolts for the drive unit according to the
specified sequence -A- to -H-.
– Turn the gearbox support - T10108- until the shaft points to
the floor.

– Unscrew the securing bolts and remove the drive unit -1-.
– Drain compressor oil completely from drive unit.
– Collect the escaping fluid in a suitable container.
– Turn the gearbox support - T10108- until the pair of gears point
upwards.
– Remove sealant residues from compressor and drive unit with

satelettronica
a rotating brush, e.g. a hand drill with a plastic brush (wear eye
protection). wage
n AG. Volkswagen AG do
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Vol t
– Carefully clean sealing d bsurfaces. They must be free of oil and
y gu
ara
se
grease. thori nte
eo
au ra
– Dirt and sealant
ss residues must not be allowed to enter the c
ce
le

space.
un

pt
an
d
itte

y li
erm

ab

Caution
ility
ot p

wit
is n

Add only the oil specified in repair set ⇒ Electronic parts cata‐
h re
ole,

logue (ETKA) .
spec
urposes, in part or in wh

t to the co

– Fill the space -arrow- with new oil (44 ml) from the repair set.
rrectne

Note
ss o
cial p

Sealant must not be applied too thickly, otherwise excess sealant

inform

may enter the space and cause damage.

mer

atio
om

Do not apply sealant until directly before the drive unit is fitted.
c

i
or

n thi
te

– Apply sealant to the sealing surface on the compressor.

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
Bead of sealant must be 2 to 3 mm thick and must run along inside rig ht
py by
edge in area of bolt holes. co Vo
by lksw
cted agen
Prote AG.
– Tighten the new securing bolts for the drive unit to “12 Nm”
according to the specified sequence -A- to -H-.
– Install supercharger ⇒ page 297

318 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3 Charge air system

Caution

The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.

Note

♦ It is recommended that spring-type clips should be installed

using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- . Volkswa AG. gen AG
agen do
♦ Secure all hose
Vol connections with hose clips
ksw es n
ot gwhich conform to
production
ise
d b standard.
y ua
ran
or tee
♦ Hose
au connections and hoses for charge air systemor must
th
a be
free
ss of oil and grease before assembly. The seal andc sealing ce
e

satelettronica
surface must be oiled lightly only for plug-in connectors
nl

pt
du

⇒ page 323 .
an
itte

y li
erm

ab
♦ Charge air system must be free of leaks.
ility
ot p

wit
, is n

h re

⇒ “3.1 Assembly overview - charge air system (Eos, Golf Plus,

hole

Golf, Touran, Scirocco, Tiguan, Sharan, Golf Cabriolet)”,

spec

page 320
es, in part or in w

t to the co

⇒ “3.2 Assembly overview - charge air system (Polo)”,

page 321
rrectness of i

⇒ “3.3 Assembly overview - charge air system (Passat, Passat

CC)”, page 322
l purpos

nform
ercia

Note
m

at
om

In the Polo, the charge air cooler is removed and installed to‐
ion
c

gether with the radiator ⇒ page 275 .

in t
or

his
ate

do
riv

⇒ “4.2 Actuator for structure-borne sound R214 and control unit

p

cum
or

for structure-borne sound J869 (Polo, left-hand drive)”,

f

en
ng

t.
yi
page 365
Co
Cop py
t. rig
gh
⇒ “3.4 Fitting hose connections with plug-in connectors”,
ht
pyri by
Vo
page 323
co lksw
by
cted agen
Prote AG.
⇒ “3.5 Checking charge air system for leaks”, page 324
⇒ “3.6 Removing and installing charge air cooler (Eos, Golf Plus,
Golf, Golf Cabriolet, Touran)”, page 327
⇒ “3.7 Removing and installing charge air cooler, Sharan”,
page 329
⇒ “3.8 Removing and installing charge air cooler (Scirocco)”, page
331
⇒ “3.9 Removing and installing charge air cooler, Tiguan”,
page 333
⇒ “3.10 Removing and installing charge air cooler (Passat, Passat
CC)”, page 335

3. Charge air system 319

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3.1 Assembly overview - charge air system

(Eos, Golf Plus, Golf, Touran, Scirocco,
Tiguan, Sharan, Golf Cabriolet)

Caution

The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.

n AG. Volkswagen AG do
wage es n
1 - Charge air cooler Vol
ks ot g
d by ua
ran
❑ Removing andoinstalling
ris
e
tee
(Eos, Golf Plus,
au
th
Golf, or
ac
Golf Cabriolet,
ss Touran)

ce
le

⇒ page 327
un

pt
an
d

❑ Removing and installing

itte

y li
rm

(Sharan) ⇒ page 329

ab
pe

ility
❑ Removing and installing
ot

satelettronica
wit
, is n

(Scirocco) ⇒ page 331

h re
hole

❑ Removing and installing

spec
(Tiguan) ⇒ page 333
es, in part or in w

t to the co
2 - 5 Nm
3 - Mountings rrectness of i
❑ For charge air cooler.
l purpos

4 - Seal
❑ Renew if damaged
nform
ercia

5 - Charge air hose

m

a
com

tio

❑ Can be secured with

n in
r

plug-in connectors or
te o

thi

screw-type clips
s
iva

do
r
rp

cum

6 - Intake manifold connection

fo

en
ng

t.
❑ With seals.
yi Co
Cop py
t. rig
7 - Throttle valve module -
gh ht
pyri by
J338-
o Vo
by c lksw
cted agen
Prote
❑ Cleaning ⇒ page 351
AG.

❑ If renewed, erase learnt

values and adapt en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester “Guided func‐
tions”.
8 - 7 Nm
9 - Hose clamp
10 - Charge air hose
11 - 10 Nm
12 - Charge air pipe
13 - Charge air pressure sender - G31- with intake air temperature sender 2 - G299-
14 - 5 Nm
15 - Charge air hose
❑ To turbocharger

320 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

16 - Charge air pipe

17 - Charge air hose
❑ Can be secured with plug-in connectors or screw-type clips

3.2 Assembly overview - charge air system

(Polo)

Caution

The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.

1 - Charge air cooler

❑ Removing and installing
⇒ page 275

satelettronica
Note

The charge air cooler is removed

and installed together with the radi‐
ator.
AG. Volkswagen AG d
agen oes
2 - Hose clip, 5.5 Nm olksw not
V gu
d by ara
e
3 - Charge air hose horis nte
eo
aut ra
4 - Charge air hose ss c
ce
e
nl

pt

5 - Throttle valve module -

du

an
itte

J338-
y li
erm

ab

❑ Cleaning ⇒ page 351

ility
ot p

wit

❑ If renewed, erase learnt

, is n

h re

values and adapt en‐

hole

spec

gine control unit - J623-

es, in part or in w

⇒ Vehicle diagnostic
t to the co

tester “Guided func‐

tions”.
rrectness of i

6 - 7 Nm
7 - Intake manifold connection
l purpos

❑ With seals.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

3. Charge air system 321

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

8 - Charge air pressure sender - G31- with intake air temperature sender 2 - G299-
9 - 10 Nm
10 - 5 Nm
11 - Mountings
12 - 10 Nm
13 - 10 Nm
14 - Charge air pipe
15 - Bracket
16 - 10 Nm
AG. Volkswagen AG d
17 - Charge air pipe agen oes
olksw not
byV gu
ara
18 - Charge air hose rised
nte
ho eo
❑ To turbocharger s aut ra
c
s
19 - Charge air hose

ce
le
un

pt
an
d
itte

y li
erm

ab
ility

satelettronica
ot p

3.3 Assembly overview - charge air system (Passat, Passat CC)

wit
is n

h re
ole,

spec
urposes, in part or in wh

1 - Charge air cooler

t to the co
❑ Removing and installing
⇒ page 335
2 - Bolt

rrectne
❑ 5 Nm

s
❑ Qty. 2
s o
cial p

f in
3 - Mountings
form
mer

❑ For charge air cooler.

atio
m

❑ Installed on left and right

o

n
c

i
or

n thi
e

4 - Screw-type clamp
t

sd
iva

o
pr

cum
r
fo

en

Caution
ng

t.
yi Co
op
The screw-type clips on
C py
ht. rig
the charge air pipes must
rig ht
py by
o Vo
be tightened to 5.5 Nm. If by c lksw
cted agen
the torque is too low or
Prote AG.

too high, the charge air

hose may slip off the
charge air pipe during
vehicle operation.

❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
5 - Charge air hose
❑ Can be secured with
plug-in connectors or
screw-type clips
❑ Installation of plug-in
connectors
⇒ page 338
6 - Intake manifold connection
❑ With seals.

322 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

7 - Throttle valve module - J338-

❑ Cleaning ⇒ page 351
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
functions”.
8 - Bolt
❑ 7 Nm
❑ Qty. 4
9 - Charge air hose AG. Volkswagen AG d
agen oes
o lksw not
10 - Charged bairy V pressure sender - G31- with intake gu
ara air temperature sender 2 - G299-
ise nte
r
11 - Bolt
ut
ho eo
ra
a c
❑s 10 Nm
s

ce
e
nl

❑ Qty. 2

pt
du

an
itte

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12 - Bolt
erm

ab
ility
ot p

❑ 5 Nm

wit
, is n

❑ Qty. 3

h re
hole

spec
13 - Charge air pipe with condensate trap
es, in part or in w

satelettronica
t to the co
❑ To remove, seal coolant hoses with hose clamps up to 40 mm - 3093-
❑ To remove, detach coolant hoses ⇒ page 323
❑ After installing, check coolant level and top up if necessary ⇒ page 198
rrectness of i
14 - Charge air hose
l purpos

❑ To turbocharger
nform
ercia

15 - Charge air pipe

m

at

16 - Charge air hose

om

ion
c

❑ Can be secured with plug-in connectors or screw-type clips

in t
or

his
e

❑ Installation of plug-in connectors ⇒ page 338

at

do
priv

cum

17 - Seal
for

en
ng

t.
yi
❑ On vehicles with push-fit charge air hoses
Co
Cop py
t.
❑ Renew if damaged
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removal of coolant hoses on charge air pipe with condensate trap

– Seal coolant hoses with hose clamps up to 40 mm - 3093-
– Open spring-type clips -arrows-.
– Pull off coolant hose -1- and charge air pipe -2-.
– After installing, check coolant level and top up if necessary
⇒ page 198

3.4 Fitting hose connections with plug-in

connectors

Note

Air hoses can be secured with plug-in connectors or screw-type

clips.

3. Charge air system 323

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Eos 2006 ➤ , Golf 2009 ➤ a,uGolf
tho
Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...e or a
4-cylinder direct-injection engine
ss (1.4 l, EA 111, turbocharger, supercharger) -c Edition 02.2019

ce
le
un

pt
an
d
itte

y li
Caution

rm

ab
pe

ility
ot

wit
The screw-type clips on the charge air pipes must be tightened

, is n

h re
to 5.5 Nm. If the torque is too low or too high, the charge air
hole

spec
hose may slip off the charge air pipe during vehicle operation.
es, in part or in w

t to the co
Caution

rrectness of i
l purpos

The seal for the push-on coupling can be damaged if the re‐
taining clip is in the locked position during installation. This
would result in leaking. Observe installation instructions.

nform
mercia

a
com

tio
Removing:

n in
r
te o

thi
– Release plug-in connector by pulling out retaining clip

s
iva

do
-arrow-. Separate hose/pipe without tools.
r
rp

cum
fo

Installing

en
ng

t.
yi Co
op py
– If renewed, place seal in groove of charge air hose. Make sure t. C

satelettronica
rig
gh ht
that the seal is correctly seated in the groove all around the yri
p by
o Vo
complete circumference and that it is not twisted.
c by lksw
cted agen
Prote AG.
– Lubricate sealing surface and seal with oil.

– Bring retaining clip to release position -1-.

– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if plug-in connector seats correctly and is properly en‐
gaged by pulling hose.

3.5 Checking charge air system for leaks

Special tools and workshop equipment required

324 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Charge air system tester - V.A.G 1687- with adapter - V.A.G

1687/10- and adapter - V.A.G 1687/14-

♦ Hose clamp pliers - VAS 6340-

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
♦ Engine bung set - VAS 6122- (not shown)
ss
ce
e
nl

pt
du

– Lift engine cover panel at points -1- and pull it forwards in di‐ an
itte

rection of -arrow-. y li
erm

ab
ility
– Press hose locking mechanism and pull hose for crankcase
ot p

wit
breather -1- off intake connecting pipe.
, is n

h re
hole

– Also pull crankcase breather hose off valve timing housing.

spec
es, in part or in w

t to the co

Caution
rrectness of i

Crankcase breather hose must be pulled off during leak test to

prevent damage to engine.
l purpos

nform
ercia

– Seal intake connecting pipe with a bung from engine bung set
- VAS 6122- .
m

at
om

ion
c

– Slacken spring-type clips -2- from intake hose and remove in‐
in t
or

take hose.
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.

3. Charge air system 325

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Renew spring-type clips -arrows- with screw-type clips from

charge air system tester - V.A.G 1687- .
– Slide the adapter - V.A.G 1687/14- onto the intake connecting
pipe and secure the hose with the relevant screw-type clip.

– Slide the adapter - V.A.G 1687/10- into the adapter - V.A.G

1687/14- and secure the adapter with the screw-type clip.
– Connect hose -1- to the charge air system tester - V.A.G
1687- .
Prepare charge air system tester - V.A.G 1687- as follows:

satelettronica
AG. Volkswagen AG d
agen oes
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d by ara
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– Unscrew pressurehoris regulating valve -2- and close valves -3- nte
eo
and -4-. s aut ra
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326 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Connect pressure hose -1- (compressed air supply) to charge

air system tester - V.A.G 1687- .

Note

If there is water in the sight glass, drain at water drain screw -6-.

– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.

Caution

The pressure must not exceed 0.5 bar. If the pressure is too
high this can cause damage to the engine.

olkswagen AG
en AG. V
– Open valve -4- and wait until the test circuit oislksfilled.
wag If neces‐ does
not
sary readjust pressure to 0.5 bar. d byV gu
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– Check the charge air system for leaks
aut
h by hearing, touching,
o eo
ra
with commercially available leak sdetector spray or using ultra‐

satelettronica
s c
sonic tester - V.A.G 1842- .

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Note
ot

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♦ Slight leaks in the area of the intake connecting pipe
hole

spec
-arrows- are permissible, as the intake hoses are not designed
es, in part or in w

for high-pressure.

t to the co
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.

rrectness of i
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
l purpos

instructions
♦ Depressurise test circuit by detaching coupling from adapter -
nform
ercia

V.A.G 1687/6- before removing adapter.

m

♦ Hose connections and hoses must be free of oil and grease

com

tion in

before assembly.
r
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thi

♦ After testing compression, secure intake hoses again with

s
iva

do
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spring-type clips.
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t.
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– Push engine cover panel down at points -1- in direction of ht. rig
rig ht
-arrow- until it engages. py by
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3.6 Removing and installing charge air cooler (Eos, Golf Plus, Golf, Golf Cab‐
riolet, Touran)

3. Charge air system 327

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

n AG. Volkswagen AG do
lkswage es n
o ot g
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u or
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ss

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
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
co lksw
by
cted agen
Prote AG.

♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-
Removing
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Removing and installing front bumper cover
– Remove air filter ⇒ page 342 .
– Pull connectors off thermal switch and radiator fan.
– Remove radiator ⇒ page 272 .

Note

To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.

– Remove retaining clamp(s) for refrigerant lines.

328 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Make a paper template with the specified dimensions.

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ility
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– Fit the template on the plastic bracket at the front right so that

spec
urposes, in part or in wh

it rests against the edges at the top and left.

t to the co
– Mark the intersection on the template -arrow- with a centre
punch.

rrectne
– Drill a hole into the plastic bracket with a 5-mm drill bit.
– Drill or cut the hole to 16 mm.

ss o

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cial p

f inform
mer

atio
om

n
c

i
or

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sd
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– Remove securing bolt -arrow-.

i

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pr

cum
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fo

en
ng

t.
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ht. rig
rig ht
py by
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– Remove securing bolts -arrows-.

– Remove charge air cooler downwards.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Specified torques:
Component Nm
Cowling to radiator 5
Radiator to charge air cooler 5
Charge air cooler to condenser 5

3.7 Removing and installing charge air cooler, Sharan

3. Charge air system 329

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

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or

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au ac
ss

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ility
ot

wit
, is n

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
♦ Refractometer - T10007 A-
com

tion in
r

♦ Hose clamp pliers - VAS 6340-

te o

thi
s
iva

do
♦ Torque wrench - V.A.G 1331-
r
rp

cum
fo

en
g

Removing
n

t.
yi Co
op py
– Remove noise insulation ⇒ General body repairs, exterior;
t. C rig
gh ht
yri
Rep. gr. 50 ; Noise insulation . p by
co Vo
by lksw
cted agen
– Remove front bumper cover ⇒ General body repairs, exterior; Prote AG.
Rep. gr. 63 ; Removing and installing front bumper cover
– Remove air filter ⇒ page 342 .
– Pull connectors off thermal switch and radiator fan.
– Remove radiator ⇒ page 272 .

330 Rep. gr.21 - Turbocharging/supercharging

 n AG. Volkswagen AG do
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Eos 2006 ➤ , Golf 2009ed➤ , Golf Cabriolet 2012 ➤ , Golf Plus
by ua 2005 ➤ , ...
ran
ir s
4-cylinder direct-injection engine (1.4 l, EA
th 111, turbocharger, supercharger) - Editione02.2019
o te
or
au ac
ss
– Remove central guide profile -A- at front end -arrows-.

ce
le
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pt
an
d
itte

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ab
pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Unscrew bolts -arrows- for charge air cooler mountings.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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cum
fo

en
ng

t.

satelettronica
yi Co
Cop py
t. rig
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pyri by
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– Unbolt condenser from charge air cooler -arrows-.

Note

The securing bolts of the condenser are difficult to access! With

the aid of a 2nd mechanic, lift the charge air cooler out of the
radiator mountings. The charge air cooler can now be moved
»back and forth« to allow access to the securing bolts.

– Secure condenser to lock carrier with cable tie.

– Take out charge air cooler from underneath.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Hose connections and hoses for charge air system must be free
of oil and grease before assembly. The seal and sealing surface
must be oiled lightly only for plug-in connectors ⇒ page 323 .
Specified torques for charge air cooler ⇒ page 320 .
Specified torques for front end ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper

3.8 Removing and installing charge air cooler (Scirocco)

3. Charge air system 331

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
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byV gu
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ab
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ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
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.

♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
Removing
– Remove bumper cover ⇒ Bumpers; Rep. gr. 63 ; Removing
and installing front bumper cover .
– Drain coolant ⇒ page 185 .
– Pull coolant hoses off radiator.
– Pull connectors off thermo switch and radiator fan.
– Remove radiator securing bolts and remove radiator with fan
downwards.

Note

To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.

– Remove retaining clamp(s) for refrigerant lines.

332 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove securing bolts -arrows-.

– Remove charge air cooler downwards.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Filling with new coolant ⇒ page 185 .
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Specified torques:olkswage es n
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Component
or
ise teeNm
h
ut or
Cowling
ss to radiator
a 5ac

ce
le

Radiator to charge air cooler 5

un

pt
an
d
itte

Charge air cooler to condenser 5

y li
rm

ab
pe

ility
ot

3.9 Removing and installing charge air cooler, Tiguan

wit
, is n

h re
hole

spec
es, in part or in w

Special tools and workshop

t to the co
equipment required

satelettronica
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
r
rp

cum
fo

en
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t.
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t. rig
gh ht
pyri by
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♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Torque wrench - V.A.G 1331-

3. Charge air system 333

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
– Remove bracket -1- by unscrewing securing bolts -arrows-.

satelettronica
– Push securing clip at charge air cooler in direction of -arrow-
and pull hose -arrow- off.
– Also remove second hose from charge air cooler.

n AG. Volkswagen AG do
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– Disconnect connector -1-. ir se tee
tho
u or
a ac
– Drain coolant; to do this, pull hose -2- off.
ss
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
rrectness of i

– Release retaining clip and pull connection -arrow- off radiator.

l purpos

– Also pull off connection at bottom of radiator.

nform
ercia

– Bring lock carrier into service position ⇒ General body repairs,

exterior; Rep. gr. 50 ; Body - front; Lock carrier; Service po‐
m

sition .
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.

334 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolts -arrows- and remove cowling upwards

together with radiator fan - V7- .

Note

The radiator fan - V7- and the cowling may only be renewed com‐
plete.

– Remove securing bolt -arrow-.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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– Unscrew bolts -arrows- and remove radiatoradownwards.
ut
h
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

– Remove securing bolts -arrows-.

– Remove charge air cooler downwards.
nform
ercia

Installing
m

at
om

Installation is carried out in the reverse order. When installing,

on
c

note the following:

in t
or

his
ate

Filling with new coolant ⇒ page 185 .

do
priv

cum
or

Specified torques:
f

en
ng

t.
yi Co
op py
Component Nm
t. C rig
gh ht
pyri by
Cowling to radiator 5
co Vo
by lksw
cted agen
Prote
Radiator to charge air cooler 5
AG.

Charge air cooler to condenser 5

3.10 Removing and installing charge air cooler (Passat, Passat CC)

3. Charge air system 335

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
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

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an
itte

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erm

ab
ility
ot p

wit
, is n

h re

♦ Refractometer - T10007 A-
hole

spec
es, in part or in w

♦ Hose clamp pliers - VAS 6340-

t to the co

♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-

Removing
rrectness of i

– Remove noise insulation or skid plate ⇒ General body repairs,

l purpos

exterior; Rep. gr. 50 ; Removing and installing noise insulation

or skid plate .
nform
ercia

– Remove front bumper ⇒ General body repairs, exterior; Rep.

m

gr. 63 ; Assembly overview - front bumper .

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.

336 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Vehicles with push-fit charge air hoses

– Release securing clip on right of charge air cooler in direction
of -arrow- and pull off hose -arrow-.
– Release and pull off charge air hose in same way on left-hand
side.

Vehicles with screw-type hose clips on charge air hoses

– Loosen hose clip -arrow-.
– Pull off charge air hose -1- on left of charge air cooler -2-.
– Loosen hose clip on right-hand side as well and pull off charge
air hose.

satelettronica
Continued for all vehicles
– Drain coolant ⇒ page 198 .
– Remove air filter ⇒ page 342 .

– Release retaining clip -arrow-.

– Pull off coolant hose -1- from radiator.

n AG. Volkswagen AG do
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pt
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an
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erm

ab

– Undo and remove bolts -arrows- of cowling.

ility
ot p

wit

– Release connectors -1- and pull off.

, is n

h re
hole

– Remove cowling downwards.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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cu
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f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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337
Prote AG.
3. Charge air system
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew bolts -arrows-.

– Remove radiator -1- downwards.

– Undo and remove coolant pump bolts -arrows- of the radiator

support.
– Pull out bottom of radiator from mounting.
– Tilt radiator backwards.
Vehicles with air conditioning system

satelettronica
Note

Make sure that the coolant lines/hoses are not excessively

stretched, kinked or bent.

– Undo and remove condenser bolts -arrows-.

– Secure condenser to lock carrier.
Continued for all vehicles
– Remove radiator downwards. AG. Volkswagen AG d
agen oes
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Installing ed b ara
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Install in reverse order of removal.
aut When doing this, observe the ra
c
following: ss
ce
e
nl

pt
du

Vehicles with screw-type hose clips on charge air hoses

an
itte

y li
erm

ab
ility

Caution
ot p

wit
, is n

h re

The screw-type clips on the charge air pipes must be tightened

hole

spec

to 5.5 Nm. If the torque is too low or too high, the charge air
es, in part or in w

hose may slip off the charge air pipe during vehicle operation.
t to the co

Vehicles with push-fit charge air hoses

rrectness of i
l purpos

Note
nf
ercia

Note installation of charge air hoses.

rm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
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m
f

en
ng

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

338 Rep. gr.21 - Turbocharging/supercharging

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– If oil seal is renewed, place seal in groove of charge air hose.

Ensure that seal is correctly seated around groove and is not
twisted.
– Coat sealing surface and oil seal with oil.
– Bring retaining clip to release position -1-.
olkswagen AG
en AG. V
– Push charge air hose into coupling as far as stop.
olks
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– Bring retaining clip to locking position -2-ris and then
ed press nte
charge air hose again. au
tho eo
ra
ss c
– Pull on hose to ensure that plug-in connector is properly seat‐

ce
e
nl
ed and engaged.

pt
du

an
itte

y li
Continued for all vehicles
erm

ab
ility
ot p

Fill with new coolant ⇒ page 198 .

wit
, is n

h re
– Electrical connections and routing ⇒ Current flow diagrams,
hole

spec
Electrical fault finding and Fitting locations.
es, in part or in w

t to the co
Specified torque

rrectness of i

satelettronica
Component Specified torque
l purpos

Radiator to charge air cooler 5 Nm

nform
ercia

Cowling to radiator 5 Nm
m

Charge air cooler to lock carrier 5 Nm

at
om

ion
Condenser to charge air cooler 5 Nm
c

in t
or

his
e

Screw-type hose clips on charge air pipes 5.5 Nm

at

do
priv

cum
for

en
ng

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

3. Charge air system 339

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

24 – Mixture preparation - injection

1 Air filter
⇒ “1.1 Assembly overview - air filter”, page 340
⇒ “1.2 Assembly overview - air filter (Polo)”, page 341
⇒ “1.3 Removing and installing air filter housing”, page 342
⇒ “1.4 Removing and installing air filter housing (Polo)”,
page 343
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1 - 1.6 Nm

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2 - Air filter upper part

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3 - Vacuum hose

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satelettronica
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is n

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ole,

Caution

spec
urposes, in part or in wh

To avoid damage to the

t to the co
connection and vacuum
hose, do not use sharp-
edged tools to remove

rrectne
the hose.

ss
❑ Renew if damaged

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cial p

f in
❑ From camshaft housing.

form
mer

4 - Spring-type clip

atio
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n
❑ Remove and install us‐
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or

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ing spring-type clip pli‐
thi
te

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ers - VAS 5024A- .

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5 - Intake hose
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7 - Intake air guide cop Vo
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8 - Air filter lower part
AG.

❑ With captive securing

bolt.
❑ Specified torque: 8 Nm
❑ With intake connection.
9 - Water drain hose
❑ When installing, arrows
on lower part of air filter
and water drainage
hose must align.
10 - O-ring
❑ Renew
11 - Filter element

340 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.2 Assembly overview - air filter (Polo)

1 - Spring-type clip
❑ Remove and install with
hose clip pliers - VAS
6340- .
2 - Intake hose
3 - Air filter upper part
4 - 1.6 Nm
❑ Tighten with torque
screwdriver - VAS
6494- .
5 - Seal
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11 - Rubber mounting
12 - Rubber mounting

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13 - Water drain hose
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14 - O-ring

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15 - Intake air duct, 3 Nm

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16 - Intake connecting pipe
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1. Air filter 341

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
olkswagen AG
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1.3 Removing and installing
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Continued for all vehicles

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hole

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– Press fastener -arrows- and pull intake air duct upwards.
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– Release spring-type clip -1- and pull intake hose and vacuum
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– Loosen securing bolt -2- and pull air filter housing upwards
from locating pins -arrows-.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
– Push air filter housing onto locating pins -arrows- from above.

– Tighten new securing bolt -2- to 8 Nm and slide spring-type

clip -1- with intake hose onto air filter connection.

342 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
. Volkswagen AG
gen AG
1.4 Removing and installing air filter hous‐
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– Lift engine cover panel
ss at points -1- and pull it forwards in di‐
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– Open spring-type clip -2- and pull intake hose off.

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– Pull intake hose -3- out of intake connection.

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– Unscrew securing bolt and pull air filter housing -4- upwards.

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1. Air filter 343

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rised
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2 Intake manifold

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⇒ “2.1 Assembly overview - intake manifold”, page 344

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and throttle valve module J338 ”, page 349

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⇒ “2.3 Cleaning throttle valve module J338 ”, page 351

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2.1 Assembly overview - intake manifold

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Part I

Note

♦ If hoses were pulled off during repair work, check that all hoses
are firmly connected after reinstallation.
♦ Tug on hoses having catches to make sure they are securely
seated.

344 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - Intake air temperature

sender 3 - G520- with intake
manifold pressure sender 3 -
G583-
2 - 3 Nm
3 - 7 Nm
❑ Self-tapping bolt
❑ The securing bolt may
only be tightened using
an impact wrench if the
wrench speed is max.
500 rpm and a max.
specified torque of 7 Nm
is set.
4 - Intake connecting pipe
5 - Seal
❑ Renew
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6 - Regulating
ss flap control unit
- J808-
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❑ Removing and installing
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⇒ page 349
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Note
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spec

Regulating flap control units with

es, in part or in w

plastic housing need not be adapted

t to the co

to the engine control unit - J623- .

❑ If renewed, erase learnt
rrectness of i

values and adapt en‐

gine control unit - J623-
l purpos

⇒ Vehicle diagnostic
tester “Guided functions”.
nf
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7 - 7 Nm
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❑ Self-tapping bolt
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❑ The securing bolt may only be tightened using an impact wrench if the wrench speed is max. 500 rpm
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and a max. specified torque of 7 Nm is set.
11 - 3 Nm
12 - Intake manifold pressure sender - G71-
13 - O-ring
❑ Renew

2. Intake manifold 345

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

14 - Intake manifold

Note

♦ If the intake manifold was re‐

moved, check after installing that
all hoses are securely connected
on the intake manifold.
♦ Tug on hoses having catches to
make sure they are securely
seated.
❑ To remove: Removing and installing regulating flap control unit - J808- and throttle valve module - J338-
⇒ page 349 .
15 - 20 Nm
16 - Fuel pressure sender - G247- , 22 Nm
❑ Checking fuel pressure in high-pressure section ⇒ page 362 .
17 - 80 Nm
18 - Intake manifold lower part

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If only lower part of in‐ ol ot g
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take manifold is to be re‐ ir se
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remain in cylinder head. ss

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To remove, use hold-

an
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down device - T10510-
erm

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⇒ page 347 .

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Reason: After removing

h re
injector, Teflon seal and
hole

spec
support washer must be
es, in part or in w

renewed ⇒ page 358 .

t to the co
❑ To remove and install: using "bracket for bits 5/16""" - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 347

rrectness of i
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
l purpos

intake manifold ⇒ page 349 .

19 - Seal
nform
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❑ Renew
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❑ Observe installation position

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20 - 20 Nm
or

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21 - Throttle valve module - J338-

p

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❑ Removing and installing ⇒ page 349

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❑ Cleaning ⇒ page 351 t. Cop py
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❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
gh ht
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functions”.
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22 - 7 Nm
23 - Pressure pipe
❑ From turbocharger
24 - Retaining clip
25 - 7 Nm

346 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
Removing AG. Volkswagen AG d
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– Insert hold-downbydevice
Vol - T10510- in the two holes not
gon
ua cylinder
head. rised ran
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– Push pin -1- in direction of -arrow- until hold-down device is

wit
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securely seated on injectors.

h re
ole,

– Tighten knurled nuts -1- and -2- hand-tight.

spec
urposes, in part or in wh

t to the co
– Pull lower part of intake manifold evenly off injectors.
Installing

rrectne
– Fit new gasket on cylinder head.

satelettronica
– Press lower part of intake manifold evenly onto injectors.

ss o
cial p

– Remove hold-down device - T10510- .

f inform
mer

Specified torques ⇒ page 344 .

atio
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Part II
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♦ If hoses were pulled off during repair work, check that all hoses
Co
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rig ht
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♦ Tug on hoses having catches to make sure they are securely
by c lksw
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seated.
Prote AG.

2. Intake manifold 347

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - Union
❑ For fuel supply.
2 - Fuel hose
❑ For fuel supply.
❑ Low pressure
❑ To high-pressure pump
3 - Clamp
4 - Connection hose
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
5 - Activated charcoal filter sol‐
enoid valve 1 - N80-
6 - Connection hose
7 - To pressure pipe.
AG. Volkswagen AG d
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8 - Connecting pipe Volksw not
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9 - Connection hose horis nte
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❑ To intake manifold con‐ ss a ra
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nection.

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10 - 8 Nm
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11 - Fuel line

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❑ High pressure
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❑ Specified torque for un‐
hole

spec
ion nuts: 18 Nm.
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t to the co
12 - Union
❑ To intake connecting
pipe.

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13 - Connection hose
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14 - Non-return valve

nf
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❑ For crankcase ventilation.

orm
❑ Specified torque: 10 Nm
m

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15 - Connection hose
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16 - Charge pressure control solenoid valve - N75-
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17 - Connection hose
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18 - Connection hose Cop py
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❑ To turbocharger
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19 - Union
agen
Prote AG.

20 - 5 Nm
21 - Connection hose
❑ To turbocharger
22 - Union
23 - Union
❑ For crankcase ventilation.
24 - Connection hose
❑ For crankcase ventilation.

348 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

25 - Connection hose
❑ To charge pressure control solenoid valve - N75- .
26 - Union
❑ For crankcase ventilation.
❑ Connected to valve timing housing.
❑ Specified torque: 10 Nm

2.2 Removing and installing regulating flap

control unit - J808- and throttle valve
module - J338-

Note

To remove throttle valve module - J338- , regulating flap control

unit - J808- must first be removed.

Special tools and workshop equipment required

satelettronica
♦ Torque wrench - V.A.G 1410-

AG. Volkswagen AG d
agen oes
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♦ Hose clamp pliers - VAS 6340- ss ce
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Prote AG.

2. Intake manifold 349

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing regulating flap control unit - J808-

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
– Remove securing bolts -1-.

– Pull off all connectors and hose connections on intake con‐

necting pipe -4- and regulating flap control unit - J808- .
– Detach spring-type clips and pull off hose -2- on activated
charcoal filter system solenoid valve 1 - N80- and pressure
pipe -3-.
n AG. Volkswagen AG
– Unscrew securing bolt forolkspressure pipe -3- on turbocharger
wage does

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not
and pull pressure pipe
db
y V-3- off. gu
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– Unscrew intake connecting pipe securing bolts -arrows- and

wit
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pull intake connecting pipe upwards with regulating flap con‐

h re

trol unit - J808- .

ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
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– Unscrew securing bolts -arrows-.

c

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n thi
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Removing throttle valve module - J338-

sd
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– Detach coolant hose -1- from hose clips.

fo

en
ng

t.
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Cop py
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Vo
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by
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350 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull connector -2- off intake air temperature sender 3 - G520-

with intake manifold pressure sender 3 - G583- .
– Remove charge air hose -3- from throttle valve module - J338-
and charge air pipe.

n AG. Volkswagen AG do
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– Unscrew securing bolts -arrows- and pull throttle valve module
erm

ab
- J338- from intake manifold connection.

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Installing

h re
hole

Installation is carried out in the reverse order. When installing,

spec
note the following:
es, in part or in w

t to the co
♦ Seals and O-rings must be renewed and coated lightly with
clean engine oil before installing.

satelettronica
rrectness of i
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
l purpos

♦ Secure all hose connections with hose clips which conform to

production standard.
nf
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m

atio
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– Push engine cover panel down at points -1- in direction of

o

n in
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-arrow- until it engages.

or

thi
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Specified torques:
iv

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o

Assembly overview - intake manifold ⇒ page 344 .

f

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ng

t.
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op
If a new regulating flap control unit or throttle valve module has
C py
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been installed: gh ht
pyri by
Vo
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by
– Erase learnt values and adapt engine control unit - J623- to
Prote
cted AG.
agen
regulating flap control unit and throttle valve module ⇒ Vehicle
diagnostic tester “Guided functions”.

Note

Regulating flap control units with plastic housing need not be

adapted to the engine control unit - J623- .

2.3 Cleaning throttle valve module - J338-

Note

♦ If a new engine control unit - J623- is installed the throttle valve

module must be adjusted. Adaptation must be performed only
with a new or cleaned throttle valve module, because soiling
or coking at the end stop of the throttle valve can lead to in‐
correct adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.

– Remove throttle valve module ⇒ page 349 .

2. Intake manifold 351

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Open throttle valve by hand and lock in open position using a

suitable object (e.g. wood or plastic wedge) -arrow-.

WARNING

Acetone is highly inflammable. Please comply with the acci‐

dent prevention regulations and the safety instructions when
handling highly inflammable fluids. Do not use compressed air
when cleaning the throttle valve. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.

– Thoroughly clean throttle valve housing, especially around the

closed throttle valve -arrows- using commercially available
acetone according to DIN 53247 and a brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Erase learnt values and adapt engine control unit - J623- to

satelettronica
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
tions”. AG. Volkswagen AG d
agen oes
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es, in part or in w

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rrectness of i
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Cop py
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rig ht
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by lksw
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Prote AG.

352 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

3 Injectors
en AG. V
olkswagen AG
ag does
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Vol ⇒ page 5 .
Safety precautions gu
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Generaluthnotes
or on injection eo
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♦ The
s engine control unit - J623- is capable of self-diagnosis.

ce
le

Before carrying out repairs and for fault finding, read event
un

pt
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memory. Also the vacuum hoses and connections must be

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checked (unmetered air).
rm

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♦ Fuel hoses in engine compartment must be secured only with
ot

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spring-type clips. The use of crimp-type or screw-type clips is

h re
hole

not permissible.

spec
es, in part or in w

♦ For trouble-free operation of electrical components, a voltage

t to the co
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone

rrectness of i
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
l purpos

♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces

the danger of a fire in a crash as the fuel pump is switched off

nform
ercia

via the fuel pump relay. The system also improves the starting

satelettronica
characteristics of the engine. When door is opened, the fuel
m

a
com

ti
pump is activated for 2 seconds to build up pressure in the fuel
on in
system.
r
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thi
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iva

⇒ “3.1 Assembly overview - fuel rail with injectors”, page 353

do
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⇒ “3.2 Removing and installing injectors”, page 355

en
ng

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op
⇒ “3.3 Renewing seals on injectors”, page 358
C py
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3.1 Assembly overview - fuel rail with injectors
cop Vo
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Prote AG.

3. Injectors 353
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
2 - Spring element wage
n AG. Volkswagen AG do
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❑ Renew each time after byV ua
ed ran
removing lower part of or is tee
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❑ Ensure proper seating

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on injector.

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3 - Injector, cylinder 4 - N33-
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❑ Injector, cylinder 1 -
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wit
N30-
, is n

h re
hole

❑ Injector, cylinder 2 -

spec
N31-
es, in part or in w

t to the co
❑ Injector, cylinder 3 -
N32-
❑ With Teflon seal and

rrectness of i

satelettronica
support washer.
l purpos

❑ After removing injector,

Teflon seal and support
washer must be re‐

nform
ercia

newed ⇒ page 358 .

m

a
❑ Removing and installing
com

tio
injectors ⇒ page 355 .

n in
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te o

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4 - Intake manifold lower part
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If only lower part of in‐
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take manifold is to be re‐ p by
co Vo
moved, ensure injectors
by lksw
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remain in cylinder head.
AG.

To remove, use hold-

down device - T10510-
⇒ page 347 .
Reason: After removing
injector, Teflon seal and
support washer must be
renewed ⇒ page 358 .

❑ To remove and install: using "bracket for bits 5/16""" - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 355
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
intake manifold ⇒ page 349 .

Caution

If only lower part of intake manifold is to be removed, ensure

injectors remain in cylinder head.
To remove, use hold-down device - T10510- ⇒ page 347 .
Reason: After removing injector, Teflon seal and support
washer must be renewed ⇒ page 358 .

354 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
Removing
– Insert hold-down device - T10510- in the two holes on cylinder
head.

– Push pin -1- in direction of -arrow- until hold-down device is

securely seated on injectors.
– Tighten knurled nuts -1- and -2- hand-tight.
– Pull lower part of intake manifold evenly off injectors.
Installing
– Fit new gasket on cylinder head.

satelettronica
– Press lower part of intake manifold evenly onto injectors.
– Remove hold-down device - T10510- .
Specified torques ⇒ page 344 .

3.2 Removing and installing injectors

Note safety precautions before beginning work ⇒ page 5 .

Note

Teflon seal on injector must be renewed each time after removing

injector ⇒ page 358 . n AG. Volkswagen A
age G do
ksw es n
Vol ot g
Special tools and workshop
ed
by
equipment required ua
ran
oris tee
h
♦ Torque wrench au - V.A.G 1331-
t or
ac
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
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
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o
355
by c lksw
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3. Injectors
agen
Prote AG.
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Tool set - T10133-

Removing
Remove air filter ⇒ page 342 .
Remove regulating flap control unit - J808- and throttle valve
module - J338- ⇒ page 349 . wage
n AG. Volkswagen AG do
e
olks s no
t gu
– Remove intake manifold and lower parteof
d b intake manifold
yV ara
⇒ page 344 . ho
ris nte
eo

satelettronica
t
au ra
– Press O-ring upwards by hand asss shown, and remove it from c
injector.

ce
e
nl

pt
du

an
itte

– Screw slide hammer - T10133/3- to puller - T10133/15- .

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

– Then insert puller - T10133/15- into groove -arrow- on injector.

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
o
by c lksw
cted agen
Prote AG.

356 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull injector out by tapping carefully.

Installing

– Thoroughly clean injector holesn A

inGcylinder
. Volkswaghead
en AG using nylon
brush - T10133/4- . olks
wage does
no
V t gu
by a
– Check plastic support
ris
ed washer for damage, renew if necessary
ran
tee
⇒ page 358 . utho
or
a a c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab

satelettronica
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

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

3. Injectors 357
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Renew spring element -arrow- and Teflon seal each time after
removing injectors ⇒ page 358 .
– Renew O-rings between injector and lower part of intake mani‐
fold and moisten slightly with clean engine oil.

Note

The Teflon seal on the injector must not be oiled or greased.

– Push injector into cylinder head bore to stop by hand.

Note

The injector must insert easily. If necessary wait until the seal has
contracted sufficiently.

– Ensure correct position of injectors in cylinder head.

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 344 .

satelettronica
– Install intake manifold ⇒ page 344 .
olkswagen AG
en AG. V
– Install regulating flap control unit - J808- and throttle valve olkswag does
not
module - J338- ⇒ page 349 . ed
by
V gu
ara
ris nte
Install air filter ⇒ page 342 . ho eo
aut ra
ss c
– Connect ⇒ Vehicle diagnostic tester and perform Guided

ce
e
nl

pt
Function “Deleting injector adaptation values”.
du

an
itte

y li
– Switch off ignition.
erm

ab
ility
ot p

wit
, is n

h re
Note
hole

spec
es, in part or in w

A new generation of engine control units has been introduced

t to the co
(UDS => Unified Diagnostic Service). Only engine control units of
this new generation must be adapted.

rrectness of i
3.3 Renewing seals on injectors
l purpos

Special tools and workshop equipment required

nf
ercia

or

♦ Tool set - T10133-

m
m

atio
om

n in
or c

thi
te

sd
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o
r
rp

cu
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f

en
ng

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

Procedure
Renewing Teflon seal
Remove air filter ⇒ page 342 .

358 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Remove regulating flap control unit - J808- and throttle valve

module - J338- ⇒ page 349 .
– Remove intake manifold and lower part of intake manifold
⇒ page 344 .
– Remove injectors ⇒ page 355 .
– Clean injector carefully.
– Carefully cut open seal with a knife as shown -arrow-. Avoid
contact between knife blade and valve body under all circum‐
stances.
– Remove old seal and clean seal groove in area of seal
-arrow-. Remove coking deposits using a brass wire brush.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
– Fit new oil seal -1- onto assembly
s aut cone - T10133/5- . Using ra
c
assembly sleeve - T10133/6- (knurled
s end faces seal -1-),

ce
e

gently slide seal onto assembly cone - T10133/5- as far as

nl

pt
du

an
possible.
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

– Turn assembly sleeve - T10133/6- around (knurl no longer

points to seal), and push seal -1- to end of assembly cone -
T10133/5- .
nform
ercia

– Now place assembly cone - T10133/5- with seal onto injector

m

at
om

from front. Slide seal further onto injector using assembly

ion
c

sleeve - T10133/6- .
in t
or

his
ate

do
priv

cum
for

en
ng

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

3. Injectors 359
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

The seal is not yet seated in its groove.

– Remove assembly sleeve - T10133/6- and assembly cone -
T10133/5- .
– Slide seal into annular groove by hand.
– Position spacer sleeve - T10133/11- onto valve body.
– Now push calibrating sleeve - T10133/7- over seal to stop onto
spacer sleeve - T10133/11- .

AG. Volkswagen AG d
agen
– Pull off calibrating sleeve - T10133/7- again. Volksw
oes
not
by gu
d ara
– Now push calibrating sleeve - T10133/8- over sealorto
is stop onto
e nte
eo
spacer sleeve - T10133/11- . aut
h
ra
ss c
– Pull off calibrating sleeve - T10133/8- again.

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility

satelettronica
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Now the Teflon seal has correct installation dimensions.

rrectness of i
Renewing support washer
l purpos

– Remove O-ring -3-.

– Cut support washer -2- open with a small pair of side cutters

nform
ercia

and remove it.

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
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– Pull spring element -1- off injector and replace with retaining
ht
pyri by
Vo
o
plate - T10133/12- . by c lksw
cted agen
Prote AG.
– Place new support washer -1- onto assembly cone -
T10133/13- and position onto injector as shown.

360 Rep. gr.24 - Mixture preparation - injection

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
h Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolete2012 ➤ , Golf Plus 2005 ➤ , ...
o te
ut or
4-cylinder direct-injection
ss
a
engine (1.4 l, EA 111, turbocharger, supercharger)
ac
- Edition 02.2019

ce
le
un

pt
– Slide support washer -1- into first groove -arrow- on injector

an
d
itte

y li
using calibration sleeve - T10133/17- (knurled side points to

rm

ab
injector).
pe

ility
ot

wit
, is n
– Now turn calibration sleeve - T10133/17- around (knurled side

h re
no longer points to injector). Slide calibration sleeve over sup‐
hole

spec
port washer -1- in direction of -arrow- to stop on retaining plate
es, in part or in w

- T10133/12- .

t to the co
– Pull calibrating sleeve - T10133/17- down again.

rrectness of i
l purpos

nform
ercia

The support washer now has correct installation dimensions.

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
op py

satelettronica
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Now position a new spring element -1- for retaining plate -

T10133/12- and position a new O-ring -3- in front of support
washer -2-.

Note

The Teflon seal -arrow- must not be oiled to install injector.

– Install injectors ⇒ page 355 .

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 344 .
– Install intake manifold ⇒ page 344 .
– Install regulating flap control unit - J808- and throttle valve
module - J338- ⇒ page 349 .
Install air filter ⇒ page 342 .
Further installation is carried out in reverse order of removal.

3. Injectors 361
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

4 Senders and sensors

⇒ “4.1 Checking fuel pressure sender”, page 362
⇒ “4.2 Actuator for structure-borne sound R214 and control unit
for structure-borne sound J869 (Polo, left-hand drive)”,
page 365
⇒ “4.3 Assembly overview - actuator for structure-borne sound
R214 and control unit for structure-borne sound J869 (Polo, right-
hand drive)”, page 367

4.1 Checking fuel pressure sender

Special tools and workshop equipment required
♦ Assembly tool - T10118-

satelettronica
. Volkswagen AG
♦ Double hex socket 1/2”, 27 mm - VAS 5301/7-
ksw
agen
AG does
not
ol
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♦ Digital pressure gauge - VAS 6394/1-ised b ara
nte
r
ho eo
♦ Test adapter - VAS 5570- aut ra
c
ss
ce
le
un

pt

WARNING
an
d
itte

y li
erm

ab

The injection system consists of a high-pressure section (max‐

ility
ot p

imum approx. 120 bar) and a low-pressure section (approx. 6

wit
is n

bar):
h re
ole,

spec

Prior to opening the high-pressure area, e.g. when removing

urposes, in part or in wh

the high-pressure pump, fuel rail, injectors, a fuel line, or the

t to the co

fuel pressure sender - G247- , the fuel pressure in the high-

pressure area must be reduced to a residual pressure of
approx. 6 bar. The appropriate procedure is described in the
rrectne

chapter on releasing pressure in the high-pressure section

⇒ page 6 .
ss o
cial p

f inform

Procedure
mer

atio
m

– Lift engine cover panel at points -1- and pull it forwards in di‐
o

n
c

rection of -arrow-.
i
or

n thi
te

sd
a

– Remove air filter ⇒ page 342 .

iv

o
pr

cum
r
fo

en
ng

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

362 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove fuel pressure sender - G247- -1-.

– Instead of fuel pressure sender - G247- , screw in adapter -

VAS 6394/2- and tighten to 22 Nm.

satelettronica
– Open cover -2- of digital pressure gauge - VAS 6394/1-n AG. Voand
lkswagen AG
tighten fuel pressure sender - G247- to digitall wage
kspressure gauge
does
not
Vo
to 22 Nm. ed
by gu
ara
is nte
or eo
– Screw pressure line -1- of digital apressure
ut
h gauge - VAS ra
6394/1- hand-tight to adapter - sVAS 6394/2- .
s 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

– Connect test adapter - VAS 5570- between fuel pressure

sender - G247- -1- and connector.
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

4. Senders and sensors 363

 Eos 2006 ➤ , Golf a2009
gen AG➤ , Golf Cabriolet
. Volkswagen AG
does 2012 ➤ , Golf Plus 2005 ➤ , ...
sw
4-cylinder direct-injection
y Volk engine (1.4 l, EA n111,
ot g turbocharger, supercharger) - Edition 02.2019
u
b ara
ed nte
ris
– Connect vehicle
au
tho
diagnosis, testing and information systemo-r a e
VAS 5051B-
ss -1- as follows: c

ce
le
un

– Push diagnostic cable connector -2- onto diagnostic connec‐

pt
an
d
itte

tion in driver footwell.

y li
rm

ab
pe

– Switch on ignition.

ility
ot

wit
, is n

Engine control units KWP (Keyword Protocol)

h re
hole

spec
– Press following keys on display in succession:
es, in part or in w

t to the co
Vehicle self-diagnosis

Vehicle self-diagnosis

rrectness of i
01 - Engine electronics
l purpos

011 - Measured values

nform
ercia

– Enter '248' (or '140' for engine code CKMA) and confirm with
Q.
m

a
com

tio
Display field 3 shows the actual value reported to the vehicle by

n in
r

the fuel pressure sender - G247- .

te o

thi
s
iva

do
Engine control units UDS (Unified Diagnostic Service)
r

satelettronica
rp

cum
fo

en
ng

t.
yi Co
op
Note
C py
ht. rig
rig ht
py by
co Vo
A new generation of engine control units has been introduced
by lksw
cted agen
Prote
(UDS => Unified Diagnostic Service). These new-generation en‐
AG.

gine control units require a different procedure for requesting the

required values.

– Press following keys on display in succession:

Guided function

– Confirm the test version and the brand.

– Specify vehicle model.
– Select model year.
– Determine engine version.
– Specify “engine” as vehicle system to be used.
Read measured values

– Follow the programmed steps of the tester until step »Select

displayable measured values«.
– Search for “IDE00589 Fuel Pressure” in plain text.
Done

Read

Continuation for all engine control unit versions:

364 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Switch on digital pressure gauge - VAS 6394/1- by pressing

key -A- briefly once.

Note

When button -A- is pressed for 2 seconds, the illumination will be

switched on for 20 seconds.

Digital pressure gauge - VAS 6394/1- should display 0 bar; if this

is not the case, press key -C- briefly once for zero point compen‐
sation.
– Start engine.
– Compare pressure displayed by digital pressure gauge - VAS
6394/1- with actual value of vehicle diagnosis, testing and in‐
formation system - VAS 5051B- .
The pressures may deviate by up to 5 bar.
If pressures do not correspond, fuel pressure sender - G247-
must be renewed.

satelettronica
WARNING

The injection system consists of a high-pressure section (max‐

imum approx. 120 bar) and a low-pressure section (approx. 6
bar):
Prior to opening the high-pressure area, e.g. when removing
the high-pressure pump, fuel rail, injectors, a fuel line, or the
fuel pressure sender - G247- , the fuel pressure in the high-
pressure area must be reduced to a residual pressure of
approx. 6 bar. The appropriate procedure
wage
n AGis. Vdescribed indothe
olkswagen AG
es n
chapter on releasing pressurey Vinolksthe high-pressure section ot g
ua
⇒ page 6 . ris
ed b ran
t ee
tho or
s au ac
s
ce
e
nl

pt
du

an

Note
itte

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erm

ab
ility

Once the high-pressure in the high-pressure area is reduced,

ot p

wit

open the system immediately as the pressure will rise again due
, is n

h re

to warming.
hole

spec
es, in part or in w

– Renew fuel pressure sender - G247- and again compare both

t to the co

measured values.
If measured values again fail to correspond:
rrectness of i

– Check wiring ⇒ Vehicle diagnostic tester.

l purpos

If measured values correspond:

nf
ercia

– Further testing is carried out with “Guided Fault Finding” in

or

⇒ Vehicle diagnostic tester.

m
m

atio
om

n in
c

4.2 Actuator for structure-borne sound - R214- and control unit for structure-
or

thi
te

sd
a

borne sound - J869- (Polo, left-hand drive)

iv

o
r
rp

cu
o

m
f

en
ng

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

4. Senders and sensors 365

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - 8 Nm
2 - 8 Nm
3 - Actuator for structure-borne
sound - R214-
❑ Fitting location: in ple‐
num chamber
Removing and installing

– Remove wiper arms ⇒

Electrical system; Rep.
gr. 92 ; Windscreen wip‐
er system; Removing
and installing wiper
arms .
n AG. Volkswagen AG do
– Remove plenum cham‐ olks
wage es n
ot g
ber cover andd plenum
by V ua
ran
chamber bulkhead
oris
e
⇒ tee
Body - front;
aut
h
Rep. gr. or
ac
50 . ss

ce
le
un

pt

satelettronica
4 - Connector
an
d
itte

y li
erm

ab
5 - Bracket
ility
ot p

6 - Connector wit
is n

h re
ole,

❑ For removing, push the

spec
catch outwards.
urposes, in part or in wh

t to the co

7 - Control unit for structure-

borne sound - J869-
❑ Fitting location: in ple‐
rrectne

num chamber
s

Removing and installing

s o
cial p

f in

– Remove wiper arms ⇒

form
mer

Electrical system; Rep.

atio

gr. 92 ; Windscreen wip‐

om

er system; Removing and installing wiper arms .

c

i
or

n thi
te

sd
a

– Remove plenum chamber cover ⇒ Body - front; Rep. gr. 50 .

iv

o
pr

cum
r
fo

8 - Bracket for control unit for structure-borne sound - J869-

en
ng

t.
yi Co
op
❑ is removed and installed together with the control unit for structure-borne sound - J869- .C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

366 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

4.3 Assembly overview - actuator for structure-borne sound - R214- and control
unit for structure-borne sound - J869- (Polo, right-hand drive)

1 - Bracket for control unit for

structure-borne sound - J869-
❑ is removed and installed
together with the control
unit for structure-borne
sound - J869- .
2 - Control unit for structure- AG. Volkswagen AG d
borne sound - J869- agen oes
olksw not
yV gu
❑ Fitting location: in ple‐ rised b ara
nte
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– Remove wiper arms ⇒ d
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Electrical system; Rep.
erm

ab
ility
gr. 92 ; Windscreen wip‐
ot p

wit
er system; Removing
is n

h re
and installing wiper
ole,

satelettronica
arms .

spec
urposes, in part or in wh

t to the co
– Remove plenum cham‐
ber cover ⇒ Body - front;
Rep. gr. 50 .

rrectne
3 - Connector

s
❑ For removing, push the

s o
catch outwards.
cial p

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4 - 8 Nm
mer

atio
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5 - Bracket
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6 - Actuator for structure-borne
te

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sound - R214-
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pr

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❑ Fitting location: in ple‐

en
ng

t.
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– Remove wiper arms ⇒
agen
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gr. 92 ; Windscreen wiper system; Removing and installing wiper arms .

– Remove plenum chamber cover and plenum chamber bulkhead ⇒ Body - front; Rep. gr. 50 .

7 - Connector
8 - 8 Nm

4. Senders and sensors 367

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4-cylinder direct-injection engine (1.4 sl, EA 111, turbocharger, supercharger) - Edition 02.2019

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5 High-pressure pump

rm

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ility
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wit
⇒ “5.1 Assembly overview - high-pressure pump”, page 368

, is n

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hole
⇒ “5.2 Removing and installing high-pressure pump”, page 369

spec
es, in part or in w
5.1 Assembly overview - high-pressure

t to the co
pump

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WARNING l purpos

The injection system consists of a high-pressure section (max‐

nform
ercia

imum approx. 120 bar) and a low-pressure section (approx. 6

bar):
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tio
Before opening the high-pressure section, e.g. to remove the

n in
r
te o

high-pressure pump, fuel rail, injectors, the fuel lines, or the

thi
s
fuel pressure sender - G247- , the fuel pressure in the high-
iva

do
r

pressure area must be reduced to a residual pressure of

rp

cum
fo

approx. 6 bar. The appropriate procedure is described in the

en
ng

t.
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chapter on releasing pressure in the high-pressure section
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⇒ page 6 .
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1 - Roller tappet
❑ Lightly coat with engine
oil when installing.
2 - O-ring
❑ Renew
❑ Lightly coat with engine
oil when installing.
3 - High-pressure pump with
fuel pressure regulating valve -
N276-

Caution
Only grasp high-pres‐
sure pump on housing
when removing and in‐
stalling!
When the high-pressure
piston spring package
loosens the high-pres‐
sure pump will leak and
must be replaced.

4 - 20 Nm
❑ Tighten bolts evenly.
5 - Union
❑ High pressure
6 - Union nut, 18 Nm
❑ Observe safety precau‐
tions ⇒ page 5 .
❑ Counterhold when loos‐
ening connection to
high-pressure pump.

368 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

7 - Fuel hose
❑ Low pressure
❑ With spring-type clip.
8 - Union
❑ Low pressure

5.2 Removing and installing high-pressure

pump
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

satelettronica
♦ Hose clamp pliers - VAS 6340- AG. Volkswagen AG d
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Removing
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Note safety precautions ⇒ page 5 .

l purpos

Observe rules for cleanliness ⇒ page 7 .

– Lift engine cover panel at points -1- and pull it forwards in di‐
nform
ercia

rection of -arrow-.
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WARNING
n in
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thi
s
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The injection system consists of a high-pressure section (max‐

do
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imum approx. 120 bar) and a low-pressure section (approx. 6

um
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bar):
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ng

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Prior to opening the high-pressure area, e.g. when removing
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fuel pressure sender - G247- , the fuel pressure in the high-
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pressure area must be reduced to a residual pressure of
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approx. 6 bar. The appropriate procedure is described in the

chapter on releasing pressure in the high-pressure section
⇒ page 6 .

5. High-pressure pump 369

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Separate fuel supply line -arrow-.

– Remove intake connecting pipe ⇒ Item 8 (page 345) .

– Pull connector and fuel supply line -arrows- off high-pressure

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t to the co
– Remove wiring guide -2- and take clip -4- off high-pressure
line.

rrectness of i
l purpos

Note

nf
ercia

Use a spanner to counterhold threaded connections on high pres‐

or
sure pump and on lower part of intake manifold when loosening
m
m

union nuts. atio

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o
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When the high-pressure piston spring package loosens the cop Vo
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– Loosen union nuts -3- and -1- of high-pressure line.

– Evenly unscrew securing bolts -arrows-.

370 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Pull high-pressure pump -3- and roller tappet -1- out of cam‐
shaft housing.
Installing

Caution

Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.

Installation is carried out in the reverse order. When installing,

note the following:

Note

♦ Moisten high-pressure pump roller tappet with clean engine

oil.

satelettronica
♦ The high-pressure pump O-ring must be renewed.

– Slide roller tappet -1- into camshaft housing.

– Insert new, lubricated O-ring -2- in groove of high-pressure

pump -3-.
– Place high-pressure pump -3- onto camshaft housing.

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– Screw in securing bolts -arrows- by hand until bolt heads are

spec

seated on flange.
es, in part or in w

t to the co

– Tighten securing bolts -arrows- evenly until flange is seated

on camshaft housing.
rrectness of i

Specified torque: 20 Nm
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
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sd
iva

o
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rp

cu
o

m
f

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

371
co Vo
by lksw
cted 5. High-pressure pump
agen
Prote AG.
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Tighten union nuts of high-pressure line -1- and -3- hand-tight.

– Install wiring guide -2- and fit clip -4- on high-pressure line.
Specified torque of wiring guide securing bolt: 8 Nm

Note

Use a spanner to counterhold threaded connections on high-

pressure pump and on lower part of intake manifold when tight‐
ening union nuts.

– Tighten union nut -1- of high-pressure line to 18 Nm.

– Tighten union nut -3- of high-pressure line to 18 Nm.

satelettronica
– Secure fuel supply line and connector -arrows- on high-pres‐
sure pump.

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– Reconnect fuel supply line -arrow-.

hole

spec

– Install intake connecting pipe and air filter ⇒ page 342 .

es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
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thi
s
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t.
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Cop py
t. rig
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Vo
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372 Rep. gr.24 - Mixture preparation - injection

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4-cylinder direct-injection engine (1.4 l, EA
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6 Engine control units - J623-
s c

ce
e
nl

pt
du

an
⇒ “6.3 Removing and installing engine control unit J623 (Eos)”,

itte

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page 377

erm

ab
ility
ot p
⇒ “6.4 Removing and installing engine control unit J623 with pro‐

wit
, is n
tective housing (Eos► 10.2008)”, page 378

h re
hole

spec
⇒ “6.1 Removing and installing engine control unit J623 (Golf
es, in part or in w
Plus, Touran)”, page 373

t to the co
⇒ “6.2 Removing and installing engine control unit J623 with pro‐
tective housing (Golf Plus, Touran)”, page 375

rrectness of i
⇒ “6.5 Removing and installing engine control unit J623 (Tiguan)”,
l purpos

page 380
⇒ “6.6 Removing and installing engine control unit J623 with pro‐

nf
ercia

tective housing (Tiguan)”, page 381

orm
m

atio
⇒ “6.7 Removing and installing engine control unit J623 (Sciroc‐
om

co)”, page 383

n in
or c

thi
e

⇒ “6.8 Removing and installing engine control unit J623 with pro‐
t

sd
iva

o
tective housing (Scirocco► 09.2008)”, page 384
r
rp

cu

satelettronica
o

m
f

en
ng

⇒ “6.9 Removing and installing engine control unit J623 (Golf, Golf
t.
yi Co
op
Cabriolet)”, page 386 C py
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gh ht
yri
⇒ “6.10 Removing and installing engine control unit J623 (Passat,
p by
o Vo
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Passat CC)”, page 387 Prote
cted AG.
agen

⇒ “6.11 Removing and installing engine control unit J623 with

protective housing (Golf, Eos 11.2008►, Scirocco 10.2008►, Pas‐
sat, Passat CC, Golf Cabriolet)”, page 388
⇒ “6.12 Removing and installing engine control unit J623 (Polo)”,
page 391
⇒ “6.13 Removing and installing engine control unit J623 with
protective housing (Polo)”, page 392
⇒ “6.14 Removing and installing engine control unit J623 (Shar‐
an)”, page 393
⇒ “6.15 Removing and installing engine control unit J623 with
protective housing (Sharan)”, page 394

6.1 Removing and installing engine control

unit - J623- (Golf Plus, Touran)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Switch off ignition.
– Remove wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

6. Engine control unit J623 373

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Loosen securing bolts -arrows- of control unit cover.

– Then remove securing nuts for control unit bracket -arrows-.

AG. Volkswagen AG d
agen oes
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– Release connectors on engine control unit and pull offedcon‐
by V gu
ara
nector. horis nte
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s a c
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nl

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du

an
itte

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erm

ab
ility
ot p

wit
, is n

satelettronica
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
l purpos

Installing

nf
ercia

– Push engine control unit onto control unit bracket until it en‐

or
gages in catches.

m
m

atio
m

– Fit connectors to engine control unit and lock in position.

o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
– Tighten securing bolts -arrows- to 10 Nm.
co lksw
by
cted agen
Prote AG.

374 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Tighten securing bolts -arrows- to 5 Nm.

– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install wiper arms and plenum chamber cover ⇒ Electrical AG. Volkswagen AG d
system; Rep. gr. 92 ; Windscreen wiper system; Removing lkswagen oes
not
and installing windscreen wiper system . db
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ce
e
nl

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du

an
itte

y li
erm

ab
ility
ot p

wit
6.2 Removing and installing engine control
, is n

h re
hole
unit - J623- with protective housing (Golf

spec
es, in part or in w

Plus, Touran)

t to the co
Special tools and workshop equipment required

rrectness of i
♦ Hot air blower from wiring harness repair set - VAS 1978-
l purpos

satelettronica
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
♦ Nozzle attachment from wiring harness repair set - VAS 1978- cted agen
Prote AG.

If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Switch off ignition.
– Remove wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

Note

The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.

Caution

Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.

Perform settings on hot air blower -4- as shown:

6. Engine control unit J623 375

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Turn temperature setting potentiometer -2- to maximum heat

output (600°C).
– Set two-stage switch for volume of air -3- to position 3.

WARNING

When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.

– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Then remove securing nuts for control unit bracket -arrows-.

– Release connectors on engine control unit and pull off con‐

satelettronica
nector.

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– Press catches -1- and -2- outwards. Then pull engine control an
d
itte

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unit off control unit bracket in -direction of arrow-.
rm

ab
pe

ility
Installing
ot

wit
, is n

h re

– Push engine control unit onto control unit bracket until it en‐
hole

spec

gages in catches.
es, in part or in w

t to the co

– Fit connectors to engine control unit and lock in position.

rrectness of i
l purpos

nform
ercia

– Tighten securing bolts -arrows- to 10 Nm.

m

– Install cover of protective housing.

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
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co lksw
by
cted agen
Prote AG.

376 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Tighten new shear-head bolts -arrows- evenly until heads

shear off. n AG. Volkswagen A ge G do
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– Install plenum chamber bulkhead ⇒ byGeneral
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Rep. gr. 50 ; Body - front; Plenum
ris chamber bulkhead .
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– Install wiper arms and plenum
ss
au chamber cover ⇒ Electrical ac
system; Rep. gr. 92 ; Windscreen wiper system; Removing

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and installing windscreen wiper system .

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6.3 Removing and installing engine control
unit - J623- (Eos)

rrectness of i
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
l purpos

unit”.
Removing

nform
ercia

satelettronica
– Switch off ignition.
m

at
om

ion
c

– Remove wiper arms and plenum chamber cover ⇒ Electrical

in t
or

system; Rep. gr. 92 ; Windscreen wiper system; Removing

his
ate

and installing windscreen wiper system .

do
priv

cum
for

– Remove plenum chamber bulkhead ⇒ General body repairs;

en
ng

t.
yi
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
Co
Cop py
ht. rig
– Remove securing bolts -1- and remove cover plate -2-.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Release front connector -1- from engine control unit and pull
it off.
– Lever up catch -2- slightly.
– Then press engine control unit out of retainer
-in direction of arrow-.
– Then release rear connector on engine control unit and pull it
off.
Installing
– Fit rear connector to engine control unit and lock in position.
– Push engine control unit onto bracket.
– Fit front connector to engine control unit and lock it in position.
– Install cover plate for connectors.

6. Engine control unit J623 377

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Tighten securing bolts -1- to 10 Nm.

– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .
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6.4 Removing and installing engine control

y li
rm

ab
unit - J623- with protective housing pe

ility
ot

wit
(Eos► 10.2008)
, is n

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Special tools and workshop equipment required
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♦ Hot air blower from wiring harness repair set - VAS 1978-

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mercia

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diagnostic tester and carry out the guided function “Renew control
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Prote
unit”.
AG.

Removing
– Switch off ignition.
– Remove wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

Note

The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.

Caution

Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.

Perform settings on hot air blower -4- as shown:

378 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Turn temperature setting potentiometer -2- to maximum heat

output (600°C).
– Set two-stage switch for volume of air -3- to position 3.

WARNING

When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.

– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.

– Insert a screwdriver between protective housing -A- and

bracket -arrow-.

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olkswagen AG
en AG. V
– Lever up protective housing using screwdriver -A- and in side‐ ksw
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– Bend catch open slightly -1-.

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– Then push engine control unit out of retainer -arrow-.

s

– Now release connector on engine control unit and pull off con‐
s o

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f inform

Installing
mer

atio
m

– Fit connectors to engine control unit and lock in position.

o

n
c

i
or

– Push engine control unit onto bracket.

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
Prote AG.

6. Engine control unit J623 379

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Press catch -1- against engine control unit.

– Push protective housing onto bracket.

– Tighten new shear-head bolts -1- evenly until heads shear off.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c

ce
e
nl

pt
6.5 Removing and installing engine control
du

an
itte

y li
unit - J623- (Tiguan)
erm

ab
ility
ot p

If you wish to replace the engine control unit, connect the vehicle

wit
, is n

h re
diagnosis, testing and information system - VAS 5051 B- and car‐
hole

ry out the guided function “Renew control unit”.

spec
es, in part or in w

t to the co
Removing
– Switch off ignition. rrectness of i

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

screen wiper system; Removing and installing wiper arms .
l purpos

– Remove plenum chamber cover: ⇒ General body repairs, ex‐

terior; Rep. gr. 64 ; Removing and installing plenum chamber
nf
ercia

cover
rm
m

atio
m

– Pull connector -1- off heated windscreen control unit - J505- .

o

n in
or c

– Slide connector locking devices -2- on engine control unit out‐

thi
te

sd
a

wards and pull off both connectors.

iv

o
r
rp

cu
o

– Remove securing bolts -3-.

f

en
ng

t.
yi Co
op
– Remove retainer frame with engine control unit from plenum C py
ht. rig
chamber. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

380 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing

– Slide engine control unit -1- into retaining frame in

-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.

satelettronica
– Tighten securing bolts -3- to 7 Nm.
– Fit connectors to engine control unit and slide locking devices
-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
AG. Volkswagen Agen G do
swa es
– Install plenum by
chamber
Vol
k
cover ⇒ General body
not repairs, exte‐
gu
rior; Rep.rigr.
se 64 ; Removing and installing plenum
d ara
nchamber
tee
cover .utho or
sa ac
– Install
s
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
ce
le

screen wiper system; Removing and installing wiper arms .

un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

6.6 Removing and installing engine control

h re
hole

unit - J623- with protective housing (Ti‐

spec
es, in part or in w

guan)
t to the co

If you wish to replace the engine control unit, connect the vehicle
diagnosis, testing and information system - VAS 5051B- and carry
rrectness of i

out the guided function “Renew control unit”.

l purpos

Special tools and workshop equipment required

♦ Grip pliers
nform
ercia

Removing
m

a
com

tio

– Switch off ignition.

n in
r
te o

thi

– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐

s
iva

do

screen wiper system; Removing and installing wiper arms.

r
rp

cum
fo

en
g

– Remove plenum chamber cover ⇒ General body repairs, ex‐

n

t.
yi Co
op
terior; Rep. gr. 64 ; Removing and installing plenum chamber
C py
t. rig
cover.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6. Engine control unit J623 381

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew bolts -1-.

– Cover the plenum chamber with a clean cloth so that it is not
scratched.
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly.

– Bend the upper ends -1- of locking clip outwards.

wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
– Remove shear-head bolts -2- using gripepliers
db
y and remove ara
locking clip. thoris nte
eo
au ra
c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab

satelettronica
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Slide connector locking devices -1- on engine control unit out‐
wards and pull off both connectors.

rrectness of i
– Remove engine control unit.
l purpos

Installing:

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
– Slide engine control unit -1- in direction of -arrow- in retaining
t. rig
gh ht
yri
frame until it engages. p by
co Vo
by lksw
cted agen
– Tighten the retaining frame. Prote AG.

Specified torque: 6 Nm

382 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Fit connectors to engine control unit and slide locking devices

-1- inwards.
– Take a new locking clip
wage
n AGand
. Volktighten
swagen Anew
G do shear-head bolts
es n
evenly until heads
y Volks shear off. ot g
u
b ara
ed nte
oris e
th 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
6.7 Removing and installing engine control
es, in part or in w

t to the co
unit - J623- (Scirocco)
If you wish to renew the engine control unit, connect the ⇒ Vehicle

rrectness of i
diagnostic tester and carry out the guided function “Renew control
unit”.
l purpos

Removing

satelettronica
nform
ercia

– Switch off ignition.

m

at
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
om

ion
screen wiper system; Removing and installing wiper arms .
c

in t
or

his
te

– Remove plenum chamber bulkhead ⇒ General body repairs;

a

do
riv

Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

p

cum
for

en
g

– Press retaining frame down in -direction of arrow- and remove

n

t.
yi Co
op
engine control unit. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Push connector locking devices in direction of -arrow-, and pull

connectors off.
Installing

6. Engine control unit J623 383

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Fit connectors to engine control unit and slide locking devices

onto stop in direction of -arrow-.

– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-
n AG. Volkswagen AG
– Install plenum chamber olksbulkhead ⇒ General body
wage does repairs;
not
Rep. gr. 50 ; Body
d by- front; Plenum chamber bulkhead
V gu .
ara
e nte
ris
– Install wiper uarms
tho ⇒ Electrical system; Rep. gr. 92 ; Wind‐e or a
a
screen wiper
ss system; Removing and installing wiper arms. c

ce
e
nl

pt
du

satelettronica
an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

6.8 Removing and installing engine control

t to the co

unit - J623- with protective housing

(Scirocco► 09.2008)
rrectness of i

If you wish to renew the engine control unit, connect the ⇒ Vehicle
l purpos

diagnostic tester and carry out the guided function “Renew control
unit”.
nform
ercia

Removing
m

at
om

– Switch off ignition.

ion
c

in t
or

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

his
ate

screen wiper system; Removing and installing wiper arms .

do
priv

cum
or

– Remove plenum chamber bulkhead ⇒ General body repairs;

f

en
ng

t.
yi
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
Co
Cop py
ht. rig
– Press retaining frame down in -direction of arrow- and remove rig ht
py by
engine control unit.
co Vo
by lksw
cted agen
Prote AG.

384 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Remove shear-head bolts -arrows- using pliers and remove

locking clips.

– Push connector locking devices in direction of -arrow-, and pull

connectors off.
Installing

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ed ran
– Fit connectors to engine control
thor unit and slide locking devices
is tee
onto stop in direction of -arrow-.
au or
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
rrectness of i

– Fit the two locking clips over the connector and secure with
l purpos

new shear-head bolts -arrows-.

– Tighten shear-head bolts evenly until heads shear-head off
nf
ercia

-arrows-.
orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

6. Engine control unit J623 385

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms.

6.9 Removing and installing engine control

unit - J623- (Golf, Golf Cabriolet)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing

satelettronica
– Switch off ignition.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; RemovingGand
. Volkinstalling
swagen wiper arms .
nA AG do
wage e
– Remove plenum chamber Vol bulkhead ⇒ General body
ks s no
t grepairs;
by u
Rep. gr. 50 ; Body
ris
ed - front; Plenum chamber bulkhead . arant
ee
tho o
– Press retaining
au frame down in -direction of arrow- and remove r ac
ss unit.
engine control
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

– Push connector locking devices in direction of -arrow-, and pull

ss

connectors off.
o
cial p

f inform

Installing
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.

386 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Fit connectors to engine control unit and slide locking devices

onto stop in direction of -arrow-.

– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .

satelettronica
6.10 Removing and installing engine control
unit - J623- (Passat, Passat CC)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing AG. Volkswagen AG d
agen oes
lksw not
– Switch off ignition. by Vo gu
ara
d
ise nte
– Remove windscreen wiper arms ⇒ Electrical system;
uthor
Rep. gr. eo
ra
92 ; Windscreen wiper system; Removing andss ainstalling wiper c
arms .
ce
le
un

pt
an
d

– Remove plenum chamber cover ⇒ General body repairs; Rep.

itte

y li

gr. 50 ; Front body, plenum chamber cover .

erm

ab
ility
ot p

– Press retaining frame down in -direction of arrow- and remove

wit
is n

engine control unit.

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
Prote AG.

6. Engine control unit J623 387

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push connector locking devices in edirection

n AG. Volksof
wa-arrow-,
gen AG and pull
connectors off. olkswag does
no
yV t gu
db ara
Installing ir se 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
hole

spec
es, in part or in w

t to the co
– Fit connectors to engine control unit and slide locking devices
onto stop in direction of -arrow-.

rrectness of i
l purpos

nf
ercia

orm
m

atio

satelettronica
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op
– Insert engine control unit into retaining frame and press re‐ C py
t. rig
taining frame upwards in -direction of arrow-
gh ht
pyri by
Vo
co lksw
by
– Fit plenum chamber cover ⇒ General body repairs; Rep. gr. cted agen
Prote AG.
50 ; Front body, plenum chamber cover .
– Fit windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wiper system; Removing and installing wiper
arms

6.11 Removing and installing engine control

unit - J623- with protective housing
(Golf, Eos 11.2008►, Scirocco
10.2008►, Passat, Passat CC, Golf
Cabriolet)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Switch off ignition.
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
92 ; Windscreen wiper system; Removing and installing wiper
arms .
Golf, Golf Cabriolet, Eos, Scirocco
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .

388 Rep. gr.24 - Mixture preparation - injection

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Eos 2006 ➤ , Golf 2009 h➤ oris, Golf Cabriolet 2012 ➤ , Golf Plus 2005n➤ tee , ...
t or
4-cylinder direct-injection engine (1.4 l, EAs 111, turbocharger, supercharger) - Edition 02.2019
au ac
s

ce
le
un

pt
Passat, Passat CC

an
d
itte

y li
– Remove plenum chamber cover ⇒ General body repairs; Rep.

rm

ab
pe

ility
gr. 50 ; Front body, plenum chamber cover .

ot

wit
, is n
Continued for all vehicles

h re
hole

spec
– Press retaining frame down in -direction of arrow- and remove

es, in part or in w
engine control unit.

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

c
– Unscrew shear-head bolts -arrows- using pliers.

um
fo

en
ng

t.
yi Co
op

satelettronica
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Insert screwdriver between both locking plates -arrow-.

– Carefully press screwdriver in direction of -arrow- and bend
retaining bow -1- upwards at the same time.

– Bend retaining bow -1- in direction of -arrow- until it can be

pulled off connectors.

6. Engine control unit J623 389

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push connector locking devices in direction of -arrow-, and pull

connectors off.
Installing

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

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

– Fit connectors to engine control unit and slide locking devices

wit
, is n

onto stop in direction of -arrow-.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

satelettronica
l purpos

nform
mercia

a
com

tion in
– Fit retaining bow -1- onto connectors and press it in direction
r
te o

thi
of -arrow-.
s
iva

do
r
rp

c
– Guide pin -2- to stop into hole on engine control unit.
um
fo

en
ng

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

– Secure retaining bow with shear-head bolts to engine control

unit -arrows-.
– Tighten shear-head bolts evenly until heads shear-head off
-arrows-.

390 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-
Golf, Golf Cabriolet, Eos, Scirocco
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber
wage bulkhead .
n AG. Volkswagen AG do
es
ks not
Vol gu
Passat, Passat CC d by ara
ise nte
or eo
– Fit plenum chamber cover a⇒uth General body repairs; Rep. gr. ra
50 ; Front body, plenum chamber
ss cover . c

ce
e
nl

pt
Continued for all vehicles
du

an
itte

y li
erm

– Fit windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;

ab
ility
Windscreen wiper system; Removing and installing wiper
ot p

wit
arms
, is n

h re
hole

spec
6.12 Removing and installing engine control
es, in part or in w

t to the co
unit - J623- (Polo)
If you wish to renew the engine control unit, connect the ⇒ Vehicle

rrectness of i
diagnostic tester and carry out the guided function “Renew control
unit”.

satelettronica
l purpos

Removing

nform
ercia

– Switch off ignition.

m

at
– Remove air filter ⇒ page 343 .
om

ion
c

in t
r

– Release connectors on engine control unit and pull off con‐

o

his
te

nector.
a

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.

– Press clips -arrows A- outwards and pull engine control unit

out to side -B-.
Installing
– Insert new engine control unit and press to the left.
– Fit connectors and lock in position.
– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit ⇒ Vehicle diagnostic tester “Gui‐
ded functions”.
– Read event memory, rectify any faults and then clear event
memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
– The readiness code must be generated if the event memory
has been cleared.
– Install air filter ⇒ page 343 .
– Perform road test.
– Read control unit event memory again.

6. Engine control unit J623 391

 n AG. Volkswagen AG do
wage es n
Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf yV
o Plus 2005 ➤ , ...
lks ot g
b ua
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger,
ir se
d supercharger) - Edition 02.2019 ran
tee
tho
u or
a ac
6.13 Removing and installing engine control ss

ce
le
un
unit - J623- with protective housing (Po‐

pt
an
d
itte

y li
lo)

rm

ab
pe

ility
ot
If you wish to renew the engine control unit, connect the ⇒ Vehicle

wit
, is n
diagnostic tester and carry out the guided function “Renew control

h re
hole
unit”.

spec
es, in part or in w
Removing

t to the co
– Switch off ignition.

rrectness of i
– Remove air filter ⇒ page 343 .
– Raise latch -1- and remove engine control unit -2-. l purpos

– Unscrew shear-head bolts -1- using a pair of pliers.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

satelettronica
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release connector from engine control unit and pull off.

Note

If engine control unit is to be renewed, shear-head bolts -2- must

also be unscrewed.

Installing
– Fit connectors and lock in position.
– Push the protective housing over the engine control unit.
– Install retainer for protective housing using new shear-head
bolts.
– Tighten shear-head bolts evenly until heads shear off.

– Insert engine control unit -2- into bracket on plenum chamber

bulkhead until it audibly engages in latches -1-.
– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit ⇒ Vehicle diagnostic tester “Gui‐
ded functions”.
– Read event memory, rectify any faults and then clear event
memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
– The readiness code must be generated if the event memory
has been cleared.
– Install air filter ⇒ page 343 .
– Perform road test.
– Read control unit event memory again.

392 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

6.14 Removing and installing engine control

unit - J623- (Sharan) agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
ris tee
Note utho or
a ac
ss
Removing and installing anti-theft engine control unit

ce
e
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⇒ page 394 .

an
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ab
ility
– If you wish to renew the engine control unit, connect ⇒ Vehicle

ot p
diagnostic tester and carry out guided function “Renew engine

wit
, is n

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control unit”. hole

spec
Removing
es, in part or in w

t to the co
– Switch off ignition.
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.

rrectness of i
92 ; Windscreen wiper system; Removing and installing wiper
arms .
l purpos

– Remove plenum chamber cover ⇒ General body repairs, ex‐

terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐

nform
ercia

satelettronica
view - plenum chamber cover .
m

at
om

– Remove plenum chamber bulkhead ⇒ General body repairs,

ion
c

exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

in t
or

his
te

– Raise engine control unit -1- in front area in

a

do
riv

-direction of arrow-.
p

cum
for

en
ng

– Pull engine control unit forwards out of the side guides -2-.
t.
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t. rig
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Vo
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by
cted agen
Prote AG.

– Slide connector locking devices -1- on engine control unit in

-direction of arrow- and pull off both connectors.
Installing
Specified torque of securing nuts for retaining frame: 6 Nm
– Attach connectors to engine control unit and slide locking de‐
vices inwards until they engage.

6. Engine control unit J623 393

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Push engine control unit -1- into side guides -2- in the
-direction of arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Flush-bonded windows; Assembly overview
- plenum chamber cover . gen AG
. Volkswagen AG
d wa oes
olks not
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 by; Wind‐
V gu
ara
ed
screen wiper system; Removing and installing owiper
ris arms . nte
eo
th
au ra
c
ss

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nl

pt
du

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6.15 Removing and installing engine control
erm

ab
ility
unit - J623- with protective housing
ot p

wit
, is n

(Sharan)

h re
hole

spec
Special tools and workshop equipment required
es, in part or in w

t to the co
♦ Grip pliers

satelettronica
– If you wish to renew the engine control unit, connect ⇒ Vehicle

rrectness of i
diagnostic tester and carry out guided function “Renew engine
control unit”.
l purpos

Removing

nf
ercia

– Switch off ignition.

orm
m

atio
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
om

n in
92 ; Windscreen wiper system; Removing and installing wiper
or c

arms .

thi
te

sd
iva

o
r

– Remove plenum chamber cover ⇒ General body repairs, ex‐

rp

cu
o

m
terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐
f

en
ng

t.
view - plenum chamber cover .
yi Co
Cop py
t. rig
– Remove plenum chamber bulkhead ⇒ General body repairs,
gh ht
pyri by
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
co Vo
by lksw
cted agen
Prote AG.
– Raise engine control unit -1- in front area in
-direction of arrow-.
– Pull engine control unit forwards out of the side guides -2-.

394 Rep. gr.24 - Mixture preparation - injection

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Bend upwardly projecting tabs -1- of locking bar outwards.

– Unscrew shear-head bolts -2- using a pair of pliers and remove
locking bar -3-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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pt
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erm

ab
ility
ot p

wit
, is n

h re
– Slide connector locking devices -1- on engine control unit in
hole

spec
-direction of arrow- and pull off both connectors.
es, in part or in w

t to the co
Installing
Specified torque of securing nuts for retaining frame: 6 Nm

rrectness of i
– Attach connectors to engine control unit and slide locking de‐
vices inwards until they engage.
l purpos

satelettronica
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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– Screw on a new locking bar -3- with new shear-head bolts

iv

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rp

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-2- and tighten bolts uniformly until just before heads shear off.
o

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f

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t.
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Disregard item -1-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Push engine control unit -1- into side guides -2- in the
-direction of arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Flush-bonded windows; Assembly overview
- plenum chamber cover .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .

6. Engine control unit J623 395

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

26 – Exhaust system
1 Exhaust pipes and silencers

Note

♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamping sleeve and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.

Caution

Risk of damage to flexible joint.

satelettronica
♦ 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.

⇒ “1.1 Assembly overview - silencer (Golf Plus, Eos, Scirocco,

Golf, Touran, Golf Cabriolet)”, page 397
⇒ “1.2 Assembly overview - silencers (Tiguan)”, page 398
⇒ “1.3 Assembly overview - silencers (Polo)”, page 399
⇒ “1.4 Assembly overview - silencers (Sharan)”,
olksw
page 400
AG. V agen AG
agen do
⇒ “1.5 Assembly overview Vol - silencer (Passat, Passat CC)”,
ksw es n
ot g
page 401 se
d by ua
ran
ri te
⇒ “1.6 Removing tho eo
au and installing front exhaust pipe (Tiguan with r ac
four-wheel drive)”,
ss
page 402
ce
le
un

pt

⇒ “1.7 Removing and installing front exhaust pipe (Golf Plus, Eos,
an
d
itte

y li

Scirocco, Golf, Tiguan, Touran, Golf Cabriolet)”, page 403

rm

ab
pe

ility

⇒ “1.8 Removing and installing front exhaust pipe (Sharan)”, page

ot

wit

404
, is n

h re
hole

⇒ “1.9 Removing and installing (Passat, Passat CC)”, page 405

spec
es, in part or in w

⇒ “1.10 Separating exhaust pipes, silencers (Tiguan)”,

t to the co

page 407
⇒ “1.11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scir‐
rrectness of i

occo, Golf, Touran, Golf Cabriolet)”, page 408

l purpos

⇒ “1.12 Separating exhaust pipes, silencers (Polo)”, page 410

⇒ “1.13 Separating exhaust pipes, silencers (Sharan)”,
nform
ercia

page 411
m

⇒ “1.14 Separating exhaust pipes/silencers (Passat, Passat CC)”,

com

tion in

page 412
r
te o

thi
s

⇒ “1.15 Aligning exhaust system free of stress (Passat, Passat

iva

do
r

CC)”, page 414

rp

cum
fo

en
ng

⇒ “1.16 Installation position of clamp”, page 415

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

396 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.1 Assembly overview - silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf
Cabriolet)

1 - Mounting
2 - 25 Nm
3 - Bracket
❑ Observe installation po‐
sition
4 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
❑ Separating centre and
rear silencers

satelettronica
⇒ page 408
5 - 25 Nm
6 - Bracket
❑ Observe installation po‐
sition agen
AG. Volkswagen AG d
oes
olksw not
V
7 - Mounting ed by gu
ara
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8 - Rear silencer aut
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9 - Mounting

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erm

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ility
ot p

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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

1. Exhaust pipes and silencers 397

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.2 Assembly overview - silencers (Tiguan)

n AG. Volkswagen AG do
1 - Exhaust pipe with centre
olks
wage es n
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and rear silencers d by V ua
ran
e
❑ Combined ris
tho in one unit
tee
or
with rear
ss
a silencer as
u ac
original equipment. Can

ce
le
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be renewed individually

pt
an
d

for repair purposes.

itte

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rm

ab
❑ Aligning exhaust sys‐
pe

ility
tem free of stress
ot

wit
, is n

h re
2 - 20 Nm
hole

spec
3 - Bracket
es, in part or in w

t to the co
4 - 25 Nm
5 - Bracket

rrectness of i
6 - Mounting
l purpos

7 - 25 Nm

satelettronica
nform
ercia

8 - Bracket
m

a
9 - 25 Nm
com

tion in
10 - Tunnel cross-piece
r
te o

thi
s
iva

do

11 - 25 Nm
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.

398 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.3 Assembly overview - silencers (Polo)

1 - Bracket with mounting

2 - Rear silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can wage
n AG. Volkswagen AG do
es n
s
be renewed individually yV
olk ot g
ua
for repair purposes. ir se
d b ran
tee
o
❑ Aligning exhaust sys‐ auth or
ac
tem free of stress ss

ce
le
❑ Separating exhaust un

pt
an
d
pipe and rear silencer
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⇒ page 410 .

ab
ility
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3 - Bracket

wit
is n

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❑ Observe installation po‐
ole,

spec
sition
urposes, in part or in wh

t to the co
4 - 25 Nm

satelettronica
5 - Mounting

rrectne
6 - 25 Nm
7 - 25 Nm

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

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

1. Exhaust pipes and silencers 399

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.4 Assembly overview - silencers (Sharan)

1 - of the exhaust pipe with

flexible connection (de-cou‐
pling element)
2 - 25 Nm
❑ Renew
3 - Front silencer
4 - Coupling point
❑ Marked by indentation
on exhaust pipe.
❑ As standard, exhaust
pipe and front silencers
are installed as a single agen
AG. Volkswagen AG d
oes
component. In repair ca‐ olksw not
yV gu
ses the exhaust pipe se d b ara
nte
and front silencer arethori
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supplied individually
ss au ra
c
with a double clamp for

ce
le

satelettronica
un

connecting together.

pt
an
d
itte

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❑ Cut through exhaust
erm

ab
pipe with pneumatic sa‐

ility
ot p

bre saw - V.A.G 1523A-

wit
is n

or chain pipe cutter -

h re
ole,

VAS 6254- at right

spec
angles at the separating
urposes, in part or in wh

point ⇒ page 411 .

t to the co
5 - Clamping sleeve
❑ Installation position and rrectne
specified torque
⇒ page 411
ss

❑ Tighten bolted connec‐

o
cial p

f i

tions evenly.
nform
mer

6 - Rear silencer
atio
om

❑ Aligning exhaust sys‐

n
c

i
or

tem free of stress

thi
te

sd
va

7 - Mounting
i

o
pr

cum
r
fo

❑ Renew if damaged
en
ng

t.
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op
8 - Seal
C py
t. rig
gh ht
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❑ Renew
p by
o Vo
by c lksw
cted agen
Prote AG.

400 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.5 Assembly overview - silencer (Passat, Passat CC)

1 - Clamping sleeve
❑ Installation position and
specified torque
⇒ page 415
❑ Aligning exhaust sys‐ gen AG
. Volkswagen AG
does
tem free of tension Volkswa not
⇒ page 414 . d by gu
ara
rise nte
❑ Comply with uinstruc‐
tho eo
ra
tions for alignment
ss a of c
rear silencer

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nl

pt
⇒ page 412
du

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2 - Mounting
erm

ab
ility
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3 - Centre silencer

wit
, is n

h re
❑ Combined in one unit
hole

spec
with rear silencer as
es, in part or in w

original equipment. Can

t to the co
be renewed individually
for repair purposes.

satelettronica
❑ Aligning exhaust sys‐

rrectness of i
tem free of tension
l purpos

⇒ page 414 .
❑ Separating centre and
rear silencers

nform
ercia

⇒ page 412
m

at
om

4 - Bolt ion
c

in t
r

❑ 25 Nm
o

his
ate

❑ Qty. 2
do
priv

cum
or

5 - Bracket
f

en
ng

t.
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❑ Observe installation po‐ Cop py
t. rig
sition opyri
gh by
Vo
ht
c lksw
6 - Clamping sleeve
by
cted agen
Prote AG.
❑ For repair cases
❑ Loosen to enable align‐
ment of exhaust system free of stress ⇒ page 414
❑ Installation position and specified torque ⇒ page 415
❑ Comply with instructions for alignment of rear silencer ⇒ page 412
❑ During production, front and rear silencers are installed as a single component. In case of repair, the
front and rear silencers are supplied individually and with a double clamp for connecting.
❑ Cut through exhaust pipe with e.g. pneumatic sabre saw - V.A.G 1523A- or chain pipe cutter - VAS 6254-
at right angles at the separating point ⇒ page 412 .
7 - Rear silencer
❑ Comply with instructions for alignment of rear silencer ⇒ page 412
❑ Aligning exhaust system free of tension ⇒ page 414 .
8 - Bracket
❑ Observe installation position
9 - Mounting
10 - Bolt
❑ 25 Nm
❑ Qty. 2
11 - Bolt
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel suspension, rear .

1. Exhaust pipes and silencers 401

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
❑ 90 Nm + 90°
❑ Renew after each removal
❑ M12 x 1.5 x 110
12 - Bracket

1.6 Removing and installing front exhaust

pipe (Tiguan with four-wheel drive)
Removing
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove Lambda probe after catalytic converter - G130- -1-.
– Unbolt exhaust pipe from catalytic converter
wage -arrows-.
n AG. Volkswagen AG
does
ks not
Vol gu
– Remove right drive shaft ⇒ Repairing
db
y drive shafts; Rep. gr. ara
se nte
40 ; Removing and installing
thoridrive shafts . eo
au ra
c
ss

satelettronica
ce
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un

pt
an
d
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rm

ab
pe

ility
ot

wit
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h re
hole

spec
es, in part or in w

– Remove securing bolts -1- and -2- for exhaust pipe mounting.

t to the co
– Remove exhaust pipe mounting downwards.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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rp

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– Loosen securing nuts of clamping sleeve -arrows- and slide it

n

t.
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forwards on exhaust pipe -1-. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

402 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew nuts -arrows- aand

gen Apull
G. Voexhaust
lkswagen Apipe
G do backwards.
w es n
olks o
– Push exhaustepipe
d b backwards out of mounting -1-.uara
yV tg
ris nte
utho eo
ra
a c
ss

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nl

pt
du

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itte

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
– Disconnect pendulum support -arrows-.

rrectness of i
– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐
shaft and final drive; Rep. gr. 39 ; Removing and installing
l purpos

propshaft .
– Push propshaft aside.

nform
ercia

– Lower subframe ⇒ Subframe, anti-roll bar, suspension links;

m

at
Rep. gr. 40 ; Lowering subframe .
om

satelettronica
ion
c

in t
r

– Remove exhaust pipe forwards.

o

his
ate

do
riv

Installing
p

cum
for

Installation is performed in the reverse order of removal.

en
ng

t.
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op py
Specified torques: t. C rig
gh ht
pyri by
Pendulum support ⇒ page 65
co Vo
by lksw
cted agen
Prote AG.
Exhaust pipe ⇒ page 418

1.7 Removing and installing front exhaust

pipe (Golf Plus, Eos, Scirocco, Golf, Ti‐
guan, Touran, Golf Cabriolet)
Removing
Tiguan
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
Continued for all vehicles
– Remove Lambda probe after catalytic converter - G130- -1-.
– Unbolt exhaust pipe from catalytic converter -arrows-.

1. Exhaust pipes and silencers 403

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unbolt exhaust pipe together with flexible joint -arrows-.

AG. Volkswagen AG d
agen oes
ksw not
– Loosen securing nuts of clamping sleeve -arrows- and slide by V it
o l
gu
ara
forwards on exhaust pipe -1-. rise
d
nte
tho eo
– Remove exhaust pipe -1-. ss au ra
c

ce
le

Installing
un

pt
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itte

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Installation is performed in the reverse order of removal.
erm

ab
ility
ot p

Specified torques:

satelettronica
wit
is n

h re
Exhaust pipe ⇒ page 416
ole,

spec
urposes, in part or in wh

t to the co
1.8 Removing and installing front exhaust

rrectne
pipe (Sharan)

ss o
Removing
cial p

f inform
– Remove noise insulation.
mer

atio
m

– Remove right drive shaft ⇒ Running gear, axles, steering;

o

n
c

Rep. gr. 40 ; Repairing drive shafts; Removing and installing

i
or

n thi
drive shafts .
te

sd
iva

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pr

c
– Remove Lambda probe after catalytic converter - G130- -1-.
um
r
fo

en
ng

t.
– Unbolt exhaust pipe from catalytic converter -arrows-.
yi Co
Cop py
t. rig
gh ht
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Vo
co lksw
by
cted agen
Prote AG.

404 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unbolt exhaust pipe together with flexible joint -arrows-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Loosen securing nuts of clamping sleeve -arrows- and slide it s

ce
e
nl

backwards on exhaust pipe with front silencer -1-.

pt
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– Pull exhaust pipe with front silencer slightly backwards.
erm

ab
ility
ot p

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spec
es, in part or in w

satelettronica
t to the co
rrectness of i
l purpos

– Push exhaust pipe with front silencer backwards out of mount‐

ing -1-.

nf
ercia

orm
– Remove exhaust pipe with flexible connection (de-coupling
m

atio
m

element).
o

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or c

thi
Installing
te

sd
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Installation is performed in the reverse order of removal.

rp

cu
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f

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ng

t.
Specified torques Cop
yi Co
py
t. rig
⇒ page 421 gh ht
pyri by
Vo
co lksw
by
⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive Prote
cted AG.
agen
shafts; Removing and installing drive shafts

1.9 Removing and installing (Passat, Pas‐

sat CC)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

– Remove noise insulation or skid plate ⇒ General body repairs,

exterior; Rep. gr. 50 ; Removing and installing noise insulation
or skid plate .

1. Exhaust pipes and silencers 405

 . Volkswagen AG
gen AG d
Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , VGolf olks Plus 2005 ➤ , ...
wa oes
not
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4-cylinder direct-injection engine (1.4 l, EA 111,isturbocharger,
ed b supercharger) - Editionu02.2019
ara
n
r tee
ho
ut or
– Remove wiring for Lambda probe after catalytic sconverter
s a
- ac
G130- and for alternator from cable guides -arrows-.

ce
le
un

pt
an
d
– Disconnect connector for Lambda probe after catalytic con‐

itte

y li
rm
verter - G130- .

ab
pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove Lambda probe after catalytic converter - G130- -1-.

– Open hose clip -3- and remove charge air pipe -2-.

nform
ercia

– Unbolt exhaust pipe from catalytic converter -arrows-.

m

a
com

tion in
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thi
Caution

s
iva

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rp

cum
Risk of damage to flexible joint.
fo

satelettronica
en
ng

t.
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♦ Do not allow the flexible joint to kink by more than 10°. t. Cop py
rig
gh ht
♦ Install flexible joint so that it is not under tension. pyri by
Vo
o
by c lksw
cted agen
♦ Do not damage wire mesh on decoupling element. Prote AG.

– Release connectors -1- and pull off.

– Unclip bracket -2- on subframe for electric wire to oil level and
oil temperature sender - G266- .

– Disconnect pendulum support -arrows-.

406 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew nuts -arrows A- on exhaust pipe -1-.

– Push front exhaust pipe -2- backwards out of mounting
-arrows B -.
– Remove front exhaust pipe forwards.
Installation
Install in reverse order of removal. When doing this, observe the
following:

Specified torque
Component Specified torque
Front exhaust pipe to catalytic converter 25 Nm
Exhaust pipe to front exhaust pipe 25 Nm
Pendulum support ⇒ page 67

satelettronica
1.10 Separating exhaust pipes, silencers (Ti‐
guan)
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.
Volkswagen AG
Special tools and workshop equipment
swrequired
agen
AG. does
olk not
yV gu
♦ Chain-type pipe cutter - VAS ed b6254- ara
nte
ris
ho eo
aut ra
ss c
ce
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

Or
l purpos

♦ Pneumatic sabre saw - V.A.G 1523A-

nform
ercia

Procedure
m

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.

1. Exhaust pipes and silencers 407

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Cut through exhaust pipe at separating point -2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position clamping sleeve centrally at side marks -1- and -3-
when installing.

– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
• Threaded connection faces to rear.
– Aligning rear silencer free of stress ⇒ page 408
Specified torques ⇒ page 415

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
Align rear silencer. ed by
V gu
ara
ris nte
o
– Align rear silenceraut so that dimensions -a- are identical.
h eo
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

1.11 Separating exhaust pipes/silencers

rrectness of i

(Golf Plus, Eos, Scirocco, Golf, Touran,

l purpos

Golf Cabriolet)
nform
ercia

♦ The connecting pipe can be cut through at the cutting location

m

in order to renew the centre and rear silencers separately.

at
om

ion
c

♦ Cutting location is marked by an indentation on the circumfer‐

in t
or

his
e

ence of exhaust pipe.

at

do
priv

Special tools and workshop equipment required

um
for

en
ng

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

408 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Chain-type pipe cutter - VAS 6254-

Or
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure

satelettronica
– Cut through exhaust pipe at cutting point -arrow 2- using chain-
type pipe cutter - VAS 6254- or pneumatic Asabre
G. Volkssaw
wage-nV.A.G
AG do
agen
1523A- . Volksw es n
ot
y gu
db ara
– Position clamp -4- centrallyorat
ise side marks when installing, ar‐ nte
eo
rows -1- and -3-. au
th
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

– Install clamp so that bolt ends do not protrude beyond lower

edge of clamp -arrow-.
• Threaded connection faces to rear.
rrectness of i

– Aligning rear silencer free of stress ⇒ page 410

l purpos

Specified torques ⇒ page 415

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.

1. Exhaust pipes and silencers 409

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.

1.12 Separating exhaust pipes, silencers

(Polo)
♦ For individual renewal of the rear silencer, a cutting point is
provided in the connecting pipe.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.

satelettronica
Special tools and workshop equipment required
♦ Chain-type pipe cutter - VAS 6254-

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

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

Or
h re
ole,

spec

♦ Pneumatic sabre saw - V.A.G 1523A-

urposes, in part or in wh

t to the co

Procedure
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

410 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Cut through exhaust pipe at cutting point -arrow 2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position clamping sleeve centrally at side marks -1- and -3-
when installing.

– Install clamp so that bolt ends do not protrude beyond lower

edge of clamp -arrow-.
• Threaded connection faces to rear. AG. Volkswagen AG d
agen oes
ksw
– Aligning rear silencer free of stress ⇒ page b411 yV
ol not
gu
d ara
ise nte
Mounting position and specified torque ofththe
o clamping sleeve
r eo
⇒ page 415 s au ra
c
s

satelettronica
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

Align rear silencer.

spec
es, in part or in w

– Align rear silencer so that dimensions -a- are identical.

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

1.13 Separating exhaust pipes, silencers

o
r
rp

cu
o

m
f

(Sharan)
en
ng

t.
yi Co
Cop py
t.
♦ The exhaust pipe can be cut through at the point marked in
rig
gh ht
yri by
order to renew the exhaust pipe or the front silencer separate‐ op Vo
by c lksw
ly. cted agen
Prote AG.

♦ Cutting location is marked by an indentation on the circumfer‐

ence of exhaust pipe.
Special tools and workshop equipment required

1. Exhaust pipes and silencers 411

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Chain-type pipe cutter - VAS 6254-

Or
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
WARNING orise nte
eo
th
u ra

satelettronica
s a c
To avoid injury from metal shavings, wear eye protection and s

ce
e

protective clothing.
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

– Cut through exhaust pipe at right angles at separating point

t to the co
-2- using pneumatic sabre saw - V.A.G 1523A- or chain-type
pipe cutter - VAS 6254- .

rrectness of i
– Position repair double clamp at side marks -1- and -3- when
installing.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
or

– Install double clamp so that bolt ends do not protrude beyond

f

en
ng

t.
yi
lower edge of double clamp -arrow-.
Co
Cop py
t. rig
gh
– Align exhaust system free of stress.
ht
pyri by
Vo
co lksw
by
Mounting position and specified torque of the clamping sleeve
cted agen
Prote AG.
⇒ page 415

1.14 Separating exhaust pipes/silencers

(Passat, Passat CC)
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.

412 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Cutting location is marked by an indentation on the circumfer‐

ence of exhaust pipe.
Special tools and workshop equipment required
♦ Chain-type pipe cutter - VAS 6254-

Or
♦ Pneumatic sabre saw - V.A.G 1523A-

satelettronica
BlueMotion vehicles from 11.2010
– Remove panelling of rear axle ⇒ Wheel suspension, rear;
Rep. gr. 42 ; Assembly overview: Attachments for subframe
of BlueMotion vehicles .
– Remove additional underbody panels on left and right ⇒ Body,
front; Rep. gr. 50 ; Additional underbody panels (BlueMotion)
- Assembly overview for vehicles from 11.2010 .
Continued for all vehicles
– Cut through exhaust pipe at separating point -arrow 2- at right
angles e.g. with pneumatic sabre saw - V.A.G 1523A- or chain
pipe cutter - VAS 6254- .

Separating point on exhaust pipe

n AG. Volkswagen A G do
wage es n
olks ot g
byV ua
WARNING
ris
ed ran
tee
tho or
au ac
To avoid
ss injury from metal shavings, wear eye protection and
protective clothing.
ce
e
nl

pt
du

an
itte

y li
erm

ab

– Position repair double clamp centrally between outer mark‐

ility
ot p

ings.
wit
, is n

h re
hole

spec
es, in part or in w

t to the co

Align rear silencer.

– Align rear silencer -1- so that dimensions -a- are identical.
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

413
by lksw
cted agen
Prote 1. Exhaust pipes and silencers
AG.
 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
• Nuts are below
– Ensure correct mounting position and specified torque
⇒ page 415 .
– Aligning rear silencer ⇒ page 413
– Aligning exhaust system free of tension ⇒ page 414 .

Specified torque
Component Specified torque
Double clamp ⇒ page 415

1.15 Aligning exhaust system free of stress

satelettronica
(Passat, Passat CC)
n AG. Volkswagen AG do
• Engine must be cold lkswage es n
o ot g
byV ua
ed ran
– Loosen threaded connections -3- and -4- of or front clamping
is tee
sleeve -1- ⇒ Item 6 (page 401) . auth or
ac
ss
-Arrow- points in direction of travel

ce
e
nl

pt
du

an
– Align front clamping sleeve -1- to marking -A- on front exhaust
itte

y li
erm

pipe -2-.

ab
ility
ot p

• Dimension -a- = ⇒ page 415

wit
, is n

h re
• Do not allow the bolts must be on the right and the ends to
hole

spec
protrude beyond the lower edge of the clamp.
es, in part or in w

t to the co
rrectness of i
– Push rear silencer forwards into clamp until dimension -a-
l purpos

15…17 mm is attained between mountings for body and rear

silencer. -Arrow- points in direction of travel.
nform
ercia

– Aligning rear silencer ⇒ page 413

m

at

– Note installation position and specified torque of clamping

om

io

sleeve ⇒ page 415 .

n
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.

414 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1.16 Installation position of clamp

Note

Gradual introduction of clamp with continuous clip.

Specified torque and mounting dimensions of clamping sleeve.

Clamp -A- with 2 individual clips.
Specified torque: 25 Nm.
Installation dimensions -a- 5 mm (only for front clamp)
Clamp -B- with continuous clip.
Specified torque 35 Nm
Installation dimensions -a- 8.5 mm (only for front clamp)

satelettronica
Installation dimension -a- for vehicles with marking -A- on front
exhaust pipe
1 - Clamping sleeve
2 - Front exhaust pipe
3 - Securing nut
4 - Securing nut
a - Installation dimension
A - Marking AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
Installation position of front clamp ss a ra
c
ce
le

– Install clamp so that end of bolt -arrow- does not extend be‐
un

pt
an
d

yond lower edge of clamp.

itte

y li
rm

ab
• Threaded connection faces right
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

Installation position of rear clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
nform
ercia

yond lower edge of clamp.

m

a
com

• Threaded connection faces to rear.

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.

1. Exhaust pipes and silencers 415

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2 Exhaust gas cleaning

⇒ “2.1 Assembly overview - exhaust gas treatment (Golf Plus,
Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet)”, page 416
⇒ “2.2 Assembly overview - exhaust gas treatment (Tiguan with
four-wheel drive)”, page 418
⇒ “2.3 Assembly overview - exhaust gas treatment (Polo)”, page
420
⇒ “2.4 Assembly overview - exhaust gas treatment (Sharan)”,
. Volkswagen AG
page 421 swa
gen AG does
k not
Vol gu
by
⇒ “2.5 Assembly overview - exhaust gas streatment (Passat, Pas‐ ara
ed nte
sat CC)”, page 422 thori eo
au ra
c
⇒ “2.6 Removing and installing catalytic
ss converter (Polo)”,

ce
le

page 424
un

pt
an
d
itte

y li
⇒ “2.7 Removing and installing (Passat, Passat CC)”, page 425
rm

ab
pe

ility
2.1 Assembly overview - exhaust gas treatment (Golf Plus, Eos, Scirocco, Golf,
ot

wit
, is n

Touran, Tiguan, Golf Cabriolet)

h re
hole

satelettronica
spec
es, in part or in w

t to the co
1 - Heat shield
2 - 10 Nm

rrectness of i
3 - Lambda probe after catalyt‐
l purpos

ic converter - G130-
❑ Specified torque: 50 Nm

nform
ercia

❑ Grease only the threads

with “G 052 112 A3”;
m

a
“G 052 112 A3” cannot
com

tion in
get into the slots on the
r
te o

probe body.
thi
s
iva

do

❑ If seal is leaking, nip

r
rp

cum

open and renew.

fo

en
ng

t.
yi Co
4 - Seal ht. Cop py
rig
❑ Renew rig ht
py by
co Vo
by lksw
5 - Exhaust pipe
cted agen
Prote AG.

6 - Clamping sleeve
❑ Installation position and
specified torque
⇒ page 415
❑ Tighten bolted connec‐
tions evenly.
7 - 25 Nm
❑ Renew
8 - Mounting
9 - 25 Nm
10 - Exhaust pipe
❑ With flexible connection
(de-coupling element).
❑ Do not bend flexible
connection more than
10° - otherwise it can be
damaged.

416 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
AG. Volkswagen n AG do
wage es n
olks ot g
11 - 23 Nm ed
by
V ua
ran
ris
❑ Renew tho tee
or
au ac
12 - 23 Nm ss

ce
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un

pt
❑ Renew

an
d
itte

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13 - Catalytic converter with exhaust pipe

erm

ab
ility
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14 - 25 Nm

wit
is n

h re
ole,
15 - Bracket

spec
urposes, in part or in wh
16 - Lambda probe - G39- , 50 Nm

t to the co
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-

rrectne
17 - 10 Nm

s
18 - 25 Nm

s o
cial p

f
❑ Renew studs and fastening nuts.

inform
mer

Observe tightening sequence: items -A- to -I- ⇒ page 278 .

atio
om

n
Screw the studs into cylinder head until they project only 25 mm.
c

i
or

satelettronica
thi
te

sd
a

19 - Exhaust turbocharger
iv

o
pr

cum
r
fo

en
ng

t.
yi
Caution
Co
Cop py
t. rig
Oil supply line must be
gh ht
yri by
renewed when installing
cop Vo
by lksw
cted
a new turbocharger.
agen
Prote AG.

❑ The turbocharger and the exhaust manifold can only be renewed together.
20 - Bracket

Note

♦ Retainer is discontinued.
♦ There is no need to reinstall the
retainer in cases of repair

2. Exhaust gas cleaning 417

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.2 Assembly overview - exhaust gas treatment (Tiguan with four-wheel drive)

AG. Volkswagen AG d
1 - Seal ksw
agen oes
not
ol
❑ Renew byV gu
ara
ed
ris nte
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2 - 25 Nm aut
h eo
ra
s c
❑ Renew s

ce
e
nl

pt
du

3 - Exhaust pipe

an
itte

y li
erm

ab
4 - Clamping sleeve

ility
ot p

❑ Installation position and

wit
, is n

specified torque

h re
hole

⇒ page 415

spec
es, in part or in w

❑ Tighten bolted connec‐

t to the co
tions evenly.
5 - 10 Nm

rrectness of i
6 - 25 Nm
l purpos

7 - Washer

satelettronica
8 - Pin

nf
ercia

orm
9 - Bonded rubber mounting
m

atio
om

n in
10 - 25 Nm
or c

thi
te

sd
11 - Bracket
iva

o
r
rp

cu

12 - Lambda probe after cata‐

o

m
f

en
ng

lytic converter - G130-

t.
yi Co
Cop py
❑ Specified torque: 50 Nm ht. rig
rig ht
py by
❑ Grease only the threads co Vo
by lksw
cted
with “G 052 112 A3”;
agen
Prote AG.
“G 052 112 A3” cannot
get into the slots on the
probe body.
❑ If seal is leaking, nip
open and renew.
13 - 25 Nm
14 - Spring
15 - Bracket
16 - 25 Nm
17 - Mounting
18 - Exhaust pipe
❑ Removing and installing ⇒ page 402
❑ With flexible connection (de-coupling element).
❑ Do not bend flexible connection more than 10° - otherwise it can be damaged.
19 - 23 Nm
❑ Renew
20 - 23 Nm
❑ Renew

418 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

21 - Catalytic converter with exhaust pipe

22 - 25 Nm
23 - Bracket
24 - 10 Nm
25 - Lambda probe - G39- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-
26 - 25 Nm
❑ Renew studs and fastening nuts.
Observe tightening sequence: items -A- to -I- ⇒ page 278 .

Screw the studs into cylinder head until they project only 25 mm.

27 - Exhaust turbocharger

Caution
Oil supply line must be

satelettronica
renewed when installing
a new turbocharger.

❑ The turbocharger and the exhaust manifold can only be renewed together.
28 - Bracket agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
Note rised
nte
ho eo
aut ra
♦ Retainer is discontinued.
ss c
ce
e
nl

pt

♦ There is no need to reinstall the

du

an
itte

retainer in cases of repair

y li
erm

ab
ility
ot p

29 - Heat shield
wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

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2. Exhaust gas cleaning 419

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

2.3 Assembly overview - exhaust gas treatment (Polo)

1 - Heat shield
2 - 10 Nm
3 - Exhaust turbocharger

Caution
Oil supply line must be
renewed when installing
a new turbocharger.

❑ The turbocharger and

the exhaust manifold
can only be renewed to‐
gether.
4 - Seal
❑ Renew

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6 - Clamping sleeve

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❑ Installation position and
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⇒ page 415
❑ Tighten bolted connec‐
tions evenly.

rrectne
7 - Catalytic converter with

s
front silencer

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❑ With flexible connection (de-coupling element).

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❑ Do not bend flexible connection more than 10° - otherwise it can be damaged.
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8 - Mounting
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or

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9 - Lambda probe - G39- , 50 Nm

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❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
i

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❑ Remove and install using ring spanner for Lambda probe - 3337-
en
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12 - 10 Nm
13 - Seal
❑ Renew
14 - 23 Nm
❑ Renew
15 - Lambda probe after catalytic converter - G130-
❑ Specified torque: 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.

420 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
❑ If seal is leaking, nip open and renew.
16 - 10 Nm

2.4 Assembly overview - exhaust gas treatment (Sharan)

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4 - Catalytic converter with ex‐ ot p

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haust pipe

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5 - 25 Nm

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6 - 25 Nm

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7 - To front silencer
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8 - 25 Nm
9 - Mounting

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(de-coupling element).
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10° - otherwise it can be
Co
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t. C rig
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❑ Removing and installing cop Vo
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⇒ page 403
cted agen
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11 - 23 Nm
❑ Renew
12 - Seal
❑ Renew
13 - Lambda probe after cata‐
lytic converter - G130- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ If seal is leaking, nip open and renew.
14 - 10 Nm
15 - Bracket
❑ For electrical cables
16 - Lambda probe - G39- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-
17 - 25 Nm
❑ Renew studs and fastening nuts.
Observe tightening sequence: items -A- to -I- ⇒ page 278 .

Screw the studs into cylinder head until they project only 25 mm.

2. Exhaust gas cleaning 421

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

18 - Exhaust turbocharger

Caution
Oil supply line must be
renewed when installing
a new turbocharger.

❑ The turbocharger and the exhaust manifold can only be renewed together.
19 - 10 Nm agen
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2.5 Assembly overview - exhaust gas treatment (Passat, Passat CC) ss aut ra
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1 - Heat shield itte

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2 - Nut
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❑ 10 Nm

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❑ Qty. 3

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3 - Bolt

t to the co
❑ 10 Nm
❑ Qty. 2

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4 - Seal
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5 - Exhaust pipe

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6 - Seal
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9 - Catalytic converter
❑ Removing and installing
⇒ page 425
10 - Front exhaust pipe
❑ With decoupling ele‐
ment.
❑ Do not bend flexible joint
more than 10°. Other‐
wise, it can be dam‐
aged.
❑ Removing and installing
⇒ page 405
11 - Lambda probe after catalytic converter - G130- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ If seal is leaking, nip open and renew.
12 - Nut
❑ 23 Nm
❑ Renew
❑ Qty. 2

422 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

13 - Bolt
❑ 25 Nm
❑ Qty. 2
14 - Mounting
❑ Attached to subframe
15 - Nut
❑ 23 Nm
❑ Renew
❑ Qty. 2
16 - Seal
❑ Renew
17 - Bolt
❑ 25 Nm
❑ Qty. 2
18 - Bolt
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19 - Bracket horis nte
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20 - Lambda probe - G39- , 50 Nm ss c

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❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
nl

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❑ Remove and install using ring spanner for Lambda probe - 3337-

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21 - 25 Nm
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❑ Renew studs and fastening nuts.

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Observe tightening sequence: items -A- to -I- ⇒ page 278 .
es, in part or in w

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Screw the studs into cylinder head until they project only 25 mm.

22 - Exhaust turbocharger

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Caution
Oil supply line must be

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❑ The turbocharger and the exhaust manifold can only be renewed together.
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❑ Removing and installing ⇒ page 282

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2. Exhaust gas cleaning 423

 Eos 2006 ➤ , Golf 2009 ➤ ,wGolf agen Cabriolet 2012
AG. Volkswagen AG➤
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4-cylinder direct-injection
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2.6 Removing and installing catalytic con‐ th or
au ac
ss
verter (Polo)

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Removing

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ab
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– Lift engine cover panel at points -1- and pull it forwards in di‐
ot p

wit
rection of -arrow-.
is n

h re
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
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– Unbolt heat shield over turbocharger -arrows-.

o

n
c

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or

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te

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p

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Cop py
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– Remove noise insulation securing bolts -arrows-.

– Unscrew securing nuts on turbocharger -arrows-.

– Disconnect connector -3- for Lambda probe after catalytic
converter - G130- .

424 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Also disconnect connector for Lambda probe - G39- .

– Unscrew securing bolts -1- for charge air pipe.
– Unscrew securing bolts -4- and remove bracket -5-.
– Pull upper charge air hose off turbocharger.
– Remove charge air pipe downwards.
– Press front exhaust pipe mountings from pins.

– Loosen securing nuts for clamping sleeve -arrows- and slide

clamping sleeves backwards.
– Remove catalytic converter with front silencer downwards.
Installing
Installation is performed in the reverse order of removal.
Specified torques:

satelettronica
Assembly overview - catalytic converter and add-on parts (Polo)
⇒ page 420

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2.7 Removing and installing (Passat, Pas‐
d b ran
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au ac
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Special tools and workshop equipment required

un

pt
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itte

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♦ Torque wrench - V.A.G 1331-

erm

ab
ility
ot p

wit
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t to the co
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mer

Removing
atio
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– Remove noise insulation or skid plate ⇒ General body repairs,

i
or

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exterior; Rep. gr. 50 ; Removing and installing noise insulation

t

sd
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or skid plate .
i

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pr

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– Remove front exhaust pipe ⇒ page 405 .

en
ng

t.
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Prote AG.

2. Exhaust gas cleaning 425

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Lever off engine cover panel at points -1-.

– Pull off cover panel forwards in direction of -arrow-.

– Unbolt heat shield above turbocharger -arrows-.

satelettronica
AG. Volkswagen AG d
agen oes
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– Unscrew securing nuts on turbocharger
rise
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nl

pt
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itte

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erm

ab
ility
ot p

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es, in part or in w

t to the co
rrectness of i

– Disconnect connector -3- for Lambda probe after catalytic

converter - G130- .
l purpos

– Also disconnect connector for Lambda probe - G39- .

nf
ercia

– Unscrew bolts -1- for charge air pipe.

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– Unscrew bolts -4- and remove bracket -5-.

o

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– Pull off charge air hose on top of turbocharger, loosening clip

thi
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to do so.
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– Remove charge air pipe downwards.

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Installation C py
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Install in reverse order of removal. When doing this, observe the
p by
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following: Prote
cted AG.
agen

Specified torque
Component Specified torque
Front exhaust pipe to catalytic converter 25 Nm
Catalytic converter to turbocharger 23 Nm

426 Rep. gr.26 - Exhaust system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Component Specified torque

Exhaust pipe to front exhaust pipe 25 Nm

AG. Volkswagen AG d
agen oes
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aut ra
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ab
ility
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Cop py
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2. Exhaust gas cleaning 427

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l,. VEA 111,
olkswage
turbocharger, supercharger) - Edition 02.2019
AG n AG d
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28 – Ignition system
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1 Ignition system un

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General notes on ignition system

ab
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♦ The engine control unit - J623- is capable of self-diagnosis.

wit
is n

h re
ole,

♦ For trouble-free operation of electrical components, a voltage

spec
of at least 11.5 V is necessary.
urposes, in part or in wh

t to the co
♦ In some tests, a fault may be detected and stored by the en‐
gine control unit - J623- . Therefore, after completing all the
checks and repairs, read the event memory and clear it if nec‐

rrectne
essary .
⇒ “2.2 Safety precautions when working on ignition system”, page

ss
5.

o
cial p

f inform
⇒ “1.1 Assembly overview - ignition system”, page 428
mer

atio
⇒ “1.2 Removing and installing ignition coils with output stage”,
om

n
page 429
c

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⇒ “1.3 Removing and installing engine speed sender G28 ”, page

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⇒ “1.4 Test data, spark plugs”, page 433 .

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1.1 Assembly overview - ignition system
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428 Rep. gr.28 - Ignition system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

1 - Connector
❑ Black, 4-pin.
❑ With assembly tool -
T10118- .
2 - Ignition coil 3 with output
stage - N291-
❑ Ignition coil 1 with output
stage - N70-
❑ Ignition coil 2 with output
stage - N127-
❑ Ignition coil 4 with output
stage - N292-
❑ Removing and installing
⇒ page 429
3 - Connector
❑ Black, 2-pin.
❑ For knock sensor 1 -
G61- .
❑ Connector contacts are

satelettronica
gold-plated.
4 - Knock sensor 1 - G61-
❑ Connector contacts are
gold-plated.
❑ To remove, remove su‐
percharger ⇒ page 297 .
5 - 20 Nm
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❑ The specified ltorque
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6 - Connector
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❑ Black, 3-pin.
un

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❑ For Hall sender - G40- .

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7 - Hall sender - G40-

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8 - O-ring
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❑ Renew if damaged
spec
urposes, in part or in wh

9 - 10 Nm
t to the co

10 - Spark plug, 25 Nm
❑ Remove and install with spark plug socket and extension - 3122 B-
rrectne

❑ Type and electrode gap ⇒ page 433 .

ss

11 - Wiring guide
o
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f in

❑ Bolt to camshaft housing with 5 Nm torque.

form
mer

12 - Earth cable
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om

❑ Loosen or tighten only with ignition switched off.

c

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13 - 10 Nm
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❑ Loosen or tighten only with ignition switched off.

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1.2 Removing and installing ignition coils
pyri by
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with output stage
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Prote AG.

Special tools and workshop equipment required

1. Ignition system 429

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

♦ Assembly tool - T10118-

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spec
♦ Puller - T10094 A-
es, in part or in w

t to the co
rrectness of i
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Note C py
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The ignition coil housings with output stages have been modified.
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As a result, these ignition coils can only be removed and installed
Prote AG.

with puller - T10094 A- . The previous puller - T10094- can con‐

tinue to be used if modified as described below.

– Remove marked area -2- using suitable workshop equipment

to attain the new nominal dimension -B- of 18 mm.
– Add the letter A to the end of tool designation -1-.
Removing

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.

430 Rep. gr.28 - Ignition system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

– Unscrew securing bolts -1- from crankcase breather union and

non-return valve.
– Pull off connector -2- from turbocharger air recirculation valve
- N249- and pull off hose connection -3-.
– Carefully pull hose -4- off intake manifold connection.

n AG. Volkswagen AG do
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– Fit puller - T10094 A- by Von ignition coil with final output t stage
o o g
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-arrow- o
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– Fit assembly tool - T10118- as shown.

pt
du

an
itte

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– Carefully release connector locking mechanism, and pull off
erm

ab
connector.

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wit

satelettronica
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Installing

h re
hole

spec
– Fit puller - T10094 A- on ignition coil with output stage.
es, in part or in w

t to the co
– Slide connector on ignition coil with output stage until it audibly
engages.

rrectness of i
– Press ignition coil with output stage into cylinder head in di‐
rection of -arrow-.
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– Push rubber grommet -1- into hose -2-.
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Prote AG.
– Push hose -2- onto intake manifold connection -3-.
Further installation is carried out in reverse order of removal.
Specified torques of securing bolts for crankcase breather con‐
nection and for non-return valve: 10 Nm

1.3 Removing and installing engine speed

sender - G28-
The engine speed sender - G28- is located on the sealing flange
on the flywheel end of the crankcase.

1. Ignition system 431

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019

Special tools and workshop

equipment required

satelettronica
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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aut ra
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erm

ab
ility
ot p

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, is n

h re
hole

spec
es, in part or in w

♦ Hose clamp pliers - VAS 6340-

t to the co

♦ Torque wrench - V.A.G 1331-

♦ Guide pin - T10341-
rrectness of i

♦ Locking pin - T10060 A-

l purpos

♦ Torx bit - T10370-

nf
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Removing
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– Remove compressor ⇒ page 299 .

om

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– Remove supercharger (Tiguan with four-wheel drive)

thi
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⇒ page 307 .
sd
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Cop py
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Prote AG.

432 Rep. gr.28 - Ignition system

 Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 02.2019
n AG. Volkswagen A
– Pull off connector -1- from oengine
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age speed sender -GG28-
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– Remove gasket -2- from
ris
ed cylinder block and remove engine ran
tee
speed sender - G28-
ut
h with socket - T10370- .
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Installing

ce
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un

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– Install engine speed sender - G28- and tighten securing bolt
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to 5 Nm.
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ab
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Further assembly is basically a reverse of the dismantling se‐
ot

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quence.

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es, in part or in w

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1.4 Test data, spark plugs

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Engine code CAVA, CAVB, CAVC, CTHA, CTHB, CTHC, CKMA
l purpos

CAVD, CAVE CTHD, CTHE, CTKA,

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Firing order 1-3-4-2

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Spark plugs
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VW part number 8)*) 101 905 622 03C 905 601 B 101 905 626 A
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Electrode gap 0.8 … 0.9 mm 0.7…0.8 mm 0.5 … 0.6 mm

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rp

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Specified torque 25 Nm
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Change interval ⇒ Maintenance ; Booklet ; Time or distance dependent additional work
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8) Current spark plugs ⇒ Electronic parts catalogue (ETKA)
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1. Ignition system 433