Table of Contents
- Technical data
- Engine number
- Engine data
- Removing and installing engine
- Assembly mountings
- Assembly overview - assembly mountings (Golf, Eos, Passat, CC, Scirocco)
- Assembly overview - assembly mountings (Tiguan)
- Checking adjustment of assembly mountings (engine and gearbox mountings)
- Adjusting assembly mountings (Passat 2006, CC)
- Adjusting assembly mountings (Golf, Eos, Scirocco)
- Adjusting assembly mounting (Tiguan)
- Crankshaft group
- Cylinder block (pulley end)
- Assembly overview - poly V-belt drive
- Removing and installing poly-V belt
- Removing and installing tensioner for poly V-belt (Passat 2006, CC)
- Removing and installing tensioner for poly V-belt (Golf, Eos, Scirocco)
- Removing and installing tensioner for poly V-belt (Tiguan)
- Removing and installing bracket for ancillaries
- Removing and installing vibration damper
- Renewing oil seal for vibration damper
- Cylinder block, gearbox end
- Crankshaft
- Pistons and conrods
- Cylinder block (pulley end)
- Cylinder head, valve gear
- Chain drive
- Assembly overview - timing chain covers
- Removing and installing camshaft control valve 1 N205
- Removing and installing upper timing chain cover
- Removing and installing lower timing chain cover (Passat, CC)
- Removing and installing lower timing chain cover (Golf, Eos, Scirocco)
- Removing and installing bottom timing chain cover (Tiguan)
- Camshaft timing chain - exploded view
- Removing and installing camshaft timing chain
- Assembly overview - drive chain for balance shaft
- Removing and installing drive chain for balance shaft
- Removing and installing inlet side balance shaft
- Removing and installing exhaust side balance shaft
- Checking valve timing
- Cylinder head
- Valve gear
- Chain drive
- Lubrication
- Cooling
- Cooling system
- Coolant pump, thermostat, coolant pipes
- Assembly overview - coolant pump, thermostat
- Removing and installing coolant pump
- Removing and installing toothed belt for coolant pump
- Renewing oil seal for coolant pump drive
- Removing and installing thermostat
- Removing and installing coolant temperature sender G62
- Assembly overview - coolant pipes
- Removing and installing front coolant pipes
- Removing and installing small coolant pipe
- Continued coolant circulation pump V51 - exploded view
- Removing and installing continued coolant circulation pump V51
- Radiator and radiator fans
- Assembly overview - radiator, fan cowl and radiator fan (Passat, CC, Golf, Eos, Scirocco)
- Installing radiator identification sensor G611 , engine code CBFA
- Assembly overview - radiator, radiator cowl and radiator fan (Tiguan)
- Removing and installing radiator cowl
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Removing and installing radiator (Passat, CC, Golf, Eos, Scirocco)
- Removing and installing radiator (Tiguan)
- Fuel supply system
- Safety precautions
- Rules for cleanliness
- Fuel tank (Passat, CC)
- Fuel tank (Golf, Scirocco)
- Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB,CDAA)
- Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
- Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA)
- Emptying fuel tank (engine codes CBFA, CCTA, CCTB)
- Removing and installing fuel tank
- Fuel tank (Tiguan)
- Fuel tank (Eos)
- Repairing fuel supply (Passat, CC)
- Repairing fuel supply system (Golf, Eos, Scirocco)
- Repairing fuel supply (Tiguan)
- Electronic power control (EPC)
- Activated charcoal filter system (Passat, CC, Tiguan)
- Checking fuel tank breather (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB)
- Check fuel system for leaks (engine codes CBFA, CCTA, CCTB)
- Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB, CDAA)
- Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)
- Overview of activated charcoal filter system
- Assembly overview - activated charcoal filter system (Golf)
- Assembly overview - activated charcoal filter system (Eos)
- Removing and installing activated charcoal filter
- Removing and installing fuel system diagnostic pump V144 (Golf)
- Removing and installing fuel system diagnostic pump V144 (Eos)
- Checking fuel system for leaks
- Turbocharging/supercharging
- Exhaust turbocharger
- Charge air system
- Assembly overview - charge air cooling (Passat, CC, Tiguan, Eos)
- Assembly overview - charge air cooler (Golf, Scirocco)
- Assembly overview - sound generator (Golf, Scirocco)
- Actuator for structure-borne sound R214 and control unit for structure-borne sound J869
- Turbocharging - overview
- Removing and installing charge air cooler (Golf, Eos)
- Removing and installing charge air cooler (Passat, CC, Scirocco)
- Removing and installing charge air cooler, Tiguan
- Removing and installing charge air duct to sound generator (Golf, Scirocco)
- Checking charge air system for leaks
- Mixture preparation - injection
- Safety precautions and rules for cleanliness
- Injection system
- Technical data
- Overview of fitting locations
- Assembly overview - air filter
- Removing and installing air filter housing
- Removing and installing air filter element
- Removing and installing air mass meter G70
- Assembly overview - intake manifold
- Assembly overview - fuel rail
- Removing and installing intake manifold with fuel rail
- Removing and installing injectors
- Renewing Teflon seal on injector
- Cleaning injectors
- Removing and installing fuel pressure sender G247
- Removing and installing throttle valve module J338
- Cleaning throttle valve module J338
- Assembly overview - high-pressure pump with fuel pressure regulating valve N276
- Removing and installing high-pressure pump
- Checking components
- Engine control unit J623 (Passat, CC up to 11/10)
- Engine control unit J623 (Golf, Eos to 11/08)
- Engine control unit J623 (Golf, Eos, Scirocco from 11/08; CC from 11/10)
- Engine control unit J623 (Tiguan)
- Engine control unit J623 (Scirocco to 11/08)
- Exhaust system
- Exhaust system (Passat, CC)
- Assembly overview - exhaust system (engine codes BZB, CAWA, CAWB, CGYA)
- Assembly overview - exhaust system (engine codes CCTA, CCTB, CCZA, CDAA, CDAB)
- Assembly overview - exhaust system (engine code CBFA)
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Installation position and specified torque of clamp
- Removing and installing catalytic converters with front exhaust pipe
- Check exhaust system for leaks
- Exhaust system (Golf, Eos, Scirocco)
- Assembly overview - exhaust system (engine code CAWB)
- Assembly overview - exhaust system (Golf 2004 βΊ, Eos, Scirocco, engine codes CCTA, CCZA, CCZB)
- Assembly overview - exhaust system (engine code CBFA)
- Assembly overview - exhaust system (Golf 2009βΊ, engine codes CCZA, CCZB)
- Assembly overview - exhaust system (Golf 2009 βΊ, engine codes CCTA, CDAA)
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Installation position and specified torque of clamp
- Removing and installing catalytic converters with front exhaust pipe
- Check exhaust system for leaks
- Exhaust system (Tiguan)
- Assembly overview β exhaust system (engine codes CCTA, CCTB, CCZA, CCZB, CCZC, CCZD)
- Assembly overview - exhaust system (engine codes CAWB, CCZA)
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Removing and installing catalytic converters with front exhaust pipe
- Installation position and specified torque of clamp
- Check exhaust system for leaks
- Secondary air system - engine code CBFA
- Exhaust system (Passat, CC)
- Ignition system