Service

Repair Manual
Golf 2004 ➤
Golf 2009 ➤
Golf Cabriolet 2012 ➤
Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine,
Turbocharger), Volkswagen R GmbH
CDL CDL CDLF CRZ
Engine ID BYD A C A
Edition 04.2018

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
20 - Fuel Supply
21 - Turbocharger, Supercharger
24 - Multiport Fuel Injection
26 - Exhaust System, Emission Controls
28 - Ignition/Glow Plug System

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2021 Volkswagen AG, Wolfsburg D3E8045E547

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Contents

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Engine and Transmission Mount and Pendulum Support Tightening Specifications . . . . . . 2
2 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Engine, Securing to the Engine and Transmission Holder VAS6095 . . . . . . . . . . . . . . . . 12
2.3 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Upper Crankshaft Bearing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Engine Component Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Overview - Sealing Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 Piston and Cylinder Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Accessory Bracket Bolt Tightening Sequence and Specification . . . . . . . . . . . . . . . . . . . . 34
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Piston, Piston Rings and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Crankshaft Seal, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 Sealing Flange, Transmission Side, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 44
5.5 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6 Crankshaft Sensor Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.1 Overview - Cylinder Head and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.2 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Cylinder Head Cover Bolt Tightening Sequence and Specification . . . . . . . . . . . . . . . . . . 58
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.1 Compression Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2 Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.1 Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3 Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Contents i
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4.4 Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.5 Exhaust Camshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.6 Camshaft Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.7 Camshaft Adjustment Valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.8 Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.2 Oil Filter Housing, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.1 Lubrication System Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.1 Oil Pressure and Oil Pressure Switch, Checking, 1 Pin Switch . . . . . . . . . . . . . . . . . . . . . . 122
3.2 Oil Pressure and Oil Pressure Switch, Checking, 2 Pin Switch . . . . . . . . . . . . . . . . . . . . . . 123
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2 Oil Pump with Balance Shaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Oil Filter Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.4 Oil Pressure Switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.1 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.2 Overview - Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.3 Overview - Cooling System Components, Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.4 Overview - Cooling System Components, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.5 Overview - Coolant Recirculation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.1 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.1 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.2 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.3 Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.4 Coolant Thermostat Housing with Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.5 Fan Mount with Radiator Fan V7 and Radiator Fan 2 V177, Removing and Installing . . . . 163
4.6 Radiator, Removing and Installing, Golf from MY 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.7 Radiator, Removing and Installing, Golf from MY 2009, Golf Convertible from MY 2012,
and Scirocco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.8 Auxiliary Radiator, Removing and Installing, Golf from MY 2009, Golf Convertible from MY
2012, and Scirocco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.2 High Side Fuel Pressure, Releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.3 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.4 Fuel Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

ii Contents
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2.1 Overview - Accelerator Pedal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2.2 Overview - Fuel Tank and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.3 Overview - EVAP System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.4 Overview - EVAP System Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.1 Fuel Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.2 Fuel System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.1 Accelerator Pedal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.2 Fuel Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.3 Fuel Level Sensor G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
4.5 Fuel Level Sensor 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.6 Suction Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.7 EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.8 Leak Detection Pump V144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.1 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.1 Overview - Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.2 Overview - Structure-Borne Sound Actuator and Structure-Borne Sound Control Module . . 236
2.3 Overview - Turbocharger Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.4 Overview - Turbocharger Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.1 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.2 Turbocharger Vacuum Diaphragm, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.1 Charge Air Hose, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.2 Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.3 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.4 Turbocharger Vacuum Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
1.1 OBD General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
1.2 Throttle Valve Control Module, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.1 Overview - Engine Cover with Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2.3 Overview - Fuel Rail and Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2.4 Overview - High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.1 Fuel Pressure Sensor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.2 Double Check-Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
5.1 Engine Cover and Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
5.2 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.3 Mass Airflow Sensor G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Contents iii
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5.4 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

5.5 Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336 . . . . . . . . . . 285
5.6 Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
5.7 Throttle Valve Control Module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
5.8 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
5.9 Fuel Pressure Sensor G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5.10 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.11 Fuel Injector Teflon® Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
5.12 Engine Control Module, without Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
5.13 Engine Control Module, with Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1.1 Overview - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
2 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
2.1 Exhaust Door, Checking (Golf from My 2009, Golf Cabriolet from MY 2012 and Scirocco) . .312
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3.1 Exhaust Pipe with Catalytic Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3.2 Exhaust System, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.2 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.1 Overview - Ignition System Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3.1 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
4.1 Ignition Coils with Power Output Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

iv Contents
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

00 – General, Technical Data

1 General Information
(Edition 04.2018)
K0058995521 - 07/26/2021
⇒ N1.1 umber”, page 1

1.1 Engine Number

The engine number (“engine code” and “serial number”) are
located on the left side at the engine/transmission partition.
The engine code is also stamped on the right side of the cylin‐
der head and on the cylinder block.

The engine number consists of up to nine alphanumeric char‐

acters. The first part (maximum three letters) represents the
“engine code”, the second (six digit) is the “serial number”. If
more than 999,999 engines with the same engine code are
produced, the first of the six characters is replaced with a letter.
In addition, a sticker with “Engine code” and “Serial number” is
affixed to the toothed belt cover.
The engine code is also on the vehicle data plate.
Vehicles with Four-Digit Engine Codes
Four-digit engine codes beginning with "C" are used. The first
three digits describe the mechanical structure of the engine
and are still stamped on the engine, as before. The fourth digit
describes the engine output as well as the torque and depends
on the engine control module. The four digit engine code is
found on the type plate and the vehicle data label is found on
the engine control module.

1. General Information 1
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

10 – Engine Assembly
1 Specifications
⇒ a1.1 nd Transmission Mount and Pendulum Support Tighten‐
ing Specifications”, page 2

1.1 Engine and Transmission Mount and

Pendulum Support Tightening Specifi‐
cations
Engine Mount

A = 20 Nm + an additional 90° (1/4) turn 1

B = 40 Nm + an additional 90° (1/4) turn 1
C = 60 Nm + an additional 90° (1/4) turn 1
Transmission Mount

1 = 40 Nm + an additional 90° (1/4) turn 1

2 = 60 Nm + an additional 90° (1/4) turn 1
Pendulum Support

2 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

First, secure the pendulum support to the transmission and then

to the subframe.

A = 40 Nm + additional 90° (1/4 turn) 1)

B = 100 Nm + 90° (1/4) additional turn 1)
♦ 1 Always replace

1. Specifications 3
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Removal and Installation

⇒ R2.1 emoving”, page 4
⇒ S2.2 ecuring to the Engine and Transmission Holder
VAS6095 ”, page 12
⇒ I2.3 nstalling”, page 12

2.1 Engine, Removing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm -VAG1331-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Engine and Gearbox Jack -VAS931-
♦ Spring Clip Pliers -VAS6499-
♦ Step Ladder -VAS5085-
♦ Engine/Trans. Support -T10012-
♦ Cable Ties
Removing engine. Refer to ⇒ R2.1 emoving”, page 4 .
For information on securing the engine on the engine stand.
Refer to ⇒ S2.2 ecuring to the Engine and Transmission Holder
VAS6095 ”, page 12 .
Install the engine. Refer to ⇒ I2.3 nstalling”, page 12 .
Assembly mounts. Refer to ⇒ a1.1 nd Transmission Mount and
Pendulum Support Tightening Specifications”, page 2 .

Note

♦ To perform this procedure, the ground cable must be discon‐

nected from the battery. If a coded radio is installed, obtain
the anti-theft code beforehand.
♦ The engine is removed downward together with the trans‐
mission.
♦ All cable ties which are opened or cut off when removing
the engine, must be replaced in the same position when
installing the engine.

Caution

When doing any repair work, especially in the engine com‐

partment, pay attention to the following due to clearance
issues:
♦ Route all lines and wires in their original locations.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.

Procedure
– Turn off the ignition and disconnect the ground cable from
the battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27;
Battery Disconnecting and Connecting.
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .

4 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the battery, the battery tray bolts -arrows- and tray.

– Remove the plenum chamber cover. Refer to ⇒ Body Exteri‐

or; Rep. Gr. 50; Removal and Installation.
– Remove the plenum chamber bulkhead. Refer to ⇒ Body
Exterior; Rep. Gr. 50; Description and Operation.
– Disconnect the harness connector from the Engine Control
Module (ECM).
– Release the pass through for the engine harness -arrow-
and pull it off upward.

– Remove the E-box cover by sliding both latches in the direc‐

tion of the -arrows-.

2. Removal and Installation 5

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the nuts, the generator cable -A- and the battery
cable -B- from the fuse holder.

– Remove the bolt and the ground wire -arrow- from the longi‐
tudinal member.

– Open the locking mechanisms -arrows- on the wire guide on

the longitudinal member.

– Free up the electrical connector -1- and disconnect it.

6 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Open the underlying wiring guide bracket -2-.

– Take the Engine Control Module (ECM) wiring harness out
of the wiring router and lay it on the engine.

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Lay a cloth at
the connection points before loosening the hose connections.
Then reduce the pressure by carefully removing the hose.

– Disconnect the vent line -1- and the fuel supply line -2-.

– Disconnect the vent line -2- and remove the Evaporative

Emission (EVAP) canister with the hoses, upward out of the
mount.

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50; Description and Operation
– Remove the left and right front wheel housing liners. Refer to
⇒ Body Exterior; Rep. Gr. 66; Removal and Installation.
– Remove the charge air hoses -arrows-.

2. Removal and Installation 7

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

With Front Wheel Drive (FWD)

– Remove the right drive axle heat shield -arrows-.

AWD Vehicles:
– Remove the right drive axle heat shield bolts -arrows- and
shield.

– Remove the driveshaft. Refer to ⇒ Rear Final Drives, 01Z,

0BS, 0AY and 0BR; Rep. Gr. 39; Removal and Installation.
Continuation for All Vehicles
– Remove the right and left drive axles. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40; Removal and Installa‐
tion.
– Remove the exhaust pipe with catalytic converter. Refer to ⇒
P3.1 ipe with Catalytic Converters”, page 314 .
– Move the lock carrier into the service position. Refer to
⇒ Body Exterior; Rep. Gr. 50; Description and Operation.
– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .

8 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Evacuate the Air Conditioning (A/C) system. Refer to “Re‐

frigerant Circuit” in ⇒ Refrigerant R134a Servicing; Rep.
Gr. 00; Description and Operation.
– Remove the refrigerant line bolt -arrow- and line from the
A/C compressor.

– Remove the refrigerant line bolt -arrow- and line from the
A/C condenser.

– Remove the pendulum support bolts -1, 2 and 3- and re‐

move the pendulum support.

– Disconnect all remaining electrical connectors necessary

from the engine and transmission and set aside.
– Disconnect all coolant, vacuum and intake connections from
the engine.
– Remove the shift mechanism from the transmission. Refer to
⇒ Manual Transmission; Rep. Gr. 34; Removal and Installa‐
tion.
– Clamp off the hose -A- to the clutch slave cylinder using a
-3094-.

2. Removal and Installation 9

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Pull the hose/line assembly clip -arrow- out as far as the

stop.
– Disconnect the hose/line assembly from the slave cylinder.

Caution

The clutch pedal must no longer be pressed down.

– Remove the Coolant Recirculation Pump -V50- bolts

-arrows-.

– Install the -T10012- onto the -VAG1383A-.

– Install the -T10012- to the engine as shown and tighten the
bolt -1- and nut -2- to 20 Nm.

10 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Support the engine and transmission using the -VAG1383A-.

– Remove the engine mount to engine mount bracket bolts
-arrows-.

– Remove the transmission mount to transmission mount

bracket bolts -arrows-.

Note

♦ Use the -VAS5085- to remove the bolts.

♦ Guide the engine and transmission carefully when lowering
to prevent damage to the vehicle body.

– Carefully lower the engine and transmission.

2. Removal and Installation 11

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2.2 Engine, Securing to the Engine and

Transmission Holder -VAS6095-
Special tools and workshop equipment required
♦ Engine Sling -2024A-
♦ Shop Crane - Load Cap = 700-1200 KG -VAS6100-
♦ Engine and Transmission Holder -VAS6095-
Secure the engine to the Engine and Transmission Holder -
VAS6095- when working on it.
Procedure
– Remove the transmission.
– Install the -2024A- as shown and lift the engine from the
-VAG1383A- using the -VAS6100-.

Belt pulley side: Second hole for the rail in position 1

Flywheel side: First hole for the rail in position 7

Caution

Use securing pins at the hooks in order to prevent damage to

the engine.

♦ The peg positions on the engine sling marked 1 to 4 face the

belt pulley.
♦ The bores in the rail are counted from the hook.
– Secure the engine to the -VAS6095-.

2.3 Engine, Installing

Engine and transmission mount tightening specifications. Refer
to ⇒ a1.1 nd Transmission Mount and Pendulum Support Tight‐
ening Specifications”, page 2 .
Install in reverse order of removal. Note the following:

12 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Caution

When doing any repair work, especially in the engine com‐

partment, pay attention to the following due to clearance
issues:
♦ Route all lines and wires in their original locations.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.

Procedure
– Insert new alignment sleeves for centering the engine and
transmission in the cylinder block.
– Engage the intermediate plate at the sealing flange and slide
it onto the alignment sleeves -arrows-.

– Grease the input shaft splines lightly with Grease for Clutch
Plate Splines -G000100-.
– Inspect and install the clutch and clutch mechanism. Refer to
⇒ Manual Transmission; Rep. Gr. 30.
– Make sure there is enough clearance to the subframe and
radiator when installing the engine and transmission subas‐
sembly.
– Align the engine mount as follows:
♦ There must be a distance of at least 10 mm -a- between the
engine mount bracket -2- and right longitudinal member.

♦ The casting edge on the engine mount bracket -2- must be

parallel to the engine mount support arm -1-.
– Install the pendulum support.

2. Removal and Installation 13

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

♦ Engine and transmission mount tightening specifications.

Refer to ⇒ a1.1 nd Transmission Mount and Pendulum Sup‐
port Tightening Specifications”, page 2 .
♦ Electrical connections and routing. Refer to ⇒ Electrical
Equipment; Rep. Gr. 97

– Install the right and left drive axles. Refer to ⇒ Suspension,

Wheels, Steering; Rep. Gr. 40; Removal and Installation.
– Install the exhaust pipe with catalytic converter. Refer to ⇒
P3.1 ipe with Catalytic Converters”, page 314 .
– Connect the refrigerant lines. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87; Description and Opera‐
tion.
– Install the driveshaft. Refer to ⇒ Rear Final Drives, 01Z,
0BS, 0AY and 0BR; Rep. Gr. 39; Removal and Installation.
– Install the shift mechanism and adjust if necessary. Refer to
⇒ Manual Transmission; Rep. Gr. 34; Removal and Installa‐
tion.
– Reconnect the hose/line assembly to the clutch slave cylin‐
der. Refer to ⇒ Manual Transmission; Rep. Gr. 30.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Description and Operation.
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50; Removal and Installation.
– Install the plenum chamber bulkhead. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50; Description and Operation.
– Connect the battery and complete the required steps after
connecting the battery. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27; Removal and Installation.
– Fill the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
– Connect the vehicle diagnostic tester
– Check all Diagnostic Trouble Code (DTC) memories and
erase any faults.
– Perform a road test.
– Perform a vehicle system test and correct any faults.

Note

If the DTC memory was erased, the readiness code must be

generated again. Refer to “Guided Fault Finding” in the vehicle
diagnostic tester.

Tightening Specifications
Bolted Connections Tightening
Specification
Bolts and nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm

14 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Bolted Connections Tightening

Specification
M12 60 Nm

2. Removal and Installation 15

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Special Tools

♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-

♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
♦ Engine/Gearbox Jack -VAG1383A-
♦ Spring Type Clip Pliers -VAS5024A-
♦ Step Ladder -VAS5085-
♦ Engine/Trans. Support -T10012-

16 Rep. Gr.10 - Engine Assembly

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Engine Sling -2024A-

♦ Shop Crane - Load Cap = 700-1200 KG -VAS6100-
♦ Engine and Transmission Holder -VAS6095-

3. Special Tools 17
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

13 – Crankshaft, Cylinder Block

1 General Information
⇒ C1.1 rankshaft Bearing Identification”, page 18
⇒ S2.4.2 hells - Installation Position”, page 33

1.1 Upper Crankshaft Bearing Identifica‐

tion
The upper bearing shells are allocated to the cylinder block
with the correct thickness, by the factory. Colored dots serve to
identify the bearing thicknesses.
The letters marked on the lower sealing surface of the cylinder
block identify which bearing thickness must be installed in which
location.

G = Yellow
B = Blue
W = White

Note

♦ The arrow points in the direction of travel.

♦ If the colored dot can no longer be read, use the blue bear‐
ing shell.
♦ The lower crankshaft bearing shells are always shipped as a
replacement part with a “yellow” dot.

18 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Description and Operation

⇒ C2.1 omponent Overviews”, page 19
⇒ -2.2 Sealing Flange”, page 26
⇒ -2.3 Crankshaft”, page 28
⇒ -2.4 Piston and Connecting Rod”, page 30

2.1 Engine Component Overviews

Caution

Do not bore, hone, grind or rework the cylinder bores with

shop tools. Reworking damages the surface of the cylinder
bore.

Note

♦ If large quantities of metal particles or abraded material are

detected during engine repairs, it may mean the crankshaft
or rod bearings are damaged. To prevent further damage,
perform the following steps after the repair:
♦ Clean the oil passages carefully.
♦ Replace the oil spray jets.
♦ Replace the engine oil cooler.
♦ Replace the oil filter element.

2. Description and Operation 19

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

I - Refer to ⇒ -2.1.1 Ribbed

Belt”, page 20
II - Refer to ⇒ -2.1.2 Toothed
Belt”, page 22
III - Refer to ⇒ -2.1.3 Cylinder
Block”, page 24

2.1.1 Overview - Ribbed Belt

20 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Accessory Bracket
❑ Follow the tightening
sequence. Refer to
⇒ Fig. ““Accessory
Bracket Tightening Se‐
quence”“, page 21 .
2 - Bolt
❑ 23 Nm
3 - Nut
❑ 23 Nm
4 - Generator
❑ Removing and instal‐
ling. Refer to ⇒ Elec‐
trical Equipment; Rep.
Gr. 27; Removal and
Installation.
❑ To make it easier
to position the genera‐
tor, push the threaded
bushing for the genera‐
tor bolt back slightly.
5 - Bolt
❑ 40 Nm
❑ Follow the tightening
sequence. Refer to
⇒ Fig. ““Accessory
Bracket Tightening Se‐
quence”“, page 21 .
6 - Bushing
❑ Quantity: 2
7 - Bolt
❑ 25 Nm
8 - Air Conditioning (A/C)
Compressor
❑ Removing and installing. Refer to “Refrigerant Circuit Components” in ⇒ Heating, Ventilation and Air
Conditioning; Rep. Gr. 87; Removal and Installation.
9 - Ribbed Belt
❑ Before removing, mark the rotation direction using chalk or a felt tip pen.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing. Refer to ⇒ B5.1 elt”, page 37 .
10 - Vibration Damper
11 - Bolt
❑ 20 Nm + an additional 90° (1/4) turn.
❑ Always replace.
12 - Bolt
❑ 23 Nm
13 - Ribbed Belt Tensioner
❑ Rotate the tensioner using an open end wrench to release the tension on the ribbed belt.

Accessory Bracket Tightening Sequence

2. Description and Operation 21

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2.1.2 Overview - Toothed Belt

22 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 10 Nm
2 - Upper Toothed Belt Guard
3 - Bolt
❑ 50 Nm + 180° (1/2 turn)
further
❑ Always replace.
❑ Use the Wrench - Pin
Type -3036- to loosen
and tighten.
4 - Camshaft Sprocket
❑ Installed position: se‐
cured by a woodruff
key.
5 - Bolt
❑ 10 Nm
❑ Install using locking flu‐
id.
6 - Rear Toothed Belt Guard
7 - Woodruff Key
❑ Make sure it is secure.
8 - Nut
❑ 25 Nm
9 - Toothed Belt Tensioner
10 - Coolant Pump
❑ Removing and instal‐
ling. Refer to ⇒
P4.1 ump”, page 156 .
11 - O-Ring
❑ Always replace.
12 - Bolt
❑ 25 Nm
13 - Idler Roller
14 - Bolt
❑ 15 Nm
15 - Bolt
❑ 35 Nm
16 - Idler Roller
17 - Sealing Flange
18 - Disc (Diamond Coated)
❑ Always replace.
19 - Crankshaft Toothed Belt Gear
❑ The contact surfaces between the toothed belt gear, diamond disc and crankshaft must be free of oil.
❑ Only possible to install in one position.
20 - Bolt
❑ 90 Nm + an additional 90° (1/4) turn.
❑ Always replace.

2. Description and Operation 23

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Do not lubricate.
❑ Use the Counterhold - Crankshaft Sprocket -3415- to loosen and tighten.
21 - Toothed Belt
❑ Before removing, mark the rotation direction using chalk or a felt tip pen.
❑ Check for wear.
❑ Removing and installing. Refer to ⇒ B4.3 elt”, page 69 .
22 - Lower Toothed Belt Guard
23 - Bolt
❑ 8 Nm
❑ For the lower toothed belt guard.
❑ Quantity: 7
24 - Engine Mount Bracket
25 - Bolt
❑ 45 Nm

2.1.3 Overview - Cylinder Block

24 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Knock Sensor 1 -G61-

❑ It is necessary to re‐
move the thermostat
first in order to remove
the sensor. Refer to ⇒
T4.4 hermostat Hous‐
ing with Thermostat”,
page 162 .
❑ Contacts are gold plat‐
ed.
2 - Bolt
❑ 20 Nm
❑ The tightening specifi‐
cation affects the func‐
tion of the knock sen‐
sor.
3 - Knock Sensor 2 -G66-
❑ It is necessary to re‐
move the oil filter
bracket first in order to
remove knock sensor
2. Refer to ⇒ F4.3 ilter
Adapter”, page 133 .
❑ Contacts are gold plat‐
ed.
4 - Wire Bracket
5 - Bolt
6 - Wire Bracket
7 - Bolt
8 - Gasket
❑ Always replace.
9 - Oil Filter Adapter
❑ Overview. Refer to ⇒
-2.1.3 Oil Filter Adapter”, page 119 .
10 - Bolt
❑ 15 Nm + an additional 90° (1/4) turn.
❑ Always replace.
11 - Intake Manifold Support
12 - Bolt
❑ 23 Nm
13 -
❑ 10 Nm
14 - Engine Speed Sensor -G28-
15 - Seal
❑ Always replace.
16 - Bolt
❑ 15 Nm
17 - Coolant Thermostat Housing with Thermostat
❑ Removing and installing. Refer to ⇒ T4.4 hermostat Housing with Thermostat”, page 162 .
18 - O-Ring

2. Description and Operation 25

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Always replace.
19 - Bolt
❑ 40 Nm
20 - Accessory Bracket
❑ Tightening sequence. Refer to ⇒ Fig. ““Accessory Bracket Tightening Sequence”“, page 21 .

2.2 Overview - Sealing Flange

Note

Servicing the clutch. Refer to ⇒ Manual Transmission; Rep.

Gr. 30.

26 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 90 Nm + an additional
90° (1/4) turn.
❑ Always replace.
❑ Do not lubricate.
❑ Use the Counterhold
- Crankshaft Sprocket
-3415- to loosen and
tighten.
2 - Crankshaft Toothed Belt
Gear
❑ There must be no oil
on the contact surfa‐
ces between the tooth‐
ed belt gear and crank‐
shaft.
❑ Only possible to install
in one position.
3 - Bolt
❑ 15 Nm
4 - Seal
❑ Do not lubricate or
grease the sealing lip
on the seal.
❑ Removing and instal‐
ling. Refer to ⇒
S5.2 eal, Belt Pulley
Side”, page 38 .
5 - Sealing Flange, Belt Pulley
Side
❑ Must be seated on the
alignment pins.
❑ Removing and instal‐
ling. Refer to ⇒
F5.3 lange, Belt Pulley Side”, page 41 .
❑ To remove and install, remove the oil pan.
6 - Cylinder Block
❑ Oil pump with differential shaft gear removing and installing. Refer to
❑ Crankshaft overview. Refer to ⇒ -2.3 Crankshaft”, page 28 .
❑ Piston and connecting rod overview. Refer to ⇒ -2.4 Piston and Connecting Rod”, page 30 .
7 - Bolt
❑ 60 Nm + an additional 90° (1/4) turn.
❑ Always replace
8 - Flywheel
❑ Removing and installing. Refer to ⇒ 5.5 , page 47 .
9 - Intermediate Plate
❑ Must be located on the alignment sleeves.
❑ Be careful not to damage or bend the plate when installing it.
10 - Sealing Flange with Seal
❑ Always replace as a complete unit.
❑ Removing and installing. Refer to ⇒ F5.4 lange, Transmission Side, Removing and Installing”, page
44 .
11 - Disc (Diamond Coated)

2. Description and Operation 27

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Always replace

2.3 Overview - Crankshaft

Note

♦ Before removing the crankshaft, prepare for appropriate storage, so that the sensor wheel -4- does not
make contact or become damaged.
♦ Secure the engine to the Engine and Transmission Holder -VAS6095- when working on it.

28 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 65 Nm + an additional
90° (1/4) turn.
❑ Always replace.
❑ Fully threaded.
❑ Tighten to 65 Nm to
measure the radial play
in the crankshaft; do
not tighten the addition‐
al torque.
2 - Bearing Cap
❑ Bearing cap 1: Belt pul‐
ley side
❑ Retaining tabs on the
bearing shells and
cylinder block/bearing
caps must align above
one another.
3 - Screw
❑ 10 Nm + an additional
90° (1/4) turn.
❑ Always replace.
4 - Sensor Wheel
❑ For the Engine Speed
Sensor -G28-.
❑ Replace the sensor
wheel every time the
screws are loosened.
❑ Only possible to install
in one position - the
bores are offset.
❑ Removing and instal‐
ling. Refer to ⇒
S5.6 ensor Wheel”,
page 49 .
5 - Crankshaft
❑ Axial play:
New: 0.07 to 0.23 mm

Wear limit: 0.30 mm

❑ Measure the radial clearance using Plastigauge®:
New: 0.017 to 0.037 mm

Wear limit: 0.07 mm

❑ Do not rotate the crankshaft when measuring the radial play.
❑ Crankshaft dimensions. Refer to ⇒ D3.1 imensions”, page 34 .
6 - Thrust Washers
❑ For bearing 3
7 - Bearing Shell, for the Cylinder Block
❑ With a lubricating groove.
❑ Identification for replacement part ordering. Refer to ⇒ C1.1 rankshaft Bearing Identification”, page 18 .
❑ Do not interchange used bearing shells (mark them).
8 - Sprocket

2. Description and Operation 29

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ For the oil pump drive.
9 - Bearing Shell, for the Bearing Cap
❑ Without a lubricating groove.
❑ Do not interchange used bearing shells (mark them).

2.4 Overview - Piston and Connecting Rod

⇒ C2.4.1 onnecting Rod, Separating”, page 32
⇒ S2.4.2 hells - Installation Position”, page 33

30 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Connecting Rod Bolt

❑ Tighten to 30 Nm to
measure radial play but
do not tighten further.
❑ Always replace
❑ Engine code BPY: 30
Nm + 90° (1/4 turn)
❑ Engine codes CDLA,
CDLC, CDLF and
CRZA: 45 Nm + 90°
(1/4 turn)
❑ Engine code BYD: 45
Nm + 90° (1/4 turn)
❑ Lubricate the threads
and contact surface.
2 - Bolt with Pressure Relief
Valve
❑ 27 Nm
❑ Opening pressure: 1.3
to 1.6 bar
3 - Oil Spray Jet
❑ For piston cooling
4 - Connecting Rod Bearing
Cap
❑ Note the installation po‐
sition
❑ Due to the separation
procedure (cracking) of
the connecting rod, the
cap only fits in one po‐
sition and only to the
corresponding connect‐
ing rod.
❑ Mark which cylinder to which it belongs -B-.
❑ Installed position: marks -A- face the belt pulley side
5 - Bearing Shell
❑ Note the installation position. Refer to ⇒ S2.4.2 hells - Installation Position”, page 33 .
❑ Do not interchange used bearing shells.
❑ Axial play new: 0.10 to 0.35 mm, wear limit: 0.4 mm
❑ Check the radial play with Plastigauge®: new: 0.02 to 0.06 mm, wear limit: 0.09 mm; do not rotate the
crankshaft when measuring the radial play.
6 - Connecting Rod
❑ Always replace as a set
❑ With cracked bearing cap
❑ Mark which cylinder to which it belongs -B-.
❑ Installed position: marks -A- face the belt pulley side
❑ Separating the new connecting rod. Refer to ⇒ C2.4.1 onnecting Rod, Separating”, page 32 .
7 - Circlip
8 - Piston Pin
❑ If difficult to move, heat piston to 60 °C (140 °F)
❑ Remove and install using the Pilot Drift -VW222A-
9 - Piston

2. Description and Operation 31

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Checking using the Vehicle Diagnostic Tester ⇒ Fig. ““Piston, Checking”“, page 35 .
❑ Mark the installation position and cylinder allocation
❑ Arrow on piston crown points toward belt pulley side
❑ Install with piston ring compressor
❑ Cylinder Bore, Checking. Refer to ⇒ Fig. ““Cylinder Bore, Checking”“, page 36 .
❑ Piston and Cylinder Dimensions. Refer to ⇒ a3.2 nd Cylinder Dimensions”, page 34 .
10 - Piston Rings
❑ Offset gaps by 120°
❑ Use piston ring pliers for removing and installing
❑ Markings face toward piston crown
❑ Checking the piston ring gap. Refer to ⇒ Fig. ““Piston Ring Gap, Checking”“, page 35 .
❑ Checking the groove clearance. Refer to ⇒ Fig. ““Piston Ring Groove Clearance, Checking”“, page
35 .

2.4.1 New Connecting Rod, Separating

New connecting rods might not be completely separated at the
location where they should be. If the connecting rod bearing
cap cannot be removed by hand, proceed as follows:
– Mark the cylinder where the connecting rod belongs. Refer
to ⇒ -2.4 Piston and Connecting Rod”, page 30 .
– Lightly clamp the connecting rod in a vise equipped with
aluminum protective pads.

Note

♦ Only clamp the connecting rod gently to avoid damaging it.

♦ Clamp the connecting rod below the dotted line.

– Loosen the bolts -arrows- approximately 5 turns.

– Carefully tap against the connecting rod bearing cap in di‐
rection of -arrow- with a plastic hammer until the cap is
loose.

32 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2.4.2 Bearing Shells - Installation Position

Bearing shell -1- with connecting rod oil filler hole -arrow-.

Bearing shell -2- without oil filler hole for connecting rod cover.
– Place the bearing shells centrally into connecting rod and
connecting rod bearing cap.
The dimension -a- must be the same at left and right.

2. Description and Operation 33

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Specifications
⇒ D3.1 imensions”, page 34
⇒ a3.2 nd Cylinder Dimensions”, page 34
⇒ B3.3 racket Bolt Tightening Sequence and Specification”,
page 34

3.1 Crankshaft Dimensions

(Dimensions are in mm)
Honing Dimen‐ Crankshaft Bearing Connecting Rod
sion Pin Diameter Bearing
Pin Diameter
Basic dimension 54.00 -0.017 47.80 -0.022
-0.037 -0.042
1st oversize 53.75 -0.017 47.55 -0.022
-0.037 -0.042
2nd oversize 53.50 -0.017 47.30 -0.022
-0.037 -0.042
Stage III 53.25 -0.017 47.05 -0.022
-0.037 -0.042

3.2 Piston and Cylinder Dimensions

Caution

Do not bore, hone, grind or rework the cylinder bores with

shop tools. Reworking damages the surface of the cylinder
bore.

Piston Diameter Cylinder Bore

Diameter
Basic dimension mm 82.465 1 82.51

♦ 1Dimension is without the graphite coating (0.02 mm thick).

The graphite coating wears off.

3.3 Accessory Bracket Bolt Tightening Se‐

quence and Specification

– Tighten the bolts in the sequence shown to 40 Nm.

34 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Diagnosis and Testing

⇒ P4.1 iston Rings and Cylinder Bore, Checking”, page 35

4.1 Piston, Piston Rings and Cylinder

Bore, Checking
Piston Ring Gap, Checking

Special tools and workshop equipment required

♦ Feeler Gauge
– Insert the ring from above, down to the lower end of the
cylinder bore at a right angle, approximately 15 mm from the
cylinder edge.
Piston Ring Gap
New Wear limit
Compression rings mm 0.20 to 0.40 0.8
Oil scraping ring mm 0.25 to 0.50 0.8
Piston Ring Groove Clearance, Checking

Special tools and workshop equipment required

♦ Feeler Gauge
– Clean the ring groove before checking.
Piston Ring Ring to Groove Clearance
New Wear limit
Compression rings mm 0..06 to 0.20
0.09
Oil scraping ring mm 0.03 to 0.06 0.15
Piston, Checking

4. Diagnosis and Testing 35

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Special tools and workshop equipment required

♦ Outside Micrometer 75-100 mm -VAS6071-
– Measure approximately 10 mm from the lower edge of the
piston skirt, offset 90° to the piston axis.
Deviation from nominal dimension: Max. 0.04 mm
Cylinder Bore, Checking

Special tools and workshop equipment required

♦ Cylinder Dial Bore Gauge -VAS6078-
– Measure diagonally at 3 positions transversely -A- and longi‐
tudinally -B-.
– Deviation from nominal dimension: Max. 0.08 mm

Note

The cylinder bore measurement must not be performed if the

cylinder block is installed on the -VAS6095-, since inaccurate
measurements are possible.

36 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Removal and Installation

⇒ B5.1 elt”, page 37
⇒ S5.2 eal, Belt Pulley Side”, page 38
⇒ F5.3 lange, Belt Pulley Side”, page 41
⇒ F5.4 lange, Transmission Side, Removing and Installing”,
page 44
⇒ 5.5 , page 47
⇒ S5.6 ensor Wheel”, page 49
⇒ B5.7 elt Tensioner, Removing and Installing”, page 49

5.1 Ribbed Belt

Special tools and workshop equipment required
♦ Locking Pin -T10060A-
Removing
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Description and Operation.
– Mark the rotation direction of the ribbed belt.
With an Evaporative Emission (EVAP) Canister Inside the En‐
gine Compartment
– Release the EVAP canister and remove it upward in direc‐
tion of -arrow- out of the mount with the lines still connected.

Continuation for All

– Rotate the tensioner, in the direction of -arrow- to release
the tension on the belt.

– Secure the tensioner using the -T10060A-.

5. Removal and Installation 37

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the ribbed belt.

Installing
– Install in reverse order of removal. Note the following:

Note

♦ When installing the ribbed belt, note the rotation direction of

the belt and be sure that the belt is seated correctly on the
pulleys.
♦ Route the ribbed belt over the Air Conditioning (A/C) com‐
pressor as last.

After installing the ribbed belt, start the engine and make sure
the ribbed belt is running correctly.

5.2 Crankshaft Seal, Belt Pulley Side

Special tools and workshop equipment required
♦ Puller - Crankshaft Seal -3203-
♦ Counterhold - Crankshaft Sprocket -3415-
♦ Seal Installer - Crankshaft Seal -T10053-
♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
Removing
– Remove the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .
– Remove the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
– Loosen the crankshaft toothed belt gear bolt by holding the
gear using the -3415-.

38 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– To guide the -3203-, install the bolt back into the crankshaft
by hand until seated.

– Remove the inner portion of the -3203- 9 rotations (approxi‐

mately 20 mm) from the outer portion and secure it using the
with knurled thumb screw.
– Grease the threaded head of the -3203-, position it and
forcefully screw it as far as possible into the seal.

– Loosen the knurled thumb screw and turn the inner portion
against the crankshaft until the seal is pulled out.
Installing
– Remove any oil residue on the crankshaft journal with a
clean cloth.
– Position the -T10053/1- on the crankshaft journal.

5. Removal and Installation 39

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Slide the dry seal over the guide sleeve onto the crankshaft.
– Press in the seal using the -T10053- and the -T10053/2-
(M16 x 1.5 x 60) until seated.

Note

♦ The contact surfaces between the toothed belt gear, dia‐

mond disc and crankshaft must be free of oil.
♦ The crankshaft toothed belt gear bolt must be replaced.
♦ The threads and shoulder must be free of oil and grease.

– Install the crankshaft toothed belt gear -2- with the disc -3-
and tighten the bolt -1- hand tight.

– Secure the crankshaft toothed belt gear using the -3415-.

40 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Tighten new bolt to 90 Nm + an additional 90° (1/4) turn, the

additional turn may occur in several stages.
Further installation is in the reverse order of the removal proce‐
dure.
Install the toothed belt and adjust the timing. Refer to ⇒
B4.3 elt”, page 69 .

5.3 Sealing Flange, Belt Pulley Side

Special tools and workshop equipment required
♦ Counterhold - Crankshaft Sprocket -3415-
♦ Seal Installer - Crankshaft Seal -T10053-
♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
♦ Hand Drill with Plastic Brush Attachment
♦ Flat Scraper
♦ Silicone Sealant -D176404A2-
Removing
– Remove the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .
– Remove the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
– Rotate the crankshaft slightly backward.
– Loosen the crankshaft toothed belt gear bolt by holding the
gear using the -3415-.

– Drain the engine oil.

– Remove the oil pan. Refer to ⇒ P4.1 an”, page 125 .
– Remove the sealing flange, belt pulley side.

5. Removal and Installation 41

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the sealing flange, if necessary use a rubber mallet

and tap it gently.
– Remove any sealant residue on the cylinder block using a
flat blade scraper.
– Cover the seal with a clean cloth.
– Remove any sealant still on the sealing flange using a rotat‐
ing plastic brush. Wear protective eyewear.

– Clean the sealing surface so that it is free of oil and grease.

Installing
– Cut the sealant tube nozzle at the front mark (nozzle diame‐
ter: approximately 3 mm.
– Apply a sealant bead with a diameter of about 2 to 3 mm
to the clean sealing surface of the sealing flange as shown
-arrows-.

Note

♦ Cover the seal with a clean cloth before applying the sealant
bead.
♦ The sealant bead must not be thicker than 2 to 3 mm. Other‐
wise excess sealant could enter the oil pan and clog the oil
intake tube.
♦ Note the expiration date of the sealant .
♦ The sealing flange must be installed within 5 minutes after
application of the sealant.

♦ To attach the sealing flange with the installed seal, use the
-T10053/1-.
♦ After installing, allow the sealant to dry for approximately 30
minutes. Only after then may the engine oil be added.

42 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Position the sealing flange immediately and tighten all the

bolts -arrows- hand tight.

– Tighten the sealing flange bolts in a diagonal sequence.

Tightening specification: 15 Nm
– Remove any excess sealant.
– Install the oil pan. Refer to ⇒ P4.1 an”, page 125 .
– If necessary, install the seal. Refer to ⇒ S5.2 eal, Belt Pulley
Side”, page 38 .

Note

♦ The contact surface between the crankshaft toothed belt

gear, diamond disc and crankshaft must be free of oil.
♦ The crankshaft toothed belt gear bolt must be replaced.
♦ The threads and shoulder must be free of oil and grease.

– Install the crankshaft toothed belt gear -2- with the disc -3-
and tighten the bolt -1- hand tight.

– Secure the crankshaft toothed belt gear using the -3415-.

5. Removal and Installation 43

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Tighten the new bolt to 90 Nm + an additional 90° (1/4) turn,

the additional turn may occur in several stages.
Further installation is in the reverse order of removal.
Install the toothed belt and adjust the timing. Refer to ⇒
B4.3 elt”, page 69 .

5.4 Sealing Flange, Transmission Side,

Removing and Installing
Special tools and workshop equipment required
♦ Crank Shaft Seal Installer - Guide Piece -T10122/6- or
Crank Shaft Seal Installer - Guide Piece -T10122/6A- from
Crankshaft Seal Installer Kit -T10122B- or Assembly Device
-T10122C-
♦ Guide Piece to Crankshaft Seal Install Kit - Guide Piece
-T10122/1- from the Crankshaft Seal Installer Kit -T10122B-
or Assembly Device -T10122C-
♦ Hand drill with plastic brush insert
♦ Protective Eyewear
♦ Refer to the Parts Catalog for the correct sealant.
Removing

– Remove the flywheel. Refer to ⇒ 5.5 , page 47 .

– Unhook the intermediate plate from the sealing flange and at
the alignment sleeves -arrows-.
– Remove the bolts -1 through 8-.

44 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the sealing flange.

Installing

Install in the reverse order of removal while noting the following:

– To prevent contamination of the lubricating system, place a
clean cloth over the open part of the oil pan.

WARNING

Danger of eye injury.

♦ Wear protective eyewear.

– Remove any sealant residue.

– Clean the sealing surfaces.

Note

Check the expiration date of the silicone sealant.

– Cut the tube nozzle at the front marking (nozzle diameter:

approximately 2 mm).
– Apply the silicone sealant -arrow- to the clean sealing sur‐
face of the sealing flange.

5. Removal and Installation 45

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

• Sealant bead thickness: 2 to 3 mm.

Note

Check the sealing lip of the sealing flange, it must not be kinked
or damaged.

♦ The sealing lip must be pointed to the engine after installing.

Otherwise, oil leaks could occur.
♦ Install the sealing flange within five minutes of applying the
silicone sealant.

– Inspect the -T10122/6A- -B-; it must not have any sharp

edges or be dirty.

46 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Mount the -T10122/1- -A- on the -T10122/6A- -B-.

– With the outside facing forward, slide the sealing flange -C-
onto the -T10122/6A- -B-.
– Remove the -T10122/1- -A-.
– Insert the -T10122/6A- -A- with the sealing flange -B- on the
crankshaft journal.

Note

It is not necessary to tighten the bolts -arrows-

– Slide the Sealing Flange -B- over the -T10122/6A- -A- on the
crankshaft journal.
– Remove the -T10122/6A- -A-.
• After installing the sealing flange, the sealant must dry for
approximately 30 minutes. Only afterward may the engine oil
be replenished.
Tightening Specifications
♦ Refer to ⇒ -2.2 Sealing Flange”, page 26

5.5 Flywheel
Special tools and workshop equipment required
♦ Flywheel Retainer -3067-

5. Removal and Installation 47

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Removing

Caution

The dual mass flywheel can be damaged by removing the

bolts -B- with an air powered or impact wrench.
Only remove the bolts for the dual mass flywheel by hand.

Remove the transmission. Refer to ⇒ Manual Transmission;

Rep. Gr. 34; Removal and Installation.
– Rotate the flywheel -A- until the bolts -B- line up with the
holes -arrows-.
– Be careful the bolt heads do not get caught on the flywheel
when removing them -B-.
– Insert the -3067- in the hole on the cylinder block.

– Mark the flywheel position to the engine.

– Remove the flywheel.
Installing
Install in reverse order of removal. Note the following:
– Replace the bolts.

48 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Tightening Specification
Component Nm
Dual mass flywheel to crankshaft 60 + 90°1
♦ 1 90° corresponds to 1/4 turn.

5.6 Crankshaft Sensor Wheel

– Always replace the sensor wheel -2- each time the screws
-1- are removed.

Note

♦ After tightening a second time, the attachment point of the

countersunk screws of the sensor wheel are so deformed
that the screw heads -3- lie on the crankshaft -arrows- and
the sensor wheel is loose underneath the screws.
♦ The sensor wheel can only be installed in one position. The
holes are offset.
♦ Tightening specification. Refer to ⇒ -2.3 Crankshaft”, page
28 .

5.7 Ribbed Belt Tensioner, Removing and

Installing
Removing
– Remove the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .
– Remove the bolts.
– Remove the ribbed belt tensioner.
Installing
Install in reverse order of removal. Note the following:
Tightening Specifications
♦ Refer to ⇒ C2.1 omponent Overviews”, page 19

5. Removal and Installation 49

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

6 Special Tools

Special tools and workshop

equipment required

♦ Puller - Crankshaft Seal -3203-

♦ Counterhold - Crankshaft Sprocket -3415-
♦ Seal Installer - Crankshaft Seal -T10053-
♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-

50 Rep. Gr.13 - Crankshaft, Cylinder Block

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Locking Pin -T10060A-

♦ Crank Shaft Seal Installer - Guide Piece -T10122/6- or

Crank Shaft Seal Installer - Guide Piece -T10122/6A- from
Crankshaft Seal Installer Kit -T10122B- or Assembly Device
-T10122C-

♦ Guide Piece to Crankshaft Seal Install Kit - Guide Piece

-T10122/1- from the Crankshaft Seal Installer Kit -T10122B-
or Assembly Device -T10122C-

♦ Flywheel Retainer -3067-

♦ Not illustrated:
♦ Outside Micrometer 75-100 mm -VAS6071-
♦ Cylinder Dial Bore Gauge -VAS6078-

6. Special Tools 51
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

15 – Cylinder Head, Valvetrain

1 Description and Operation
⇒ -1.1 Cylinder Head and Cover”, page 52
⇒ -1.2 Valvetrain”, page 55

1.1 Overview - Cylinder Head and Cover

Note

♦ When installing a replacement cylinder head, all of the con‐

tact surfaces between the hydraulic lash adjusters, roller
rocker arms and cam running surfaces on the camshaft must
be lubricated before installing the cylinder head cover.
♦ Only remove the plastic protectors installed to protect the
open valves immediately before installing the cylinder head.
♦ Replace the cylinder head bolts.
♦ If the cylinder head is going to be replaced, then it is also
necessary to replace all the coolant.

52 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 10 Nm
❑ Tightening sequence.
Refer to ⇒ H4.1 ead
Cover”, page 62 .
2 - Cylinder Head Cover
❑ Removing and instal‐
ling. Refer to ⇒
H4.1 ead Cover”, page
62 .
3 - Gasket
❑ Replace if damaged or
leaking.
4 - Crankcase Ventilation
Valve
5 - Cap
6 - Gasket
❑ Replace if damaged or
leaking.
7 - Bolt
❑ 4 Nm
8 - Cylinder Head Cover Gas‐
ket
❑ Replace if damaged or
leaking.
9 - Vacuum Pump
10 - Bolt
❑ 4 Nm
11 - Camshaft Adjustment
Valve 1 -N205-
❑ Removing and instal‐
ling. Refer to ⇒ C4.7 amshaft Adjustment Valve 1 N205 ”, page 101 .
12 - O-Ring
❑ Always replace.
13 - Bolt
❑ 10 Nm
14 - Wire Bracket
15 - Seal
❑ Replace if damaged or leaking.
16 - Bolt
❑ 10 Nm
17 - Housing
18 - Gasket
❑ Always replace.
19 - Transport Strap
20 - Bolt
❑ 25 Nm
21 - Stud Bolt
❑ 10 Nm

1. Description and Operation 53

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ For the intake manifold.
22 - Partition
23 - Cylinder Head Gasket
❑ Always replace.
❑ Note the installed position: The part number faces the cylinder head.
24 - Bolt
❑ 10 Nm
25 - Camshaft Position Sensor -G40-
26 - Seal
27 - Stud Bolt
❑ 10 Nm
❑ For the toothed belt tensioner.
28 - Stud Bolt
❑ 20 Nm
❑ For the exhaust manifold.
29 - Cylinder Head
❑ Checking for distortion. Refer to ⇒ Fig. ““Checking the Cylinder Head for Distortion”“, page 54 .
30 - Bolt
❑ 40 Nm + an additional 180° (1/2) turn.
❑ Always replace.
❑ Follow the loosening and tightening sequence. Refer to ⇒ H4.2 ead”, page 63 .

Checking the Cylinder Head for Distortion

– Check the cylinder head for distortion at several locations

using the -VAS6075- and a feeler gauge.
♦ Maximum permissible distortion: 0.05 mm
– Replace the cylinder head if the maximum distortion is ex‐
ceeded.

54 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1.2 Overview - Valvetrain

Note

♦ Cylinder heads with cracks between the valve seats, or the

valve seat and the spark plug threads, can continue to be
used without reducing the service life, as long as the cracks
have a max. width if 0.3 mm, or only the first 4 threads of the
spark plug threads are cracked.
♦ The cylinder head and guide frame must be replaced togeth‐
er.
♦ Do not start the engine for approximately 30 minutes after
installing the camshafts. The hydraulic lash adjusters must
seat themselves (otherwise the valves will crash into the
pistons).
♦ After working on the valvetrain and hydraulic lash adjusters,
carefully rotate the crankshaft by hand at least 2 full revolu‐
tions before starting to be sure that valves do not strike the
pistons.
♦ Always replace the gaskets and seals.

1. Description and Operation 55

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 50 Nm + an additional
180° (1/2) turn.
❑ Always replace.
❑ Use the Wrench - Pin
Type -3036- to loosen
and tighten.
2 - Camshaft Sprocket
❑ Use the Wrench - Pin
Type -3036- to loosen
and tighten.
3 - Seal
❑ Removing and instal‐
ling. Refer to ⇒
C4.5 amshaft Seal”,
page 95 .
4 - Cylinder Head
5 - Valve Guide
❑ Checking. Refer to ⇒
G3.2 uide, Checking”,
page 61 .
6 - Valve Stem Seal
❑ Removing and instal‐
ling. Refer to ⇒
S4.4 tem Seals”, page
90 .
7 - Valve Spring
8 - Spring Seat
9 - Valve Retainer
10 - Hydraulic Lash Adjuster
❑ Do not interchange.
❑ Lubricate the contact
surfaces.
11 - Woodruff Key
❑ Make sure it is secure.
12 - Exhaust Camshaft
❑ Check the radial clearance using Plastigauge® (the roller rocker arms are removed);
Wear limit: 0.1 mm

Run out: maximum 0.035 mm

13 - Guide Frame
❑ With integrated camshaft bearings.
❑ Clean the sealing surface, reworking is not permitted.
❑ Remove any old sealant residue.
14 - Bolt
❑ 8 Nm + an additional 90° (1/2) turn.
❑ Always replace.
15 - Camshaft Adjuster
❑ Removing and installing. Refer to ⇒ A4.6 djuster”, page 97 .
16 - Bolt
❑ 20 Nm + an additional 45° (1/8) turn.

56 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Use the Wrench - Pin Type -3036- to loosen and tighten.
17 - Intake Camshaft
❑ Check the radial clearance using Plastigauge®:
Wear limit: 0.1 mm

Run out: maximum 0.035 mm

18 - Chain Tensioner
❑ Secure using the Locking Pin -T10115- before removing.
19 - Timing Chain
❑ Removing and installing. Refer to ⇒ A4.6 djuster”, page 97 .
❑ Check for wear.
20 - Bolt
❑ 10 Nm
21 - Bolt
❑ 10 Nm
22 - Camshaft Position Sensor -G40-
23 - Exhaust Valve
❑ Do not grind, only hand lapping is permitted.
❑ Valve dimensions. Refer to ⇒ D2.1 imensions”, page 58 .
❑ Valve guide, checking. Refer to ⇒ G3.2 uide, Checking”, page 61 .
24 - Intake Valve
❑ Do not grind, only hand lapping is permitted.
❑ Valve dimensions. Refer to ⇒ D2.1 imensions”, page 58 .
❑ Valve guide, checking. Refer to ⇒ G3.2 uide, Checking”, page 61 .
25 - Sealing Cap
❑ Always replace.
❑ Removing: Insert a screwdriver into the center of the cap and pry out.
❑ Installing: Do not use sealant, press in 1 to 2 mm using the Seal Installer - Propshaft -3334-.

1. Description and Operation 57

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Specifications
⇒ D2.1 imensions”, page 58
⇒ H2.2 ead Cover Bolt Tightening Sequence and Specification”,
page 58

2.1 Valve Dimensions

Intake and exhaust valves must not be re-faced by grinding.
Only hand lapping is permitted.

Dimension Intake Valve Exhaust Valve

Diameter mm 33.75 to 33.95 27.90 to 28.10
-a-
Diameter mm 5.98 5.95
-b-
-c- mm 103.97 101.87
α ∠° 45 45

2.2 Cylinder Head Cover Bolt Tightening

Sequence and Specification

– Tighten the cylinder head cover bolts in multiple steps and in

the sequence shown to 10 Nm.
Cylinder Head Bolt Tightening Sequence and Specification
– Tighten the cylinder head bolt in the sequence as follows:

58 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Stage Tighten
1 – Tighten the bolts to 40 Nm using a torque
wrench.
2 – Tighten the bolts an additional 90° (1/4) turn
using a ratchet.
3 – Tighten the bolts an additional 90° (1/4) turn
using a ratchet.

2. Specifications 59
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Diagnosis and Testing

⇒ P3.1 ressure, Checking”, page 60
⇒ G3.2 uide, Checking”, page 61

3.1 Compression Pressure, Checking

Special tools and workshop equipment required
♦ Spark Plug Removal Tool -3122B-
♦ Puller - Ignition Coil -T40039-
♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-
♦ Compression Tester Kit -VAG1763-
♦ Compression Tester Kit - Adapter 5A -VAG1381/5A-
Test Conditions
• The engine oil temperature must be at least 30 °C (86 °F).
• The voltage supply is OK.
Procedure
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remover the ignition coils with the power output stage. Re‐
fer to ⇒ C4.1 oils with Power Output Stages”, page 323 .
– Remove the spark plugs using the -3122B-.
– Check the compression using the -VAG1763- and the -
VAG1381/5A-.

Note

Using the tester. Refer to the operating instructions.

– Have a second technician operate the starter.

– Operate the starter until the tester shows no further pressure
increase.
Compression Pressure
New Bar Positive Wear Limit Bar Difference between
Pressure Positive Pressure Cylinders Bar Posi‐
tive Pressure
11.0 through 14.0 7.0 bar (101.52 psi) Max. 3.0 bar (43
bar (160 to 203 psi) psi)
– To complete the procedure, check the Engine Control Mod‐
ule (ECM) Diagnostic Trouble Code (DTC) memory and
erase any DTCs that may have been stored when testing
and making repairs.

Note

If the DTC memory was erased, the readiness code must be

generated again. Refer to “Guided Fault Finding” in the vehicle
diagnostic tester.

60 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3.2 Valve Guide, Checking

Special tools and workshop equipment required
♦ Dial Gauge Holder -VW387-
♦ Dial Gauge 0-10 mm -VAS6079-
Test Sequence
– Insert the new valve into the guide. The valve stem tip must
seal with the guide. Due to the slight difference in stem
dimensions, ensure that only an intake valve is used in the
intake guide and an exhaust valve in the exhaust guide.

– Determine the tilt clearance. Wear limit: 0.8 mm

If the tilt clearance is exceeded:
– Replace the cylinder head.

3. Diagnosis and Testing 61

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Removal and Installation

⇒ H4.1 ead Cover”, page 62
⇒ H4.2 ead”, page 63
⇒ B4.3 elt”, page 69
⇒ S4.4 tem Seals”, page 90
⇒ C4.5 amshaft Seal”, page 95
⇒ A4.6 djuster”, page 97
⇒ C4.7 amshaft Adjustment Valve 1 N205 ”, page 101
⇒ 4.8 , page 102

4.1 Cylinder Head Cover

Special tools and workshop equipment required
♦ Hose Clip Pliers -VAS5024A-
♦ Puller - Ignition Coil -T40039-
Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remove the bolts -arrows-.

– Remover the ignition coils with the power output stage. Re‐
fer to ⇒ C4.1 oils with Power Output Stages”, page 323 .
– Disconnect the lines -2, 3 and 4- from the cylinder head
cover.

– Disconnect the crankcase vent tube and remove the turbo‐

charger heat shield bolts -1-.

62 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the vent hose -2- from the cylinder head cover to
the turbocharger.
– Loosen the cylinder head cover bolt working from the out‐
side towards the inside.
– Remove the cylinder head cover.
Installing
Install in reverse order of removal. Note the following:

Note

Replace the seals and the cylinder head cover gasket if they
are damaged.

– Tighten the cylinder head cover bolts in multiple steps and in

the sequence shown.
– Make sure the upper toothed belt guard is installed correctly.

Tightening Specifications
– Refer to ⇒ -1.1 Cylinder Head and Cover”, page 52 .
Component Nm
Cylinder head cover to cylinder head 10
Toothed belt guard to cylinder block 101
♦ 1 use locking fluid

4.2 Cylinder Head

Special tools and workshop equipment required
♦ Drip Tray -VAG1306- or Drip Tray for VAS6100 -VAS6208-
♦ Torque Wrench 1331 5-50 Nm -VAG1331-

4. Removal and Installation 63

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Torque Wrench 1332 40-200 Nm -VAG1332-

♦ Hose Clip Pliers -VAS5024A-
♦ Polydrive Bit Drive Socket -T10070-
♦ Puller - Ignition Coil -T40039-

Caution

When doing any repair work, especially in the engine com‐

partment, pay attention to the following due to clearance
issues:
♦ Route lines of all types (for example, fuel, hydraul‐
ic, Evaporative Emission (EVAP), coolant, refrigerant,
brake fluid and vacuum) and electrical wiring so that the
original routing is followed.
♦ To prevent damage to the lines, make sure there is suffi‐
cient clearance to all moving or hot components.

Removing
• The engine must be no more than warm to touch.

Note

♦ All cable ties which are opened or cut off when removing,
must be replaced in the same position when installing.
♦ Do an oil change if the oil is dirty. Refer to Maintenance
Procedures, Rep. Gr. 03, Maintenance Procedures.

– First, check to see if a coded radio is installed. If so obtain

the anti-theft code.
– Disconnect the battery ground cable with the ignition turned
off. Refer to ⇒ Electrical Equipment; Rep. Gr. 27; Removal
and Installation.
– Remove the plenum chamber bulkhead. Refer to ⇒ Body
Exterior; Rep. Gr. 50; Description and Operation.
– Remove the intake manifold. Refer to ⇒ M5.4 anifold”, page
282 .
– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
– Remove the left wheel housing liner, front section and the
right front wheel housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66; Removal and Installation.
– Remove the exhaust pipe with catalytic converter. Refer to ⇒
P3.1 ipe with Catalytic Converters”, page 314 .
– Reposition the charge air hose clamp -arrow- and discon‐
nect the hose from charge air cooler.

64 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the bolts -arrows- and remove the charge air pipe.

– Disconnect all electrical wires from turbocharger and set

aside.
– Remove the oil supply pipe and the coolant supply pipe bolts
-arrows- from the turbocharger .

– Remove the oil return pipe bolts -arrows- from the turbo‐
charger.

4. Removal and Installation 65

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the bolts -1 and 2- and the turbocharger support.

– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27; Removal and Installation.
– Remove the battery tray bolts -arrows- and tray.

– Remove the coolant hoses -1 and 2- .

– Disconnect all electrical wires required from the cylinder

head and set aside.
– Remove the wire bracket and set the wiring harness to the
side.

66 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the coolant flange bolts -arrows-.

– Remove the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .

– Remove the -T10060A- from the ribbed belt tensioner.
– Remove the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
– Remove the cylinder head cover. Refer to ⇒ H4.1 ead Cov‐
er”, page 62 .
– Follow the sequence shown for loosening the cylinder head
bolts.

Note

Verify that all hose and wire connections for the engine, the
transmission and the body have been disconnected.

– Remove the cylinder head.

4. Removal and Installation 67

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing

Note

♦ There must be no oil or coolant in the blind holes for the

cylinder head bolts in the cylinder block.
♦ Only remove the new cylinder head gasket from its packag‐
ing immediately before installing.
♦ Handle the new gasket with extreme care. Damaging will
lead to leaks.
♦ Replace the cylinder head bolts.

– Insert clean cloths into the cylinders so that no dirt or abra‐

sive powder can get between the cylinder wall and piston.
– Do not allow dirt or abrasive powder to get into the coolant
either.
– Carefully clean the sealing surfaces on the cylinder head
and cylinder block. Avoid introducing scratches or scoring
(do not use sandpaper with grit below 100).
– Carefully remove any metal particles, emery remains and
the cloths.
– In the event the crankshaft has been rotated in the mean‐
time: Set the piston for cylinder 1 to Top Dead Center (TDC)
and rotate the crankshaft back again slightly.
– Install the new cylinder head gasket. The part number must
be legible.
– Pay attention to the alignment pins -arrows- in the cylinder
block.

– Set the cylinder head in place.

– Insert the cylinder head bolts and tighten them hand tight.
– Tighten the cylinder head bolt in the sequence as follows:

68 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Stage Tighten
1 – Tighten the bolts to 40 Nm using a torque
wrench.
2 – Tighten the bolts an additional 90° (1/4) turn
using a ratchet.
3 – Tighten the bolts an additional 90° (1/4) turn
using a ratchet.
– Install the cylinder head cover. Refer to ⇒ H4.1 ead Cover”,
page 62 .
– Install the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
Further installation is in the reverse order of removal.
Fill with new coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .

4.3 Toothed Belt

⇒ B4.3.1 elt, Golf from MY 2009”, page 69
⇒ B4.3.2 elt, Golf from MY 2004, Golf from MY 2009, Golf
Cabrio from MY 2010 and Scirocco from MY 2009”, page 79

4.3.1 Toothed Belt, Golf from MY 2009

Special tools and workshop equipment required
♦ Engine Support Bridge -10-222A-
♦ Engine Support Bridge - Engine Bracket -10-222A/1-
♦ Engine/Gearbox Support Shackle (2 pc.) -10-222A/12-
♦ Engine Support Bridge - Engine Support 18 -10-222A/18-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Tensioning Strap -T10038-
Removing
– Remove the engine cover and air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .

WARNING

Hot steam may escape when opening the reservoir. Wear

protective eyewear and protective clothing to prevent eye
injury and scalding. Cover the cap with a cloth and carefully
open the cap.

– Open and close the coolant reservoir to reduce the pressure.

4. Removal and Installation 69

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Unclip the wiring harness -1-.

– Disconnect the connector -5-.

– Remove the coolant hose -3-, to do so open the spring
clamp.
– Remove the bolts -2-.
– Set the coolant reservoir -4- aside.

WARNING

♦ The fuel supply line is under pressure. Always wear pro‐

tective eyewear and protective clothing to prevent inju‐
ries and fuel from coming in contact with your skin. Wrap
a cloth around the connection before loosening hose
connections. Remove the hose connection carefully to
release the pressure.
♦ For safety reasons, remove the Fuel Pump Control Mod‐
ule -J538- fuse from the fuse panel before opening the
fuel system. This prevents the fuel pump from being
activated by the driver door contact switch. Fuse assign‐
ment. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations.

– Release the catches and disconnect the fuel line -1- from the
connection.

– Loosen the clamps -arrow- and disconnect the coolant hose.

Collect escaping coolant with a rag.

70 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .

– Remove the bolts -2-.

– Remove the ribbed belt tensioner.

– Remove the bolt -1-.

– Slightly remove the loosened fuel lines.

– Support the -10-222A/12- in the eyes to the engine and en‐
gage in the accessories bracket.
– Place the -10-222A- with the -10-222A/1- and -10-222A/18-
as shown on the longitudinal member.

4. Removal and Installation 71

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Place the -10-222A/1- on the fender ridge -arrow-.

– Engage the -10-222A/10- in the -10-222A/12- -arrow-.
– Secure the -10-222A- with the -T10038- as shown.

– To secure the -10-222A- guide the -T10038- through the

gas-filled strut mount for the hood.
– Remove the bolts -arrows-.

– Remove the toothed belt guard.

– Remove the right wheel housing liner front section. Refer to
⇒ Body Exterior; Rep. Gr. 66; Wheel Housing Liner; Front
Wheel Housing Liner, Removing and Installing.
– Remove the bolts -arrows-.

72 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

The charge air pipe can remain installed.

– Set camshaft gear to marking for “TDC” by turning crank‐

shaft -arrows-. Marking on camshaft gear must align with
arrow on toothed belt guard.

– Remove vibration damper/belt pulley.

Note

♦ The TDC markings must align before removing vibration

damper.
♦ Crankshaft must not be rotated any more until TDC position
is marked with an assisting mark.

– Remove the bolt -3-.

4. Removal and Installation 73

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

The next step is necessary in order to be able to raise the

engine far enough.

– Remove the bolts -2 and 3- for the pendulum support.

– Remove the bolt -4-.

– Remove the bolts -2-.

– Remove the support -1-.
– Remove the bolts -3-.
– Remove the bolts -arrows-.

74 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the complete engine mount.

Caution

Make sure that no components/hoses are damaged, over-

stretched or torn when lifting the engine using -10-222A-.

– Remove the bolts -1 and 2- to do this lift the engine with the
-10-222A-.

Note

The bolt -1- is located in a hole in the wheel housing. Remove

the plugs from the hole.

– Remove the bolts -arrows- from the toothed belt guard lower
section.

– Remove the bolts -arrows- from the toothed belt guard.

4. Removal and Installation 75

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the toothed belt guard downward from the engine.

– Remove the engine mount upward from the engine.
– Mark the TDC position -arrow-.
– Mark direction of rotation of toothed belt.
– Loosen the tensioning roller and remove the toothed belt.
– Turn the crankshaft slightly backward.

Installing
Install in reverse order of removal. Note the following:

Note

♦ The crankshaft may not be at TDC by turning the camshaft

(there is a risk of damaging the vents/piston crowns).
♦ The engine must be no more than warm to touch.

– Position the camshaft and crankshaft onto the onto the TDC
marking.

76 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Place the toothed belt onto the crankshaft sprocket (observe

direction of rotation).
– Install the toothed belt in the following sequence; tensioning
roller, camshaft sprocket, coolant pump and lastly the idler
roller -arrow-.

Note

Make sure the tensioning roller fits correctly inside the cylinder
head.

– Turn the hex socket wrench toward the right in the direction
of -arrow- to tension the toothed belt until the notch is above
the tab (toothed belt is over tensioned).

– Relieve the tension in the toothed belt again.

– Tension the toothed belt until the notch is across from the
tab.
– Tighten nut.

4. Removal and Installation 77

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Rotate crankshaft 2 additional turns in direction of engine

rotation until engine stands again at TDC. For this it is
necessary that the last 45° (1/8 rotation) is turned without
interruption.
– Check the toothed belt tension. Target value: tab and notch
are positioned across from each other.
– Check the valve timing. The markings must correspond
-arrows-.
If the markings do not match:
– Repeat the adjustment for the valve timing.
If the markings match:
– Bring the engine mount into the installed position.

Align the Engine Mount

♦ There must be a distance -a- of at least 10 mm present
between engine support and right longitudinal member.

♦ Casting edge on engine support -2- must stand parallel to

the support arm -1-.
Tightening Specifications
♦ Refer to ⇒ C2.1 omponent Overviews”, page 19
♦ Refer to ⇒ a1.1 nd Transmission Mount and Pendulum Sup‐
port Tightening Specifications”, page 2
Component Tightening Specification
Washer fluid reservoir filler tube bolt 5 Nm
Coolant expansion tank bolts 5 Nm

78 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4.3.2 Toothed Belt, Golf from MY 2004, Golf

from MY 2009, Golf Cabrio from MY
2010 and Scirocco from MY 2009
Special tools and workshop equipment required
♦ Engine Support Bracket -T10339-
♦ Insert Pad For Front Fender -T40045- (Golf from MY 2004)
♦ Engine Support Bridge - Engine Support 18 -10-222A/18-
♦ Engine Support Bridge - Engine Bracket -10-222A/1- (Golf
from MY 2004)
♦ Engine Support Bridge -10-222A-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Engine Support Bridge - Engine Support Feet -10-222A/8-
(Golf from MY 2009, Golf Cabriolet from MY 2012, and Scir‐
occo)
Removing
– Remove the engine cover and air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .

WARNING

♦ The fuel supply line is under pressure. Always wear pro‐

tective eyewear and protective clothing to prevent inju‐
ries and fuel from coming in contact with your skin. Wrap
a cloth around the connection before loosening hose
connections. Remove the hose connection carefully to
release the pressure.
♦ For safety reasons, remove the Fuel Pump Control Mod‐
ule -J538- fuse from the fuse panel before opening the
fuel system. This prevents the fuel pump from being
activated by the driver door contact switch. Fuse assign‐
ment. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations.

– Disconnect the bleed line -1- and the fuel supply line -2-.

– Disconnect the bleed line -2- and remove the EVAP canister
-A- with hoses upward out of the mount.

4. Removal and Installation 79

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

WARNING

Hot steam may escape when opening the reservoir. Wear

protective eyewear and protective clothing to prevent eye
injury and scalding. Cover the cap with a cloth and carefully
open the cap.

– Open and close the coolant reservoir to reduce the pressure.

– Loosen the clamps -arrow- and disconnect the coolant hose.
Collect escaping coolant with a rag.

– Remove the -1- connector, loosen the coolant reservoir and

set it aside.

– Remove the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .

– Remove the ribbed belt tensioning damper -A- and secure
the -T10339- on both of the upper threaded holes.

80 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Golf from MY 2004

– Install the -10-222A- with -10-222A/1- and -10-222A/18- onto
the fly wheel edges.

– Insert the -T40045- as shown under the right and left fly
wheel edge and support the engine in the installed position.

Caution

Ensure that the fender edges are not damaged.

Golf from MY 2009, Golf Cabriolet from MY 2012

– Support both of the -10-222A/8- in the lower area with elec‐
trical tape -arrow- so that the fly wheel is not damaged.

4. Removal and Installation 81

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Install the -10-222A- with -10-222A/8- and -10-222A/18- onto

the longitudinal member.

Note

Install the -10-222A/8- next to the bolt -arrow 2- just before

raising it -arrow 1-.

Continuation for All Vehicles

– Remove the bolts -arrows- and remove the toothed belt cov‐
er.

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50; Body Front, Noise Insulation.

82 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the wheel housing liner- front section and the front
right front wheel housing liner. Refer to ⇒ Rep. Gr. 66.
– Remove the bolts -arrows- and remove the charge air pipe
and hoses.

– Set camshaft gear to marking for “TDC” by turning crank‐

shaft. Marking on camshaft gear must align with arrow on
toothed belt guard.

– Remove vibration damper/belt pulley.

Note

♦ The TDC markings must align before removing vibration

damper.
♦ Crankshaft must not be rotated any more until TDC position
is marked with an assisting mark.

– Remove the underlying bolts from the lower section of the

toothed belt guard -arrows-.

4. Removal and Installation 83

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Mark the TDC position -arrow-.

– Remove the bolt -3-.

Note

The next step is necessary in order to be able to raise the

engine far enough.

– Remove the bolts -2 and 3- for the pendulum support.

84 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Unscrew mounting bolts of subframe mount/engine bracket

-arrows- and remove subframe mount completely.

Caution

Make sure that no components/hoses are damaged, over-

stretched or torn when lifting the engine using -10-222A-.

– Loosen the upper bolts -1 and 2- for the engine mount and
remove them, while lifting the engine with the -10-222A-.

– Remove both of the upper bolts from the toothed belt guard
-arrows- and remove the toothed belt guard downward from
the engine.
– Remove the engine mount upward from the engine.
– Mark direction of rotation of toothed belt.
– Loosen the tensioning roller and remove the toothed belt.
– Turn the crankshaft slightly backward.

4. Removal and Installation 85

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
Install in reverse order of removal. Note the following:

Note

♦ The crankshaft may not be at TDC by turning the camshaft

(there is a risk of damaging the vents/piston crowns).
♦ The engine must be no more than warm to touch.

Perform the following:

– Position the camshaft and crankshaft onto the onto the TDC
marking.

– Place the toothed belt onto the crankshaft sprocket (observe

direction of rotation).
– Install the toothed belt in the following sequence; tensioning
roller, camshaft sprocket, coolant pump and lastly the idler
roller -arrow-.

86 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

Be sure tensioning roller is properly seated in cylinder head.

– Turn the hex socket wrench toward the right in the direction
of the -arrow- to tension the toothed belt until the notch is
above the tab (toothed belt is over tensioned).

– relieve the tension in the toothed belt again.

– Tension the toothed belt until the notch is across from the
tab.
– Tight the securing nut to 25 Nm.
– Rotate crankshaft 2 additional turns in direction of engine
rotation until engine stands again at TDC. For this it is
necessary that the last 45° (1/8 rotation) is turned without
interruption.
– Check the toothed belt tension. Target value: tab and notch
are positioned across from each other.
– Check the valve timing. The markings must correspond
-arrows-.

4. Removal and Installation 87

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

If the markings do not match:

– Repeat the adjustment for the valve timing.
If the markings match:
– Bring the engine mount into the installed position.
– Install the toothed belt guard from below -arrows-.

– Install vibration damper/belt pulley with new bolts. Tightening

specification: 20 Nm + 90° additional turn.
– Check the valve timing. The markings must correspond
-arrows-.

– Tighten both of the upper bolts for the toothed belt guard
-arrows-.

88 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Attach the engine mount to the cylinder block and tighten the
bolts by hand.

Note

Note different length of bolts. Bolt -3- is approximately 25mm

shorter than bolts -1 and 2-.

– Tighten the lower bolt -3-; to do this lower the engine with
the -10-222A-.
– Tighten all bolts to 45 Nm.
– Install the engine subframe mount. Tightening specification.
Refer to ⇒ a1.1 nd Transmission Mount and Pendulum Sup‐
port Tightening Specifications”, page 2 .
– Bring the contact surfaces together using the -10-222A- to
tighten the bolts for the engine subframe mount and the
engine mount -arrows-.

– Align the engine mount as follows:

♦ There must be a distance -a- of at least 10 mm present
between engine support and right longitudinal member.

4. Removal and Installation 89

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Casting edge on engine support -2- must stand parallel to

the support arm -1-.
– Tighten the bolts for the subframe, engine and engine brack‐
et. Tightening specification. Refer to ⇒ a1.1 nd Transmission
Mount and Pendulum Support Tightening Specifications”,
page 2 .
– Remove the -10-222A-.
– Remove the -T10339- and install the ribbed belt tensioning
damper.
– Install the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .
– Reconnect the fuel type- and bleed line making sure that the
decoupling elements are stable and secure.
– Install the coolant reservoir.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Body Front, Noise Insulation.
– Place the fuse for the Fuel Pump Control Module -J538-
back into the fuse panel.
– Install the engine cover/air filter.

4.4 Valve Stem Seals

(With the cylinder head installed)
Special tools and workshop equipment required
♦ Spark Plug removal Tool -3122B-
♦ Puller - Valve Seal -3364-
♦ Seal Installer - Valve Stem -3365-
♦ Valve Cotter Tool Kit - Adapter -T40012-
♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-
♦ Valve Cotter Tool Kit -VAS5161-
♦ Valve Cotter Tool Kit - Guide Plate 19B -VAS5161/19B-
Removing
– Remove the camshafts. Refer to ⇒ 4.8 , page 102 .
– Remove the roller rocker arms and lay them on a clean sur‐
face while making sure not to switch the roller rocker arms.
– Remove the spark plugs using -3122B-.
– Install the -VAS5161/19B- onto the cylinder head as shown
using the -VAS5161/12-.

90 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Move the piston for the respective cylinder to the Bottom

Dead Center (BDC) position.
– Install the -T40012- into the spark plug threads and apply a
constant pressure of at least 6 bar (87 psi) positive pressure.
– Loosen any stuck valve retainers using the -VAS5161/3- and
a plastic mallet.

– Install the -VAS5161/6- with the -VAS5161/5- in the -

VAS5161/19B-.

– Insert the -VAS5161/8- into the -VAS5161/19B-.

– Engage the -VAS5161/2- on the -VAS5161/6-.

4. Removal and Installation 91

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

The -VAS5161/2- must engage on the exhaust side as illustra‐

ted.

– Press the -VAS5161/8- down while rotating its knurled

thumb screw to the right until the points engage in the valve
retainers.
– Move the knurled thumb screw back and forth slightly. This
presses the valve retainers apart and captures them in the
assembly cartridge.
– Release the -VAS5161/2-.
– Remove the -VAS5161/8-.
– Remove the valve stem seals using the -3364-.

– If the -3364- cannot be used because there is not enough

space, drive out the roll pin -arrow- using a drift and remove
the impact attachment.

92 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Position the lower part of the -3364- on the valve stem seal.
– Insert a drift -1- in the hole in the lower section of the remov‐
al tool.
– Using the drift as a lever, remove the valve stem seal in
direction of -arrow-.

Installing
– Place the plastic sleeve -A- on the valve stem to prevent
damage to new valve stem seal -B-.

– Oil the sealing lip of valve stem seal -B-, insert it onto the
-3365- and carefully slide it onto the valve guide.
– Remove the plastic sleeve -A-.
– Insert the valve spring and spring plate.
– Install the -VAS5161- components as illustrated.
Intake Side

4. Removal and Installation 93

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Exhaust Side

Note

If the valve retainers were removed from the assembly car‐

tridge, they must be inserted into -VAS5161/18- next.

Press the -VAS5161/8- onto the valve insertion device from

above and take up the valve retainers.

– Press the -VAS5161/8- down with the -VAS5161/2- and ro‐

tate the cartridge knurled thumb screw back and forth while
pulling up.
– Release the -VAS5161/2- with the knurled thumb screw
pulled.
– Remove the -VAS5161- components.
Further installation is in the reverse order of removal.
– Install the camshafts. Refer to ⇒ 4.8 , page 102 .

94 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4.5 Exhaust Camshaft Seal

Special tools and workshop equipment required
♦ Puller - Camshaft Seal -2085-
♦ Puller - Camshaft Seal Bolt -2085/2-
♦ Wrench - Pin Type -3036-
♦ Seal Installer - Camshaft -T10071-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
♦ Puller - Camshaft Wheel -T40001- with Puller - Camshaft
Wheel Claw 7 -T40001/6- and -T40001/7-
♦ Seal Installer - Intermediate Shaft -T10353-
Removing
– Remove the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
– Loosen the camshaft sprocket bolt approximately 10 mm
(use the -3036-).

– Remove the camshaft sprocket using the -T40001-, the -

T40001/6- and -T40001/7-.

The -T40001- supports itself on the bolt -arrow-.

– Remove the bolt and the camshaft sprocket.
– To guide the seal puller, thread the -2085/2- into the cam‐
shaft by hand until seated.

4. Removal and Installation 95

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the inner portion of the -2085- 2 rotations (approxi‐

mately 3 mm) from the outer portion and secure it with the
knurled thumb screw.
– Grease the threaded head of the -2085-, position and force‐
fully screw it as far as possible into the seal.
– Loosen the knurled thumb screw and turn the inner part
against the camshaft until the seal is removed.

Installing
– Remove any oil residue on the camshaft using a clean cloth.
– Tape over the groove on the taper of the camshaft with
commercially available adhesive tape (for example, Scotch®
tape).
– Carefully slide the seal onto the camshaft.
– Use the -T10071/4- to press the seal with the -T10071-, the
-T10353- and the washer -arrow- all the way until they are
seated.

96 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

The -T10353- is needed to compensate for the length of the

-T10071/4-. Washers can also be used.

– Insert the woodruff key into the camshaft.

– Insert the camshaft sprocket. To tighten the bolt, counter
hold the camshaft sprocket using the -3036-.
Tightening specification. Refer to ⇒ -1.2 Valvetrain”, page 55 .

Note

♦ When turning the camshaft, the pistons may not be at Top

Dead Center (TDC) for any cylinder. Valves/pistons may be
damaged.
♦ Be sure the woodruff key is properly seated.

– Install the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .

– Install the ribbed belt. Refer to ⇒ B5.1 elt”, page 37 .
Further installation is in the reverse order of removal.
– Fill with new coolant. Refer to ⇒ D1.1 raining and Filling”,
page 140 .

4.6 Camshaft Adjuster

Special tools and workshop equipment required
♦ Camshaft Adjuster Socket -T40080-
♦ Camshaft Clamp -T10252-
♦ Toothed Belt Tensioner -T10020-
♦ Locking Pin -T10115-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
Removing
– Remove the high pressure pump. Refer to ⇒ P5.8 ressure
Pump”, page 291 .
– Remove the cylinder head cover. Refer to ⇒ H4.1 ead Cov‐
er”, page 62 .
– Remove the refrigerant hoses -1 and 2-, remove the bolt -3-
and loosen the coolant pipe from the heat shield.

4. Removal and Installation 97

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the wire bracket bolt -arrow-.

– Remove the vacuum pump.

– Remove the housing bolts -arrows- from the camshaft ad‐
juster.

– Bring the mark on the camshaft sprocket to alignment with

the mark on the toothed belt guard. The notches in the cam‐
shafts -arrows- now face toward each other vertically.

98 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Install the -T10252- as shown and secure using the bolts

-arrows-.

– Loosen the bolt from the camshaft adjuster using the -

T40080-.
– Press the chain tensioner together -arrow A- and secure it
using the -T10115- -arrow B-.

– Remove the bolt from the camshaft adjuster and remove it

with the chain.
Installing
• Camshafts are secured using the -T10252-.

– Lay the chain onto the camshaft adjuster.

– Hold the camshaft adjuster in front of the exhaust camshaft
so that the notch -A- and the pin -B- are positioned across
from one another.

4. Removal and Installation 99

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– With the chain in this position, first route it on the intake

camshaft sprocket at the top -arrow-.

– Rotate the intake camshaft in the direction of -arrow A- slow‐

ly using the -T10020- until the camshaft adjuster fits on the
camshaft.

Note

If the pin does not fit into the notch: Remove it and lay the new
chain on top.

– Use the -T40080- to tighten the new bolt. Tightening specifi‐

cation: 20 Nm + an additional 45° (1/8) turn.
– Remove the -T10115- -arrow B-.

100 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Further installation is in the reverse order of removal.

– Install the vacuum pump. Refer to ⇒ -1.1 Cylinder Head and
Cover”, page 52 .
– Install the cylinder head cover. Refer to ⇒ H4.1 ead Cover”,
page 62 .
– Install the high pressure pump. Refer to ⇒ P5.8 ressure
Pump”, page 291 .

4.7 Camshaft Adjustment Valve 1 -N205-

Special tools and workshop equipment required
♦ Torque Wrench 1783 - 1/4" Drive Ratchet -VAS6234-
♦ TORX® Bit Set -VAG1766-
♦ Hose Clip Pliers -VAS5024A-
♦ Torque Wrench 1783 - 2-10 Nm -VAG1783-
Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Disconnect the connector -1-.

– Loosen the wiring harness bracket -2-.

– Remove the bolt -3-.

Note

Do not pull out the camshaft adjustment valve 1 at the connec‐

tor.

– Remove the bolts -arrows- and the camshaft adjustment

valve 1 from the housing.

4. Removal and Installation 101

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing

Note

♦ The camshaft adjustment valve 1 as well as the housing

must be free of dirt and contaminants.
♦ Remove the new camshaft adjustment valve 1 from packag‐
ing only prior to installation.

Caution

♦ The camshaft adjustment valve 1 must not be subjected

to knocks and impacts.

– Coal the seal with engine oil.

– Install the camshaft adjustment valve 1 carefully into the
housing and push it all the way in by hand perpendicular to
the valve axis.
– Tighten the bolts to 4 Nm.
Further installation is in reverse order of removal
– Install the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .

4.8 Camshafts
Special tools and workshop equipment required
♦ Puller - Camshaft Wheel -T40001-
♦ Wrench - Pin Type -3036-
♦ Seal Installer - Propshaft -3334-

102 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Removing

Note

♦ The sealing surfaces on the bottom of the guide frame and

on the top of the cylinder head must not be worked.
♦ Camshaft bearings are integrated in the cylinder head and in
the guide frame. Before removing the guide frame, tension
on the toothed belt must be released.
♦ If the guide frame was loosened, the camshaft seal and the
sealing cap must be replaced.

– Remove the camshaft adjuster. Refer to ⇒ A4.6 djuster”,

page 97 .
– Remove the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
– Loosen the camshaft sprocket bolt approximately 10 mm
(use the -3036-).

– Remove the camshaft sprocket using the -T40001- and the

-T40001/6- and -T40001/7-.

The -T40001- supports itself on the bolt -arrow-.

– Remove the bolt and camshaft sprocket.
– Remove the rear toothed belt guard from the cylinder head.
– Loosen the bolts for the guide frame evenly working from the
outside towards the inside and remove the guide frame.
– Carefully remove the camshafts upward and place them on
a clean surface.
– Remove any old sealant from the groove in the guide frame
as well as from the sealing surfaces.

4. Removal and Installation 103

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Make sure that no dirt or sealant residue can get into the
cylinder head.

Installing

Note

♦ The sealing surfaces must be completely free of oil and

grease.
♦ The pistons must not be positioned at Top Dead Center
(TDC).
♦ Make sure that all roller rocker arms make contact correctly
on the valve stem tips.

– Lubricate the running surfaces of both camshafts.

– Place the camshaft carefully into the camshaft bearings in
the cylinder head. The camshaft lobes -A- for cylinder 4
must face each other.

– Apply a light sealant bead of Sealant -D154103A1- evenly in

the groove in the guide frame as shown in the illustration.

104 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

♦ The sealant must not be applied too thick. Wipe off any
excess sealant with a lint-free cloth, if necessary.
♦ Placing the guide frame in place and tightening the bolts it
should occur without interruption, since the sealant begins
to harden immediately when the sealing surfaces come into
contact.
♦ Note the expiration date of the sealant.

– Place the guide frame onto the cylinder head.

– Gently tighten the new bolts from working from the inside
toward the outside in several stages.
– Tighten the bolts to 8 Nm + an additional 90° turn in the
sequence shown.

– Drive the sealing cap in approximately 1 to 2 mm using the

Seal Installer - Propshaft -3334-.
– Install the camshaft seal. Refer to ⇒ C4.5 amshaft Seal”,
page 95 .
– Install the rear toothed belt guard.
– Insert the woodruff key into the camshaft.
– Insert the camshaft sprocket. To tighten the bolt, counter
hold the camshaft sprocket using the -3036-.
Tightening specification. Refer to ⇒ -1.2 Valvetrain”, page 55 .

4. Removal and Installation 105

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

♦ When turning the camshaft, the pistons may not be at TDC

for any cylinder. Valves/pistons may be damaged.
♦ Be sure the woodruff key is properly seated.

– Install the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .

– Install the camshaft adjuster. Refer to ⇒ A4.6 djuster”, page
97 .
– Install the cylinder head cover. Refer to ⇒ H4.1 ead Cover”,
page 62 .
Further installation is in the reverse order of removal.

106 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Special Tools

Special tools and workshop

equipment required

♦ Engine Support Bracket -T10339-

♦ Insert Pad For Front Fender -T40045- (Golf from MY 2004)
♦ Engine Support Bridge - Engine Support 18 -10-222A/18-
♦ Engine Support Bridge - Engine Bracket -10-222A/1- (Golf
from MY 2004)
♦ Engine Support Bridge -10-222A-
♦ Torque Wrench 1332 40-200Nm -VAG1332-

5. Special Tools 107

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Engine Support Bridge -10-222A-

♦ Engine Support Bridge - Engine Bracket -10-222A/1-
♦ Engine/Gearbox Support Shackle (2 pc.) -10-222A/12-
♦ Engine Support Bridge - Engine Support 18 -10-222A/18-
♦ Torque Wrench 1332 40-200Nm -VAG1332-
♦ Tensioning Strap -T10038-

108 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Drip Tray -VAG1306-

♦ Torque Wrench 5-50 Nm -VAG1331-
♦ Torque Wrench 1332 40-200 NM -VAG1332-
♦ Hose Clip Pliers -VAS5024A-
♦ Polydrive Bit Drive Socket -T10070-
♦ Puller - Ignition Coil -T40039-

5. Special Tools 109

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Camshaft Adjuster Socket -T40080-

♦ Camshaft Clamp -T10252-
♦ Toothed Belt Tensioner -T10020-
♦ Locking Pin -T10115-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-

♦ Seal Installer - Intermediate Shaft -T10353-

110 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Puller - Camshaft Wheel -T40001-

♦ Hose Clip Pliers -VAS5024A-

♦ Dial Gauge 0-10 mm -VAS6079-

♦ Dial Gauge Holder -VW387-

5. Special Tools 111

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Engine Support Bridge - Engine Support Feet -10-222A/8-

♦ Wrench - Pin Type -3036-

112 Rep. Gr.15 - Cylinder Head, Valvetrain

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

17 – Lubrication
1 General Information
⇒ O1.1 il”, page 113
⇒ F1.2 ilter Housing, Draining”, page 113

1.1 Engine Oil

Capacity
For the correct engine oil capacity. Refer to the ⇒ Fluid Capaci‐
ty Tables; Rep. Gr. 03.
Changing the oil. Refer to the ⇒ Maintenance Intervals; Rep.
Gr. 03.
Marks on the Oil Dipstick

1 - MAX. mark
2 - MIN. mark
a - Oil level is near the MAX mark: do not add oil!
b - Oil level in the center area: Engine old can be added.
c - Oil level is near the MIN. mark: fill with approximately 0.5
liter of oil.

1.2 Oil Filter Housing, Draining

Special tools and workshop equipment required
♦ Oil Drain Adapter -T40057-

Note

When installing the -T40057-, a valve in the oil filter housing is

opened. If the -T40057- is removed, the valve is closed again.

– Remove the cap -arrow- from the oil filter housing.

1. General Information 113

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Keep the hose for the -T40057- in a drip tray and install the
-T40057- onto the oil filter housing.

– Allow the engine oil to drain.

114 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Description and Operation

⇒ S2.1 ystem Component Overview”, page 115

2.1 Lubrication System Component Overview

Note

♦ If large quantities of metal particles or abraded material are detected during engine repairs, it may mean
the crankshaft or rod bearings are damaged. To prevent further damage, perform the following steps after
the repair:
♦ Clean the oil passages carefully.
♦ Replace the oil spray jets.
♦ Replace the engine oil cooler.
♦ Replace the oil filter element.
♦ The oil level must not exceed the MAX mark - danger of damaging the catalytic converter.

I - Refer to ⇒ -2.1.1 Oil Pan”,

page 115
II - Refer to ⇒ -2.1.2 Oil
Pump and Balance Shaft
Drive”, page 117
III - Refer to ⇒ -2.1.3 Oil Filter
Adapter”, page 119

2.1.1 Overview - Oil Pan

2. Description and Operation 115

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 15 Nm
2 - Oil Dipstick
❑ Marks. Refer to ⇒ Fig.
““Marks on the Oil Dip‐
stick”“, page 113 .
❑ The oil level must not
be above the MAX.
mark!
3 - Guide Tube
4 - Guide Tube
5 - Intermediate Plate
6 - Oil Pump with Balance
Shaft Drive
❑ With a pressure relief
valve: 12 bar (174 psi)
❑ Removing and instal‐
ling. Refer to ⇒
P4.2 ump with Balance
Shaft Drive”, page 128 .
7 - Bolt
❑ 15 Nm + an additional
90° (1/4) turn.
❑ Always replace.
❑ Note the differences in
the bolt lengths. Refer
to ⇒ Fig. ““Bolt Allo‐
cation for the Balance
Shaft Drive”“, page
132 .
8 - Bolt
❑ 15 Nm
❑ Tightening sequence.
Refer to ⇒ P4.1 an”, page 125 .
9 - Bolt
❑ 8 Nm
❑ For the charge air pipe.
10 - Oil Pan
❑ Clean the sealing surface before installing.
❑ Removing and installing. Refer to ⇒ P4.1 an”, page 125 .
11 - Bolt
❑ 15 Nm
12 - Oil Drain Plug
❑ 30 Nm
❑ Always replace.
❑ With a permanent seal.
13 - Chain Sprocket
14 - Bolt
❑ 10 Nm
15 - Shield

116 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

16 - Oil Level Thermal Sensor -G266-

17 - Seal
❑ Always replace.
❑ Lubricate before installing.
18 - Bolt
❑ 20 Nm + an additional 90° (1/4) turn
❑ Always replace.
19 - Protective Plate
20 - Chain
21 - Sealing Flange
❑ Must be located on the alignment sleeves.
❑ Removing and installing. Refer to ⇒ F5.3 lange, Belt Pulley Side”, page 41 .
❑ To remove and install, remove the oil pan. Refer to ⇒ P4.1 an”, page 125 .
❑ Seal replacing. Refer to ⇒ S5.2 eal, Belt Pulley Side”, page 38 .

2.1.2 Overview - Oil Pump and Balance Shaft Drive

2. Description and Operation 117

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Protective Plate
2 - Chain
❑ Mark the direction of
travel (installed posi‐
tion) using a colored
mark before removing.
3 - Alignment Sleeves
4 - Intermediate Plate
5 - Oil Pump with Balance
Shaft Drive
❑ Before installing, check
to be sure both
alignment sleeves are
present for centering.
❑ Removing and instal‐
ling. Refer to ⇒
P4.2 ump with Balance
Shaft Drive”, page 128 .
6 - Bolt
❑ 9 Nm
7 - Windage Tray
❑ Prevents engine oil
from foaming up.
8 - Bolt
❑ 40 Nm
9 - Bolt
❑ 8 Nm
10 - Oil Intake Pipe
❑ Clean the screen if it is
dirty.
11 - O-Ring
❑ Always replace.
12 - Bolt
❑ 15 Nm + an additional 90° (1/4) turn.
❑ Always replace.
❑ Note the differences in the bolt lengths. Refer to ⇒ Fig. ““Bolt Allocation for the Balance Shaft Drive”“,
page 132 .
13 - Outer Rotor
❑ Check contact surfaces for groove build up.
❑ Mark must be visible.
14 - Inner Rotor
❑ Check the contact surfaces for groove build up.
15 - Oil Pump Cover
16 - Chain Sprocket
17 - Bolt
❑ 20 Nm + an additional 90° (1/4) turn.
❑ Always replace.
18 - Chain Tensioner with Tensioning Rail
❑ Preload to install. Refer to ⇒ T4.2.1 ensioner, Pre-tensioning”, page 133 .

118 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

19 - Bolt
❑ 15 Nm

2.1.3 Overview - Oil Filter Adapter

2. Description and Operation 119

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Vent Tube
❑ For crankcase ventila‐
tion.
2 - Oil Pressure Switch -F1-
❑ 21 Nm
❑ 1.4 bar, (20.30 psi)
black
❑ Checking the 1 pin
oil pressure switch.
Refer to ⇒ P3.1 re‐
ssure and Oil Pressure
Switch, Checking, 1 Pin
Switch”, page 122 .
❑ Checking the 2 pin
oil pressure switch.
Refer to ⇒ P3.2 re‐
ssure and Oil Pressure
Switch, Checking, 2 Pin
Switch”, page 123 .
❑ Removing and instal‐
ling. Refer to ⇒ O4.4 il
Pressure Switch F1 ”,
page 134 .
❑ With a ground wire for
the oil pressure switch
(only for the 1 pin oil
pressure switch).
3 - Bolt
❑ 15 Nm
❑ For the ground wire for
the 1 pin oil pressure
switch.
4 - Bracket
5 - Bolt
❑ 15 Nm
6 - Engine Oil Cooler
❑ See the note. Refer to ⇒ S2.1 ystem Component Overview”, page 115 .
❑ Make sure there is enough space to the surrounding components.
❑ Coolant hose connection diagram. Refer to ⇒ H2.1 ose Connection Diagram”, page 145 .
7 - Gasket
❑ Always replace.
8 - Oil Filter Housing
❑ 25 Nm
❑ Remove and install using the Wrench - Oil Filter -3417-.
❑ Draining. Refer to ⇒ F1.2 ilter Housing, Draining”, page 113 .
9 - Cap
10 - Seal
❑ Always replace.
❑ Install when lubricated.
❑ Service flag upward.
11 - Oil Filter Element
❑ Drain the oil filter housing before removing. Refer to ⇒ F1.2 ilter Housing, Draining”, page 113 .

120 Rep. Gr.17 - Lubrication

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Replacing. Refer to the Maintenance Procedures, Rep. Gr. 03, Maintenance Procedures.
12 - Bolt
❑ 15 Nm + an additional 90° (1/4) turn.
❑ Always replace.
13 - Oil Baffle
❑ Installed position. Refer to ⇒ Fig. ““Oil Baffle Installed Position”“, page 121 .
14 - Gasket
❑ Always replace.
15 - Oil Filter Adapter
❑ With the pressure relief valve, approximately 4 bar (58 psi).
❑ Removing and installing. Refer to ⇒ F4.3 ilter Adapter”, page 133 .

Oil Baffle Installed Position

2. Description and Operation 121

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Diagnosis and Testing

⇒ P3.1 ressure and Oil Pressure Switch, Checking, 1 Pin
Switch”, page 122
⇒ P3.2 ressure and Oil Pressure Switch, Checking, 2 Pin
Switch”, page 123

3.1 Oil Pressure and Oil Pressure Switch,

Checking, 1 Pin Switch
Special tools and workshop equipment required
♦ Oil Pressure Gauge Kit -VAG1342-
♦ Voltage Tester -VAG1527B-
♦ Connector Test Set -VAG1594C-

Note

1 and 2 pin oil pressure switches are installed. Check which oil
pressure switch is installed. Check the oil pressure and oil pres‐
sure switch (2 pin oil pressure switch). Refer to ⇒ P3.2 ressure
and Oil Pressure Switch, Checking, 2 Pin Switch”, page 123 .

• The engine oil level is OK

• The engine oil temperature is at least 80 °C (176 °F) (cool‐
ant fan must start up once).

Note

Function test and servicing the optical and acoustic oil pressure
indicator: “Function and Component Selection” in the vehicle
diagnostic tester.

– Remove the Oil Pressure Switch -F1- and install it in the oil
pressure gauge.

– Thread the oil pressure gauge into the oil filter adapter in
place of the oil pressure switch.
– Connect the brown wire on the gauge to ground (-).
– Connect the -VAG1527B- with adapter cables from the
-VAG1594C- to battery positive (+) and the oil pressure
switch. The Light Emitting Diode (LED) must not light up.
– If the LED lights up, replace the oil pressure switch .
If the LED does not light up:

122 Rep. Gr.17 - Lubrication

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Start the engine and increase the engine speed. The LED
must come on at 1.2 to 1.6 bar (17.4 to 23.2 psi) pressure. If
not, replace the oil pressure switch.
– Increase the engine speed further. At 2000 RPM/min and an
oil temperature of 80 °C (176 °F), the oil pressure must be
between 2.7 and 4.5 bar (39.16 to 65.26 psi).
At higher engine speeds the oil pressure must not exceed 7.0
bar (101.52 psi).
If the specification is not obtained:
– Check the oil intake pipe strainer for contamination.

Note

Also, mechanical damage, for example, bearing damage can

also be the cause of too low oil pressure.

If no malfunction can be found:

– Replace the oil pump. Refer to ⇒ P4.2 ump with Balance
Shaft Drive”, page 128 .
If the specification is exceeded:
– Check the oil passages.
– If necessary, replace oil filter adapter with pressure relief
valve.

3.2 Oil Pressure and Oil Pressure Switch,

Checking, 2 Pin Switch
Special tools and workshop equipment required
♦ Oil Pressure Gauge Kit -VAG1342-
♦ Vehicle Diagnostic Tester - Test Adapter - 2 Pin -VAS5256-
♦ Multi-Meter -VAG1526D-

Note

1 and 2 pin oil pressure switches are installed. Check which oil
pressure switch is installed. Check the oil pressure and oil pres‐
sure switch (1 pin oil pressure switch). Refer to ⇒ P3.1 ressure
and Oil Pressure Switch, Checking, 1 Pin Switch”, page 122 .

• The engine oil level is OK

• The engine oil temperature is at least 80 °C (176 °F) (cool‐
ant fan must start up once).

Note

Function test and servicing the optical and acoustic oil pressure
indicator: Refer to “Function and Component Selection” in the
Vehicle Diagnostic Tester.

– Remove the Oil Pressure Switch -F1- and install it in the oil
pressure gauge.

3. Diagnosis and Testing 123

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Thread the oil pressure gauge into the oil filter adapter in
place of the oil pressure switch.
– Attach the -VAS5256- to the oil pressure switch.
– Connect the -VAG1526 D- to the -VAS5256- and set it for
the continuity test.
• The oil pressure switch must be open at less than 1.2 bar
(17.4).
– Start the engine and increase the engine speed: The oil
pressure switch must close at 1.2 to 1.6 bar (17.4 to 23.2
psi). Replace the oil pressure switch if it does not.
– Increase the engine speed further. At 2000 RPM/min and an
oil temperature of 80 °C (176 °F), the oil pressure must be
between 2.7 and 4.5 bar (39.16 to 65.26 psi).
At higher engine speeds the oil pressure must not exceed 7.0
bar (101.52 psi).
If the specification is not obtained:
– Check the oil intake pipe strainer for contamination.

Note

Also, mechanical damage, for example, bearing damage can

also be the cause of too low oil pressure.

If no malfunction can be found:

– Replace the oil pump with balance shaft drive. Refer to ⇒
P4.2 ump with Balance Shaft Drive”, page 128 .
If the specification is exceeded:
– Check the oil passages.
– If necessary, replace the oil filter adapter with pressure relief
valve.

124 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Removal and Installation

⇒ P4.1 an”, page 125
⇒ P4.2 ump with Balance Shaft Drive”, page 128
⇒ F4.3 ilter Adapter”, page 133
⇒ O4.4 il Pressure Switch F1 ”, page 134

4.1 Oil Pan

Special tools and workshop equipment required
♦ T Bar and Socket 10 mm -3185-
♦ Hex Ball Socket -T10058-
♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-
♦ Flat Scraper
♦ Silicone Sealant -D 176 404 A2-
Removing
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Description and Operation.
– Drain the engine oil.

Note

Observe disposal regulations!

– Remove the charge air pipe bolts -arrows-.

– Remove the bolts -1 and 2-.

– Remove the oil return line bolts -arrows-.

4. Removal and Installation 125

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the connector -1- for the Oil Level Thermal Sen‐
sor -G266-.
– Remove the transmission to oil pan bolts -arrows-.

– Loosen the oil pan bolts on the flywheel side using the
-3185- and remove them using the -T10058-.
– Remove the remaining bolts and remove the oil pan. If nec‐
essary loosen it by applying light strikes with a rubber mallet.
– Remove any sealant residue on the cylinder block using a
flat blade scraper.
– Use a rotating plastic brush to remove any remaining sealant
on the oil pan.

126 Rep. Gr.17 - Lubrication

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing

Note

♦ Note the expiration date of the sealant.

♦ The oil pan must be installed and tightened immediately
after application of the sealant.

– Cut the sealant tube nozzle at the front mark (nozzle diame‐
ter: approximately 0.12 in).

– Apply silicone sealant to the clean oil pan sealing surfaces

as shown. The sealant bead must be:
♦ 2 to 0.3 mm thick
♦ Run around inside of the bolt holes -arrows-

Note

♦ The sealant bead must not be thicker. The extra sealant will
get into the oil pan and can clog the intake pipe strainer for
the oil pump.
♦ With the transmission removed, the oil pan must seat flush
with the cylinder block.
♦ With the transmission installed, the oil pan must make con‐
tact on the transmission.
♦ After installing the oil pan, allow the sealant to dry for ap‐
proximately 30 minutes. Only after then may the engine oil
be added.

– Immediately install the oil pan and the bolts as follows:

1 - Tighten all the oil pan to cylinder block bolts lightly in a
diagonal sequence.
2 - Tighten the oil pan to transmission lightly.
3 - Tighten all the oil pan to cylinder block bolts lightly in a
diagonal sequence.
4 - Tighten the oil pan to transmission bolts to 40 Nm.
5 - Tighten all the oil pan to cylinder block bolts in a diagonal
sequence to 15 Nm.
Further installation is in the reverse order of removal.

4. Removal and Installation 127

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4.2 Oil Pump with Balance Shaft Drive

⇒ T4.2.1 ensioner, Pre-tensioning”, page 133 .
Special tools and workshop equipment required
♦ Connecting Pin -T10027-
♦ Silicone Sealant -D176404A2-
Removing
– Remove the oil pan. Refer to ⇒ P4.1 an”, page 125 .
– Remove the protective plate. If necessary, release the re‐
taining tabs -arrows- through the openings with a small
screwdriver.

– Position the crankshaft in the Top Dead Center (TDC) posi‐

tion for cylinder 1.

128 Rep. Gr.17 - Lubrication

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

Make sure there is a mark on the balance shaft chain sprocket

aligned with the securing hole -arrow-. Mark the position with
a waterproof marker if the mark is missing. The mark will be
needed later when installing.

– Loosen the bolt for the oil pump chain sprocket. Counter
hold the vibration damper center bolt.

Caution

The chain sprocket driving differential shafts must not be

loosened!

– Release the tension on the chain rail using a screwdriver

-arrow- and secure it using a 3 mm hex wrench -1-.

– Remove the chain sprocket from the oil pump and disen‐
gage the chain from the balance shaft drive.

4. Removal and Installation 129

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the bolts -1 and 2- to remove the windage tray.

– Loosen the bolts for the balance shaft drive working from
the outside toward the inside and remove it. Refer to ⇒
-2.1.2 Oil Pump and Balance Shaft Drive”, page 117 .

Installing and Adjusting

• The chain tensioner is pre-tensioned. Refer to ⇒ T4.2.1 en‐
sioner, Pre-tensioning”, page 133 .
– Place the frame as shown onto the alignment sleeves
-arrows- for the balance shaft drive.

130 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Install the oil pump with the balance shaft drive and the
intermediate plate. Tighten the new bolts in a diagonal se‐
quence working from the inside to the outside to 15 Nm + an
additional 90° (1/4) turn.

Note

Note the different length of the bolts . Refer to ⇒ Fig. ““Bolt

Allocation for the Balance Shaft Drive”“, page 132 .

– Position the crankshaft in the TDC position for cylinder 1.

– The mark on the balance shaft chain sprocket -arrow- is

aligned with the securing hole.

4. Removal and Installation 131

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Secure the chain sprocket in this position using the -

T10027-. Place the chain onto the chain sprocket for the
balance shaft.

– Install the chain sprocket for the oil pump and tighten the
bolt by hand.

Note

The oil pump chain sprocket fits only in one position. To install,
only the oil pump must be rotated.

– Remove the -T10027- and the 3 mm hex wrench -1-. Secure

the chain sprocket for the oil pump (tightening specification:
20 Nm + an additional 90° (1/4) turn). Counter hold the cen‐
tral bolt for the vibration damper.

– Install the oil pan. Refer to ⇒ P4.1 an”, page 125 .

Further installation is in the reverse order of removal.
Bolt Allocation for the Balance Shaft Drive

132 Rep. Gr.17 - Lubrication

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

A - M7 x 40 bolt
B - M7 x 70 bolt
C - M7 x 90 bolt
D - M7 x 55 bolt
E - Sealing plug with O-ring

4.2.1 Chain Tensioner, Pre-tensioning

– Tension the piston by hand, push in, in the direction of the
-arrow-.

– Press the chain rail in the direction of the -arrow- and secure
is using a 3 mm hex wrench -1-.

4.3 Oil Filter Adapter

Removing
– Remove the intake manifold. Refer to ⇒ M5.4 anifold”, page
282 .
– Remove the coolant pipes. Refer to ⇒ P4.3 ipes”, page 160 .

4. Removal and Installation 133

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the bolts -A and B- to remove the engine oil cooler.

– Disconnect the connector -A- from the oil pressure switch

and remove the bolt -B- for the ground wire.
– Remove the bolts -arrows- and remove the oil filter adapter.

Installing
– Replace the gaskets -7 and 14-. Refer to ⇒ -2.1.3 Oil Filter
Adapter”, page 119 .
– Install the oil baffle.
– Install the oil filter adapter and tighten the bolts evenly to 15
Nm.
– Install the engine oil cooler with the bracket for the coolant
pipes.
Further installation is in the reverse order of removal.

4.4 Oil Pressure Switch -F1-

Special tools and workshop equipment required
♦ Socket and Jointed Extension - 24 mm -T40175-
Removing
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Description and Operation.
– Remove the left charge air hose -1 and 2-.

134 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the harness connector -1- from the bracket

and disconnect the connector -arrow- from the oil pressure
switch.

With a 1 Pin Oil Pressure Switch

– Remove the bolt -B- for the ground cable (ignore the ar‐
rows).

Continuation for All

– Remove the oil pressure switch using the -T40175-.

4. Removal and Installation 135

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
– Insert the oil pressure switch by hand and tighten it to 20
Nm.

Note

In the case of a 1 pin oil pressure switch, check whether the

ground wire is connected.

Further installation is in the reverse order of removal.

136 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Special Tools

Special tools and workshop

equipment required

♦ Oil Pressure Gauge Kit -VAG1342-

♦ Voltage Tester -VAG1527B-
♦ Connector Test Set -VAG1594C-

5. Special Tools 137

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ T Bar and Socket 10 mm -3185-

♦ Hex Ball Socket -T10058-
♦ Torque Wrench (5-50 Nm) -VAG1331-

♦ Connecting Pin -T10027-

138 Rep. Gr.17 - Lubrication

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Oil Drain Adapter -T40057-

♦ Socket and Jointed Extension - 24 mm -T40175-

♦ Multi-Meter -VAG1526D-

♦ Vehicle Diagnostic Tester - Test Adapter - (2-pin) -VAS5256-

5. Special Tools 139

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

19 – Cooling System
1 General Information
⇒ D1.1 raining and Filling”, page 140

1.1 Coolant, Draining and Filling

Special tools and workshop equipment required
♦ Refractometer -T10007 A-
♦ Drip Tray -VAG1306-
♦ Spring Clip Pliers -VAS6499-
♦ Cooling System Charge Kit -VAS6096-
♦ Cooling System Tester - Adapter -VAG1274/8-

Note

When replacing the expansion tank and when performing main‐

tenance work, make sure there are always two silicate cartridg‐
es in the expansion tank. Refer to the Parts Catalog . The sili‐
cate cartridges must not be removed.

⇒ D1.1.1 raining”, page 140 .

⇒ F1.1.2 illing”, page 141 .

1.1.1 Coolant, Draining

Note

♦ Drained coolant must be stored in a clean container for dis‐

posal or reuse.
♦ Follow all waste disposal regulations.

WARNING

The coolant system is under pressure when the engine is

warm.
There is a risk of scalding due to hot steam and hot coolant.
Reduce the pressure by covering the coolant expansion tank
cap with a cloth and carefully opening it.

Perform the following procedures:

– Open the coolant expansion tank cap.
– Remove the noise insulation ⇒ Body Exterior; Rep. Gr. 50;
Removal and Installation.
– Release the quick-release coupling -arrow- and remove the
coolant hose from the radiator.

140 Rep. Gr.19 - Cooling System

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Engine Code BYD

– Remove the hose from the engine oil cooler -arrow-.

Engine Codes CDLA, CDLC, CDLF and CRZA

– Remove the lower coolant hose to the Coolant Recirculation
Pump -V50- -arrow- and allow the coolant to drain.

1.1.2 Coolant, Filling

Caution

Only mix distilled water with coolant additives. Using distilled

water provides optimum corrosion protection.

1. General Information 141

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

♦ The mixture of the water used greatly influences the effec‐

tiveness of the coolant. The water quality to be used is
based on the contents, which can be specific to a country
or even a region. Distilled water fulfills all requirements. For
this reason, use distilled water when adding coolant or filling
coolant for the first time.
♦ Use only coolant additives listed. Refer to the Parts Catalog.
Other coolant additives may above all reduce the corrosion
protection effect significantly. The damage resulting from this
may lead to loss of coolant and consequently to severe en‐
gine damage.
♦ Coolant with the correct mixture ratio prevents freezing and
corrosion damage and calcium deposits. Additionally, the
boiling temperature will be raised. For this reason the cool‐
ing system must be filled with coolant additive year-round.
♦ Because of its high boiling point, the coolant contributes to
engine reliability under heavy engine loads, particularly in
countries with tropical climates.
♦ The -T10007A- MUST be used to determine the current
freeze protection value.

♦ Protection against frost must be assured down to minimum

-25 °C (-13 °F) (in arctic climatic countries down to approxi‐
mately -36 °C (-32.8 °F)). When stronger freeze protection
is needed due to the climate, the freeze protection may be
increased. But only down to -48 °C (-54 °F), otherwise the
effectiveness of the coolant decreases.
♦ The coolant concentration must not be reduced by adding
water even in warmer seasons and in warmer countries. The
frost protection must be at least -25 °C (-13 °F)
♦ Read the freeze protection value on the scale for the coolant
additive that has been added.
♦ The temperature on the -T10007A- corresponds to
the »freezing point«. At this temperature, ice crystals may
begin to form in the coolant.
♦ Used coolant cannot be used again.
♦ Only use water/coolant additive to lubricate the coolant ho‐
ses.

Coolant Mixture Ratio

• Coolant additive (40%) and water (60%) for freeze protection
down to -25 ℃ (-13 °F).

142 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

• Coolant additive (50%) and water (50%) for freeze protection

down to -36 ℃ (-33 °F).
• For the correct coolant additive. Refer to the Parts Catalog.
Perform the following procedures:
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Removal and Installation.
With -VAS6096-:
– Install the -VAG1274/8- on the expansion tank.
– Fill the coolant circuit using the -VAS6096-. Refer to the
Cooling System Filler Unit -VAS6096- Operating Instruc‐
tions.
Without -VAS6096-:
– Slowly add coolant until it reaches the upper marking on the
reservoir.

– Close the reservoir.

Vehicles without Parking Heater
– Start engine and maintain an engine speed of approximately
2000 RPM for approximately three minutes.
– Allow engine to run until Radiator Fan -V7- turns on.
Vehicles with Parking Heater and Heater Coolant Shut-Off
Valve -N279-

Caution

Parking heater should only be switched on if coolant circuit is

filled as described below.

– Connect the Vehicle Diagnostic Tester as follows:

1. General Information 143

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Connect the diagnostic cable connector to the diagnostic

connection inside the driver footwell.
– Start engine and maintain an engine speed of approximately
2000 RPM for approximately three minutes.
– Press buttons for “Vehicle Self-Diagnosis”, “18 - Parking
Heater” and “03 - Output Diagnostic Test Mode (DTM)” on
display in succession.
– Press the right arrow button in the display until the output
diagnostic test mode for the Heater Coolant Shut-Off Valve
-N279- is shown.
– Now select the output diagnostic test mode for the Heater
Coolant Shut-Off Valve -N279-. Maintain the engine at 2000
RPM for approximately 1 minute more.
– Allow engine to run until Radiator Fan -V7- turns on.
Continuation for All Vehicles

WARNING

The coolant system is under pressure when the engine is

warm.
There is a risk of scalding due to hot steam and hot coolant.
Reduce the pressure by covering the coolant expansion tank
cap with a cloth and carefully opening it.

– Check the coolant level and fill if necessary. When engine

is warm, coolant level must be at top marking and when the
engine is cold, it must be in the middle of the hatched field.

144 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Description and Operation

⇒ H2.1 ose Connection Diagram”, page 145
⇒ -2.2 Coolant Pump/Thermostat”, page 147
⇒ -2.3 Cooling System Components, Body Side”, page 149
⇒ -2.4 Cooling System Components, Engine Side”, page 151
⇒ -2.5 Coolant Recirculation Pump”, page 153

2.1 Coolant Hose Connection Diagram

2. Description and Operation 145

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Radiator
❑ Replace the coolant af‐
ter replacing.
❑ Removing and instal‐
ling. Refer to ⇒
R4.7 emoving and In‐
stalling, Golf from MY
2009, Golf Convertible
from MY 2012, and
Scirocco”, page 166 .
2 - Coolant Recirculation
Pump -V50-
❑ The direction of coolant
flow in the after-run op‐
eration is opposite the
illustrated direction of
flow.
❑ The functions can be
checked with Output
Diagnostic Test Mode
(DTM). Refer to the Ve‐
hicle Diagnostic Tester.
3 - Bypass Thermostat
❑ Not available in the US/
Canadian market.
4 - Coolant Thermostat Hous‐
ing with Coolant Thermostat
❑ Coolant thermostat
checking. Refer to
“Function and Com‐
ponent Selection” in
the Vehicle Diagnostic
Tester.
5 - Coolant Pump
❑ Removing and instal‐
ling. Refer to ⇒
P4.1 ump”, page 156 .
6 - Cylinder Head/Cylinder Block
❑ Replace the coolant after replacing.
7 - Turbocharger
❑ Removing and installing. Refer to ⇒ 4.3 , page 252 .
8 - Expansion Tank

Note

Make sure when replacing the ex‐

pansion tank and for maintenance
work that there is always a silicate
cartridge in the expansion tank.
Refer to the Parts Catalog. The
silicate cartridge must not be re‐
moved.
❑ With the sealing cap.
❑ Perform a leak test on the cooling system using the Cooling System Tester -VAG1274B- and Cooling
System Tester - Adapter -VAG1274/8-.
9 - Heater Core
❑ Replace the coolant after replacing.

146 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

10 - Hose
❑ Not available.
❑ Only with a automatic transmission.
11 - Transmission Oil Cooler
❑ Not available.
❑ Only with a automatic transmission.
12 - Bypass Thermostat
❑ Not available.
❑ Only with a automatic transmission.
13 - Water Connection
14 - Engine Oil Cooler
15 - Intake Manifold
❑ Removing and installing. Refer to ⇒ M5.4 anifold”, page 282 .
16 - Hose
❑ Only with a auxiliary cooler.
17 - Auxiliary Cooler
❑ Optional equipment.
❑ Removing and installing. Refer to ⇒ R4.8 adiator, Removing and Installing, Golf from MY 2009, Golf
Convertible from MY 2012, and Scirocco”, page 167 .
18 - Hose
❑ Only with a auxiliary cooler.

2.2 Overview - Coolant Pump/Thermostat

2. Description and Operation 147

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 15 Nm
2 - Coolant Pump
❑ Removing and instal‐
ling. Refer to ⇒
P4.1 ump”, page 156 .
3 - O-Ring
❑ Always replace
4 - Coolant Thermostat with
Housing
❑ Removing and instal‐
ling. Refer to ⇒
T4.4 hermostat Hous‐
ing with Thermostat”,
page 162 .
5 - O-Ring
❑ Always replace
6 - Front Coolant Pipe 1
❑ Removing and instal‐
ling. Refer to ⇒
P4.3 ipes”, page 160 .
7 - Bolt
❑ 9 Nm
8 - Engine Coolant Tempera‐
ture Sensor on Radiator Out‐
let -G83-
❑ Removing and instal‐
ling. Refer to ⇒
T4.2 emperature Sen‐
sor”, page 158 .
9 - O-Ring
❑ Always replace
10 - Clamp
11 - Coolant Hose
❑ With a mount for the Engine Coolant Temperature Sensor on Radiator Outlet -G83-
12 - O-Ring
❑ Always replace
13 - Bolt
❑ 9 Nm
14 - O-Ring
❑ Always replace

148 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2.3 Overview - Cooling System Compo‐

nents, Body Side

Note

♦ Auxiliary Radiator, Removing and Installing, Golf from MY

2009, Golf Convertible from MY 2012. Refer to ⇒ R4.8 adia‐
tor, Removing and Installing, Golf from MY 2009, Golf Con‐
vertible from MY 2012, and Scirocco”, page 167 .
♦ When replacing the expansion tank and when performing
maintenance work, make sure there are always two silicate
cartridges in the expansion tank. Refer to the Parts Catalog.
The silicate cartridges must not be removed.

2. Description and Operation 149

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Cap
❑ Check using Cool‐
ing System Tester -
VAG1274- and Cooling
System Tester - Adapt‐
er -VAG1274/9-
❑ The pressure relief
valve must open at 1.4
to 1.6 bar (20.30 to
23.20 psi)
2 - Connector
3 - 5 Nm
4 - Expansion Tank

Note

When replacing the expansion tank

and when performing maintenance
work, make sure there are always
two silicate cartridges in the expan‐
sion tank. Refer to the Parts Cat‐
alog. The silicate cartridges must
not be removed.
❑ Perform a leak test for the coolant system using the Cooling System Tester -VAG1274B- and Cooling
System Tester - Adapter -VAG1274/8-.
5 - Sealing Strip
❑ Not Installed
6 - O-Ring
❑ Replace if damaged
7 - Lower Coolant Hose
❑ To the connection for the coolant thermostat
8 - Bolt
❑ 5 Nm
9 - Bolt
❑ 5 Nm

150 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

10 - Radiator Fan 2 -V177-

❑ Removing and Installing. Refer to ⇒ M4.5 ount with Radiator FanV7 and Radiator Fan 2 V177,
Removing and Installing”, page 163 .
11 - Radiator Fan -V7-
❑ Removing and Installing. Refer to ⇒ M4.5 ount with Radiator FanV7 and Radiator Fan 2 V177,
Removing and Installing”, page 163 .
❑ With Radiator Fan Control Module -J293-
12 - Connector
13 - Fan Mount
❑ Removing and Installing. Refer to ⇒ M4.5 ount with Radiator FanV7 and Radiator Fan 2 V177,
Removing and Installing”, page 163 .
14 - Radiator
❑ Removing and Installing, Golf from MY 2004. Refer to ⇒ R4.6 emoving and Installing, Golf from MY
2004”, page 165 .
❑ Removing and installing (Golf from MY 2009, Golf Cabriolet from MY 2012). Refer to ⇒ R4.7 emoving
and Installing, Golf from MY 2009, Golf Convertible from MY 2012, and Scirocco”, page 166 .
❑ After replacing, replace the entire amount of coolant.
15 - Upper Coolant Hose
❑ To the Connection on the Cylinder Head

2.4 Overview - Cooling System Compo‐

nents, Engine Side

WARNING

The coolant system is under pressure when the engine is

warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering coolant reservoir cap with a
cloth and carefully opening.

Note

♦ When the engine is warm the cooling system is under pres‐

sure. The pressure must be released, if necessary, before
repairing
♦ Secure all hose connections using hose clamps appropriate
for the model type.
♦ Hose Clip Pliers -VAG1921- or Hose Clip Pliers -VAS5024A-
are recommended for installing spring clamps.
♦ Replace the gaskets and seals.
♦ The arrows on the coolant pipes and coolant hoses must line
up across from each other.
♦ Make sure when replacing the expansion tank and for main‐
tenance work that there is always a silicate cartridge in the
expansion tank. Refer to the Parts Catalog. The silicate car‐
tridge must not be removed.

2. Description and Operation 151

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 40 Nm
2 - Bolt
❑ 23 Nm
3 - Coolant Line
4 - Connecting Hose
5 - O-Ring
❑ Always replace.
6 - Water Connection
7 - Bolt
❑ 10 Nm
8 - Retaining Clip
9 - O-Ring
❑ Always replace.
10 - Engine Coolant Temper‐
ature Sensor -G62-
❑ Removing and instal‐
ling. Refer to ⇒
T4.2 emperature Sen‐
sor”, page 158 .
11 - Connecting Hose
12 - Distributor Piece
13 - Connecting Hose
14 - Connecting Hose
15 - Connecting Hose
16 - Coolant Line
❑ Removing and instal‐
ling. Refer to ⇒
P4.3 ipes”, page 160 .
17 - Bolt
❑ 5 Nm
18 - Connecting Hose
19 - Coolant Line
❑ Removing and installing. Refer to ⇒ P4.3 ipes”, page 160 .
20 - Bolt
❑ 10 Nm
21 - Coolant Thermostat Housing with Coolant Thermostat
❑ Coolant thermostat checking. Refer to “Function and Component Selection” in the vehicle diagnostic
tester
❑ Opening begins at 87 ℃ (188.6 °F).
22 - Bolt
❑ 15 Nm
23 - Coolant Pump
❑ Removing and installing. Refer to ⇒ P4.1 ump”, page 156 .
24 - Bolt
❑ 15 Nm

152 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2.5 Overview - Coolant Recirculation Pump

1 - Nut
❑ 3 Nm
2 - Coolant Line
3 - Spring Clamp
4 - Coolant Line
❑ To the turbocharger
5 - Coolant Hose
6 - Bracket
7 - Coolant Hose
❑ To the radiator input.
8 - Coolant Recirculation
Pump -V50-
❑ The functions can be
checked with Output
Diagnostic Test Mode
(DTM) in the Vehicle
Diagnostic Tester.
9 - Bolt
❑ 5 Nm
10 - Nut
❑ 5 Nm

2. Description and Operation 153

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Diagnosis and Testing

⇒ S3.1 ystem, Checking for Leaks”, page 154

3.1 Cooling System, Checking for Leaks

Special tools and workshop equipment required
♦ Cooling System Tester -VAG1274B-
♦ Cooling System Tester - Adapter -VAG1274/8-
♦ Cooling System Tester - Adapter -VAG1274/9-

Note

Make sure when replacing the expansion tank and for mainte‐
nance work that there is always a silicate cartridge in the expan‐
sion tank. Refer to the Parts Catalog. The silicate cartridge must
not be removed.

Test Conditions
• The engine is at operating temperature.
Test Sequence

WARNING

The coolant system is under pressure when the engine is

warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering coolant reservoir cap with a
cloth and carefully opening.

– Remove the coolant expansion tank cap.

– Install the -VAG1274/8- onto the coolant expansion tank.
– Clamp the -VAG1274B/1- on the -VAG1274/8-.
– Connect the -VAG1274B/1- to the -VAG1274B- using the
hose provided.

154 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Generate a positive pressure of approximately 1.0 bar (14.5

psi) using the hand pump of the cooling system tester.

DANGER!

Risk of scalding! Reduce the pressure before disconnect‐

ing the -VAG1274 B- from the connecting hose or -
VAG1274B/1-. To do this, press the pressure release valve
on the -VAG1274B- until the pressure gauge displays »0«.

If the pressure drops:

– Search for a leaking area and repair the malfunction.
Checking the Pressure Relief Valve in the Cap
– Install the cap onto the -VAG1274/9-.
– Clamp the -VAG1274B/1- onto the -VAG1274/9-.
– Connect the -VAG1274B/1- to the -VAG1274B- using the
hose provided.

– Actuate the hand pump.

• The pressure release valve must open at 1.4 to 1.6 bar
(20.30 to 23.20 psi).

3. Diagnosis and Testing 155

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Removal and Installation

⇒ P4.1 ump”, page 156
⇒ T4.2 emperature Sensor”, page 158
⇒ P4.3 ipes”, page 160
⇒ T4.4 hermostat Housing with Thermostat”, page 162
⇒ M4.5 ount with Radiator FanV7 and Radiator Fan 2 V177,
Removing and Installing”, page 163
⇒ R4.7 emoving and Installing, Golf from MY 2009, Golf Con‐
vertible from MY 2012, and Scirocco”, page 166
⇒ R4.8 adiator, Removing and Installing, Golf from MY 2009,
Golf Convertible from MY 2012, and Scirocco”, page 167
⇒ R4.6 emoving and Installing, Golf from MY 2004”, page 165

4.1 Coolant Pump

Special tools and workshop equipment required
♦ Shop Crane Drip Tray -VAS6208-
♦ Hose Clip Pliers -VAS5024A-

Note

Make sure when replacing the expansion tank and for mainte‐
nance work that there is always a silicate cartridge in the expan‐
sion tank. Refer to the Parts Catalog. The silicate cartridge must
not be removed.

Removing

WARNING

The coolant system is under pressure when the engine is

warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering coolant reservoir cap with a
cloth and carefully opening.

– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page

140 .
– Remove the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
– Remove coolant pump bolts -1-.
– Remove the coolant pump -2-.
– Remove the O-ring -3-.

156 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
Install in reverse order of removal. Note the following:
– Replace the O-ring.
– Clean and/or smooth the O-ring sealing surface.
– Lubricate the new O-ring -3- with coolant.

– Install the coolant pump -2-.

• Installed position: The sealing plug in the housing points
downward.
– Install the coolant pump bolts -1-.
– Install the toothed belt. Refer to ⇒ B4.3 elt”, page 69 .
– Fill the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
Tightening Specifications
Component Nm
Coolant pump to cylinder block 15
Toothed belt guard to cylinder block 10 1
♦ 1 install using locking fluid

4. Removal and Installation 157

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4.2 Coolant Temperature Sensor

⇒ E4.2.1 ngine Coolant Temperature Sensor G62 ”, page 158
⇒ E4.2.2 ngine Coolant Temperature Sensor on Radiator G83 ”,
page 159

4.2.1 Engine Coolant Temperature Sensor -

G62-
Removing

WARNING

The coolant system is under pressure when the engine is

warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering coolant reservoir cap with a
cloth and carefully opening.

• Engine cold.
– Briefly open the coolant reservoir cap to reduce the residual
pressure in the coolant system.
– Remove the engine cover/air filter. Refer to ⇒ C5.1 over and
Air Filter”, page 278 .
– Disconnect the connector -1- from the Engine Coolant Tem‐
perature Sensor -G62-.

Note

Use a cloth to catch any leaking coolant.

– Remove the retaining clip and the Engine Coolant Tempera‐

ture Sensor -G62-.

Installing
Install in reverse order of removal. Note the following:

Note

♦ Replace the O-ring.

♦ To prevent coolant loss, install the Engine Coolant Tempera‐
ture Sensor -G62- immediately into the connection.

158 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Check the coolant level. Refer to ⇒ D1.1 raining and Filling”,

page 140 .

4.2.2 Engine Coolant Temperature Sensor

on Radiator -G83-
Removing

WARNING

The coolant system is under pressure when the engine is

warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering coolant reservoir cap with a
cloth and carefully opening.

• Engine cold.
– Briefly open the coolant reservoir cap to reduce the residual
pressure in the coolant system.
– Remove noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Noise insulation.
– Disconnect the connector -2- from the Engine Coolant Tem‐
perature Sensor on Radiator Outlet -G83-.

Note

Use a cloth to catch any leaking coolant.

– Remove the retaining clip -1- and the Engine Coolant Tem‐
perature Sensor on Radiator Outlet -G83-.

Installing
Install in reverse order of removal. Note the following:

Note

♦ Replace the O-ring.

♦ Insert the new Engine Coolant Temperature Sensor on Radi‐
ator Outlet -G83- immediately in the connection to prevent
coolant loss.

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50; Noise Insulation.

4. Removal and Installation 159

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Check the coolant level. Refer to ⇒ D1.1 raining and Filling”,

page 140 .

4.3 Coolant Pipes

Special tools and workshop equipment required
♦ Hose Clip Pliers -VAS5024A-

Note

Make sure when replacing the expansion tank and for mainte‐
nance work that there is always a silicate cartridge in the expan‐
sion tank. Refer to the Parts Catalog. The silicate cartridge must
not be removed.

Removing
– Remove the engine cove with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remove the Turbocharger Recirculation Valve -N249- -1-
with the housing and remove the hose. Refer to ⇒
-2.1 Charge Air Cooler”, page 234 .

– Loosen the clamp -1-.

– Remove the bolt -2-.

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Description and Operation.

160 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the connector -3-.

– Remove the bolt -4-, pull the pipe off the charge air cooler
and remove it downward.
– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
– Disconnect the connectors -arrows-.

– Remove the coolant hoses from the coolant pipes -arrows-.

– Remove the hose -A-, remove the retainer -B- and then
remove the front coolant pipe.

– Loosen the connector -A- from the mount, remove the hose
-B- and the bolts -C- and then remove the coolant pipe.

4. Removal and Installation 161

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
Install in the reverse order of removal.

4.4 Coolant Thermostat Housing with

Thermostat

Note

Check the coolant thermostat. Refer to “Function and Compo‐

nent Selection” in the vehicle diagnostic tester.

Removing
– Remove the generator. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27; Removal and Installation.
– Remove the coolant pipes. Refer to ⇒ P4.3 ipes”, page 160 .
– Remove the retaining clips -1- to remove the coolant hose
-2- from the coolant thermostat housing.

– Remove the bolts -arrows- and then remove the thermostat

housing with the thermostat from the engine.

162 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
– Clean the O-ring sealing surface.
– Replace the O-ring and lubricate it with coolant.
– Attach the coolant thermostat housing to the cylinder block
and tighten the bolts evenly to 15 Nm.
– Further installation is in the reverse order of removal.

4.5 Fan Mount with Radiator Fan -V7- and

Radiator Fan 2 - V177-, Removing and
Installing
Tensioning Strap -T10038-
Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remove the upper bolts -upper arrows- for the fan shroud.

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50; Description and Operation.
– Remove the pendulum support bolts -2 and 3-.

4. Removal and Installation 163

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Pull the engine toward the rear approximately 15 mm using

the -T10038-.

– Disconnect the connector -1- and remove the lower fan

shroud bolts -lower arrows-.

– Remove the fan shroud downward.

– Disconnect the connector -1- and free up the wires, if re‐
quired.
– Remove the nuts -arrows- and remove the fan(s), if required.

164 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
Install in the reverse order of removal. Note the following:
For the correct tightening specifications. Refer to ⇒ -2.3 Cool‐
ing System Components, Body Side”, page 149 .
– Install the pendulum support. Refer to ⇒ a1.1 nd Trans‐
mission Mount and Pendulum Support Tightening Specifica‐
tions”, page 2 .

4.6 Radiator, Removing and Installing, Golf

from MY 2004
Special tools and workshop equipment required
♦ Refractometer -T10007 A-
♦ Drip Tray -VAG1306-
♦ Spring Clip Pliers -VAS6499-
♦ Cooling System Charge Kit -VAS6096-
♦ Cooling System Tester - Adapter -VAG1274/8-

Note

When replacing the expansion tank and when performing main‐

tenance work, make sure there are always two silicate cartridg‐
es in the expansion tank. Refer to the Parts Catalog. The sili‐
cate cartridges must not be removed.

Removing
– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
– Remove the charge air hose -arrows-.

4. Removal and Installation 165

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Move the lock carrier into the service position. Refer to

⇒ Body Exterior; Rep. Gr. 50; Description and Operation.
– Pull off coolant hoses from radiator.
– Remove the radiator fan mount and the radiator fan. Refer to
⇒ M4.5 ount with Radiator FanV7 and Radiator Fan 2 V177,
Removing and Installing”, page 163 .

Note

To prevent damage to condenser and also to the refrigerant

lines/hoses, ensure that the pipes and hoses are not stretched,
kinked or bent.

– Remove the bolts -arrows- from the radiator.

– Remove the radiator downward.

Installing
Install in reverse order of removal. Note the following:
– If a new radiator is installed, do not reuse the previous cool‐
ant.
– Fill the coolant. Refer to ⇒ F1.1.2 illing”, page 141 .
Tightening specifications. Refer to ⇒ -2.3 Cooling System Com‐
ponents, Body Side”, page 149 .

4.7 Radiator, Removing and Installing, Golf

from MY 2009, Golf Convertible from
MY 2012, and Scirocco

Note

When replacing the expansion tank and when performing main‐

tenance work, make sure there are always two silicate cartridg‐
es in the expansion tank. Refer to the Parts Catalog. The sili‐
cate cartridges must not be removed.

Removing
– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
– Move the lock carrier into the service position. Refer to
⇒ Body Exterior; Rep. Gr. 50; Description and Operation.
– Remove the radiator fan mount. Refer to ⇒ M4.5 ount with
Radiator FanV7 and Radiator Fan 2 V177, Removing and
Installing”, page 163 .

166 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the air guide from the lock carrier -arrows- and
remove the air guide.

– Pull off coolant hoses from radiator.

– Remove the bolts -1 and 2- and remove the radiator upward.

Installing
Install in reverse order of removal.
Tightening specifications. Refer to ⇒ -2.3 Cooling System Com‐
ponents, Body Side”, page 149 .
– Fill the coolant. Refer to ⇒ F1.1.2 illing”, page 141 .

4.8 Auxiliary Radiator, Removing and In‐

stalling, Golf from MY 2009, Golf Con‐
vertible from MY 2012, and Scirocco

Note

When replacing the expansion tank and when performing main‐

tenance work, make sure there are always two silicate cartridg‐
es in the expansion tank. Refer to the Parts Catalog. The sili‐
cate cartridges must not be removed.

Removing
– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
– Remove the coolant hoses -1 and 2- from the auxiliary radia‐
tor.

4. Removal and Installation 167

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the left front section of the wheel housing liner and
the left front wheel housing liner. Refer to ⇒ Rep. Gr. 66;
Removal and Installation.
– Remove the auxiliary radiator -1- -arrows- and the air guide.

Installing
Install in reverse order of removal.
– Fill the coolant. Refer to ⇒ F1.1.2 illing”, page 141 .

168 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Special Tools

Special tools and workshop

equipment required

♦ Refractometer -T10007A-
♦ Drip Tray -VAG1306-
♦ Hose Clip Pliers -VAS5024A-
♦ Cooling System Charge Kit -VAS6096-
♦ Cooling System Tester - Adapter -VAG1274/8-

5. Special Tools 169

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Tensioning Strap -T10038-

♦ Cooling System Tester -VAG1274B-

♦ Cooling System Tester - Adapter -VAG1274/9-

♦ Hose Clip Pliers -VAS5024A-

170 Rep. Gr.19 - Cooling System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

20 – Fuel Supply
1 General Information
⇒ P1.1 recautions”, page 171
⇒ S1.2 ide Fuel Pressure, Releasing”, page 172
⇒ W1.3 orking Conditions”, page 173
⇒ T1.4 ank, Draining”, page 174

1.1 Safety Precautions

WARNING

Fuel pressure in the high pressure pipe can be up to 150 bar

(2176 psi)! Follow the safety precautions when releasing the
high side fuel pressure.
♦ High side fuel pressure, releasing. Refer to ⇒ S1.2 ide
Fuel Pressure, Releasing”, page 172 .
♦ The fuel supply line is under pressure. Always wear pro‐
tective eyewear and protective clothing to prevent inju‐
ries and fuel from coming in contact with your skin. Wrap
a cloth around the connection before removing a fuel
hose. Remove the hose connection carefully to release
the pressure.
For safety reasons, interrupt the current to the fuel pump
before opening the fuel system. Otherwise the fuel pump will
activate when the drivers door is opened. Use one of the
following ways to interrupt the current:
♦ Battery, disconnecting
or
♦ Remove the fuel pump control module fuse
or
♦ Disconnect the connector from the fuel delivery unit
flange or the fuel pump control module.

Caution

When doing any repair work, especially in the engine com‐

partment, pay attention to the following due to clearance
issues:
♦ Route lines of all types (for example, fuel, hydraul‐
ic, Evaporative Emission (EVAP), coolant, refrigerant,
brake fluid and vacuum) and electrical wiring so that the
original routing is followed.
♦ To prevent damage to the lines, make sure there is suffi‐
cient clearance to all moving or hot components.

1. General Information 171

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

To Reduce the Risk of Personal Injury and/or Damage to the

Fuel Injection and Ignition System, Always Observe the Follow‐
ing:
♦ Do not touch or disconnect ignition coils with power output
stages when the engine is running or turning at starter
speed.
♦ Only disconnect and reconnect wires for the injection and
ignition system, including test leads, when the ignition is
turned off.
Always Observe the Following When Removing and Installing
the Fuel Level Sensor or the Fuel Pump From a Full or Partially
Filled Fuel Tank.
♦ Before starting work, place a extracting hose from an ex‐
haust extractor that is switched on near the fuel tank open‐
ing. This will extract the fuel vapors. If no exhaust extraction
system is available, a radial fan (as long as motor is not in
air flow) with a displacement greater than 15 m3/h can be
used.
♦ Prevent fuel from contacting skin! Wear fuel resistant gloves!
If Special Testing Equipment is Required During a Road Test,
Note the Following:
♦ Test and measuring instruments must be secured to the rear
seat and operated by a second person from that location.
♦ If the vehicle is involved in a collision while testing and
measuring equipment is operated from the front passenger
seat, the person sitting in that seat could be seriously injured
when the airbag deploys.

1.2 High Side Fuel Pressure, Releasing

WARNING

The fuel injection system is separated into a high pressure

side, where the pressure is a maximum of approximately 150
bar (2175 psi) and a low pressure side, where the pressure is
approximately 6 bar (87 psi).
Before opening the high pressure side, for example to re‐
move the fuel pressure sensor, the fuel pressure must be
reduced to a residual pressure of approximately 6 bar (87
psi). The procedure for this is as follows:

– Disconnect the Fuel Pressure Regulator Valve -N276- con‐

nector -arrow-.

– Allow the engine to idle for approximately 10 seconds.

172 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

♦ When the fuel pressure regulator valve connector is discon‐

nected during idle, the high side pressure decreases to ap‐
proximately 6 bar (87 psi).
♦ After the high side pressure has been decreased, the high
pressure side must be opened immediately. Otherwise, the
pressure can increase again due to the warming of the fuel.

– Turn off the ignition.

WARNING

The fuel system is under pressure!

♦ Always wear protective eyewear and protective clothing
to prevent injuries and fuel from coming in contact with
your skin.
♦ Before loosening line connections, place a cloth around
the connection point. Then release pressure by carefully
pulling off the line.

– Place a clean cloth around the connection point and careful‐

ly open in order to release the residual pressure of approxi‐
mately 6 bar (87 psi). Leaking fuel must be absorbed.
– Check the Engine Control Module (ECM) Diagnostic Trouble
Code (DTC) memory after completing the procedure. Erase
all the faults stored in the DTC memory that may have oc‐
curred when the connectors were disconnected.

Note

If the DTC memory was erased, the readiness code must be

generated again. Refer to “Guided Fault Finding” in the vehicle
diagnostic tester.

1.3 Clean Working Conditions

When working on the fuel supply/injection system, pay careful
attention to the following “5 rules” of cleanliness:
♦ Always clean the connection locations and the area around
them before loosening.
♦ Place removed parts on a clean surface and cover them
using lint free cloths.
♦ Carefully cover or seal, unpacked components if repairs can‐
not be performed immediately.
♦ Only install clean components: Remove the replacement
parts from their packaging just prior to installing them. Do
not use parts that have been stored loose (for example, in a
tool box, etc.).
♦ When the system is open: Avoid working with compressed
air and do not move the vehicle if possible.

1. General Information 173

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1.4 Fuel Tank, Draining

⇒ t1.4.1 he Fuel Delivery Unit Installed”, page 174
⇒ t1.4.2 he Tank is More Than 3/4 Full”, page 176
⇒ t1.4.3 he Tank is Less Than 3/4 Full”, page 178
Special tools and workshop equipment required
♦ Fuel Extracting Device -VAS5190-
♦ Wrench - Fuel Sending Unit -T10202-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
– Read the safety precautions before starting. Refer to ⇒
P1.1 recautions”, page 171 .

1.4.1 with the Fuel Delivery Unit Installed

Special tools and workshop equipment required
♦ Fuel Extraction - Adapter 3 -VAS5190/3-
♦ Vehicle Diagnostic Tester - Test Adapter 5-pin -VAS5565-
♦ Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A-

WARNING

♦ The fuel supply line is under pressure. Always wear pro‐

tective eyewear and protective clothing to prevent inju‐
ries and fuel from coming in contact with your skin. Wrap
a cloth around the connection before removing a fuel
hose. Remove the hose connection carefully to release
the pressure.
♦ Connect the Fuel Extracting Device -VAS5190- ground
wire to the vehicles ground wire.

– Disconnect the fuel supply line -arrow- and wipe up the leak‐
ing fuel with a clean cloth.

Note

Press the locking ring to release the fuel line.

– Connect the Fuel Extracting Device -VAS5190- and the Fuel

Extraction - Adapter 3 -VAS5190/3- to the fuel supply line.

174 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the rear seat bench. Refer to “Rear Seats” in

⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Remove the cover from the fuel delivery unit.

– Disconnect the connector -arrow-.

– Connect the Vehicle Diagnostic Tester - Test Adapter 5-pin

-VAS5565- between the connectors on the fuel delivery unit
and cover.

1. General Information 175

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Connect the Injection Rate Comparison Meter Kit - Remote

Cable -VAG1348/3A- to the Vehicle Diagnostic Tester - Test
Adapter 5-pin -VAS5565- and to the battery positive (+) ter‐
minal.

Note

This step allows the fuel pump to run when the engine is not
running.

– Remove the cap from the fuel filler tube.

– Operate the Injection Rate Comparison Meter Kit - Remote
Cable -VAG1348/3A- and the shut off lever on the Fuel Ex‐
tracting Device -VAS5190- until the fuel tank is empty.

1.4.2 When the Tank is More Than 3/4 Full

Caution

Secure the -VAS5190- ground wire to a bare area on the

chassis.

– Remove the cone piece -2- from the shaft piece -1- on the
-VAS5190-.

– Apply a mark -arrow- on the suction hose 1,180 mm -a- from

the end of the suction hose.

176 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the cap from the fuel filler tube.

– Insert the shaft piece -1- for the -VAS5190- into the fuel tank
filler tube.

– Slide the suction hose into the fuel tank far enough so the
mark -arrow- applied earlier is aligned with the shaft piece.

Note

A ball valve -2- that must not be damaged by the suction hose
-3- is located in the fuel tank -1- at the lower end of the filler
tube. Therefore, slide in the suction hose only up to the mark
-arrow- applied earlier.

– Drain the fuel tank as much as possible through the filler

tube.
– Remove the suction hose carefully.

Note

♦ When no more fuel can be extracted, the tank is emptied

only enough for the flanges to be opened without danger.
The tank may be removed while containing the remaining
fuel.
♦ To drain the fuel tank completely. Refer to ⇒ t1.4.3 he Tank
is Less Than 3/4 Full”, page 178 .

1. General Information 177

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1.4.3 When the Tank is Less Than 3/4 Full

Note

To drain the fuel tank completely, the fuel must be extracted

through the fuel delivery unit flange and fuel level sensor 2
flange.

– Remove the rear seat bench. Refer to “Rear Seats” in

⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Remove the cover for the fuel delivery unit.

– Disconnect the connector -arrow-.

WARNING

The fuel system is under pressure! Always wear protective

eyewear and protective clothing to prevent injuries and fuel
from coming in contact with your skin. Wrap a cloth around
the connection before removing a fuel hose. Remove the
hose connection carefully to release the pressure.

– Disconnect the fuel lines -1 and 2- from the flange.

178 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

Press the locking ring to release the fuel lines.

– Remove the lock ring using the -T10202-.

– Lift the flange.

– Insert the suction hose from the -VAS5190- as far as possi‐
ble into the fuel tank and siphon out the fuel.
Draining the Fuel Tank at the Fuel Level Sensor 2 Flange
– Remove the cover.

– Disconnect the connectors -1 and 2-.

1. General Information 179

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the lock ring using the -T10202-.

– Lift the flange.

– Insert the suction hose from the -VAS5190- as far as possi‐
ble into the fuel tank and siphon out the fuel.
Reinstall the flanges if only the fuel tank needed to be drained.
Refer to ⇒ Fig. ““Installed Position of the Fuel Delivery Unit
Flange and the Fuel Level Sensor 2 Flange”“, page 183 .

180 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Description and Operation

⇒ -2.1 Accelerator Pedal Module”, page 181
⇒ -2.2 Fuel Tank and Attachments”, page 181
⇒ -2.3 EVAP System Schematic”, page 184
⇒ -2.4 EVAP System Component”, page 186

2.1 Overview - Accelerator Pedal Module

1 - Connector
❑ Black, 6 pin
2 - Accelerator Pedal Position
Sensor -G79- and Accelera‐
tor Pedal Position Sensor 2
-G185-
❑ Not adjustable.
❑ The accelerator pedal
position sensor trans‐
mits the driver control
to the Engine Control
Module (ECM).
❑ -A-: openings for the
Accelerator Pedal Mod‐
ule Release Tool -
T10238-.
❑ Removing and instal‐
ling. Refer to ⇒
P4.1 edal Module”,
page 211 .
3 - Bolt
❑ 10 Nm
4 - Cap

2.2 Overview - Fuel Tank and Attachments

Note

♦ Fuel hoses at the engine may only be secured with spring

type clamps appropriate for the model type.
♦ Hose Clip Pliers -VAS6340- or Hose Clip Pliers -VAS6362-
are recommended for installing space saving clamps.

2. Description and Operation 181

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Supply Line
❑ Black
❑ Make sure it is secure.
2 - Return Line
❑ Blue
❑ Make sure it is secure.
3 - Seal
❑ Always replace.
❑ Install into the fuel tank
dry.
❑ Lubricate with fuel on‐
ly when installing the
flange.
4 - Fuel Delivery Unit
❑ Removing and instal‐
ling. Refer to ⇒ D4.2 el‐
ivery Unit”, page 213 .
❑ Fuel pump checking.
Refer to ⇒ P3.1 ump,
Checking”, page 188 .
❑ Pay attention to the in‐
stalled position on the
fuel tank. Refer to ⇒
Fig. ““Installed Position
of the Fuel Delivery
Unit Flange and the
Fuel Level Sensor 2
Flange”“, page 183 .
❑ With the Fuel Level
Sensor -G-.
❑ Fuel level sensor re‐
moving and installing.
Refer to ⇒ F4.3 uel
Level Sensor G ”, page
217 .
❑ Clean the filter if it is dirty.
5 - Lock Ring
❑ 110 Nm
❑ Make sure it is secure.
❑ Use the Wrench - Fuel Sending Unit -T10202- for removal and installation.
6 - Fuel Filler Door Unit
❑ With a rubber cup.
❑ Removing and installing. Refer to ⇒ Body Exterior; Rep. Gr. 55; Removal and Installation.
7 - Cap
❑ Replace if damaged.
8 - Bolt
9 - Ground Connection
❑ Make sure it is secure.
10 - Bolt
❑ 10 Nm
11 - Vent Tube
12 - Fuel Level Sensor 2 -G169-
13 - Suction Jet Pump

182 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Clipped onto the fuel level sensor 2.
❑ Removing and installing. Refer to ⇒ J4.6 et Pump”, page 227 .
14 - Vent Line
15 - Vent Line
16 - Fuel Tank
❑ Support the fuel tank using the Engine/Gearbox Jack -VAG1383A- .
❑ Removing and installing. Refer to ⇒ T4.4 ank”, page 219 .
17 - Securing Strap
❑ Pay attention to the installed position.
18 - Bolt
❑ 25 Nm
❑ Always replace.
❑ Only use bolts with loose washers to secure the straps. The straps could twist when the bolts are
tightened if other bolts are used. For the correct bolts. Refer to the Parts Catalog.
19 - Heat Shield
❑ Riveted to the exhaust system mounting parts.
20 - Screw
❑ 3 Nm
21 - Fuel Filter
❑ The arrow points in the direction of flow.
❑ Installed position. Refer to ⇒ Fig. ““Fuel Filter Installed Position”“, page 183 .
22 - Vent Line
❑ Attached to the side of the fuel tank.
❑ Make sure it is secure.

Installed Position of the Fuel Delivery Unit Flange and the Fuel
Level Sensor 2 Flange

The mark on the flange must align with the mark on the fuel
tank -arrow-.

Note

The mark on the fuel tank is difficult to see.

Fuel Filter Installed Position

2. Description and Operation 183

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

The pin -2- on the filter housing must engage in the recess in
the filter bracket -1-.

2.3 Overview - EVAP System Schematic

184 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Separating Point
❑ In the right front side
of the engine compart‐
ment, under the coolant
expansion tank.
2 - Vent Line
❑ White
❑ From the Evaporative
Emission (EVAP) can‐
ister to the EVAP can‐
ister purge regulator
valve 1.
❑ Installed position: On
the right side of the un‐
derbody.
❑ Attached to the fuel
tank.
3 - Vent Line
❑ Green
❑ From the engine to the
leak detection pump.
❑ Installed position: On
the right side of the un‐
derbody.
❑ Attached to the fuel
tank.
4 - Separating Point
❑ In front of the fuel tank
on the right side, near
the fuel filter.
5 - Filler Tube
6 - Vent Line
❑ From the filler tube to
the EVAP canister.
7 - Air Filter
❑ For the leak detection pump.
8 - Leak Detection Pump -V144-
❑ Installed location: In the right rear wheel housing, under the liner.
❑ Removing and installing. Refer to ⇒ L4.8 eak Detection Pump V144 ”, page 229 .
❑ Fuel system, checking for leaks. Refer to ⇒ S3.2 ystem, Checking for Leaks”, page 202 .
9 - Connecting Line
❑ From the leak detection pump to the EVAP canister.
❑ Attached to the bracket.
10 - EVAP Canister
❑ Installed location: In the bottom of the spare tire wheel well.
❑ Removing and installing. Refer to ⇒ C4.7 anister”, page 227 .
11 - Separating Point
❑ On the back of the fuel tank, on the right side.
12 - Turbocharger
13 - Brake Booster
14 - Vacuum Pump

2. Description and Operation 185

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

15 - Non-Return Valve
❑ Installed position: The arrow points in the direction of flow.
16 - EVAP Canister Purge Regulator Valve 1 -N80-
❑ Checking. Refer to the vehicle diagnostic tester.
17 - Double Check-Valve
❑ Checking. Refer to ⇒ C4.2 heck-Valve, Checking”, page 276 .
18 - Throttle Valve Control Module -J338-
❑ Removing and installing. Refer to ⇒ T5.7 hrottle Valve Control Module J338 ”, page 290 .
❑ Cleaning. Refer to ⇒ V1.2 alve Control Module, Cleaning”, page 262 .
19 - Intake Manifold
❑ Overview. Refer to ⇒ -2.2 Intake Manifold”, page 266 .
❑ Removing and installing. Refer to ⇒ M5.4 anifold”, page 282 .

2.4 Overview - EVAP System Component

Note

♦ Hose connections are secured with either spring type or

clamp type clips.
♦ Hose Clip Pliers -VAS6340- or -VAS6362- are recommen‐
ded for installing space saving clamps.

The connectors for the fuel, vacuum and vent lines are color
coded. There is either a colored dot on the connector or the
release button is the corresponding color.
Connector Color Code
Fuel supply line Black
Fuel return line Blue
Ventilation White, Beige
Vacuum Green

186 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Fuel Tank
2 - Vent Line
❑ Behind the right rear
wheel housing liner.
3 - Vent Line
❑ On the underbody.
4 - Vent Line
❑ To the EVAP canister
purge regulator valve 1.
❑ To disconnect, press
the release button.
5 - Bolt
❑ 8 Nm
6 - EVAP Canister
❑ Installed location: In the
bottom of the spare tire
wheel well.
❑ Removing and instal‐
ling. Refer to ⇒
C4.7 anister”, page
227 .
7 - Connecting Line
❑ On the underbody.
8 - Connecting Line
❑ Behind the right rear
wheel housing liner.
9 - Bolt
❑ 3 Nm
10 - Air Filter
❑ For the leak detection
pump.
11 - Connecting Hose
12 - Bracket
❑ For the leak detection pump.
13 - Bolt
❑ 2 Nm
14 - Nut
❑ 6 Nm
15 - Leak Detection Pump -V144-
❑ Installed location: In the right rear wheel housing, under the liner.
❑ Removing and installing. Refer to ⇒ L4.8 eak Detection Pump V144 ”, page 229 .
❑ Fuel system, checking for leaks. Refer to ⇒ S3.2 ystem, Checking for Leaks”, page 202 .
16 - Connector
17 - Vacuum Line
❑ From the intake manifold.

2. Description and Operation 187

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Diagnosis and Testing

⇒ P3.1 ump, Checking”, page 188
⇒ S3.2 ystem, Checking for Leaks”, page 202

3.1 Fuel Pump, Checking

⇒ a3.1.1 nd Voltage Supply, Checking”, page 188
⇒ P3.1.2 ressure, Checking”, page 191
⇒ P3.1.3 ressure, Checking”, page 193
⇒ D3.1.4 elivery Quantity, Checking”, page 196
⇒ D3.1.5 raw, Checking”, page 200
Special tools and workshop equipment required
♦ Pressure Tester Kit -VAS6550-
♦ Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A-
♦ Vehicle Diagnostic Tester - Test Adapter - 5-pin -VAS5565-
♦ Multi-meter -VAG1715-
♦ Wrench - Fuel Sending Unit -T10202-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
♦ Measuring Container, 2 Liter

3.1.1 Function and Voltage Supply, Check‐

ing
Test Conditions
• The battery voltage is at least 11.5 volts
• The fuel pump control module fuse is fuse OK
• The fuel pump control module is OK
Test Sequence

Note

The output Diagnostic Test Mode (DTM) checks the fuel pump.

– Connect the vehicle diagnostic tester -1- as follows:

– Connect the diagnostic cable -2- connector to the diagnostic

connection inside the drivers foot well.

188 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Turn on the ignition.

– On the OBD screen, press one button after the other: 01
- engine electronics and output diagnostic test
mode .
– Push the arrow button on the display to the fuel pump elec‐
tronics output DTM.
The fuel pump must now accelerate slowly up to maximum
speed.

Note

The fuel pump runs quietly.

– Turn off the ignition.

If the Fuel Pump does not Start Up
– Remove the rear seat bench. Refer to “Rear Seats” in
⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Disconnect the connector from the fuel pump control mod‐
ule.

– Check the voltage supply between the terminal -1 and 6-

using the -VAG1715-.

• Specified value: approximately battery voltage

Voltage Supply is not OK
– Locate and repair the open circuit in the wiring using. Refer
to ⇒ Wiring diagrams, Troubleshooting & Component loca‐
tions.
Voltage Supply is OK
– Remove the cover for the fuel delivery unit.

3. Diagnosis and Testing 189

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Make sure the connector -arrow- is secure. Pull on the con‐

nector without pressing the catch. Repeat the fuel pump
functionality test if the connector was not connected correct‐
ly.

– Disconnect the connector -arrow-.

– Check the contacts on the connector and on the fuel delivery
unit for damage.

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Wrap a cloth
around the connection before removing a fuel hose. Remove
the hose connection carefully to release the pressure.

– Disconnect the fuel lines -1 and 2- from the flange.

190 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

Press the locking ring to release the fuel lines.

– Remove the lock ring using the -T10202-.

– Check if the electrical wiring between the flange and fuel

pump is connected.
If No Open Circuits are Found
– The fuel pump is faulty, replace the fuel delivery unit. Refer
to ⇒ D4.2 elivery Unit”, page 213 .

3.1.2 Fuel Pressure, Checking

Note

Output Diagnostic Test Mode (DTM) activates the fuel pump.

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Wrap a cloth
around the connection before removing a fuel hose. Remove
the hose connection carefully to release the pressure.

Test Sequence
– Disconnect the fuel supply line (metal coupling) -arrow- and
absorb the leaking fuel with a clean cloth.

3. Diagnosis and Testing 191

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04.2018

Note

Press the locking ring to unlock the fuel line.

– Connect the -VAS6550- to the fuel supply line using the

-VAS6550/1- and -VAS6550/2-.

– Make sure the drain is closed and the shut off levers are
open.
– Activate the fuel pump with output DTM to build fuel pres‐
sure.
– Read the fuel pressure.
• Specified value: 4.0 to 7.0 bar (58 to 101.5 psi).
If the fuel pressure is OK, check the residual pressure. Refer to
⇒ P3.1.3 ressure, Checking”, page 193 .
If the Specification is Exceeded
– Check the return line between the fuel filter and the fuel
pump for kinks or blockages.
If no malfunction can be found:
– The pressure relief valve in the fuel filter is malfunctioning,
replace the fuel filter.
If the Specification is Not Obtained
– Check the fuel pressure in front of the fuel filter as follows:
– Disconnect the fuel supply line -arrow- from the fuel filter.

– Connect the -VAS6550- between the fuel filter and fuel sup‐
ply line using the -VAS6550/1- and -VAS6550/2-.

192 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Make sure the drain is closed and the shut off levers are
open.

– Turn on the ignition and actuate the fuel pump using the
output DTM.
– Close the shut off lever -A- while the fuel pump is running.
The pressure must increase to a minimum of 7.0 bar (101.52
psi). If 7.0 bar (101.52 psi) is reached, open the shut off
lever again immediately!
– Replace the fuel filter if the fuel pump is OK but the pressure
relief valve in the fuel filter is faulty.
If the pressure does not increase:
– Replace the fuel delivery unit. Refer to ⇒ D4.2 elivery Unit”,
page 213 . The fuel pump is faulty.

3.1.3 Holding Pressure, Checking

• The fuel pressure is OK and the -VAS6550- is connected.
Fuel pressure checking. Refer to ⇒ P3.1.2 ressure, Check‐
ing”, page 191 .

3. Diagnosis and Testing 193

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04.2018

Test Sequence
– Activate the fuel pump with output Diagnostic Test Mode
(DTM) to build fuel pressure.
– Read the fuel pressure.
• Specified value: 4.0 to 7.0 bar (58 to 101.5 psi).
– Observe the pressure drop on the pressure tester. After 10
minutes the pressure must not drop below a 3.0 bar (43 psi)
decrease.
If the pressure drops further:
– Activate the fuel pump with output DTM to build fuel pres‐
sure.
– Close the shut off lever -B- on the pressure tester imme‐
diately after the pressure has been reached. The lever is
perpendicular to the direction of flow.

If the Pressure No Longer Drops Now

Note

Check for the leak on the engine side. Repeat the residual pres‐
sure check. Close the shut off lever -A- this time to determine if
there actually is a leak on the engine side.

– Check the high pressure pump fuel pipe for leaks.

If no malfunction can be found:
– Replace the high pressure pump. Refer to ⇒ P5.8 ressure
Pump”, page 291 .
If the Pressure Drops Again
Check for the leak on the fuel tank side. Proceed as follows:

194 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Check the fuel line to the fuel filter for leaks.

If no malfunctions are found with the fuel line:
– Check the pressure retention valve in the fuel return line, as
follows:
– Disconnect the fuel supply line -arrow- from the fuel filter.

– Connect the -VAS6550- between the fuel filter and fuel sup‐
ply line using the -VAS6550/1- and -VAS6550/2-.

– Make sure the drain is closed and the shut off levers are
open.
– Activate the fuel pump with output DTM to build fuel pres‐
sure.
– Read the fuel pressure.
• Specified value: 4.0 to 7.0 bar (58 to 101.5 psi)
– Close the shut off lever -A- once pressure has increased.

3. Diagnosis and Testing 195

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04.2018

– Observe the pressure drop on the pressure tester. After 10

minutes the pressure must not drop below a 3.0 bar (43 psi)
decrease.
If the pressure drops:
– Replace the fuel delivery unit. Refer to ⇒ D4.2 elivery Unit”,
page 213 . The pressure retaining valve in the fuel pump is
defective.
If the pressure does not drop:
– The pressure retention valve in the fuel pump is OK. The
pressure relief valve in the fuel filter is faulty. Replace the
fuel filter.

3.1.4 Fuel Delivery Quantity, Checking

– Remove the rear seat bench. Refer to “Rear Seats” in
⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Remove the cover for the fuel delivery unit.

– Make sure the connector -arrow- is secure. Without pressing

on the release, pull on the connector. If the connector was
not connected correctly, it could cause a fault.

196 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the connector -arrow-.

– Check the contacts on the connector and on the fuel delivery
unit for damage.
– Connect the -VAS5565- between the connectors on the fuel
delivery unit and cover.

– Connect the -VAG1348/3A- to the -VAS5565- and to the

battery positive (+) terminal inside the engine compartment.

Note

This step allows the fuel pump to run when the engine is not
running.

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Wrap a cloth
around the connection before removing a fuel hose. Remove
the hose connection carefully to release the pressure.

– Disconnect the fuel supply line (metal coupling) -arrow- and

absorb the leaking fuel with a clean cloth.

3. Diagnosis and Testing 197

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

Press the locking ring to release the fuel lines.

– Connect the -VAS6550- to the fuel supply line using the

-VAS6550/1- and -VAS6550/2-. Hold the other end of the
-VAS6550/1- in a measuring container.

– Make sure the drain is closed and the shut off levers are
open.

WARNING

Danger of spraying. Always wear protective eyewear and

protective clothing to prevent injuries and fuel from coming
in contact with your skin. Hold container in front of the free
connection of pressure measuring device.

– Operate the -VAG1348/3A-. Close the shut off lever -arrow-

slowly until the pressure tester reads 4 bar (58 psi). From
this point on do not move the position of the shut off lever.
– Empty the measuring container.
– The fuel delivery rate of the fuel pump is dependent on bat‐
tery voltage. Therefore, additionally, connect the -VAG1715-
to leads -1 and 5- of the -VAS5565- .

– Operate the remote control for 30 seconds while measuring

the battery voltage.
– Compare the delivered quantity of fuel with the specified
value.

198 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

*) Minimum delivery rate cm3/30 s

**) Voltage on the fuel pump with engine running in idle and the
pump is on.
Example:
During the test, a voltage of 10.5 volts is measured. This results
in a minimum delivery quantity of approximately 580 cm3/30 s.
If the Specification is Not Obtained
– Check the fuel lines for possible restrictions (kinks) or block‐
ages.
If no malfunction can be found:
– Remove the cap from the fuel filler neck and repeat the test.
If the fuel delivery quantity is now reached, check the fuel
tank ventilation.
If the Specification is Again Not Obtained
– Check the fuel filter. Refer to the following:

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Wrap a cloth
around the connection before removing a fuel hose. Remove
the hose connection carefully to release the pressure.

– Disconnect the fuel supply line -arrow- from the fuel filter.

– Connect the -VAS6550- to the fuel supply line using the

-VAS6550/1- and -VAS6550/2-. Hold the other end of the
-VAS6550/2- in the measuring container.

3. Diagnosis and Testing 199

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04.2018

– Make sure the drain is closed and the shut off levers are
open.
– Operate the -VAG1348/3A-. Close the shut off lever -arrow-
slowly until the pressure tester reads 4 bar (58 psi). From
this point on do not move the position of the shut off lever.
– Empty the measuring container.
– Repeat the fuel delivery test.
If the minimum delivery rate is now obtained:
– Replace the fuel filter.
If the minimum delivery rate is again not obtained:
– Remove the fuel delivery unit and check the filter screen for
dirt.
Only when up to now no malfunction has been detected:
– Replace the fuel delivery unit.
If the fuel delivery rate was reached, even though a fault in the
fuel supply is still suspected (for example, intermittent loss of
fuel supply):
– Check fuel pump current draw. Refer to ⇒ D3.1.5 raw,
Checking”, page 200 .

3.1.5 Current Draw, Checking

– Remove the rear seat bench. Refer to “Rear Seats” in
⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Remove the cover for the fuel delivery unit.

200 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Make sure the connector -arrow- is secure. Without pressing

on the release, pull on the connector. If the connector was
not connected correctly, it could cause a fault.

– Disconnect the connector -arrow-.

– Check the contacts on the connector and on the fuel delivery
unit for damage.
– Connect the -VAS5565- between the connectors on the fuel
delivery unit and cover.

– Connect the current clamp -A- to the red cable labeled “cur‐
rent probe” on the -VAS5565-.
– Start the engine and let it idle.
– Measure the current draw of the fuel pump.
• Specified value: Max. 9 amps.

3. Diagnosis and Testing 201

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04.2018

Note

♦ The fuel pump starting current may be higher than the speci‐
fied value briefly when starting the engine.
♦ If the malfunction in the fuel system only occurs sporadically,
the test can also be performed during a road test. A second
person is needed to do this.

If the current draw is exceeded:

– The fuel pump is faulty. Replace fuel delivery unit. Refer to ⇒
D4.2 elivery Unit”, page 213 .

3.2 Fuel System, Checking for Leaks

⇒ S3.2.1 ystem Leak Test”, page 207
⇒ -3.2.2 EVAP System Functional”, page 209
⇒ L3.2.3 eak Detection Pump V144, Checking Vacuum Supply”,
page 210
Special tools and workshop equipment required
♦ Evaporative Emissions Tester -KLI9210-
♦ Adapter for EVAP. Tester -KLI9210/55-1-
♦ Vehicle Diagnostic Tester
♦ Hose Clamps up to 25 mm -3094-
The connectors for the fuel, vacuum and ventilation lines are
color coded. There is either a colored dot on the connector or
the release button is the corresponding color.
Connector Color Code
Fuel supply line Black
Fuel return line Blue
Ventilation White, Beige
Vacuum Green
Test Conditions
• The leak detection pump detected a leak.
• Perform “Guided Fault Finding” using the vehicle diagnostic
tester.
Evaporative Emissions Tester -KLI9210- Preparation

Note

Depending on the version, the appearance of the -KLI9210-

may vary.

– Check the -KLI9210- to make sure there is enough fluid in

the smoke generator.
– Set the valve -D- to “Hold”.

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04.2018

– Open the nitrogen bottle -H-.

– Connect the measuring hose -G- to the self test connection
-B-.
– Set the valve -D- to “Test”.
– Adjust the pressure to 25 mbar (10 in H2O) using the pres‐
sure reducer -J-.
– Set the valve -D- to “Hold”.
– The pressure must now be maintained a minimum of 2 mi‐
nutes. If the pressure is not maintained, check the tester.
Fuel System, Checking for Leaks
– Connect the -KLI9210/55-1- to the vent line -A-. (Color iden‐
tification: white).

– Connect the measuring hose -G- from the -KLI9210- to the

-KLI9210/55-1-.

3. Diagnosis and Testing 203

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Set the valve -D- to “Hold”.

– Connect the vehicle diagnostic tester -1- to the vehicle.

– Start the engine and let it run in idle.

– Select the Guided Functions mode in the vehicle diagnos‐
tic tester.
– Select “Check fuel tank ventilation system for leaks” under
“Guided Functions ”.
– Start the test.
– Watch the pressure gauge on the -KLI9210-.
• The leak detection pump must pump the fuel system up to
minimum of 7 in. H2O (18 mbar).
If the he minimum pressure is not reached, but the pressure
reached does not decrease:
– Turn off the ignition and perform a pressure retention test.
Refer to ⇒ page 205 . If there is no decrease in pressure,
check the vacuum supply for the leak detection pump. Refer
to ⇒ L3.2.3 eak Detection Pump V144, Checking Vacuum
Supply”, page 210 .
If the minimum pressure is not reached and the pressure
reached decreases immediately:
– Clamp off the hose to the EVAP canister purge regulator
valve 1 using a -3094- -arrow-.

204 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Repeat the test. If the minimum pressure was reached, re‐

place the EVAP canister purge regulator valve 1.
If the minimum pressure is not reached again and the pressure
reached decreases immediately:
– There is a leak in the fuel system: Perform the “Fuel System,
Leak Test”. Refer to ⇒ S3.2.1 ystem Leak Test”, page 207 .
If the Minimum Pressure is Reached, Turn the Ignition Off.
The valve in the leak detection pump is now closed and the
pressure is maintained.
– Watch the pressure gauge:
If the pressure does not decrease, perform a pressure retention
test to locate any possible pinhole leaks. Refer to ⇒ page 205 .
If the pressure falls, clamp off the hose to the EVAP canister
purge regulator valve 1 using a -3094- -arrow-.

– If the pressure stops falling, replace the EVAP canister

purge regulator valve 1.
If the pressure continues to fall, perform the “Fuel System, Leak
Test”. Refer to ⇒ S3.2.1 ystem Leak Test”, page 207 .
Pressure Retention Test
– Set the valve -D- to “Test”. Increase the current pressure to
25 mbar (10 in. H2O).

3. Diagnosis and Testing 205

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Watch the pressure gauge -C- and the flow meter -E-. If
the flow quantity decreases and pressure increases to 10 in.
H2O, then the fuel system is full.

Note

Depending on the level in the fuel tank, this procedure may take
up to 3 minutes.

– After the pressure has stabilized, set the valve -D- to “Hold”.
• After 5 minutes the pressure must not drop below 8 in. H2O
(20 mbar).
If the Pressure is Not Maintained for 5 Minutes, the Leak Should
be Localized as Follows:
– First, check the EVAP canister purge regulator valve 1 for
leaks. Clamp off the hose to the EVAP canister purge regu‐
lator valve 1 using a -3094- -arrow-.

– Set the valve -D- to “Test” and repeat the pressure test.

206 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Watch the pressure gauge -C- and the flow meter -E-. If
the flow quantity decreases and pressure increases to 10 in.
H2O, then the fuel system is full.
– After the pressure has stabilized, set the valve -D- to “Hold”.
– If the pressure stops falling, replace EVAP canister purge
regulator valve 1.
If the pressure continues to fall, perform the “Fuel System, Leak
Test”. Refer to ⇒ S3.2.1 ystem Leak Test”, page 207 .
After completing the work, perform the guide function “Check
tank ventilation system for leaks” using the Vehicle Diagnostic
Tester.

3.2.1 Fuel System Leak Test

Test Conditions
• The procedure “Fuel System, Checking for Leaks” was per‐
formed. Refer to ⇒ S3.2 ystem, Checking for Leaks”, page
202 .
• The -KLI9210- with the -KLI 9210/55-1- is connected to the
vehicle

– Connect the -KLI9210- to the vehicles battery.

– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66; Removal and Installation.
– Clamp off the hose between the leak detection pump and
the air filter using a -3094- -arrow-.

3. Diagnosis and Testing 207

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04.2018

– Set the valve -D- to “Test”.

– Watch the pressure gauge -C- and the flow meter -E-. If
the flow quantity decreases and pressure increases to 10 in.
H2O, then the fuel system is full.
– After the pressure has stabilized, set the valve -D- to “Hold”.
• After 5 minutes the pressure must not drop below 8 in. H2O
(20 mbar).
– If the pressure stops falling, replace the leak detection
pump.
If The Pressure is Not Maintained for a Minimum of 5 Minutes or
if No Pressure is Built Up, Localize the Leak As Follows:
– Set the valve -D- to “Test” and fill the system with smoke.
– While the fuel system is being filled, press the smoke gener‐
ator button -I- for approximately one minute.
The fuel system is now under pressure and filled with smoke.
– Check all fuel system lines and hoses for escaping smoke.
Also check the fuel cap.

208 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

♦ Illuminate components and hoses with a strong flood light,

the smoke will be more visible.
♦ To check for leaks at accessible locations, also use a ultra‐
sonic measuring device or commercially available leak de‐
tection spray.
♦ Depending on how long the fault finding lasts, the smoke
generator button may need to be pressed again. This en‐
sures there is enough smoke present in the fuel system.
♦ To check the fuel pump and fuel delivery unit flange, the
assembly openings in the vehicle interior must be opened.

– Replace any leaking hoses or components.

After completing the work, perform the guided function “Check
tank ventilation system for leaks” using the vehicle diagnostic
tester.

3.2.2 Overview - EVAP System Functional

1 - Evaporative Emission
(EVAP) Canister
2 - Adapter for EVAP. Tester -
KLI9210/55-1- Installed Loca‐
tion
❑ Used during the fuel
system leak test.
3 - EVAP Canister Purge
Regulator Valve 1 -N80-
4 - Vent Line
❑ Throttle Valve Control
Module -J338-
5 - Solenoid Valve
❑ For the leak detection
pump.
6 - Vacuum Line
❑ To the intake manifold.
7 - Air Filter
❑ For the leak detection
pump.
8 - Leak Detection Pump -
V144-
9 - Fuel Tank
10 - Cap

3. Diagnosis and Testing 209

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3.2.3 Leak Detection Pump -V144-, Check‐

ing Vacuum Supply
Special tools and workshop equipment required
♦ Turbocharger Tester Kit -VAG1397A-
♦ T-Piece -251201346-
♦ 6 mm Diameter Hose

Note

Leak detection pump installed location: inside the right rear

wheel housing, under the liner.

– Remove the wheel and the right rear wheel housing liner.
Refer to ⇒ Body Exterior; Rep. Gr. 66; Removal and Installa‐
tion.
– Disconnect the vacuum line -1- from the leak detection
pump.

– Connect the -VAG1397A-, using the T-piece and 6 mm di‐

ameter hose, between the vacuum line -1- and the leak
detection pump -2-.
– Turn on the measuring range I (absolute pressure measur‐
ing).
– Connect the Vehicle Diagnostic Tester and start the engine.
– Select the Guided Functions mode in the vehicle diagnos‐
tic tester .
– Select “Check fuel tank ventilation system for leaks” under
guided functions.
– Start the test.
– Watch the display on the -VAG1397A- while the test is run‐
ning.
• The pressure must pulsate and must not rise above 0.700
bar (10.15 psi) (absolute pressure) during the test.
– If the pressure rises above 0.700 bar (10.15 psi) during the
test, the vacuum supply is too low. Make sure the vacuum
line to the intake manifold is not kinked or plugged up.

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Removal and Installation

⇒ P4.1 edal Module”, page 211
⇒ D4.2 elivery Unit”, page 213
⇒ F4.3 uel Level Sensor G ”, page 217
⇒ T4.4 ank”, page 219
⇒ F4.5 uel Level Sensor 2 G169 ”, page 224
⇒ J4.6 et Pump”, page 227
⇒ C4.7 anister”, page 227
⇒ L4.8 eak Detection Pump V144 ”, page 229

4.1 Accelerator Pedal Module

Special tools and workshop equipment required
♦ Release Tool -T10238-
Removing
– Remove the steering column cover retainers -arrows- and
cover.

– Pry out the cap -3- using a screwdriver.

– Remove the bolt -2-.

– Disconnect the connector -1- -arrow- from the accelerator
pedal module.

4. Removal and Installation 211

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Using the -T10238-, insert it all the way as shown into the
openings provided and remove the accelerator pedal mod‐
ule.

Installing
– Connect the connector -1- to the accelerator pedal module
-4-. Lock the connector -arrow-.

– Push the accelerator pedal module onto the studs -5-.

– Insert the centering pin -6- into the hole in the floor panel.
– Tighten the bolt -2- to secure the accelerator pedal module
and replace the cap -3- .
– Install the steering column cover and retainers -arrows-.

212 Rep. Gr.20 - Fuel Supply

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Tightening Specification
Component Nm
Accelerator pedal module to body 10

4.2 Fuel Delivery Unit

Special tools and workshop equipment required
♦ Wrench - Fuel Sending Unit -T10202-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-

Caution

Conditions
• The fuel tank may be a maximum of 3/4 full. This en‐
sures the fuel level is below the fuel delivery unit flange.

Note

♦ When replacing the fuel delivery unit, check the fuel tank for
visible contamination and clean if necessary.
♦ Drain the fuel tank as necessary using the -VAS5190-. Refer
to ⇒ T1.4 ank, Draining”, page 174 .
♦ Read the safety precautions before starting. Refer to ⇒
P1.1 recautions”, page 171 .
♦ Pay attention to the rules of cleanliness. Refer to ⇒
W1.3 orking Conditions”, page 173 .
♦ Fuel tank and attachments overview. Refer to ⇒ -2.2 Fuel
Tank and Attachments”, page 181 .

Removing
– Remove the rear seat bench. Refer to “Rear Seats” in
⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Remove the cover for the fuel delivery unit.

– First, check that the connector -arrow- is secured in position,

then pull on the connector without pressing the release to
make sure the connection is secure. If the connector was not
connected correctly, it could cause a fault.

4. Removal and Installation 213

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04.2018

– Disconnect the connector -arrow-.

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Wrap a cloth
around the connection before removing a fuel hose. Remove
the hose connection carefully to release the pressure.

– Disconnect the fuel lines -1 and 2- from the flange.

Note

Press the locking ring to release the fuel lines.

– Remove the lock ring using the -T10202-.

– Pull the flange and the seal out from the opening in the fuel
tank and lay them aside with the lines still attached.

214 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the fuel line -1- for the suction jet pump through
the opening of the fuel tank. Press the release button to do
this.

– Disconnect the fuel line -2-.

– Remove the fuel delivery unit.

Note

♦ If the delivery unit is to be replaced then drain the old deliv‐

ery unit before disposal.
♦ Follow disposal regulations.

Installing
– Replace the seal.
– Install the fuel delivery unit seal into the fuel tank opening
dry.
– Coat the inner side of the seal with fuel.
– When installing the fuel delivery unit, be sure not to bend the
fuel level sensor arm.
– Install the fuel line -2- until it engages audibly.

4. Removal and Installation 215

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Install the fuel line -1- for the suction jet pump until it engag‐
es audibly.
– Press the flange downward against the spring force and
move it into its installed position.

• The tab -2- on the flange must lie between the tabs -1 and 3-
on the fuel tank.
• The -arrow- points in the direction of travel.
– Tighten the lock ring.
• Tightening specification: 110 Nm
– Connect the supply line -1- (black).

– Connect the return line -2-. It is blue or has a blue mark.

216 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Connect the connector -arrow-.

– Pull on the couplings and connector to make sure they are

fastened securely.
The rest of the installation is performed in the reverse order of
removal. Note the following:
♦ Pull on the line connections to make sure they are secure!
♦ The -arrow- on the cover points in the direction of travel.

Adapt the Engine Control Module (ECM) to the fuel pump if the
fuel delivery unit was replaced. Refer to “Guided Functions” in
the Vehicle Diagnostic Tester.

4.3 Fuel Level Sensor -G-

Note

Phased-in introduction of fuel delivery units with changed fuel

level sensors.

Removing (Old Version)

– Remove the fuel delivery unit. Refer to ⇒ D4.2 elivery Unit”,
page 213 .
– Write down the colors of the wires for installing later.
– Release the connections -arrows- and remove the wires
-1, 2 and 3-. Bend the hooks back.

4. Removal and Installation 217

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Lift the retaining tabs -4 and 5- with a screwdriver and pull

the fuel level sensor downward and off -arrow-.
Installing
– Insert the fuel level sensor in the guides on the fuel delivery
unit and push upward until it engages.
– Connect the connectors -1 through 3-. Pay attention to the
color coding.
– Pull on the connectors to make sure they are secure.
– Install the fuel delivery unit. Refer to ⇒ D4.2 elivery Unit”,
page 213 .
Removing (New Version)
– Remove the fuel delivery unit. Refer to ⇒ D4.2 elivery Unit”,
page 213 .
– Move the fuel level sensor slightly to the side and upward in
the direction of the -arrow- at the same time.

– If the sensor cannot be released this way, also press the

retaining tabs -arrows- to the side slightly.

218 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Write down the colors of the wires for installing later.

– Release and disconnect the connectors -1 through 3- and
bend back the hooks on the connector.

Installing
– Connect the connectors -1 through 3-. Pay attention to the
color coding.

– Pull on the connectors to make sure they are secure.

– Insert the fuel level sensor in the guides on the fuel delivery
unit and push down until it engages.
– Install the fuel delivery unit. Refer to ⇒ D4.2 elivery Unit”,
page 213 .

4.4 Fuel Tank

Special tools and workshop equipment required
♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-
♦ Engine/Gearbox Jack -VAG1383A-

4. Removal and Installation 219

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Removing
– Read the safety precautions before starting. Refer to ⇒
P1.1 recautions”, page 171 .
– Drain the fuel tank using the -VAS5190-. Refer to ⇒
T1.4 ank, Draining”, page 174 .
– Remove the right rear wheel.
– Remove the rear right wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66; Removal and Installation.
– Remove the bolt for the fuel flap unit and remove fuel flap
unit. Refer to ⇒ Body Exterior; Rep. Gr. 55; Removal and
Installation.
– Remove the fuel filler tube bolts -1- from the body.

– Unclip the electrical wire on the filler connection -2-.

– Remove the rear seat bench. Refer to “Rear Seats” in
⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Remove the cover for the fuel delivery unit.

– Disconnect the connector -arrow-.

220 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the cover for the Fuel Level Sensor 2 -G169-.

– Disconnect the connectors -1 and 2- .

– Remove the rear muffler. Refer to ⇒ -1.1 Exhaust System”,

page 308 .
– Remove the driveshaft. Refer to ⇒ Rear Final Drives 01Z,
0BS, 0AY and 0BR; Rep. Gr. 39; Removal and Installation.

WARNING

The fuel system is under pressure! Always wear protective

eyewear and protective clothing to prevent injuries and fuel
from coming in contact with your skin. Wrap a cloth around
the connection before removing a fuel hose. Remove the
hose connection carefully to release the pressure.

– Disconnect the vent line -1- (white) and the fuel line -2-
(black) at the connecting point.

4. Removal and Installation 221

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

Press the locking ring to release the fuel lines.

– Remove the connector from the All Wheel Drive Control

Module -J492-.

– Remove tensioning straps and bolts. Support the fuel tank

using the -VAG1383A- beforehand.

– Carefully lower the fuel tank.

Note

The fuel filler tube must be “removed” between the chassis

and rear subframe. To do so, lift the fuel tank down from the
-VAG1383A- with the help of a second technician.

Installing
– Clip the wire for the all wheel drive control module to the fuel
tank.

222 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– With a second technician assisting, guide the fuel filler neck

between the rear subframe and chassis.
– Lay the fuel tank on the -VAG1383A-.
– Slowly lift the fuel tank into the installed position and secure
it with the securing straps and bolts -arrows-.

Note

♦ Only use bolts with loose washers to secure the fuel tank
straps. The straps could twist when the bolts are tightened if
other bolts are used. For the correct bolts. Refer to the Parts
Catalog
♦ Tightening specifications: Fuel tank and attachment over‐
view. Refer to ⇒ -2.2 Fuel Tank and Attachments”, page
181 .

– Connect the connector to the all wheel drive control module.

Further installation is in the reverse order of removal. Note the

following:

4. Removal and Installation 223

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Make sure the vent and fuel lines are not kinked.
♦ Do not interchange the supply and return lines (the return
line is blue or has a blue mark, the supply line is black).
♦ Pull on the line connections to make sure they are secure.
♦ Check the ground connection from the fuel tank/body to the
filler tube.
♦ Adapt the Engine Control Module (ECM) to the fuel pump
if the fuel delivery unit was replaced. Refer to “Guided Func‐
tions” in the vehicle diagnostic tester.

4.5 Fuel Level Sensor 2 -G169-

Special tools and workshop equipment required
♦ Wrench - Fuel Sending Unit -T10202-
♦ Torque Wrench 1332 (40-200 Nm) -VAG1332-
• The fuel tank may be a maximum of 1/2 full.

Note

♦ Make sure the fuel level sensor is not bent.

♦ Drain the fuel tank as necessary using the -VAS5190-. Refer
to ⇒ T1.4 ank, Draining”, page 174 .
♦ Read the safety precautions before starting. Refer to ⇒
P1.1 recautions”, page 171 .
♦ Pay attention to the rules of cleanliness. Refer to ⇒
W1.3 orking Conditions”, page 173 .

Removing
– Remove the rear seat bench. Refer to “Rear Seats” in
⇒ Body Interior; Rep. Gr. 72; Removal and Installation.
– Remove the left cover for the fuel level sensor 2.

– Disconnect the connectors -1 and 2- .

224 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the lock ring using the -T10202-.

– Pull the fuel level sensor 2 slightly upward and unclip the
suction jet pump.

Installing

Caution

Do not bend the fuel level sensor 2 float arm when installing.

– Insert fuel level sensor 2 into the fuel tank.

– Connect the suction jet pump to the sensor in the inside of
the fuel tank. The catches must engage.

4. Removal and Installation 225

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Replace the seal.

– Install the fuel delivery unit seal into the fuel tank opening
dry.
– Coat the inner side of the seal with fuel.
– Note the fuel level sensor 2 installed location. Refer to ⇒ Fig.
““Installed Position of the Fuel Delivery Unit Flange and the
Fuel Level Sensor 2 Flange”“, page 183 .
– Make sure that the seals are in their correct positions.
– Tighten the lock ring.

• Tightening specification: 110 Nm

– Connect the connectors and the connections.
– Install the cover.

Note

The arrow on the cover must point in the direction of travel.

– Install the rear seat bench. Refer to “Rear Seats” in ⇒ Body

Interior; Rep. Gr. 72; Removal and Installation.

226 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4.6 Suction Jet Pump

Note

♦ On All Wheel Drive (AWD) vehicles, the fuel must be pum‐

ped out of the fuel level sensor 2 area and to the fuel deliv‐
ery unit due to the shape of the fuel tank. A suction jet pump
pumps the fuel from the left chamber to the right chamber in
the fuel tank.
♦ Only check the fuel level sensor 2 if the engine shuts off due
to low fuel but the fuel gauge indicates the tank is still 1/4
full.

Procedure
– Remove the fuel delivery unit. Refer to ⇒ D4.2 elivery Unit”,
page 213 .
– Remove the fuel level sensor 2. Refer to ⇒ F4.5 uel Level
Sensor 2 G169 ”, page 224 .
– Remove the suction jet pump from the side of the fuel level
sensor 2 (left side of vehicle).
– Check that the fuel hoses/lines on the suction jet pump are
installed securely and are not damaged.
– Check that the suction jet pump is currently clean.

4.7 EVAP Canister

Special tools and workshop equipment required
♦ Engine/Gearbox Jack -VAG1383A-
Removing
– Remove the center and rear mufflers.
– Remove the heat shield retainers -arrows- and shield.

– Place the -VAG1383A- under the rear subframe for support.

– Loosen the rear subframe bolts -arrows- and lower it approx‐
imately 20 mm.

4. Removal and Installation 227

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Slowly lower the rear subframe using the -VAG1383A-.

– Press the release button and remove the vent line -A-.

– Remove the bolts -B-.

– Open the tabs with a screwdriver in the direction of the
-arrow A-. Turn the Evaporative Emission (EVAP) canis‐
ter approximately 90° to the right in the direction of the
-arrow B- and then remove it.

Installing
Install in reverse order of removal. Note the following:
– Attach the vent lines so that it audibly latches.
– Install the rear subframe. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 42; Removal and Installation.
Tightening Specification
Component Nm
EVAP canister to body 8

228 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4.8 Leak Detection Pump -V144-

Removing
– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66; Removal and Installation.
– Disconnect the vacuum line -1-.
– Disconnect the connector -2-.
– Press the release button and remove the vent line -3-.
– Remove the nuts -arrows-.
– Remove the leak detection pump and bracket.

Installing
Install in reverse the order of removal. Note the following:
• The vent line -3- must engage audibly.
– Install the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66; Removal and Installation.
Tightening Specifications
– Refer to the ⇒ -2.4 EVAP System Component”, page 186 .

4. Removal and Installation 229

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Special Tools

Special tools and workshop

equipment required

♦ Pressure Tester Kit -VAS6550-

♦ Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A-
♦ Vehicle Diagnostic Tester - Test Adapter - 5 Pin -VAS5565-
♦ Multi-meter -VAG1715-
♦ Wrench - Fuel Sending Unit -T10202-
♦ Torque Wrench 1332 Pressure Tester Kit - hose 1(40-200
Nm) -VAG1332-

230 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Accelerator Pedal Module Release Tool -T10238-

♦ Torque Wrench 1331 (5-50 Nm) -VAG1331-

♦ Engine/Gearbox Jack -VAG1383A-

♦ Turbocharger Tester Kit -VAG1397A-

♦ Fuel Extraction - Adapter 3 -VAS5190/3-

5. Special Tools 231

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Fuel Extracting Device -VAS5190-

♦ Hose Clamps up to 25mm -3094-

♦ Not illustrated:
♦ Evaporative Emissions Tester -KLI9210-
♦ EVAP. Tester - Adapter -KLI9210/55-1-

232 Rep. Gr.20 - Fuel Supply

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

21 – Turbocharger, Supercharger
1 General Information
⇒ W1.1 orking Conditions”, page 233

1.1 Clean Working Conditions

When working on the turbocharger, carefully observe the follow‐
ing “5 rules” of cleanliness:
♦ Always clean the connection locations and the area around
them before loosening.
♦ Place removed parts on a clean surface and cover them
using lint free cloths.
♦ Carefully cover or seal, unpacked components if repairs can‐
not be performed immediately.
♦ Only install clean components: Remove the replacement
parts from their packaging just prior to installing them. Do
not use parts that have been stored loose (for example, in a
tool box, etc.).
♦ When the system is open: Avoid working with compressed
air and do not move the vehicle if possible.

1. General Information 233

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Description and Operation

⇒ -2.1 Charge Air Cooler”, page 234
⇒ -2.2 Structure-Borne Sound Actuator and Structure-Borne
Sound Control Module”, page 236
⇒ -2.3 Turbocharger Schematic”, page 237
⇒ -2.4 Turbocharger Component”, page 239

2.1 Overview - Charge Air Cooler

Caution

The charge air pipe/hose clamps must be tightened to 5.5

Nm. An insufficient or excessive tightening torque can cause
the charge air hose to come off the charge air pipe while
driving.

234 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Bolt
❑ 5 Nm
2 - Bracket
❑ For the charge air cool‐
er.
3 - Charge Air Cooler
❑ Removing and instal‐
ling. Refer to ⇒ A4.2 ir
Cooler”, page 250 .
4 - Clamp
5 - Bolt
❑ 10 Nm
6 - Charge Air Pipe
❑ Installing. Refer to ⇒
A4.1 ir Hose, Instal‐
ling”, page 249 .
7 - Charge Air Hose
❑ Installing. Refer to ⇒
A4.1 ir Hose, Instal‐
ling”, page 249 .
8 - Clamp
9 - To the Intake Tube
❑ Refer to -7- in ⇒
-2.4.3 Wastegate By‐
pass Regulator Valve
and Intake Tube”, page
242 .
10 - Charge Air Hose
❑ To the throttle valve
control module.
11 - Clamp
12 - Charge Air Pipe
13 - Bolt
❑ 10 Nm
14 - Clamp
15 - Charge Air Hose
16 - Clamp
17 - Seal
❑ Always replace.
18 - Charge Air Pressure Sensor -G31-
19 - Bolt
❑ 5 Nm
20 - Bolt
❑ 10 Nm
21 - Clamp
22 - Hose
23 - Clamp
24 - Intermediate Flange

2. Description and Operation 235

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

25 - Turbocharger Recirculation Valve -N249-

❑ Installed position. Refer to ⇒ Fig. ““Installed Position of the Turbocharger Recirculation Valve ”“, page
236 .
26 - Bolt
❑ 7 Nm
27 - Seal
❑ Always replace.
28 - Clamp
29 - Hose

Installed Position of the Turbocharger Recirculation Valve

2.2 Overview - Structure-Borne Sound Actuator and Structure-Borne Sound

Control Module
The plenum chamber cover and bulkhead must be removed
to remove and install. Refer to ⇒ Body Exterior; Rep. Gr. 50;
Description and Operation.

236 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Structure-Borne Sound
Control Module -J869-
❑ Installed location: In the
plenum chamber.
❑ Remove the plenum
chamber cover and
bulkhead to remove
and install.
2 - Bolt
❑ 8 Nm
3 - Nut
❑ 8 Nm
4 - Structure-Borne Sound
Actuator Bracket
5 - Nut
❑ 15 Nm
6 - Bolt
❑ 8 Nm
7 - Bolt
❑ 8 Nm
8 - Structure-Borne Sound
Actuator -R214-
❑ Installed location: In the
plenum chamber.
❑ Remove the plenum
chamber cover and
bulkhead to remove
and install.
9 - Structure-Borne Sound
Control Module Bracket
10 - Nut
❑ 8 Nm

2.3 Overview - Turbocharger Schematic

2. Description and Operation 237

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Turbocharger Recircula‐
tion Valve -N249-
❑ Installed position. Re‐
fer to ⇒ Fig. ““Instal‐
led Position of the Tur‐
bocharger Recirculation
Valve ”“, page 236 .
2 - Throttle Valve Control
Module -J338-
❑ Removing and instal‐
ling. Refer to ⇒
T5.7 hrottle Valve Con‐
trol Module J338 ”,
page 290 .
❑ Clean. Refer to ⇒
V1.2 alve Control Mod‐
ule, Cleaning”, page
262 .
3 - Pressure Regulator Valve
for the Crankshaft Housing
Ventilation
4 - To the EVAP Canister
❑ Overview of EVAP can‐
ister system. Refer to
⇒ -2.3 EVAP System
Schematic”, page 184 .
5 - Charge Air Regulation
Vacuum Diaphragm
❑ Turbocharger - over‐
view. Refer to ⇒
-2.4 Turbocharger
Component”, page
239 .
❑ Checking. Refer to
⇒ V3.2 acuum Di‐
aphragm, Checking”,
page 247 .
6 - Wastegate Bypass Regulator Valve -N75-
❑ Turbocharger - overview. Refer to ⇒ -2.4 Turbocharger Component”, page 239 .
7 - Turbocharger
❑ Turbocharger - overview. Refer to ⇒ -2.4 Turbocharger Component”, page 239 .
❑ Removing and installing. Refer to ⇒ 4.3 , page 252 .
8 - Brake Booster
9 - Check Valve
10 - Mass Air Flow Sensor -G70-
❑ Removing and installing. Refer to ⇒ M5.3 ass Airflow Sensor G70 ”, page 281 .
11 - Air Filter
❑ The air filter is located inside the engine cover.
❑ Removing and installing. Refer to ⇒ C5.1 over and Air Filter”, page 278 .
12 - Coolant Connection
13 - Vacuum Pump
14 - Check Valve
15 - Oil Filter Bracket

238 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

16 - EVAP Canister Purge Regulator Valve 1 -N80-

❑ Overview of EVAP canister system. Refer to ⇒ -2.3 EVAP System Schematic”, page 184 .
17 - Double Check Valve
❑ Checking. Refer to ⇒ C4.2 heck-Valve, Checking”, page 276 .
18 - Charge Air Pressure Sensor -G31-
19 - Charge Air Cooler
❑ Removing and installing. Refer to ⇒ A4.2 ir Cooler”, page 250 .
❑ Charge air system, checking for leaks. Refer to ⇒ A3.1 ir System, Checking for Leaks”, page 245 .

2.4 Overview - Turbocharger Component

Note

♦ Secure all hose connections using hose clamps appropriate

for the model type.
♦ Hose connections and charge air system hoses must be
free of oil and grease before installing. The sealing ring and
sealing surfaces must only be lightly oiled with the hose
couplings. Refer to ⇒ A4.1 ir Hose, Installing”, page 249 .
♦ The charge air system must be properly sealed.
♦ Replace the self-locking nuts.
♦ Spring Clip Pliers -VAS6499- or Hose Clip Pliers -VAG1921-
are recommended for installing spring clamps.
♦ Fill the turbocharger with engine oil at the oil supply pipe
connection.
♦ After installing the turbocharger, let the engine idle for ap‐
proximately 1 minute. The engine must not increase in en‐
gine speed. This ensures there is adequate oil supply to the
turbocharger.
♦ Pay attention to the rules of cleanliness. Refer to ⇒
W1.1 orking Conditions”, page 233 .

2. Description and Operation 239

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

I - Refer to ⇒ -2.4.1 Turbo‐

charger and Coolant Return
Pipe”, page 240
II - Refer to ⇒ -2.4.2 Coolant
Supply and Oil Pipes”, page
242
III - Refer to ⇒ -2.4.3 Waste‐
gate Bypass Regulator Valve
and Intake Tube”, page 242

2.4.1 Overview - Turbocharger and Coolant Return Pipe

240 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Gasket
❑ Always replace.
2 - Nut
❑ 20 Nm
❑ Always replace.
❑ Coat the stud bolts for
the exhaust manifold
with hot bolt paste.
❑ For the hot bolt paste.
Refer to the Parts Cata‐
log.
3 - Banjo Bolt
❑ 35 Nm
4 - Seal
❑ Always replace.
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 23 Nm
❑ Installed with 2 brack‐
ets only on the coolant
return pipe.
7 - Coolant Return Pipe
❑ Gradual introduction of
coolant return pipes
with a bracket.
8 - Turbocharger
❑ Removing and instal‐
ling. Refer to ⇒ 4.3 ,
page 252 .
9 - Support
10 - Bolt
❑ 30 Nm
❑ Coat the bolt with hot bolt paste.
❑ For the hot bolt paste. Refer to the Parts Catalog.
11 - Bolt
❑ 30 Nm
❑ Coat he bolt with hot bolt paste.
❑ For the hot bolt paste. Refer to the Parts Catalog.
12 - Support
13 - Bolt
❑ 23 Nm
14 - Nut
❑ 30 Nm
❑ Do not loosen to remove the turbocharger.
❑ Always replace.
❑ Coat the stud bolts on the exhaust manifold with hot bolt paste.
❑ For the hot bolt paste. Refer to the Parts Catalog.

2. Description and Operation 241

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

15 - Bracket

2.4.2 Overview - Coolant Supply and Oil Pipes

1 - Seal
❑ Always replace.
2 - Banjo Bolt
❑ 30 Nm
3 - Oil Supply Pipe
4 - Turbocharger
❑ Removing and instal‐
ling. Refer to ⇒ 4.3 ,
page 252 .
5 - Bolt
❑ 9 Nm
6 - Banjo Bolt
❑ 30 Nm
7 - Seal
❑ Always replace.
8 - Banjo Bolt
❑ 35 Nm
9 - Seal
❑ Always replace.
10 - Coolant Supply Pipe
11 - Bolt
❑ 23 Nm
12 - Banjo Bolt
❑ 35 Nm
13 - Bolt
❑ 9 Nm
14 - Seal
❑ Always replace.
15 - Gasket
❑ Always replace.
16 - Oil Return Pipe
17 - Bolt
❑ 9 Nm
18 - Gasket
❑ Always replace.

2.4.3 Overview - Wastegate Bypass Regulator Valve and Intake Tube

242 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Turbocharger
❑ Can only be replaced
with the exhaust mani‐
fold and vacuum dia‐
phragm.
❑ Removing and instal‐
ling. Refer to ⇒ 4.3 ,
page 252 .
2 - Hose
❑ To the Evaporative
Emission (EVAP) can‐
ister.
3 - Gasket
❑ Always replace.
4 - Bolt
❑ 9 Nm
5 - Heat Shield
6 - Vent Tube
7 - Intake Tube
❑ Note the installed posi‐
tion. Refer to ⇒ Fig.
““Installed Position of
the Intake Tube”“, page
244 .
8 - Seal
❑ Always replace.
9 - To Turbocharger Recircu‐
lation Valve
❑ Refer to -29- in ⇒
-2.1 Charge Air Cool‐
er”, page 234 .
10 - Clamp
11 - Gasket
❑ Note the installed position. Refer to ⇒ Fig. ““Installed Position of the Intake Tube”“, page 244 .
12 - Vacuum Diaphragm
❑ Checking. Refer to ⇒ V3.2 acuum Diaphragm, Checking”, page 247 .
13 - Connection
14 - Hose
15 - Seal
❑ Always replace.
16 - Banjo Bolt
❑ 8 Nm
17 - Hose
18 - Bolt
❑ 3 Nm
19 - Wastegate Bypass Regulator Valve -N75-
20 - Hose
21 - Seal
❑ Always replace.

2. Description and Operation 243

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

22 - Connection
23 - Clip
24 - Bolt
❑ 9 Nm

Installed Position of the Intake Tube

244 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Diagnosis and Testing

⇒ A3.1 ir System, Checking for Leaks”, page 245
⇒ V3.2 acuum Diaphragm, Checking”, page 247

3.1 Charge Air System, Checking for

Leaks
Special tools and workshop equipment required
♦ Turbo System Tester Kit -VAG1687-
♦ Turbo System Tester Kit - Adapter 5 -VAG1687/5-
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Description and Operation.
– Release the clamp -A- and disconnect the hose -B- from the
charge air pipe.

– Install the -VAG1687/5- onto the charge air pipe -A- and turn
it approximately 90° -B-.

Prepare the -VAG1687- as follows:

– Remove the pressure regulator valve -2- and close the
valves -3 and 4-.

3. Diagnosis and Testing 245

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

In order to be able to turn the pressure regulator valve -2-, the

rotary knob must be pulled upward.

– Connect the -VAG1687- as illustrated.

– Connect the compressed air hose -1- (pressurized air sup‐

ply) to the -VAG1687-.

Note

If water is located in the viewing glass, drain it via the water

drain plug -6-.

– Open the valve -3-.

– Set the pressure to 0.5 bar (7.25 psi) using the pressure
regulator valve -2-.

246 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Caution

Pressure must not exceed 0.5 bar (7.25 psi)! A pressure set
too high may damage the engine.

– Open the valve -4- and wait until the testing circuit has filled.
If necessary, adjust the pressure to 0.5 bar (7.25 psi).
– Inspect the charge air system for poorly sealed areas by
listening, feeling, using commercially available leak detection
spray or by using the -VAG1842-.

Note

♦ Charge air hose installing. Refer to ⇒ A4.1 ir Hose, Instal‐

ling”, page 249 .
♦ A small quantity of air dissipates via the valves in engine. A
pressure retention test is not possible for this reason.
♦ Using the -VAG1842-. Refer to the operating instructions.
♦ Before removing the adapter, discharge pressure in testing
circuit by pulling off the coupling from -VAG1687/5-.
♦ Hose connections and charge air system hoses must be free
of oil and grease before installing.

3.2 Turbocharger Vacuum Diaphragm,

Checking
Special tools and workshop equipment required
♦ Hand Vacuum Pump -VAS6213-
Test Conditions
♦ The hose between the turbocharger, the wastegate bypass
regulator valve, and vacuum diaphragm must not be kinked.
♦ The wastegate bypass regulator valve must be OK.
Procedure
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Connect the -VAS6213- to the vacuum diaphragm -arrow-.

– Adjust the slide ring -1- on the -VAS6213- to the -B- position
for “Pressure”.

3. Diagnosis and Testing 247

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Caution

The pressure must not exceed 750 mbar. If the pressure is

exceeded, the vacuum diaphragm can be damaged.

– Operate the -VAS6213- several times, watch the linkage

while doing this.
The linkage -A- must move approximately 300 mbar (4.35 psi)
and be at approximately 700 mbar (10.15 psi) at the end posi‐
tion.
Actuator lift is approximately 10 mm.

Note

If pressure cannot be raised with the -VAS6213- or the pressure

drops immediately, check the -VAS6213- and connecting hoses
for leaks. If no malfunction can be found: Replace the vacuum
diaphragm. Refer to ⇒ V4.4 acuum Diaphragm”, page 260 .

248 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Removal and Installation

⇒ A4.1 ir Hose, Installing”, page 249
⇒ A4.2 ir Cooler”, page 250
⇒ 4.3 , page 252
⇒ V4.4 acuum Diaphragm”, page 260

4.1 Charge Air Hose, Installing

Caution

The connector coupling sealing ring can be damaged if the

clamp is in the locked position when installing. This would
result in a leak. Follow the assembly instructions.

Removing
– Release the coupling element by pulling the clip -arrow-.
Disconnect the hose/pipe without the help of tools.

Installing
– When replacing, ensure that the sealing ring sits all the
way around and completely in the groove, and that it is not
turned.
– Lubricate the sealing surfaces and the seal.
– Bring the securing clip into the release position -1-.

4. Removal and Installation 249

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Slide the charge air hose all the way onto the pipe.
– Bring the clip into the locking position -2- and then press on
the charge air hose again.
– Check for the correct seating and proper locking of the con‐
nector by pulling on the hose.

4.2 Charge Air Cooler

Removing
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Removal and Installation.
– Remove the bumper cover. Refer to ⇒ Body Exterior; Rep.
Gr. 63; Removal and Installation.
– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page
140 .
– Remove the charge air hoses -arrows-.

– Remove the fan shroud. Refer to ⇒ M4.5 ount with Radiator

FanV7 and Radiator Fan 2 V177, Removing and Installing”,
page 163 .
– Remove the radiator. Refer to ⇒ R4.7 emoving and Instal‐
ling, Golf from MY 2009, Golf Convertible from MY 2012,
and Scirocco”, page 166 .
The Air Conditioning (A/C) pipes are bolted to the right side of
the charge air cooler. To remove the bolt, proceed as follows:
– Create a paper template with the specified dimensions.

250 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Position the template on the right front plastic support so it

aligns with the top and left edges.

– Mark the cutting points on the template -arrow- with a punch.

– Drill a hole in the plastic support with a 5 mm drill bit.
– Drill or cut the hole to 16 mm.
– Remove the bolt -arrow- for the A/C pipe.

– Remove the charge air cooler bracket bolts -1-.

4. Removal and Installation 251

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

The A/C condenser bolts are difficult to access. With the help of
a second technician, lift the charge air cooler out of the lower
mounts. Now the charge air cooler can be tilted back and forth
and the bolts are accessible.

– Remove the A/C condenser bolts -arrows- from the charge

air cooler .
– Attach the A/C condenser and the cable tie to the lock carri‐
er.
– Remove the charge air cooler downward.

Installing
Install in reverse order of removal. Note the following:
♦ Charge air hose connections and charge air system hoses
must be free of oil and grease before installing. On connec‐
tor couplings, the seal and sealing surfaces must only be
lightly oiled. Refer to ⇒ A4.1 ir Hose, Installing”, page 249 .

4.3 Turbocharger
Special tools and workshop equipment required
♦ Hose Clip Pliers -VAS5024A-
♦ Tensioning Strap -T10038-

252 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Caution

If mechanical damage is found on the turbocharger, for ex‐

ample, a destroyed compression wheel, it is not enough to
just replace the turbocharger. Perform the following steps to
prevent subsequent damage.
♦ Check the air filter housing, the air filter element and the
intake hoses for contamination.
♦ Check entire charge air circuit and cooler for contamina‐
tion.
If contaminants are found in the charge air circuit, the entire
circuit must be cleaned and the cooler replaced if necessary.

Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remove the spring clamps -1 and 2- to remove the intake
hose.

– Drain the coolant. Refer to ⇒ D1.1 raining and Filling”, page

140 .
– Remove the right front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66; Removal and Installation.
– Remove the charge air hose -arrow- from the charge air
cooler.

– Remove the bolts -arrows- and remove the charge air pipe.

4. Removal and Installation 253

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the connector -1 and 2- and unclip the wire.

– Remove the bolts -arrows- and remove the supports from

the turbocharger.
– Disconnect the connector for the Heated Oxygen Sensor
-G39- -arrow- and free up the wire.

– Disconnect the connectors from the ignition coils and the

wiring harness and lay them aside.

254 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the coolant line -arrow- from the coolant expan‐

sion tank.

– Remove the coolant hoses -1 and 2-.

– Remove the coolant line -3-.

– Remove the upper coolant hose from the heater core
-arrow-.

– Remove the heat shield and coolant pipe -arrows-.

4. Removal and Installation 255

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the vent tube for the crankcase ventilation and heat
shield from the turbocharger -1-.

– Pull out and remove the crankcase ventilation from the cylin‐
der head cover -2-.
– Remove the Evaporative Emission (EVAP) canister line to
the turbocharger from the cylinder head cover -3-.
– Loosen the oil supply pipe bolts -4- at the turbocharger .
– Remove both of the upper nuts for the front exhaust pipe to
turbocharger.

– Remove the right drive axle heat shield bolts -arrows- and
shield.

256 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the exhaust pipe with catalytic converter. Refer to ⇒

P3.1 ipe with Catalytic Converters”, page 314 .
– Remove the oil supply pipe and the coolant supply pipe bolts
-arrows- from the turbocharger.

– Remove the oil return pipe bolts -arrows- from the turbo‐
charger.

– Remove the bolts -1 and 2- and the turbocharger support.

4. Removal and Installation 257

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

The following step is necessary to achieve some more room

between the cylinder head and the bulkhead.

– Remove the pendulum support bolts -2 and 3-.

– Pull the engine toward the rear with the -T10038- approxi‐
mately 20 mm.

– Disconnect the coolant pipe -arrow-.

Note

♦ The bracket nuts do not have to be loosened.

♦ Bolt -1- is installed only on coolant pipes with 2 brackets.

– Remove the bolt -1- for the coolant pipe and remove the
upper nuts -arrows-.

258 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the turbocharger upward.

Installing

Caution

If mechanical damage is found on the turbocharger, for ex‐

ample, a destroyed compression wheel, it is not enough to
just replace the turbocharger. Perform the following steps to
prevent subsequent damage.
♦ Check the air filter housing, the air filter element and the
intake hoses for contamination.
♦ Check entire charge air circuit and cooler for contamina‐
tion.
If contaminants are found in the charge air circuit, the entire
circuit must be cleaned and the cooler replaced if necessary.

Install in reverse order of removal. Note the following:

♦ Charge air hose installing. Refer to ⇒ A4.1 ir Hose, Instal‐
ling”, page 249 .
♦ Replace the seals, sealing rings and self-locking nuts.
♦ Fill the turbocharger with engine oil at the connection for the
oil supply pipe.
♦ Install the coolant supply pipe together with the turbocharger
♦ Charge air hose connections and charge air system hoses
must be free of oil and grease before installing. Sealing ring
and sealing surfaces must only be lightly oiled with connec‐
tor couplings. Refer to ⇒ A4.1 ir Hose, Installing”, page 249 .
♦ Secure all of the hose connections with hose clamps that
correspond to the model type
After installing the turbocharger, let the engine idle for approx‐
imately 1 minute to ensure adequate oil supply to the turbo‐
charger.
Tightening Specifications
– Refer to ⇒ -2.4 Turbocharger Component”, page 239 .
Component Nm
Pendulum supports to transmission Refer to
⇒ Fig. ““Pen‐
dulum Sup‐
port”“, page 2
Turbocharger to cylinder head 201
Oil supply pipe to turbocharger 30

4. Removal and Installation 259

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Component Nm
Oil return pipe to turbocharger 9
Coolant supply pipe to turbocharger 35
Turbocharge support to cylinder block 302
Turbocharger support to turbocharger 302
Right charge air pipe to oil pan 10
♦ 1 Replace nuts
♦ 2 Use hot bolt paste. Refer to the Parts Catalog.

4.4 Turbocharger Vacuum Diaphragm

Removing
– Remove the turbocharger. Refer to ⇒ 4.3 , page 252 .
– Loosen the locking plate above the linkage rod from the
turbocharger.
– Loosen the lock nut -2-.
– Disconnect the linkage from the turbocharger -3-.
– Remove the vacuum diaphragm -1- from the turbocharger
-arrows-.

Installing
Install in reverse order of removal. Note the following:
– Install the turbocharger. Refer to ⇒ 4.3 , page 252 .
Tightening Specifications
Component Nm
Vacuum diaphragm to turbocharger 10

260 Rep. Gr.21 - Turbocharger, Supercharger

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Special Tools
Special tools and workshop equipment required
♦ Tensioning Strap -T10038-

♦ Turbo System Tester Kit -VAG1687-

♦ Hose Clip Pliers -VAS5024A-

♦ Hand Vacuum Pump -VAS6213-

♦ Not illustrated:
♦ Turbo System Tester Kit Adapter 5 -VAG1687/5-

5. Special Tools 261

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

24 – Multiport Fuel Injection

1 General Information
⇒ G1.1 eneral Information”, page 262
⇒ V1.2 alve Control Module, Cleaning”, page 262

1.1 OBD General Information

♦ Fuel hoses in the engine compartment may only be secured
with spring type clamps appropriate for the model type. The
use of clamp or screw type clamps is not permissible.
♦ The ignition must be turned off when disconnecting the bat‐
tery. Obtain the radio code for radios with an anti-theft code
before disconnecting the battery.
♦ Follow all steps after reconnecting the battery. Refer to
⇒ Electrical Equipment; Rep. Gr. 27; Removal and Installa‐
tion.
♦ For trouble free operation of the electrical components a
voltage of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine, will not be burnt in the engine and will
damage the oxygen sensor.
♦ If the engine only starts briefly and then turns off again after
troubleshooting, repairs or checking of the components, it
may be that the immobilizer is blocking the Engine Control
Module (ECM). The ECM must then be adapted if necessa‐
ry.
♦ To complete the procedure, check the ECM Diagnostic Trou‐
ble Code (DTC) memory and erase any DTCs that may have
been stored when testing and making repairs. If the DTC
memory was erased, the readiness code must be generated
again. Refer to “Guided Fault Finding” in the vehicle diag‐
nostic tester.
♦ Vehicles with an airbag are equipped with an emergency
fuel shut off system. It reduces the risk of fire in a collision
because the fuel pump relay switches the fuel pump off.
♦ When the drivers side door is opened, the fuel pump is
activated for 2 seconds so that pressure builds in the fuel
system. This improves comfort of engine startup behavior.

1.2 Throttle Valve Control Module, Clean‐

ing
Special tools and workshop equipment required
♦ Acetone

Note

♦ Follow all safety precautions. Refer to ⇒ P1.1 recautions”,

page 171 .
♦ Pay attention to the rules of cleanliness. Refer to ⇒
W1.3 orking Conditions”, page 173 .
♦ The throttle valve connections must not be damaged when
cleaning.

262 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Procedure
– Remove the throttle valve control module. Refer to ⇒
T5.7 hrottle Valve Control Module J338 ”, page 290 .
– Open the throttle valve by hand and hold it in the open posi‐
tion using a suitable object (for example, a plastic or wooden
wedge) -arrow-.

WARNING

Acetone is easily flammable. Observe accident prevention

measures and safety information when working with easily
flammable fluids. Do not used compressed air when cleaning
the throttle valve. Always wear protective eyewear and pro‐
tective clothing to prevent injuries and fuel from coming in
contact with your skin.

– Clean the throttle valve connections, especially near the

closed throttle valve, with standard acetone and a brush.

– Wipe the throttle valve connections with a lint free cloth.

– Allow the acetone to dry completely and reinstall the cleaned
throttle valve control module.
– Adapt the Engine Control Module (ECM) to the throttle valve
control module. Refer to “Guided Functions” in the Vehicle
Diagnostic Tester.

1. General Information 263

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Description and Operation

⇒ -2.1 Engine Cover with Air Filter”, page 264
⇒ -2.2 Intake Manifold”, page 266
⇒ -2.3 Fuel Rail and Injectors”, page 268
⇒ -2.4 High Pressure Pump”, page 270

2.1 Overview - Engine Cover with Air Filter

264 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Mass Airflow Sensor -G70-

❑ Replace the seal. Refer
to ⇒ Fig. ““Mass Airflow
Sensor Seal Installed
Position ”“, page 265 .
❑ Removing and instal‐
ling. Refer to ⇒
M5.3 ass Airflow Sen‐
sor G70 ”, page 281 .
2 - Screw
❑ 3 Nm
3 - Engine Cover/Upper Air
Filter Housing
❑ Clean off any dirt,
leaves and salt residue.
❑ Removing and instal‐
ling. Refer to ⇒
C5.1 over and Air Fil‐
ter”, page 278 .
4 - Clamp
5 - Intake Air Duct
6 - Air Filter Element
❑ Always use an original
air filter element.
❑ Removing and instal‐
ling. Refer to ⇒ F5.2 il‐
ter”, page 280 .
❑ Note the change inter‐
vals. Refer to Mainte‐
nance Intervals, Rep.
Gr. 03.
7 - Lower Air Filter Housing
❑ Clean off any dirt,
leaves and salt residue.
8 - Screw
❑ 3 Nm
9 - Heat Shield
10 - Rubber Grommet
❑ Note the installation marks.
11 - Intake Tube
❑ With a connection to the turbocharger recirculation valve, see -29-. Refer to ⇒ -2.1 Charge Air
Cooler”, page 234 .
❑ Note the installation marks.
❑ Check for debris and leaves in the tube.

Mass Airflow Sensor Seal Installed Position

2. Description and Operation 265

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

The smooth side of the seal -2- must contact the mass airflow
sensor -1- (magnified view).

2.2 Overview - Intake Manifold

266 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Nut
❑ 10 Nm
2 - Clamp
3 - Bolt
❑ 3 Nm
4 - Stud Bolt
❑ 10 Nm
5 - Gasket
❑ Always replace.
6 - Intake Manifold
❑ With the intake mani‐
fold flaps.
❑ Removing and instal‐
ling. Refer to ⇒
M5.4 anifold”, page
282 .
7 - Connecting Link
8 - Intake Flap Motor -V157-
with Intake Manifold Runner
Position Sensor -G336-
❑ Removing and instal‐
ling. Refer to ⇒
I5.5 ntake Flap Motor
V157 with Intake Mani‐
fold Runner Position
Sensor G336 ”, page
285 .
9 - Bolt
❑ 7 Nm
10 - To Evaporative Emission
(EVAP) Canister
11 - Hose
12 - EVAP Canister Purge Regulator Valve 1 -N80-
13 - Hose
14 - Double Check-Valve
❑ Checking. Refer to ⇒ C4.2 heck-Valve, Checking”, page 276 .
15 - Intake Manifold Support
16 - Bolt
❑ 25 Nm
17 - Nut
❑ 10 Nm
18 - Bonded Rubber Bushing
19 - Throttle Valve Control Module -J338-
❑ With EPC Throttle Drive -G186-, EPC Throttle Drive Angle Sensor 1 -G187- and EPC throttle drive
angle sensor 2 -G188-.
❑ Removing and installing. Refer to ⇒ T5.7 hrottle Valve Control Module J338 ”, page 290 .
20 - Bolt
❑ 7 Nm
21 - Seal

2. Description and Operation 267

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Replace if damaged.
22 - Bolt
❑ 5 Nm
23 - Intake Air Temperature Sensor -G42-
24 - Bolt
❑ 10 Nm

2.3 Overview - Fuel Rail and Injectors

WARNING

Follow the safety measures for releasing the high side fuel.
Refer to ⇒ S1.2 ide Fuel Pressure, Releasing”, page 172 .

268 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Cylinder 1 Fuel Injector -

N30- to Cylinder 4 Fuel Injec‐
tor -N33-
❑ Removing and instal‐
ling. Refer to ⇒
I5.10 njectors”, page
294 .
2 - Bolt
❑ 8 Nm
3 - Fuel Rail
❑ Removing and instal‐
ling. Refer to ⇒
R5.6 ail”, page 288 .
4 - Low Pressure Fuel Hose
❑ To the high pressure
pump.
5 - Pressure Relief Valve
❑ 30 Nm
❑ To remove and in‐
stall, remove the in‐
take manifold. Refer to
⇒ M5.4 anifold”, page
282 .
6 - Plate Nut
7 - Low Pressure Pipe
❑ Tighten the union nut to
22 Nm.
❑ Counter hold the pres‐
sure relief valve when
loosening the union
nuts.
❑ Check the tightening
specification for the
pressure relief valve
before installing.
❑ Do not install when under tension.
8 - Bracket
9 - High Pressure Pipe
❑ Tighten the union nuts to 27 Nm.
❑ Counter hold the threaded connection when loosening the union nuts.
❑ Check the tightening specification for the threaded connection before installing.
❑ Do not install when under tension.
10 - Bolt
❑ 3 Nm
11 - Connector
❑ For the fuel injectors.
12 - Connector
❑ For -16 and 17-.
13 - Connector
❑ For -11-.
14 - Wire Strip
15 - Clip

2. Description and Operation 269

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Attach to the intake manifold sleeve on the right side at the bottom.
16 - Connector
❑ For the Camshaft Position Sensor -G40-.
17 - Connector
❑ For the fuel pressure sensor.
18 - Bolt
❑ 5 Nm
19 - Fuel Pressure Sensor -G247-
❑ 22 Nm
❑ Coat the thread and sealing point with clean engine oil.
❑ Removing and installing. Refer to ⇒ F5.9 uel Pressure Sensor G247 ”, page 293 .
❑ Checking. Refer to ⇒ P4.1 ressure Sensor, Checking”, page 274 .
20 - Threaded Connection
❑ 30 Nm

2.4 Overview - High Pressure Pump

270 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Cam Follower
❑ Replace if damaged.
2 - O-Ring
❑ Always replace.
❑ Before installing, lubri‐
cate with clean engine
oil.
3 - High Pressure Pump
with Fuel Pressure Regulator
Valve -N276-
❑ Removing and instal‐
ling. Refer to ⇒ P5.8 re‐
ssure Pump”, page
291 .
4 - Bolt
❑ 10 Nm
5 - Union Nut
❑ 27 Nm
❑ Counter hold the threa‐
ded connection when
loosening.
❑ Check the tightening
specification for the
threaded connection in‐
side the high pressure
pump before installing.
❑ Install the fuel pipe free
of stress.
6 - High Pressure Pipe
❑ Always follow the safe‐
ty precautions when re‐
ducing the high side
fuel pressure. Refer to
⇒ S1.2 ide Fuel Pres‐
sure, Releasing”, page 172 .
7 - Threaded Connection
❑ 30 Nm
❑ Replace only after it has been loosened.
❑ Always leave the old seal in the high pressure pump when replacing the threaded connection it is
pinched during initial assembly by the supplier and cannot be removed. The new threaded connection
has a biting edge for sealing.
8 - Low Pressure Fuel Hose
❑ Secured with a spring type clamp.
9 - Banjo Bolt with Conical Seal Seat
❑ Not installed in the US/Canadian market.
❑ 15 Nm
❑ Always replace.
❑ Install the fuel pipe free of stress.
❑ Counter hold the threaded connection when loosening.
10 - Fuel Pipe
❑ Not installed in the US/Canadian market.
❑ Low pressure.
11 - Threaded Connection

2. Description and Operation 271

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ Not installed in the US/Canadian market.
❑ 30 Nm
❑ Replace only after it has been loosened.
❑ Always leave the old seal in the high pressure pump when replacing the threaded connection it is
pinched during initial assembly by the supplier and cannot be removed. The new threaded connection
has a biting edge for sealing.
12 - High Pressure Pipe Threaded Connection
❑ 40 Nm
❑ Do not loosen the threaded connection, just retighten it.
13 - Low Fuel Pressure Sensor -G410-
❑ 15 Nm
14 - Seal
❑ Always replace

272 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Specifications
⇒ D3.1 ata”, page 273

3.1 Technical Data

Engine Code CRZA
Idle check
Idle speed 1 RPM 660 to 860
Engine Control Module (ECM)
System designation Motronic MED 9.1
Part number: Refer to the Parts Catalog
Engine speed (RPM) limitation RPM approximately 6800
♦ 1If the ECM voltage supply drops below 12 volts, the idle
speed is increased in stages up to 990 RPM. Idle speed is
not adjustable.

3. Specifications 273
 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Diagnosis and Testing

⇒ P4.1 ressure Sensor, Checking”, page 274
⇒ C4.2 heck-Valve, Checking”, page 276

4.1 Fuel Pressure Sensor, Checking

Special tools and workshop equipment required
♦ Elbow Assembly Tool -T10118-
♦ Double Hexagon Socket, 1/2, 27mm -VAS5301/7-
♦ Pressure Sensor Tester -VAS6394-
♦ Vehicle Diagnostic Tester - Test Adapter - 3 Pin -VAS5570-
Procedure

WARNING

♦ The fuel pressure sensor is under pressure. Always

wear protective eyewear and protective clothing to pre‐
vent injuries and fuel from coming in contact with your
skin. Wrap a cloth around the connection point before
loosening the fuel pressure sensor. Then release pres‐
sure by carefully loosening.

– Remove the fuel pressure sensor. Refer to ⇒ F5.9 uel Pres‐

sure Sensor G247 ”, page 293 .
– Remove the locking bolt -2- and install the fuel pressure
sensor in the -VAS6394/1-. Tightening specification: 22 Nm.

– Coat the -VAS6294/2- sealing point with clean engine oil and
install it in the fuel rail. Tightening specification: 22 Nm.

– Connect the -VAS6394/1- pressure line to the -VAS6394/2-.

274 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Connect the fuel pressure sensor -1- and the connector for
the fuel pressure sensor using the -VAS5570-.
– Reinstall the engine cover with air filter and connect the
Mass Airflow Sensor -G70-.
– Press the button -A- once briefly to turn on the -VAS6394/1-.

Note

♦ Holding the button -A- for 2 seconds switches on the illumi‐

nation for 20 seconds.
♦ If the -VAS6394/1- does not display 0 bar (0 psi), set it back
to zero. Refer to the operating instructions.

– Connect the vehicle diagnostic tester to the diagnostic con‐

nector.
– Turn on the ignition.
– Press the following buttons on the vehicle diagnostic tester
screen one after another:
OBD
OBD ►
01 - engine electronics ►
011 - measured values ►

4. Diagnosis and Testing 275

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Select the measured values block 1 4 0 and quit with Q .

Display field 3 shows the fuel pressure actual value as meas‐
ured by the fuel pressure sensor.
– Start the engine.
– Compare the pressure displayed on -VAS6394/1- with the
actual value displayed on the vehicle diagnostic tester.
• The pressures may have a maximum difference of 5 bar
(72.5 psi).
– If the difference is greater than 5 bar (72.5 psi), replace the
fuel pressure sensor.

WARNING

The -VAS6394- is under high fuel pressure. Disconnect the

connector from the fuel pressure sensor when the engine is
running. This reduces the pressure to approximately 6 bar
(87 psi). Turn off the ignition. Place a cloth around the fuel
pressure sensor , then carefully loosen the sensor to release
the remaining pressure.

– Repeat the test with the new fuel pressure sensor and com‐
pare both values.
If the Measured Value Do Not Match Again:
– Check the wiring. Refer to the vehicle diagnostic tester.

4.2 Double Check-Valve, Checking

Special tools and workshop equipment required
♦ Hand Vacuum Pump -VAS6213-
Test Sequence
– Disconnect the connectors -arrows- from the EVAP Canister
Purge Regulator Valve 1 -N80- and the Low Fuel Pressure
Sensor -G410-.

– Remove the Evaporative Emission (EVAP) canister purge

regulator valve 1 -B- from the hose -A-.
– Place the slide ring -1- for the -VAS6213- in position in direc‐
tion of -arrow A- for “vacuum”.

276 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Connect the -VAS6213- to the hose for the double check-

valve -arrow-.

– Operate the -VAS6213- several times. The vacuum must

build up pressure.
If there is no vacuum, replace the EVAP canister.

4. Diagnosis and Testing 277

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Removal and Installation

⇒ C5.1 over and Air Filter”, page 278
⇒ F5.2 ilter”, page 280
⇒ M5.3 ass Airflow Sensor G70 ”, page 281
⇒ M5.4 anifold”, page 282
⇒ I5.5 ntake Flap Motor V157 with Intake Manifold Runner Posi‐
tion Sensor G336 ”, page 285
⇒ R5.6 ail”, page 288
⇒ T5.7 hrottle Valve Control Module J338 ”, page 290
⇒ P5.8 ressure Pump”, page 291
⇒ F5.9 uel Pressure Sensor G247 ”, page 293
⇒ I5.10 njectors”, page 294
⇒ I5.11 njector Teflon® Seal”, page 297
⇒ C5.12 ontrol Module, without Anti-Theft Protection”, page 300
⇒ C5.13 ontrol Module, with Anti-Theft Protection”, page 302

5.1 Engine Cover and Air Filter

Special tools and workshop equipment required
♦ Torque Wrench 1783 - 2-10 Nm -VAG1783-
♦ Hose Clip Pliers -VAS6340-
Removing
– Release the spring clamps -B- with the -VAS6340- and re‐
move the air guide from the engine cover -A-.

Disconnect the connector -2- from the Mass Airflow Sensor

-G70-

278 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove wiring harness.

– Loosen the retaining clips -arrows A-.
– Unclip the hose from the mounts -2-.
– Lift the engine cover in the direction of the
-arrows 3, 4, 5, and 6- one after the other and lift it off.

Installing

Note

Do not lubricate the engine cover rubber grommets -arrows-

before installation.

– Make sure that the 4 rubber grommets -arrows- are inserted

correctly into the engine cover with air filter when installing.

– Position the engine cover in the installed position and press

the rubber grommets onto the ball studs at the same time.
Further installation is in the reverse order of removal.

5. Removal and Installation 279

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5.2 Air Filter

Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remove the intake air guide -arrow-.

– Remove the screws -arrows-.

– Disconnect the engine cover. Pay attention to the retainers

-arrows-.

– Remove the air filter element from the engine cover.

280 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing

Note

♦ Always use an original equipment air filter element.

♦ The air filter housing must be clean.
♦ Note the following when blowing out the air filter housing
with compressed air: To avoid malfunctions, cover the Mass
Airflow (MAF) sensor with a clean cloth.

– Check the MAF sensor and the intake air duct for salt resi‐
due, dirt, and leaves.
– Make sure the air filter element is centered inside the lower
air filter housing when installing.
– Carefully position the engine cover/upper air filter hosing on
the lower section. When doing this, make sure that the upper
section is not placed crooked onto the air filter element.
Check the sealing lip on the air filter element.
Further installation is in the reverse order of removal.

5.3 Mass Airflow Sensor -G70-

Removing
– Disconnect the Mass Airflow (MAF) sensor connector -2-.

– Remove the MAF sensor screws and carefully remove it

from the engine cover with air filter.
Installing
For problem free operation of the MAF sensor it is very impor‐
tant to observe the following notes and procedures.
MAF Sensor Seal Installed Position

5. Removal and Installation 281

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

The smooth side of the seal -2- must contact the MAF sensor
-1- (see the magnified view).

Note

♦ If the air filter element is very dirty or soaked, dirt particles or

moisture may have contaminated the MAF sensor and may
be causing false mass airflow values. This results in a reduc‐
tion of power, since a lower injection quantity is calculated.
♦ Always use an original equipment air filter element.

– Replace the seal for the MAF sensor. Make sure it is instal‐
led correctly otherwise the air could get in.
– Check the intake air duct (intake air side) for salt residue, dirt
and leaves.
– Check the intake passages up to the air filter element for
dirt. If any contaminants are discovered, clean the air filter
housing (upper and lower parts) of salt residue, dirt and
leaves (if necessary, clean by washing or vacuuming).
Further installation is in the reverse order of removal.

5.4 Intake Manifold

WARNING

Follow the safety measures for releasing the high side fuel
pressure. Refer to ⇒ S1.2 ide Fuel Pressure, Releasing”,
page 172 .

282 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

♦ Pay attention to the rules of cleanliness. Refer to ⇒

W1.3 orking Conditions”, page 173 .
♦ If a fuel injector was pulled out of the cylinder head when
removing the intake manifold, the Teflon seal must be re‐
placed. Refer to ⇒ I5.11 njector Teflon® Seal”, page 297 .
♦ Intake manifold overview. Refer to ⇒ -2.2 Intake Manifold”,
page 266 .

Removing
– Remove the throttle valve control module. Refer to ⇒
T5.7 hrottle Valve Control Module J338 ”, page 290 .
– Disconnect all of the necessary connections.
– Remove the vacuum hose between the intake manifold and
the vacuum pump.

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Lay a cloth at
the connection points before loosening the hose connections.
Then reduce the pressure by carefully removing the hose.

– Disconnect the fuel supply line -2-.

– Disconnect the vent line -arrow 2-.

Remove the vacuum lines -arrows- from the intake manifold and
from the cylinder head cover.

5. Removal and Installation 283

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

WARNING

The fuel lines are pressurized! Always wear protective eye‐

wear and protective clothing to prevent injuries and fuel from
coming in contact with your skin. Lay a cloth at the connec‐
tion points before loosening the hose connections. Then re‐
lease pressure by carefully loosening the union nut.

– Loosen both of the fuel lines on the high pressure pump.

– Loosen the coolant pipe and oil dipstick guide from the
intake manifold -arrows- and pull off the oil dipstick guide
upward from the engine.

– Remove the intake manifold support -arrows- and remove

the connector -arrow- from the fuel pressure sensor.
– Remove all of the bolts from the intake manifold.
– Carefully remove the intake manifold and the fuel rail from
the cylinder head.

284 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
Install in reverse order of removal. Note the following:
If a fuel injector was pulled out of the cylinder head when re‐
moving the intake manifold, replace the Teflon® seal on the fuel
injector. Refer to ⇒ I5.11 njector Teflon® Seal”, page 297 .
Replace the O-rings between the fuel injectors and fuel rail and
coat them lightly with clean motor oil.
Position the intake manifold with the fuel rail on the cylinder
head and press evenly onto the fuel injectors.
If the intake flap motor or intake manifold was replaced, the
intake manifold runner position sensor must be adapted to the
Engine Control Module (ECM). Refer to “Guided Functions” in
the vehicle diagnostic tester.
Tightening Specifications
Tightening Specification Nm
Intake manifold bolts 10
Intake manifold support bolt 23
Intake manifold support nut 10
Fuel lines to high pressure Refer to ⇒ -2.4 High Pressure
pump Pump”, page 270 .
Intake flap motor bolts 7

5.5 Intake Flap Motor -V157- with Intake

Manifold Runner Position Sensor -
G336-
Special tools and workshop equipment required
♦ Assembly Tool -T10118-
♦ Commercially available 1/4" Reversible Ratchet, for example
Ratchet 2264
♦ T30 TORX® Bit
Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remove the air duct bolts -arrow- and duct from the lock
carrier.

5. Removal and Installation 285

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the turbocharger recirculation valve -1- with the

intermediate flange and remove the hose. Refer to ⇒
-2.1 Charge Air Cooler”, page 234 .

– Remove the vacuum lines -arrows-.

– Disconnect the following connections:

Note

It is easier to open connectors that are hard to access when

using the -T10118-.

♦ Intake flap motor connector

♦ EVAP canister purge regulator valve 1 connector
♦ Manifold absolute pressure sensor connector
♦ Throttle valve control module connector
♦ Low fuel pressure sensor connector
– Disconnect the connectors -arrows-.

286 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Loosen the wiring bracket -A- and move the wiring harness
to the side.
– Remove the bracket for the connector from the coolant pipe
-arrows-.

Note

♦ Loosen the nut with the left arrow just enough so that the
bracket can moved to the side.
♦ Plastic brackets are attached.
♦ To improve clarity, the intake manifold is shown removed in
the graphic.

– Pry the connecting rod -arrow- off the intake flap motor.

– Remove the bolts -1 and 2- using the 1/4" reversible ratchet

T30 TORX® bit.

5. Removal and Installation 287

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Note

The rear bolts -arrow- can only be removed with the reversible
ratchet. The space between the bolt and coolant pipe is very
small.

– Remove the intake flap motor from the intake manifold.

Installing
Install in reverse order of removal. Note the following:
– Position the bolts -1 and 2- by hand to avoid damaging the
threads.

– Install the turbocharger recirculation valve. Refer to ⇒

-2.1 Charge Air Cooler”, page 234 .
If the intake flap motor or intake manifold was replaced, the
intake manifold runner position sensor must be adapted to the
Engine Control Module (ECM). Refer to “Guided Functions” in
the vehicle diagnostic tester.

5.6 Fuel Rail

WARNING
♦ You must remove the fuse for the fuel pump control mod‐
ule before starting any repairs of the vehicle’s fuel system.
Failing to do so could result in fire and personal injuries.
♦ Do not turn on the ignition, open the front doors, or attempt
to start the engine at any time while any part of the ve‐
hicle’s fuel system is unassembled. Failing to heed this
warning could result in fire and personal injury

288 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Removing
– Remove the intake manifold. Refer to ⇒ M5.4 anifold”, page
282 .
– Remove the hoses from the Evaporative Emission (EVAP)
canister.
– To do this, open the hose clamps -1-.

– Loosen both bolts -arrows- from the fuel rail.

– Remove the hose connection -1- from the intake manifold
and loosen both of the bolts -arrows-.

– Loosen the union nut for both of the fuel pipes -2 and 3-.
– Counter hold at the pressure relief valve.
– Carefully lift the connecting rod from the intake flap motor
-4-.
– Remove the intake flap motor -5-.
– Remove the fuel rail from the intake manifold.

5. Removal and Installation 289

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
– Install in reverse order of removal.
For the tightening specifications. Refer to ⇒ -2.3 Fuel Rail and
Injectors”, page 268 .

5.7 Throttle Valve Control Module -J338-

Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Remove the turbocharger recirculation valve -1- with the
intermediate flange and remove the hose. Refer to ⇒
-2.1 Charge Air Cooler”, page 234 .

– Loosen the hose clamp -1-.

– Remove the bolt -2-.
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50; Description and Operation.
– Disconnect the connector -3-.
– Remove the bolt -4-, pull the pipe off the charge air cooler
and remove it downward.
– Remove the 4 bolts for the throttle valve control module and
remove the throttle valve control module.

290 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
Install in reverse order of removal. Note the following:
– Install the turbocharger recirculation valve. Refer to ⇒
-2.1 Charge Air Cooler”, page 234 .
– If there is a new throttle valve control module installed, adapt
the Engine Control Module (ECM) to the throttle valve con‐
trol module. Refer to “Guided Functions” in the vehicle diag‐
nostic tester.

5.8 High Pressure Pump

WARNING

♦ Follow the safety measures for releasing the high side

fuel pressure. Refer to ⇒ S1.2 ide Fuel Pressure, Re‐
leasing”, page 172 .
♦ For safety reasons, remove the fuel pump control mod‐
ule fuse from the fuse panel before opening the fuel
system. This prevents the fuel pump from being activa‐
ted by the drivers door contact switch. Fuse assignment.
Refer to ⇒ Wiring diagrams, Troubleshooting & Compo‐
nent locations.

Note

♦ Do not disassemble the high pressure pump!

♦ Read the safety precautions before starting. Refer to ⇒
P1.1 recautions”, page 171 .
♦ Pay attention to the rules of cleanliness. Refer to ⇒
W1.3 orking Conditions”, page 173 .

Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Set the engine to Top Dead Center (TDC).
– Disconnect the connectors -1 and 2-.

5. Removal and Installation 291

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04.2018

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Lay a cloth at
the connection points before loosening the hose connections.
Then reduce the pressure by carefully removing the hose.

– Loosen both of the fuel lines at the high pressure pump.

– Open the hose clamp -1- and remove the fuel hose.

– Counter hold the connection -2- and remove the fuel pipe
-3-.
– Remove the bolts -arrows- and carefully remove the high
pressure pump.

Note

The cam follower can remain inserted in the cylinder head un‐
der some circumstances.

Installing
– Replace the O-ring for the high pressure pump and coat
lightly with clean motor oil.
– Check the cam follower for damages and reinsert it into the
cylinder head.
– Carefully attach the high pressure pump to the cylinder head
and tighten the bolts -arrows- by hand.

292 Rep. Gr.24 - Multiport Fuel Injection

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Attach the fuel pipe by hand.

Note

Check the tightening specification for the threaded connection

before installing the fuel pipes.

– Tighten all of the bolts to the required tightening specifica‐

tion. Refer to ⇒ -2.4 High Pressure Pump”, page 270 .
– Place the fuse for the fuel pump control module back into the
fuse panel.
The rest of the installation is performed in the reverse order of
removal.

5.9 Fuel Pressure Sensor -G247-

Special tools and workshop equipment required
♦ Assembly Tool -T10118-
♦ Double Hexagon Socket, 1/2, 27mm -VAS5301/7-

WARNING

♦ Follow the safety measures for releasing the high side

fuel pressure. Refer to ⇒ S1.2 ide Fuel Pressure, Re‐
leasing”, page 172 .
♦ For safety reasons, remove the fuel pump control mod‐
ule fuse from the fuse panel before opening the fuel sys‐
tem. This prevents the fuel pump from being activated
by the driver door contact switch. Fuse assignment. Re‐
fer to ⇒ Wiring diagrams, Troubleshooting & Component
locations.

Removing
– Loosen the coolant pipe and oil dipstick guide from the
intake manifold -arrows- and pull off the oil dipstick guide
upward from the engine.

5. Removal and Installation 293

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Release the fuel pressure sensor connector using the -

T10118-.

WARNING

The fuel supply line is under pressure. Always wear protec‐

tive eyewear and protective clothing to prevent injuries and
fuel from coming in contact with your skin. Lay a cloth at
the connection points before loosening the hose connections.
Then reduce the pressure by carefully removing the hose.

– Remove the fuel pressure sensor using the -VAS5301/7-.

Installing
Install in reverse order of removal. Note the following:
For the correct tightening specifications. Refer to ⇒ -2.3 Fuel
Rail and Injectors”, page 268 .

5.10 Fuel Injectors

Special tools and workshop equipment required
♦ Injector/Combustion Chamber Seal Tool Set -T10133-

WARNING
Any type of fuel leak will result in an increased risk of fire.
Do not turn on the ignition, open the front doors, or attempt to
start the engine at any time while any part of the vehicle’s fuel
system is unassembled. Failing to heed this warning could
result in fire and personal injury

WARNING
♦ You must remove the fuse for the fuel pump control mod‐
ule before starting any repairs of the vehicle’s fuel system.
Failing to do so could result in fire and personal injuries.
♦ Do not turn on the ignition, open the front doors, or attempt
to start the engine at any time while any part of the ve‐
hicle’s fuel system is unassembled. Failing to heed this
warning could result in fire and personal injury

Note

-T10133/2- was changed and is now called -T10133/2-A-. If the

new tool is not available, the old one can be modified.

294 Rep. Gr.24 - Multiport Fuel Injection

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Modifying the -T10133/2- to Create -T10133/2-A-

Special tools and workshop equipment required
♦ Round File approximately 6 mm
– File a semi-circle as shown in the illustration. The semi-circle
allows the tool to slide farther onto the fuel injector. This
provides the tool with a larger contact surface.
– Mark the modified tool with an “A” at the end of the tool
number.

Fuel Injector, Individual Parts

1- Radial compensation (replace)

2- Combustion chamber seal (Teflon seal) - replace, the seal
must not be greased or be handled with any other lubri‐
cant during installation.
3- Groove on fuel injector
4- Support washer (replace)
5- O-ring (replace, coat lightly with clean engine oil when
installing)
6- Support ring

Note

With the fuel injector installed, the radial compensation -1- is

clipped into the support ring -6-. To remove the fuel injector, the
support ring must be separated from the fuel injector in order
to install the -T10133/2- into the indentation on the fuel injector
-3-.

5. Removal and Installation 295

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Removing
– Remove the intake manifold. Refer to ⇒ M5.4 anifold”, page
282 .
– Cover the intake passages with a clean cloth.
– Move the retaining hooks on the radial compensation to the
side using a screwdriver and pull off support ring from fuel
injector.

Note

The radial compensation retaining hooks are damaged by this

(retaining hooks break). The radial compensation should be
replaced before reinstalling fuel injector.

– Insert the -T10133/2A- into the groove on the fuel injector.

– Mount the -T10133/16-, turn the bolt -1- and remove the fuel
injector.
Installing

Note

♦ The Teflon seal on the fuel injector may not be oiled or

greased.
♦ Possibly an opened intake valve hinders the cleaning. In this
case, the engine must be turned further by hand using a
ratchet on the crankshaft.

– Clean the holes in the cylinder head for the fuel injectors
thoroughly using a -T10133/4-.

296 Rep. Gr.24 - Multiport Fuel Injection

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Replace the O-ring, radial compensation, support washer

and Teflon seal for the fuel injector. Refer to ⇒ I5.11 njector
Teflon® Seal”, page 297 .
– Slide the fuel injector into the bore cylinder head as far as
the stop using the -T10133/9-.

– Make sure the fuel injectors are positioned correctly inside

the cylinder head.

5.11 Fuel Injector Teflon® Seal

Special tools and workshop equipment required
♦ Injector/Combustion Chamber Seal Tool Set -T10133-

Note

The Teflon seal must not be oiled.

Procedure
– Carefully remove the old Teflon® seal with the appropriate
tool (for example, cut the seal open with a razor blade,

5. Removal and Installation 297

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

spread it outward with a small screwdriver and remove it for‐

ward). When doing this, be sure not to damage the groove
and the rib in the groove base.
– Thoroughly clean the fuel injector around the seal -arrow-
and remove any deposits (coking) using a brass brush.

– Carefully cut the seal using a knife.

– Clean the seal.
– Place a new seal onto the -T10133/5- and slide the -
T10133/6- as far as possible onto the -T10133/5-.

– Turn the -T10133/6- and slide the seal all the way to the end
on the -T10133/5-.

– Place the -T10133/5- onto the fuel injector and slide the seal
onto the fuel injector with the Assembly Sleeve -T10133/6-.

298 Rep. Gr.24 - Multiport Fuel Injection

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Remove the -T10133/5- and slide the seal on with the

-T10133/6- all the way up to the groove.
– Press the -T10133/7- with a slight turning motion (approxi‐
mately 180°) onto the fuel injector until it stops.

– Turn the -T10133/7- in the opposite direction and remove it.

– Press the -T10133/8- with a slight turning motion (approxi‐
mately 180°) onto the fuel injector until it stops.

– Turn the -T10133/8- in the opposite direction and remove it.

– Replace the O-ring on the fuel injector and the support
washer.
– Install the fuel injector again with the support ring -1- and clip
in the radial compensation -2- on the support ring.

5. Removal and Installation 299

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5.12 Engine Control Module, without Anti-

Theft Protection

Note

If the Engine Control Module (ECM) will be replaced, connect

the vehicle diagnostic tester and perform the guided function
“Replacing Engine Control Module”.

Removing
– Turn off the ignition.
– Remove the windshield wiper arm. Refer to ⇒ Electrical
Equipment; Rep. Gr. 92; Removal and Installation.
– Remove the plenum chamber bulkhead. Refer to ⇒ Body
Exterior; Rep. Gr. 50; Description and Operation.
– Press the frame downward in the direction of -arrow- and
remove the ECM.

– Push the locking mechanism for the connector in the direc‐

tion of the -arrows- and remove the connector.

300 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing
– Connect the connector to the ECM and push the locking
mechanism all the way until the stop in the direction of the
-arrow-.

– Place the ECM into the frame and press the frame upward in
the direction of the -arrow-.

– Install the plenum chamber bulkhead. Refer to ⇒ Body Exte‐

rior; Rep. Gr. 50; Description and Operation.
– Install the windshield wiper arm. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 92; Removal and Installation.

5. Removal and Installation 301

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5.13 Engine Control Module, with Anti-Theft

Protection

Note

♦ If the Engine Control Module (ECM) will be replaced, con‐

nect the vehicle diagnostic tester and perform the guided
function “Replacing Engine Control Module”.
♦ The threads on the shear bolts may have locking compound
on them. Heat the shear bolts using a -VAS1978/14- so they
are easier to remove. Do not to damage any wires, connec‐
tors or components nearby when doing this.

Removing
– Turn off the ignition.
– Remove the windshield wiper arm. Refer to ⇒ Electrical
Equipment; Rep. Gr. 92; Removal and Installation.
– Remove the plenum chamber bulkhead. Refer to ⇒ Body
Exterior; Rep. Gr. 50; Description and Operation.
– Press the frame downward in the direction of the -arrow- and
remove the ECM.

– Remove the shear bolts -arrows- with the pliers.

– Slide the screwdriver between both of the locking plates

-arrow-.

302 Rep. Gr.24 - Multiport Fuel Injection

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Carefully press the screwdriver in the direction of the -arrow-

and at the same time bend the securing bracket -1- upward.
– Bend the locking bracket -1- in the direction of the -arrow-
until it can be removed from the connectors.

– Push the locking mechanism for the connector in the direc‐

tion of the -arrow- and remove the connector.

Installing
– Connect the connector to the ECM and push the locking
mechanism all the way until the stop in the direction of the
-arrow-.

5. Removal and Installation 303

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Place the securing bracket -1- onto the connector and press
it in the direction of the -arrow-.

– Guide the bolts -2- all the way into the opening on the ECM
until they stop.
– Secure the locking bracket to the ECM with new shear bolts
-arrows- .

– Tighten the shear bolts evenly until the bolt heads shear off.
– Place the ECM into the frame and press the frame upward in
the direction of the -arrow-.

304 Rep. Gr.24 - Multiport Fuel Injection

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Install the plenum chamber bulkhead. Refer to ⇒ Body Exte‐

rior; Rep. Gr. 50; Description and Operation.
– Install the windshield wiper arm. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 92; Removal and Installation.

5. Removal and Installation 305

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

6 Special Tools
Special tools and workshop equipment required
♦ Elbow Assembly Tool -T10118-

♦ Injector/Combustion Chamber Seal - Adapter -T10133-

♦ Pressure Sensor Tester -VAS6394-

♦ Vehicle Diagnostic Tester - Test Adapter 3-pin -VAS5570-

♦ Hand Vacuum Pump -VAS6213-

306 Rep. Gr.24 - Multiport Fuel Injection

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Torque Wrench 1783 - 2-10 Nm -VAG1783-

♦ Double Hexagon Socket, 1/2, 27mm -VAS5301/7-

♦ Hose Clip Pliers -VAS6340-

6. Special Tools 307

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

26 – Exhaust System, Emission Controls

1 Description and Operation
⇒ -1.1 Exhaust System”, page 308

1.1 Overview - Exhaust System

Note

♦ The coupling element in the exhaust pipe with catalytic con‐

verter must not be bent more than 10°, otherwise it may be
damaged.
♦ Gaskets and self-locking nuts must be replaced.
♦ After exhaust system repairs, make sure the exhaust system
is not under stress and is far enough from the body. If nec‐
essary, loosen the clamping sleeve and align the muffler
and exhaust pipe so that there is adequate distance to the
body and that the weight is evenly distributed among the
suspended mounts.
♦ The exhaust manifold and turbocharger are one component
removing and installing. Refer to ⇒ 4.3 , page 252 .

308 Rep. Gr.26 - Exhaust System, Emission Controls

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4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Nut
❑ 40 Nm
❑ Always replace
❑ Coat the stud bolts on
the exhaust manifold
with Hot Bolt Paste -G
052 112 A3-.
2 - Heated Oxygen Sensor -
G39-
❑ 55 Nm
❑ Bank 1, sensor 1
❑ Only use Hot Bolt
Paste -G 052 112 A3-
to grease the threads,
do not let the paste get
onto the slits of the oxy‐
gen sensor body.
3 - Exhaust Pipe with Catalyt‐
ic Converter

Cau‐
tion
Danger of causing dam‐
age to the coupling ele‐
ment.
Do
♦ not bend the cou‐
pling element more than
10°.
Do
♦ not stretch the cou‐
pling element.
Do
♦ not damage the wire
mesh on the coupling el‐
ement.

❑ Protect the catalytic

converter from shocks
and impact stress.
❑ Removing and installing. Refer to ⇒ P3.1 ipe with Catalytic Converters”, page 314 .
❑ Align the exhaust system free of tension. Refer to ⇒ S3.2 ystem, Aligning”, page 316 .
4 - Oxygen Sensor after Three Way Catalytic Converter -G130-
❑ 55 Nm
❑ Bank 1, sensor 2
❑ Only use Hot Bolt Paste -G 052 112 A3- to grease the threads, do not let the paste get onto the slits of
the oxygen sensor body.
5 - Clamping Sleeve
❑ Before tightening, ensure the exhaust system is free of tension. Refer to ⇒ S3.2 ystem, Aligning”, page
316 .
❑ Installed position. Refer to ⇒ Fig. ““Clamping Sleeve Position”“, page 310 .
6 - Nut
❑ 23 Nm
❑ Tighten the nuts evenly.
7 - Retaining Loop
❑ Replace if damaged.
8 - Suspended Mount
9 - Bolt

1. Description and Operation 309

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018
❑ 23 Nm
10 - Vacuum Hose
❑ To the vacuum control until
❑ Individual parts of the vacuum control unit. Refer to ⇒ Fig. ““Individual Components of Vacuum Control
Unit”“, page 310
❑ Not available on all models
11 - Vacuum Actuator
❑ Check using the Vehicle Diagnostic Tester. Refer to ⇒ D2.1 oor, Checking (Golf from My 2009, Golf
Cabriolet from MY 2012 and Scirocco)”, page 312
❑ Not available on all models
12 - Rear Muffler
❑ Align the exhaust system free of tension. Refer to ⇒ S3.2 ystem, Aligning”, page 316 .
13 - Bolt
❑ 23 Nm
14 - Suspended Mount
15 - Bolt
❑ 23 Nm
16 - Bracket
❑ Riveted with a heat shield.
17 - Bolt
❑ 23 Nm
18 - Suspended Mount
19 - Gasket
❑ Always replace.

Clamping Sleeve Position

– Install the clamping sleeve in the angled position shown.

• α = approximately 20°
• The threaded connections are toward the right.
• The nuts are toward the top.
Individual Components of Vacuum Control Unit

310 Rep. Gr.26 - Exhaust System, Emission Controls

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Separating Point
2 - to Intake Manifold
3 - Vacuum Reservoir
4 - Bracket
5 - Exhaust Door Valve 1 -N321-
6 - To exhaust door vacuum actuator -item 11- ⇒ Item 11 (page
310)
Installed location of the vacuum control module is in the left rear
wheel housing

1. Description and Operation 311

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Diagnosis and Testing

2.1 Exhaust Door, Checking (Golf from My

2009, Golf Cabriolet from MY 2012 and
Scirocco)
Special tools and workshop equipment required
♦ Hand Vacuum Pump -VAS6213-

Note

The function of the exhaust flap can be checked with the output
diagnostic test mode using the Vehicle Diagnostic Tester.

Test Sequence
• Vacuum lines and hose connections not leaking
• Vacuum lines not blocked or porous
– Remove the hose from the vacuum adjusting element for the
exhaust flap.
– Connect the Hand Vacuum Pump -VAS6213- to the vacuum
adjusting element -A-.

Note

The exhaust flap for the Golf is shown.

– Set the slide ring -1- on the Hand Vacuum Pump -VAS6213-
in position -A- for “vacuum”.

312 Rep. Gr.26 - Exhaust System, Emission Controls

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Generate pressure with the Hand Vacuum Pump -VAS6213-

and watch the linkage.
Golf

• The linkage must move to the left and the exhaust flap
-arrow- must close
– Ventilate the Hand Vacuum Pump -VAS6213-.
• The linkage must move to the right and the exhaust door
-arrow- must open.
Scirocco and Golf Cabriolet from MY 2012

• The linkage for the vacuum adjusting element -1- must be

moved backwards.
– Ventilate the Hand Vacuum Pump -VAS6213-.
• Linkage must move toward front.
Continuation for All Vehicles
If linkage does not move:
– Check that the linkage moves easily and check the vacuum
adjusting element for leaks.

2. Diagnosis and Testing 313

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Removal and Installation

⇒ P3.1 ipe with Catalytic Converters”, page 314
⇒ S3.2 ystem, Aligning”, page 316

3.1 Exhaust Pipe with Catalytic Converters

Removing
– Remove the engine cover with air filter. Refer to ⇒ C5.1 over
and Air Filter”, page 278 .
– Disconnect the heated oxygen sensor connector -arrow- and
free up the wire.

– Remove the driveshaft. Refer to ⇒ Rear Final Drives, 01Z,

0BS, 0AY and 0BR; Rep. Gr. 39; Removal and Installation.
– Remove the exhaust pipe to turbocharger nuts -arrows-.

– Remove the nuts -arrows- and slightly pull the vehicle floor
cover downward.

314 Rep. Gr.26 - Exhaust System, Emission Controls

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Disconnect the oxygen sensor after three way catalytic con‐

verter connector -arrow- and free up the wire.

– Remove exhaust system suspended mount bolts -arrows-.

– Remove the front cross member nuts -arrows- and cross

member.

Caution

Danger of causing damage to the coupling elements.

♦ Do not bend the coupling element in the front exhaust
pipe more than 10°.

– Loosen the clamping sleeve -1- and push it rearward.

– Remove the exhaust pipe with the catalytic converter.
Installing
Install in reverse order of removal. Note the following:

3. Removal and Installation 315

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

♦ Coat the turbocharger stud bolts with Hot Bolt Paste -

G052112A3-.
♦ Replace gaskets and self-locking nuts.
♦ Install the exhaust system free of stress. Refer to ⇒ S3.2 ys‐
tem, Aligning”, page 316 .
Tightening Specifications
Component Nm
Exhaust pipe to turbocharger 40
Cross member to body 25
Suspended mount to sub‐ 23
frame
Clamping sleeve 23

3.2 Exhaust System, Aligning

• Align the exhaust system when cold
– Loosen the nuts -3 and 4- on the front clamping sleeve -1-.

– Align the front clamping sleeve -1- to the mark -A- on the
exhaust pipe -2- (-arrow- faces in the direction of travel).
• -a- = 5 mm
• The nuts must be at the right and must not project beyond
the lower edge of the clamping sleeve.
– Hand tighten the front nut -3- on the clamping sleeve.
– Push the exhaust system far enough forward so that the
pretension at the retaining loop for rear muffler equals 15 to
17 mm -a-.

– Tighten the front clamping sleeve nuts -3 and 4- evenly to 25

Nm in this position.

316 Rep. Gr.26 - Exhaust System, Emission Controls

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Clamping sleeve location. Refer to ⇒ Fig. ““Clamping Sleeve

Position”“, page 310 .

3. Removal and Installation 317

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Special Tools
Special tools and workshop equipment required
♦ Hand Vacuum Pump -VAS6213-

318 Rep. Gr.26 - Exhaust System, Emission Controls

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

28 – Ignition/Glow Plug System

1 General Information
⇒ P1.1 recautions”, page 319
⇒ S1.2 ystem”, page 319

1.1 Safety Precautions

To reduce the risk of personal injury and/or damage to the fuel
injection and ignition system, always observe the following:
♦ Do not touch or disconnect ignition coils with power output
stages when the engine is running or turning at starter
speed.
♦ Only disconnect and reconnect wires for the injection and
ignition system, including test leads, if the ignition is turned
off
If special testing equipment is required during a road test, note
the following:
♦ Test and measuring instruments must be secured to the rear
seat and operated by a second person from this location.
If the vehicle is involved in a collision while testing and measur‐
ing equipment is operated from the front passenger seat, the
person sitting in that seat could be seriously injured when the
airbag deploys.

1.2 Ignition System

♦ For trouble free operation of the electrical components a
voltage of at least 11.5 volt is necessary.
♦ Check the Engine Control Module (ECM) Diagnostic Trouble
Code (DTC) memory after completing the procedure. Erase
all DTC entries which may have been caused by tests and
repairs. If the DTC memory was erased, the readiness code
must be generated again. Refer to “Guided Fault Finding” in
the vehicle diagnostic tester.
♦ If the engine only starts briefly and then turns off again after
troubleshooting, repairs or checking of the components, it
may be that the immobilizer is blocking the ECM. The ECM
may have to be adapted. Refer to “Guided Functions” in the
vehicle diagnostic tester.

1. General Information 319

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

2 Description and Operation

⇒ -2.1 Ignition System Component”, page 320

2.1 Overview - Ignition System Component

Note

The Engine Speed Sensor -G28- is on the cylinder block. See

-14- in ⇒ -2.1.3 Cylinder Block”, page 24 .

320 Rep. Gr.28 - Ignition/Glow Plug System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

1 - Knock Sensor 1 -G61-

❑ It is necessary to re‐
move the thermostat
first in order to remove
the sensor. Refer to ⇒
T4.4 hermostat Hous‐
ing with Thermostat”,
page 162 .
❑ Contacts are gold plat‐
ed.
2 - Knock Sensor 2 -G66-
❑ It is necessary to re‐
move the oil filter
bracket first in order to
remove knock sensor.
Refer to ⇒ F4.3 ilter
Adapter”, page 133 .
❑ Contacts are gold plat‐
ed.
3 - Ignition Coil with Power
Output Stage -(N70, N127,
N291, N292)-
❑ Removing and instal‐
ling. Refer to ⇒
C4.1 oils with Power
Output Stages”, page
323 .
4 - Spark Plug
❑ Tightening specifica‐
tion. Refer to ⇒
D3.1 ata and Spark
Plugs”, page 322 .
❑ If the spark plug is re‐
place, grease the igni‐
tion coil with power out‐
put stage. Refer to ⇒
page 324 .
❑ Type and electrode gap. Refer to ⇒ D3.1 ata and Spark Plugs”, page 322 .
❑ Remove and install using the Spark Plug Removal Tool -3122B-.
5 - Bolt
❑ 20 Nm
❑ Tightening specification affects the function of the knock sensor.
6 - Bolt
❑ 10 Nm
7 - Camshaft Position Sensor -G40-
❑ Contacts are gold plated.
8 - O-Ring

2. Description and Operation 321

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

3 Specifications
⇒ D3.1 ata and Spark Plugs”, page 322

3.1 Test Data and Spark Plugs

Engine Code CRZA
Ignition sequence 1-3-4-2
Spark plugs
VW/Audi 101 905 631 H
Electrode gap 0.7 to 0.8 mm
Tightening specification 25 Nm
Change intervals Refer to the Maintenance Intervals, Rep. Gr.
03

322 Rep. Gr.28 - Ignition/Glow Plug System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

4 Removal and Installation

⇒ C4.1 oils with Power Output Stages”, page 323

4.1 Ignition Coils with Power Output

Stages
Special tools and workshop equipment required
♦ Puller - Ignition Coil -T40039-
Removing

Note

♦ Follow all safety precautions. Refer to ⇒ P1.1 recautions”,

page 319 .
♦ Ignition system component overview. Refer to ⇒ -2.1 Igni‐
tion System Component”, page 320 .
♦ To remove the ignition coils, place the -T40039- on the top
most thick rib -arrow- of the ignition coils with power output
stages.
♦ The lower ribs may be damaged if they are used.

– Release the connector and disconnect all the connectors at

the same time from the ignition coils.

– Remove all of the ignition coils from the spark plug shaft
using the -T40039-.

4. Removal and Installation 323

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

Installing

Note

♦ The ignition coils with power output stages must be greased

with Poly Lubricant -G 052 141 A2- to install new spark
plugs. This prevents the sealing hose on the ignition coil
from sticking on the spark plug. The lubricant must spread
onto the spark pug when installing the ignition coil.
♦ New ignition coils with power output stages are already
greased when delivered.

– Apply a thin coating of Poly Lubricant -G 052 141 A2-

around the ignition sealing hose -arrow-. The lubricant area
must be 1 to 2 mm thick.

– Install the ignition coils loosely into the spark plug shaft.
– Align the ignition coils to the connectors in direction of
-arrows- and connect all of the connectors to the ignition
coils.

324 Rep. Gr.28 - Ignition/Glow Plug System

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

– Press the ignition coils evenly onto the spark plugs by hand.

4. Removal and Installation 325

 Golf 2004 ➤, Golf 2009 ➤, Golf Cabriolet 2012 ➤, Scirocco 2009 ➤
4-Cylinder Fuel Injection Engine (2.0L Engine, Turbocharger), Volkswagen R GmbH - Edition
04.2018

5 Special Tools
Special tools and workshop equipment required
♦ Puller - Ignition Coil -T40039-

326 Rep. Gr.28 - Ignition/Glow Plug System

 Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair
work. You must answer that you have read and you understand these WARNINGS and
CAUTIONS before you will be allowed to view this information.

 If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual,
we suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially
urge you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be
covered wholly or in part by any of the extensive warranties issued by Volkswagen.

 Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

 Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only.
Always check with your authorized Volkswagen retailer parts department for the latest information.

 Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the Volkswagen Factory Approved Scan
Tool (ST).

 Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not
support a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never
work under a vehicle that is supported solely by a jack. Never work under the vehicle while the engine is
running.

 For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting
the battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock
up and become inoperable, even if the correct code is used in a later attempt.

 If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it

 Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you
from being fully alert.

 Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.

 Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid.
Wear goggles, gloves and other protective clothing whenever the job requires working with harmful substances.

 Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work
near machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery,
severe injury could result.

 Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners
with new parts where indicated, and any other time it is deemed necessary by inspection.

Page 1 of 3
© 2018 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without
notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0
 Cautions & Warnings
 Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the
vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can
ignite spilled fuel or oil.

 Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

 Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or
be crushed by heavy parts.

 Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.

 Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills
at once, but do not store the oily rags, which can ignite and burn spontaneously.

 Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening
torque listed.

 Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.

 Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose
of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local
ordinances that govern the disposal of wastes.

 The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should
be serviced only by trained automotive service technicians using approved refrigerant recovery/recycling
equipment, trained in related safety precautions, and familiar with regulations governing the discharging and
disposal of automotive chemical refrigerants.

 Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.

 Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will
increase system pressure and may cause the system to burst.

 When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).

 Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.

Page 2 of 3
© 2018 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without
notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0
 Cautions & Warnings
 Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at
the battery with the boosting cables attached. Wait at least one minute before boosting the battery a second
time.

 Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the Volkswagen Factory Approved Scan Tool (ST) or an approved
equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.

 Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have
been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the
tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely
remove the tire from the rim before attempting any repair.

 When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

I have read and I understand these Cautions and Warnings.

Page 3 of 3
© 2018 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without
notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0