Volkswagen 2015 Golf GTI Operating instructions

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Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition
Engine ID CNT
A
CXB
A
CNS
A
CXB
B
CNS
B
CXC
A
CXC
B
Edition 04.2015
Service
Service Department. Technical Information
ProCarManuals.com

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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
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B80416622
ProCarManuals.com

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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions, Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety Precautions, Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Cooling System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine Number/Engine Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Engine Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Wire Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Cooler and Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Engine and Transmission, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Engine, Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Engine Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Transmission Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Pendulum Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5 Engine, Supporting in Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.6 Subframe Mount, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.7 Subframe Mount, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 Overview - Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.5 Auxiliary Components Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.6 Engine Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1 Overview - Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2 Flywheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3 Sealing Flange, Removing and Installing, Transmission Side . . . . . . . . . . . . . . . . . . . . . . 59
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Main Bearing Shells Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
Contents i
ProCarManuals.com

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3.4 Crankshaft Needle Bearing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.5 Crankshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.7 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Overview - Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.3 Balance Shaft Sealing Ring, Replacing, Intake Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.1 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.2 Pistons, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.3 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.4 New Connecting Rod, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.5 Connecting Rods, Checking Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Overview - Camshaft Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 Cylinder Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.4 Vacuum Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.5 Compression Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2 Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.1 Overview - Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.2 Timing Chain Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.3 Vibration Damper Sealing Ring, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.1 Overview - Camshaft Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2 Overview - Balance Shaft Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.3 Camshaft Timing Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.4 Balance Shaft Drive Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.5 Chain Length, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.6 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2 Camshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.3 Camshaft Adjustment Valve 1 N205 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 160
4.4 Camshaft Adjustment Valve 1 N205 and Exhaust Camshaft Adjustment Valve 1 N318 ,
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.5 Sliding Bar Ball, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.6 Valve Stem Seals, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5 Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.1 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.2 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.3 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1 Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Overview - Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.3 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.4 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.5 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
ii Contents
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1.6 Oil Level Thermal Sensor G266 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 190
2 Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.1 Overview - Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.2 Engine Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.3 Mechanical Switch Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3 Crankcase Housing Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.1 Overview - Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.2 Oil Separator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4 Oil Filter/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.1 Overview - Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.2 Overview - Oil Pressure Switch/Oil Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . 198
4.3 Oil Pressure Switch F1 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.4 Reduced Oil Pressure Switch F378 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 200
4.5 Oil Pressure Switch, Level 3 F447 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 201
4.6 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.7 Piston Cooling Nozzle Control Valve N522 , Removing and Installing . . . . . . . . . . . . . . . . 205
4.8 Oil Pressure Regulation Valve N428 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 206
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1 Cooling System/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.1 Connection Diagram - Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.2 Coolant System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.3 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2 Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.1 Overview - Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.2 Overview - Electric Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.3 Overview - Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.4 After-Run Coolant Pump V51 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.5 Coolant Shut-Off Valve N82 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.6 Transmission Coolant Valve N488 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 231
2.7 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.8 Coolant Pump Toothed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.9 Engine Temperature Control Actuator N493 , Removing and Installing . . . . . . . . . . . . . . . . 237
2.10 Engine Coolant Temperature Sensor G62 , Removing and Installing . . . . . . . . . . . . . . . . 238
2.11 Engine Coolant Temperature Sensor on Radiator Outlet G83 , Removing and Installing . . 239
3 Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.1 Overview - Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.2 Front Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.3 Upper Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4 Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.1 Overview - Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.2 Overview - Auxiliary Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.3 Overview - Fan Shroud and Radiator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.4 Radiator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.5 Fan Shroud, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.6 Coolant Fan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.7 Auxiliary Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.1 Overview - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.2 Turbocharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
Contents iii
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1.3 Charge Pressure Actuator V465 , Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
2 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.1 Overview - Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Overview - Charge Air Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.3 Charge Air Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.4 Charge Air Pressure Sensor G31 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 269
2.5 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1 Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1.1 Overview - Component Location, Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1.2 High Fuel Pressure, Reducing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.1 Overview - Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.2 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.3 Intake Manifold-Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.4 Fuel Injector Seals, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.5 Fuel Injectors, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3.1 Overview - Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3.2 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.1 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.2 Overview - Intake Manifold Lower Section with Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.3 Intake Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4.4 Fuel Rail, Removing and Installing, Direct Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . 309
4.5 Throttle Valve Control Module GX3 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 309
4.6 Throttle Valve Control Module, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
5 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
5.1 Overview - Structure Borne Sound Actuator and Control Module . . . . . . . . . . . . . . . . . . . . 313
5.2 Fuel Pressure Sensor G247 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.3 Fuel Pressure Sensor G247 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.4 Low Fuel Pressure Sensor G410 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 318
6 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6.1 Engine Control Module J623 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
7 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
7.1 Overview - High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
7.2 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
8 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.1 Overview - Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.2 Oxygen Sensor 1 before Catalytic Converter GX10 , Removing and Installing . . . . . . . . . . 333
8.3 Oxygen Sensor 1 after Catalytic Converter GX7 , Removing and Installing . . . . . . . . . . . . 334
9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1 Exhaust Pipes/Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.1 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.2 Exhaust Pipes/Mufflers, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
1.3 Muffler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
1.4 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
1.5 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
1.6 Clamping Sleeve Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
2 Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
iv Contents
ProCarManuals.com

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2.1 Overview - Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
2.2 Catalytic Converter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3 Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.1 Overview - Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.2 Secondary Air Injection Pump Motor V101 , Removing and Installing . . . . . . . . . . . . . . . . 353
3.3 Secondary Air Injection Solenoid Valve N112 , Removing and Installing . . . . . . . . . . . . . . 353
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
1 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
1.1 Overview - Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
1.2 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.3 Ignition Coils with Power Output Stages, Removing and Installing . . . . . . . . . . . . . . . . . . 357
1.4 Knock Sensor 1 G61 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
1.5 Camshaft Position Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
1.6 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
Contents v
ProCarManuals.com

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Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
vi Contents
ProCarManuals.com

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00 – General, Technical Data
1 Safety Precautions
(Edition 04.2015)
⇒ 1.1 Safety Precautions, Working on Fuel Supply System,
page 1 .
⇒ 1.2 Start/Stop System Safety Precautions, page 1 .
⇒ 1.3 Safety Precautions, Road Test with Testing Equipment,
page 1 .
⇒ 1.4 Ignition System Safety Precautions, page 2 .
⇒ 1.5 Cooling System Safety Precautions, page 2 .
1.1 Safety Precautions, Working on Fuel
Supply System
There Is a Risk of Injury Because the Fuel Is under High Pressure.
Fuel system is under high pressure. Injury from fuel squirting out
is possible.
– Release the fuel system before opening the fuel system.
Procedure for releasing the fuel high pressure. Refer to
⇒ 1.2 High Fuel Pressure, Reducing, page 283 .
Burn Risk Due to Escaping Fuel.
With the battery connected, the door contact switch activates the
fuel pump when opening the driver door. Escaped fuel can ignite
and lead to fire.
– Before opening the fuel system interruption the power supply
for the fuel pump.
1.2 Start/Stop System Safety Precautions
There Is a Risk of Injury from the Engine Starting Unexpectedly.
The engine can start unexpectedly for vehicles while the start/stop
system is activated. If the Start/Stop System is activated, is rec‐
ognized by a message in the instrument cluster.
– Deactivate the Start/Stop System: switch off the ignition.
1.3 Safety Precautions, Road Test with
Testing Equipment
There Is a Risk of Injury Due to Unsecured Testing Equipment.
If the front passenger airbag activates during an accident unse‐
cured testing equipment becomes a dangerous projectile.
– Secure testing equipment on the rear seat.
or
– Have a second person operate testing equipment on the rear
seat.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
1. Safety Precautions 1
ProCarManuals.com

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1.4 Ignition System Safety Precautions
There Is a Risk of Injury Due to Electric Shock.
With the engine running the ignition system is under high voltage.
Electric shock is possible through contact with the ignition system.
– Never touch or remove ignition wires when engine is running
or turning at starting speed.
Danger of Damaging the Components.
An engine wash as well as connecting and disconnecting electri‐
cal component wires with the engine running can cause damage.
– Switch off the ignition before connecting and disconnecting
wires.
– Switch off the ignition before an engine wash.
1.5 Cooling System Safety Precautions
There Is a Risk of Burns from Hot Coolant.
The coolant system is under pressure when the engine is warm.
Risk of scalding due to hot steam and hot coolant.
– Wear safety gloves.
– Wear protective eyewear.
– Reduce the pressure: cover the coolant reservoir cap with a
cloth and carefully open.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
2 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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2 Identification
⇒ 2.1 Engine Number/Engine Characteristics, page 3
2.1 Engine Number/Engine Characteristics
Engine Number
The engine number (engine codes and serial number) are lo‐
cated at the engine/transmission joint.
The engine code is also printed behind the oil filter on the cylinder
block.
There is also a label glued to the timing chain cover with the en‐
gine code and serial number.
The first three digits describe the mechanical structure of the en‐
gine and are still stamped on the engine. The fourth digit de‐
scribes the engine output and torque and depends on the engine
control module. Four-digit engine codes are found on the type
plate and vehicle data label. It can also be read via the Engine
Control Module (ECM).
Note
Vehicle data label locations. Refer to ⇒ Maintenance ; Booklet
36.1 ; General Information; Vehicle Data Label
Engine Data
Code Letters CXBA CXBB CNSA CNSB
Manufactured from 07/2014 07/2014 07/2014 07/2014
Emissions values SULEV SULEV SULEV SULEV
Displacement liter 1.8 1.8 1.8 1.8
Output kW at RPM 125 at 4800 to
6200
125 at 4520 to
6250
125 at 4800 to
6200
125 at 4500 to
6200
Torque Nm at RPM 250 at 1500 to
4700
270 at 1600 to
4200
250 at 1500 to
4700
270 at 1500 to
4400
Bore diameter in mm 82.5 82.5 82.5 82.5
Stroke mm 84.1 84.1 84.1 84.1
Compression ratio 9.6:1 9.6:1 9.6:1 9.6:1
RON 95 95 95 95
Fuel Injection System Direct fuel in‐
jection
Direct fuel in‐
jection
Direct fuel in‐
jection
Direct fuel in‐
jection
Ignition se‐
quence
1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Turbocharger Turbocharger Turbocharger Turbocharger Turbocharger
Variable valve timing Intake and ex‐
haust camshaft
Intake and ex‐
haust camshaft
Intake and ex‐
haust camshaft
Intake and ex‐
haust camshaft
Valve stroke
adjustment
No No No No
Secondary Air Injection (AIR) Yes No Yes Yes
Valves per cylinder 4 4 4 4
Oil pressure control Yes Yes Yes Yes
Code Letters CXCA CNTA
Manufactured from 07/2014 From 11/2013
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
2. Identification 3
ProCarManuals.com

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Code Letters CXCA CNTA
Emissions values SULEV SULEV
Displacement liter 2.0 2.0
Output kW at RPM 155 at 4300 to 6200 155 at 4300 to 6200
Torque Nm at RPM 350 at 1600 to 4200 350 at 1600 to 4200
Bore diameter in mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 9.6:1 9.6:1
RON 95 95
Fuel Injection System Direct fuel injection Direct fuel injection
Ignition sequence 1-3-4-2 1-3-4-2
Turbocharger Turbocharger Turbocharger
Variable valve timing Intake and exhaust
camshaft
Intake and exhaust
camshaft
Valve stroke adjust‐
ment
Yes Yes
Secondary Air Injection (AIR) Yes Yes
Valves per cylinder 4 4
Oil pressure control Yes Yes
Codes CXCB
Manufactured from 12/2014
Emissions values SULEV
Displacement liters 2.0
Output kW at RPM 162 at 4500 to 6200
Torque Nm at RPM 350 at 1600 to 4400
Bore diameter in mm 82.5
Stroke mm 92.8
Compression ratio 9.6:1
Research Octane Number (RON) 95
Injection System Direct fuel injection
Ignition sequence 1-3-4-2
Turbocharger, Supercharger Turbocharger
Variable valve timing Intake and exhaust camshaft
Valve stroke adjustment Yes
Secondary air injection (AIR) Yes
Valves per cylinder 4
Oil pressure control Yes
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
4 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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3 Repair Information
⇒ 3.1 Clean Working Conditions, page 5 .
⇒ 3.2 Engine Contaminants, page 5 .
⇒ 3.3 Contact Corrosion, page 5 .
⇒ 3.4 Wire Routing and Securing, page 5 .
⇒ 3.5 Cooler and Condenser Assembly, page 6 .
⇒ 3.6 Vacuum System, Checking, page 6 .
3.1 Clean Working Conditions
When working on the fuel supply/injection system, pay careful at‐
tention to the following 5 rules of cleanliness:
♦ Thoroughly clean the connecting points and the surrounding
area before loosening.
♦ Place the removed parts on a clean surface and cover them.
Only use lint-free cloths!
♦ Carefully cover or seal opened components if the repair will
not be done immediately.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been stored loose (for example, in tool boxes etc.).
♦ If the system is open: do not work with compressed air. Do not
move vehicle.
♦ Make sure no fuel gets onto the fuel hoses. If necessary, wipe
off the fuel hoses immediately.
♦ Protect any disconnected connectors from dirt and moisture
and connect them only when they are completely dry.
3.2 Engine Contaminants
Special tools and workshop equipment required
♦ Engine Bung Set - VAS6122-
♦ To prevent foreign objects from entering when working on the
engine, seal open intake and exhaust channels with suitable
plugs, for example from the Engine Bung Set - VAS6122- .
3.3 Contact Corrosion
Contact corrosion can occur if incorrect fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating are
installed.
In addition, rubber or plastic parts and adhesives are made of
non-conductive materials.
If there are doubts about whether the parts are suitable, then use
new parts. Refer to the Parts Catalog.
3.4 Wire Routing and Securing
♦ Mark the individual fuel, hydraulic and vacuum lines, the EVAP
system lines or the electrical wires before disconnecting and/
or removing them. This will prevent a mix-up when reconnect‐
ing them and will ensure the original installation location is
kept.
♦ If necessary, draw sketches or take pictures.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
3. Repair Information 5
ProCarManuals.com

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♦ Due to the limited space inside the engine compartment, be
especially careful when working near moving or hot parts to
avoid damaging the lines.
3.5 Cooler and Condenser Assembly
When assembled correctly, the radiator, condenser and turbo‐
charger may have slight impressions on their fins. It is not dam‐
age. Do no replace the cooler, condenser or turbocharger
because of impressions like that.
3.6 Vacuum System, Checking
Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAS6213-
Procedure
– Check all vacuum lines in the vacuum system for:
♦ Cracks
♦ Damage caused by animals
♦ Crimps
♦ Leaks
– Check the vacuum lines leading both to and from the solenoid
valve to the respective component.
– If there is a fault, check all the vacuum lines for the named
component, but also all the vacuum lines to the other compo‐
nents.
– If using the Hand Vacuum Pump - VAS6213- does not produce
any pressure or if the pressure drops again right away, then
check the hand vacuum pump and the connection hoses for
leaks.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
6 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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4 Special Tools
Special tools and workshop equipment required
♦ Hand Vacuum Pump - VAS6213-
♦ Engine Bung Set - VAS6122-
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
4. Special Tools 7
ProCarManuals.com

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10 – Engine Assembly
1 Engine, Removing and Installing
⇒ 1.1 Engine, Removing, page 8 .
⇒ 1.2 Engine and Transmission, Separating, page 19 .
⇒ 1.3 Engine, Securing on Engine and Transmission Holder,
page 23 .
⇒ 1.4 Engine, Installing, page 24 .
1.1 Engine, Removing
Special tools and workshop equipment required
♦ Engine and Gearbox Jack - VAS6931-
♦ Engine/Gearbox Jack - Engine Support - T10359A-
♦ Engine/Gearbox Jack - Pin - T10359/2-
♦ Engine/Gearbox Jack - Adapter - T10359/3-
♦ Fuse Element from Transmission Support - 3282-
♦ Pry Lever - 80–200-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Hose Clamps - Up To 25mm - 3094-
♦ Protective Eyewear
♦ Safety Gloves
♦ Step Ladder
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Bolts - Engine Mount
Note
The engine with transmission is removed downward. For this rea‐
son it is necessity to remove the subframe.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
8 Rep. Gr.10 - Engine Assembly
ProCarManuals.com

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Procedure
CAUTION
The coolant system is under pressure when the engine is warm.
Risk of scalding due to hot steam and hot coolant.
Possibility of burning or scalding the skin and other parts of the
body.
– Wear safety gloves.
– Wear protective eyewear.
– Reduce the pressure: cover the coolant reservoir cap with a
cloth and carefully open.
– Remove the cap -arrow- from the coolant expansion tank.
– Remove the subframe and steering gear. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe
with Steering Gear, Removing and Installing .
– Remove the left and right front wheel housing liners front sec‐
tion. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing
Liner; Front Wheel Housing Liner, Removing and Installing .
– Place the Shop Crane - Drip Tray - VAS6208- underneath.
– Disconnect the connector -1-.
– Lift the clamp -3- and remove the lower right coolant hose from
the radiator.
– Allow the coolant to drain.
– Remove the engine cover. Refer to
⇒ 3.1 Engine Cover, Removing and Installing, page 38 .
– Remove the bolts -1 and 3-.
– Open the retainer in direction of -arrow- and remove the cover
-2-.
– Free up the coolant hose -2-.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
1. Engine, Removing and Installing 9
ProCarManuals.com

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– Open the retaining tabs in direction of -arrows-, remove the
upper air duct -1-.
– Disconnect the vacuum hose -1-.
– Loosen the clamp -2- and remove the air guide hose.
– Remove the air filter housing -3-.
– Remove the left and right bolts -arrow-.
– Unclip the air guide lower section -1- and remove.
– Remove the battery tray. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery Tray, Removing and Installing .
– Disconnect the vacuum hose -2-.
– Press the release button on the vacuum hose -1-, remove the
hose from the vacuum pump.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
10 Rep. Gr.10 - Engine Assembly
ProCarManuals.com

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Vehicles without Auxiliary Heater
– Lift the clamps -arrows-, remove the coolant hoses from the
heater heat exchanger.
– Hold the coolant hoses downward and drain the coolant.
Vehicles with Parking Heater
– Loosen the hose clamp -1-, lift the clamps -arrows- and re‐
move the coolant hoses.
Continuation for All Vehicles
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
1. Engine, Removing and Installing 11
ProCarManuals.com

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– Remove the connectors -1 and 2- from the holder and discon‐
nect them. Then free up the electric wires.
– Remove the bolt -2- and the screw-type clamp.
– Remove the nuts -1 and 3-.
Note
♦
The installed position is shown in the illustration with the en‐
gine removed.
♦ Ignore -4-.
CAUTION
Fuel system is under pressure.
Risk of injury from fuel spraying out.
– Wear protective eyewear.
– Wear safety gloves.
– Reduce the pressure: Lay clean cloths around the connec‐
tion location and carefully open the connection point.
– Disconnect the hose couplings -1 and 2-. Refer to ⇒ Fuel
Supply System; Rep. Gr. 20 ; Connector Couplings; Connec‐
tor Couplings, Separating . Loosen the hose clamp from the
expansion tank -3-.
– Loosen the clamps -1 and 2- and remove the coolant hoses.
Golf 2015 ➤ , Golf Variant 2015 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 04.2015
12 Rep. Gr.10 - Engine Assembly
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