2012 Volkswagen Passat Download Service & Repair Manual
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Repair Manual
Passat (NMS - US) 2012 ➤
Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA
288)
Engine ID
CVC
A
DEK
A
Edition 09.2016
Service
Service Department. Technical Information
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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
23 - Diesel 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 D4B8044BE84
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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions when Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 2
1.3 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety Precautions when Working on Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety Precautions when Working on SCR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Safety Precautions when Working on Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Engine Number/Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Foreign Objects in Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Line Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Radiator and Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Selective Catalytic Reduction (SCR) System Adaptation Value, Adapting . . . . . . . . . . . . 7
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Engine and Transmission, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Engine, Securing to Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Engine Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Transmission Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Pendulum Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Engine, Supporting in Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Subframe Mount, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.7 Subframe Mount, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.1 Overview - Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.2 Overview - Belt Pulley Side Sealing Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.5 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.6 Sub-Assembly Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Engine Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.8 Sealing Flange, Removing and Installing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Overview - Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2 Flywheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Sealing Flange, Removing and Installing, Transmission Side . . . . . . . . . . . . . . . . . . . . . . 56
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
Contents i
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3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3 Crankshaft Needle Bearing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4 Crankshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1 Overview - Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2 Pistons, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Piston Projection, Measuring at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.4 Piston and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.5 Connecting Rods, Checking Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Overview - Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.3 Cylinder Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.4 Cylinder Head Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.5 Fuel Injector Seals, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.6 Camshaft Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.7 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2 Toothed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.1 Overview - Toothed Belt Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.2 Overview - Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.3 Toothed Belt Guard, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.4 Toothed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.5 Toothed Belt, Removing from Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.2 Camshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.3 Camshaft Seal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.4 Camshaft Adjuster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.5 Camshaft Adjustment Valve 1 N205 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 130
3.6 Hydraulic Lifter, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.7 Valve Stem Seals, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.8 Control Valve from the Camshaft Adjuster, Removing and Installing . . . . . . . . . . . . . . . . . . 138
4 Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.1 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.3 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1 Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Overview - Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.3 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.4 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.5 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.6 Oil Level Thermal Sensor G266 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 162
2 Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3 Oil Filter/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.1 Overview - Oil Filter Housing/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.2 Oil Pressure Switch F1 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.3 Reduced Oil Pressure Switch F378 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 166
Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
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3.4 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.5 Oil Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.6 Oil Pressure Regulation Valve N428 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 170
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1 Coolant System/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.1 Connection Diagram - Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.2 Overview - Engine Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.3 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.4 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2 Coolant Pump/Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.1 Overview - Coolant Pump/Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.2 Overview - Electric Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.3 Overview - Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.4 Electric Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.5 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.6 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.7 Coolant Thermostat, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.8 Cylinder Head Coolant Valve N489 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 206
2.9 Engine Coolant Temperature Sensor G62 , Removing and Installing . . . . . . . . . . . . . . . . 207
2.10 Engine Coolant Temperature Sensor on Radiator Outlet G83 , Removing and Installing . . 209
3 Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.1 Overview - Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.2 Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4 Radiator/Radiator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.1 Overview - Radiator/Radiator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.2 Radiator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.3 Charge Air Cooling Circuit Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 224
4.4 Fan Shroud with Radiator Fan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.5 Radiator Fan V7 / Right Radiator Fan V35 , Removing and Installing . . . . . . . . . . . . . . . . 227
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.1 Overview - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.2 Turbocharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.3 Turbocharger Vacuum Diaphragm, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.4 Turbocharger Connections, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2.1 Overview - Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2.2 Charge Air Pressure Sensor G31 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 249
2.3 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.4 Charge Air Cooler, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.1 Schematic Overview - Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.2 Component Location Overview - Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
1.3 Fuel System, Filling/Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
1.4 Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.1 Connection Diagram - Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
Contents iii
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2.2 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3 Fuel Injectors/High Pressure Reservoir (Rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3.1 Overview - Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3.2 Overview - High Pressure Reservoir (Rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3.3 Fuel Injectors, Adapting Correction Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.4 Fuel Injectors, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.5 Fuel Injectors, Checking Return Quantity with Engine Running . . . . . . . . . . . . . . . . . . . . . . 275
3.6 Fuel Injectors, Checking Return Quantity at Cranking Speed . . . . . . . . . . . . . . . . . . . . . . 278
3.7 Open Fuel Injectors, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.8 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3.9 High Pressure Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.10 High Pressure Reservoir (Rail), Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.1 Overview - Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.2 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
5 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.1 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Throttle Valve Control Module J338 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 294
5.3 Intake Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
6.1 Fuel Pressure Regulator Valve N276 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 301
6.2 Fuel Pressure Regulator Valve N276 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
6.3 Fuel Pressure Sensor G247 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
6.4 Mass Airflow Sensor G70 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
6.5 Differential Pressure Sensor G505 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 310
6.6 Exhaust Pressure Sensor 1 G450 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 311
6.7 Charge Air Temperature Sensor in Front Of Charge Air Cooler G810 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
6.8 Charge Air Temperature Sensor after Charge Air Cooler G811 , Removing and Installing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
6.9 Fuel Temperature Sensor G81 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 313
6.10 NOx Sensor Control Module GX30 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 314
6.11 Overview - NOx Sensor Control Module GX30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
6.12 Fuel Low Pressure Temperature and Pressure Sensor GX20 , Removing and Installing . . 318
7 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
7.1 Engine Control Module J623 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
7.2 Engine Control Module J623 with Protective Housing, Removing and Installing . . . . . . . . 321
8 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
8.1 Overview - High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
8.2 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
9 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
9.1 Overview - Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
9.2 Heated Oxygen Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1 Exhaust Pipes/Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.1 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.2 Front Exhaust Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.3 Exhaust Pipes/Mufflers, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.4 Rear Muffler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.5 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.6 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
1.7 Tail Pipes, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2 Emissions Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
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2.1 Overview - Emissions Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
2.2 Emissions Control Module, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
2.3 Exhaust Door Control Unit J883 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 352
3 Selective Catalytic Reduction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3.1 Overview - Reducing Agent Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3.2 Overview - Reducing Agent Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
3.3 Overview - Reducing Agent Delivery Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3.4 Reducing Agent Tank, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3.5 Reducing Agent Delivery Line, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 359
3.6 Reducing Agent Delivery Module, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 361
3.7 Reducing Agent Injector N474 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3.8 Reducing Agent Heater Control Module J891 , Removing and Installing . . . . . . . . . . . . . . 365
3.9 Overview - Reducing Agent Injector N474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
3.10 Reducing Agent Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
3.11 Reducing Agent Delivery Line, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
4 Exhaust Temperature Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4.1 Overview - Exhaust Temperature Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4.2 Exhaust Gas Temperature Sensor 1 G235 , Removing and Installing . . . . . . . . . . . . . . . . 375
4.3 Exhaust Gas Temperature Sensor 2 G448 , Removing and Installing . . . . . . . . . . . . . . . . 376
4.4 Exhaust Gas Temperature Sensor 3 G495 , Removing and Installing . . . . . . . . . . . . . . . . 378
4.5 Exhaust Gas Temperature Sensor 4 G648 , Removing and Installing . . . . . . . . . . . . . . . . 379
5 Exhaust Gas Recirculation (EGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
5.1 Overview - Exhaust Gas Recirculation (EGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
5.2 Overview - EGR Valve 1 GX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
5.3 EGR Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
5.4 EGR Valve 1 GX5 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
5.5 EGR Valve 2 GX6 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
5.6 EGR Temperature Sensor G98 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 388
5.7 EGR Cooler, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.1 Overview - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.2 Glow Plug, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
1.3 Automatic Glow Time Control Module J179 , Removing and Installing . . . . . . . . . . . . . . . . 398
1.4 Camshaft Position Sensor G40 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 399
1.5 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
Contents v
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Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
vi Contents
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00 – General, Technical Data
1 Safety Precautions
(Edition 09.2016)
⇒ “1.1 Safety Precautions when Working on Fuel Supply System”,
page 1
⇒ “1.2 Safety Precautions when Working on Vehicles with Start/
Stop System”, page 2
⇒ “1.3 Safety Precautions during Road Test with Testing Equip‐
ment”, page 2
⇒ “1.4 Safety Precautions when Working on Cooling System”,
page 2
⇒ “1.5 Safety Precautions when Working on SCR System”, page
3
⇒ “1.6 Safety Precautions when Working on Exhaust System”,
page 4
1.1 Safety Precautions when Working on
Fuel Supply System
Note the following When Working on the Fuel System:
WARNING
Very hot fuel can cause burns.
♦ In extreme cases, the temperature of the fuel lines and fuel
can reach up to 100 °C (212 °F) after stopping the engine.
Let the fuel cool down before opening any line connec‐
tions, otherwise there is a danger of scalding.
♦ Wear safety gloves.
♦ Wear protective eyewear.
There Is a Risk of Injury Due to the Fuel Being under Pressure.
The fuel system is under pressure. Injuries are possible from fuel
spraying out.
Before opening the fuel system:
– Wear protective eyewear.
– Wear safety gloves.
– Reduce the pressure: place clean cloths around the connec‐
tion point and carefully open the connection point.
Risk of a Fire Due to Leaking Fuel.
When the battery is connected, the door contact switch activates
the fuel pump when opening the driver door. Leaking fuel can
ignite and start a fire.
– Before opening the fuel system, interrupt the power supply to
the fuel pump.
Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
1. Safety Precautions 1
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1.2 Safety Precautions when Working on
Vehicles with Start/Stop System
There Is a Risk of Injury Due to the Engine Starting Unexpectedly.
The engine can start unexpectedly on vehicles with an activated
Start/Stop System. A message in the instrument cluster indicates
whether the Start/Stop System is activated.
– Deactivate the Start/Stop System: switch off the ignition.
1.3 Safety Precautions during Road Test
with Testing Equipment
There Is a Risk of Injury Caused by Unsecured Testing Equip‐
ment.
If the front passenger airbag deploys during an accident, unse‐
cured testing equipment becomes a dangerous projectile.
– Secure the testing equipment on the rear seat.
or
– Have a second technician operate the testing equipment on
the rear seat.
1.4 Safety Precautions when Working on
Cooling System
Risk of Scalding Due to Hot Coolant
The cooling 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 by covering the coolant expansion tank
cap with a cloth and carefully opening it.
Passat (NMS - US) 2012 ➤ , Passat (NMS - US) 2016 ➤
4-Cylinder Common Rail (2.0L, 4V, Turbocharger, EA 288) - Edition 09.2016
2 Rep. Gr.00 - General, Technical Data
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Introducing the 2012 Volkswagen Passat Download Service & Repair Manual, an essential tool for owners and enthusiasts of the 2012 Volkswagen Passat. This comprehensive manual provides detailed information and step-by-step instructions for servicing and repairing your vehicle.
Whether you are a professional mechanic or a DIY enthusiast, this manual is designed to help you maintain and repair your Volkswagen Passat with ease. It covers a wide range of topics, including engine, transmission, electrical system, suspension, brakes, and more.
Key features of the 2012 Volkswagen Passat Download Service & Repair Manual:
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Models covered:
- 2012 Volkswagen Passat S
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- 2012 Volkswagen Passat TDI
With the 2012 Volkswagen Passat Download Service & Repair Manual, you can confidently tackle any maintenance or repair task on your Volkswagen Passat. Don't let a small issue become a big problem - equip yourself with this comprehensive manual today!
