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Workshop Manual
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,
Golf 2009 ➤ , Passat 2006 ➤ ,
Passat CC 2009 ➤ , Scirocco 2009 ➤ ,
Tiguan 2008 ➤
4-cyl. injection engine (1.8 and 2.0 l engine, chain
drive)
Engine ID
CAW
A
CAW
B
CBF
A
CCT
A
CCT
B
BZB
CGY
A
CCZ
B
CCZ
A
CDA
A
CCZ
C
CDA
B
CCZ
D
Edition 10.2016
Service
Service Department. Technical Information
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List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition 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 K0058895320
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Separating gearbox from engine and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Assembly overview - assembly mountings (Golf, Eos, Passat, CC, Scirocco) . . . . . . . . . . 21
2.2 Assembly overview - assembly mountings (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 24
2.4 Adjusting assembly mountings (Passat 2006 ▶, CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Adjusting assembly mountings (Golf, Eos, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.6 Adjusting assembly mounting (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3 Removing and installing tensioner for poly V-belt (Passat 2006 ▶, CC) . . . . . . . . . . . . . . 39
1.4 Removing and installing tensioner for poly V-belt (Golf, Eos, Scirocco) . . . . . . . . . . . . . . 42
1.5 Removing and installing tensioner for poly V-belt (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . 46
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.8 Renewing oil seal for vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1 Assembly overview - sealing flange on gearbox side and dual-mass flywheel/drive plate
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.1 Assembly overview - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . 83
1.3 Removing and installing upper timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.4 Removing and installing lower timing chain cover (Passat, CC) . . . . . . . . . . . . . . . . . . . . 85
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
Contents i
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1.5 Removing and installing lower timing chain cover (Golf, Eos, Scirocco) . . . . . . . . . . . . . . 91
1.6 Removing and installing bottom timing chain cover (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . 98
1.7 Camshaft timing chain - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.8 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.9 Assembly overview - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.10 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.11 Removing and installing inlet side balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.12 Removing and installing exhaust side balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.13 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.1 Cylinder head - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.2 Renewing oil non-return valve in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.3 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.6 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.3 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1 Sump and oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Removing and installing coarse oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.6 Removing and installing oil pressure control valve N428 (engine codes CCZA, CCZB, CCZC,
CCZD, CDAA, CDAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3 Oil filter, engine oil cooler and oil pressure switch (engine codes CAWA, CAWB, CBFA,
CCTA, CCTB, BZB, CGYA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.1 Assembly overview - oil filter, engine oil cooler and oil pressure switch F1 . . . . . . . . . . . . 212
3.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4 Oil filter, engine oil cooler and oil pressure switch (engine codes CCZA, CCZB, CCZC, CCZD,
CDAA, CDAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.1 Assembly overview - oil filter, engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.4 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 219
4.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2 Coolant pump, thermostat, coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.3 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
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2.4 Renewing oil seal for coolant pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.5 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 246
2.7 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.8 Removing and installing front coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.9 Removing and installing small coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.10 Continued coolant circulation pump V51 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.11 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 255
3 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3.1 Assembly overview - radiator, fan cowl and radiator fan (Passat, CC, Golf, Eos, Scirocco)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3.2 Assembly overview - radiator, radiator cowl and radiator fan (Tiguan) . . . . . . . . . . . . . . . . 259
3.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.4 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 261
3.5 Removing and installing radiator (Passat, CC, Golf, Eos, Scirocco) . . . . . . . . . . . . . . . . . . 262
3.6 Removing and installing radiator (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3 Fuel tank (Passat, CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
3.1 Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB,
CDAA, CDAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
3.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB) . . . . . . . . . . . . . . . . . . 269
3.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3.4 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4 Fuel tank (Golf, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.1 Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB,
CDAA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB) . . . . . . . . . . . . . . . . . . 280
4.3 Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA) . . . . 282
4.4 Emptying fuel tank (engine codes CBFA, CCTA, CCTB) . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
5 Fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6 Fuel tank (Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
6.1 Assembly overview - fuel tank (engine codes CAWA, CAWB, CCZA, CCZB) . . . . . . . . . . 301
6.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB) . . . . . . . . . . . . . . . . . . 303
6.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
6.4 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
7 Repairing fuel supply (Passat, CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
7.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
7.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
7.3 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
8 Repairing fuel supply system (Golf, Eos, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
8.3 Checking fuel pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
9 Repairing fuel supply (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
9.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
9.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
9.3 Removing and installing suction-jet pump, fuel filter and pressure limitation valve . . . . . . 357
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
Contents iii
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9.4 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
9.5 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
9.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
10 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
10.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
10.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
11 Activated charcoal filter system (Passat, CC, Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
11.1 Assembly overview - activated charcoal filter system (engine codes BZB, CAWA, CAWB,
CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, CDAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
11.2 Assembly overview - activated charcoal filter system (engine codes CBFA, CCTA, CCTB)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
11.3 Checking fuel tank breather (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB,
CCZC, CCZD, CDAA, CDAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
11.4 Check fuel system for leaks (engine codes CBFA, CCTA, CCTB) . . . . . . . . . . . . . . . . . . 383
12 Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB,
CGYA, CCZA, CCZB, CDAA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
12.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
12.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
13 Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB) . . . . . . 395
13.1 Overview of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
13.2 Assembly overview - activated charcoal filter system (Golf) . . . . . . . . . . . . . . . . . . . . . . . . 397
13.3 Assembly overview - activated charcoal filter system (Eos) . . . . . . . . . . . . . . . . . . . . . . . . 398
13.4 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
13.5 Removing and installing fuel system diagnostic pump V144 (Golf) . . . . . . . . . . . . . . . . . . 400
13.6 Removing and installing fuel system diagnostic pump V144 (Eos) . . . . . . . . . . . . . . . . . . 401
13.7 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1.2 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
1.4 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
1.5 Adjusting turbocharger vacuum unit (engine codes BZB, CGYA, CDAA, CDAB) . . . . . . . . 425
1.6 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
2.1 Assembly overview - charge air cooling (Passat, CC, Tiguan, Eos) . . . . . . . . . . . . . . . . . . 430
2.2 Assembly overview - charge air cooler (Golf, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
2.3 Assembly overview - sound generator (Golf, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
2.4 Actuator for structure-borne sound R214 and control unit for structure-borne sound J869
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
2.5 Turbocharging - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
2.6 Removing and installing charge air cooler (Golf, Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
2.7 Removing and installing charge air cooler (Passat, CC, Scirocco) . . . . . . . . . . . . . . . . . . 438
2.8 Removing and installing charge air cooler, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
2.9 Removing and installing charge air duct to sound generator (Golf, Scirocco) . . . . . . . . . . 440
2.10 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
1.1 General information on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
2.2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
2.3 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
2.4 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
iv Contents
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2.5 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
2.6 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
2.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
2.8 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
2.9 Removing and installing intake manifold with fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
2.10 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
2.11 Renewing Teflon seal on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
2.12 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
2.13 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
2.14 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
2.15 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
2.16 Assembly overview - high-pressure pump with fuel pressure regulating valve N276 . . . . 474
2.17 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
3 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
3.1 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
3.2 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
4 Engine control unit J623 (Passat, CC up to 11/10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
4.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
4.2 Removing and installing engine control unit with protective housing . . . . . . . . . . . . . . . . . . 484
5 Engine control unit J623 (Golf, Eos to 11/08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
5.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
5.2 Removing and installing engine control unit with protective housing . . . . . . . . . . . . . . . . . . 486
6 Engine control unit J623 (Golf, Eos, Scirocco from 11/08; CC from 11/10) . . . . . . . . . . . . 490
6.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
6.2 Removing and installing engine control unit with protective housing . . . . . . . . . . . . . . . . . . 491
7 Engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
7.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
7.2 Removing and installing engine control unit with protective housing . . . . . . . . . . . . . . . . . . 496
8 Engine control unit J623 (Scirocco to 11/08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
8.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
8.2 Removing and installing engine control unit with protective housing . . . . . . . . . . . . . . . . . . 499
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1 Exhaust system (Passat, CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1.1 Assembly overview - exhaust system (engine codes BZB, CAWA, CAWB, CGYA) . . . . . . 501
1.2 Assembly overview - exhaust system (engine codes CCTA, CCTB, CCZA, CDAA, CDAB)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
1.3 Assembly overview - exhaust system (engine code CBFA) . . . . . . . . . . . . . . . . . . . . . . . . 505
1.4 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
1.6 Installation position and specified torque of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
1.7 Removing and installing catalytic converters with front exhaust pipe . . . . . . . . . . . . . . . . 510
1.8 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
2 Exhaust system (Golf, Eos, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
2.1 Assembly overview - exhaust system (engine code CAWB) . . . . . . . . . . . . . . . . . . . . . . . . 513
2.2 Assembly overview - exhaust system (Golf 2004 ►, Eos, Scirocco, engine codes CCTA,
CCZA, CCZB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
2.3 Assembly overview - exhaust system (engine code CBFA) . . . . . . . . . . . . . . . . . . . . . . . . 518
2.4 Assembly overview - exhaust system (Golf 2009►, engine codes CCZA, CCZB) . . . . . . . . 520
2.5 Assembly overview - exhaust system (Golf 2009 ►, engine codes CCTA, CDAA) . . . . . . 522
2.6 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
2.7 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
2.8 Installation position and specified torque of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
2.9 Removing and installing catalytic converters with front exhaust pipe . . . . . . . . . . . . . . . . 526
2.10 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
Contents v
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3 Exhaust system (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
3.1 Assembly overview – exhaust system (engine codes CCTA, CCTB, CCZA, CCZB, CCZC,
CCZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
3.2 Assembly overview - exhaust system (engine codes CAWB, CCZA) . . . . . . . . . . . . . . . . 533
3.3 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
3.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
3.5 Removing and installing catalytic converters with front exhaust pipe . . . . . . . . . . . . . . . . 536
3.6 Installation position and specified torque of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
3.7 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
4 Secondary air system - engine code CBFA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
4.1 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
4.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 542
4.3 Removing and installing secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . 543
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
1.3 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
1.4 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 546
1.5 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
1.7 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
vi Contents
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00 – Technical data
1 Engine number
(VRL009686; Edition 10.2016)
The engine number (“code letters” and “serial number”) can be
found at the joint between the engine and gearbox.
The engine code is also stamped on the cylinder block behind the
oil filter.
Vehicles with four digit engine codes
Four-digit engine codes are being introduced, starting with letter
“C”. The first 3 digits show the mechanical design of engine and
are stamped on the engine as previously. The fourth digit shows
the engine output and torque and varies according to engine con‐
trol unit. The four-digit engine code can be found on the identifi‐
cation plate and on the vehicle data sticker. It can also be read
from the engine control unit.
Note
Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;
Vehicle data sticker .
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
1. Engine number 1
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2 Engine data
Identification code BZB CAWA CAWB CBFA CCTA CCTB
Manufactured from
Golf 2004 ► --- --- 05.08 ► 03.08 ► 03.08 ► ---
Eos --- --- 05.08 ► 05.08 ► 05.08 ► --
Tiguan --- 02.08 ► 02.08 ► --- 01.08 ► 05.08 ►
Scirocco --- --- 05.08 ► --- --- ---
Passat 2006 ► 11.07 ► --- 03.08 ► 03.08 ► 03.08 ► 03.08 ►
CC 03.08 ► --- 05.08 ► 10.09 ► 06.08 ► ---
Golf 2009 ► --- --- --- 07.09 ► 07.09 ► ---
Exhaust emission standard EU 4 EU 4 EU 4 SULEV ULEV 2 ULEV 2
Displace‐
ment
l 1.8 2.0 2.0 2.0 2.0 2.0
Power kW at rpm 118/5000 125/5500 147/5100 147/5100 147/5100 125/5500
Torque Nm at rpm 250/1500 280/1700 280/1700 280/1700 280/1700 280/1500
Bore Diameter, mm 82.5 82.5 82.5 82.5 82.5 82.5
Stroke mm 84.1 92.8 92.8 92.8 92.8 92.8
Compression ratio 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1
RON
95
1)
95 95 95 95 95
Ignition/injection system FSI FSI FSI FSI FSI FSI
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Charging Exhaust
turbo‐
charger
Exhaust tur‐
bocharger
Exhaust
turbo‐
charger
Exhaust
turbo‐
charger
Exhaust tur‐
bocharger
Exhaust
turbo‐
charger
Camshaft timing adjustment Yes Yes Yes Yes Yes Yes
Secondary air injection No No No Yes No No
Valves per cylinder 4 4 4 4 4 4
Oil pressure control No No No No No No
Identification code CGYA CCZA CCZB CCZC CCZD CDAA CDAB
Manufactured from
Golf 2004 ► --- --- --- --- --- --- ---
Eos --- 05.09 ► 10.09 ► --- --- --- ---
Tiguan --- 10.09 ► 05.11 ► 10.09 ► 05.11 ► --- ---
Scirocco --- --- 10.09 ► --- --- --- ---
Passat 2006 ► 11.08 ► 10.09 ► --- --- --- 10.09 ► 10.09 ►
CC 10.09 ► 10.09 ► 11.10 ► --- --- 10.09 ► 10.09 ►
Golf 2009 ► --- --- 01.09 ► --- --- 05.09 ► ---
Exhaust emission
standard
EU 4 EU 5 EU 5 EU 5 EU 5 EU 5 EU 4
Displace‐
ment
l 1.8 2.0 2.0 2.0 2.0 1.8 1.8
Power kW at rpm 112/5000 147/5100 155/5300 125/4300 132/4300 118/4500 112/5000
Torque Nm at rpm 250/1500 280/1700 280/1700 280/1700 280/1700 250/1500 250/1500
Bore Diameter,
mm
82.5 82.5 82.5 82.5 82.5 82.5 82.5
Stroke mm 84.1 92.8 92.8 92.8 92.8 84.1 84.1
Compression ratio 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1 9.6:1
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 10.2016
2 Rep. gr.00 - Technical data
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Description
Discover the 2013 Volkswagen Tiguan OEM Service & Repair Manual, a comprehensive guide designed to assist in the maintenance and repair of your Volkswagen Tiguan.
Whether you're a professional mechanic or a DIY enthusiast, this manual is meticulously developed for the S, SE, SE 4Motion, SEL, SEL 4Motion, R-Line, and R-Line 4Motion models. It provides detailed explanations, step-by-step instructions, and clear illustrations, empowering you to perform any repair or service task with confidence.
- S model
- SE model
- SE 4Motion model
- SEL model
- SEL 4Motion model
- R-Line model
- R-Line 4Motion model
Covering both routine maintenance procedures and complex repairs, this manual equips you with the essential knowledge and guidance necessary to ensure optimal performance of your Volkswagen Tiguan. By relying on the precise information provided, you can save time and money while effectively managing your vehicle's care.
Secure your 2013 Volkswagen Tiguan OEM Service & Repair Manual today and take control of your vehicle's maintenance and repair needs.
