CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...

4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

13 – Crankshaft group
1 Cylinder block (pulley end)
Assembly overview - poly V-belt drive ⇒ pageen36
AG.. Volkswagen AG does ag
ol not ksw
Removing and installing poly V-belt b⇒
y Vpage 38 gu
ara
ed
ris nte
Removing and installing tensioner
utho for poly V-belt (Passat 2006 ▶, eo
CC) ⇒ page 39 . ss
a ra
c

ce
le

Removing and installing tensioner for poly V-belt (Golf, Eos, Scir‐
un

pt
an
d

occo) ⇒ page 42 .
itte

y li
erm

ab
Removing and installing tensioner for poly V-belt (Tiguan)

ility
ot p

⇒ page 46 .

wit
is n

h re
Removing and installing bracket for ancillary units ⇒ page 49 .
ole,

spec
urposes, in part or in wh

Removing and installing vibration damper ⇒ page 50

t to the co
Renewing oil seal for vibration damper ⇒ page 57 .

1.1 Assembly overview - poly V-belt drive

rrectne

[Link]
ss
1 - Vibration damper

o
cial p

f in
❑ With poly V-belt pulley

form
mer

❑ Removing and installing

atio
m

⇒ page 50
o

n
c

i
or

n
2 - O-ring
thi
te

sd
va

❑ Renew
i

o
pr

cum
r
fo

en
ng

3 - Bolt yi
t.
Co
op
❑ Renew
C py
t. rig
gh ht
yri
❑ Removing and installing p by
co Vo
lksw
⇒ page 50
by
cted agen
Prote AG.
❑ 150 Nm + 90° (1/4 turn)
further
❑ Use counterhold -
T10355- when loosen‐
ing and tightening
4 - Poly V-belt
❑ Check for wear
❑ Do not kink

Caution
Danger of destruction
due to reverse running
direction in the case of a
poly V-belt that has al‐
ready run.
Before
♦ removing the poly
V-belt, use a piece of
chalk or a felt pen to mark
the running direction.

❑ Removing and installing

⇒ page 38
❑ When installing, make
sure it is properly seated on pulleys.

36 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

5 - Tensioning device for poly V-belt

❑ Swing with open-end spanner to slacken poly V-belt.
❑ Lock with locking pin - T10060 A- .
❑ Components of tensioner for poly V-belt ⇒ page 37
❑ Removing and installing (Passat, CC) ⇒ page 39
❑ Removing and installing (Golf, Eos, Scirocco) ⇒ page 42
❑ Removing and installing (Tiguan) ⇒ page 46
6 - Ancillary bracket
❑ With oil pressure switch - F1- , oil filter and engine oil cooler
❑ Removing and installing ancillary bracket ⇒ page 49 .
❑ Removing and installing engine oil cooler ⇒ page 220
7 - Bolt
❑ 10 Nm
8 - Alternator
❑ Removing and installing ⇒ Rep. gr. 27
9 - Bolt

[Link]
❑ 23 Nm
10 - Bolt
❑ Tightening sequence ⇒ page 38
11 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant lines AG. Volkswagen AG d
agen oes
❑ Removing and installing ⇒ Rep. gr. 87 olksw not
byV gu
ara
ed
12 - Bolt horis nte
eo
ut
❑ 25 Nm ss a ra
c

ce
le

13 - Dowel sleeve
un

pt
an
d
itte

❑ For air conditioner compressor.

y li
rm

ab
pe

ility
ot

wit
, is n

h re
Components of tensioner for poly V-belt
hole

spec
1- Tensioning device for poly V-belt
es, in part or in w

t to the co
2- Support element
3- Ancillary bracket
rrectness of i
4- Centring sleeve
l purpos

5- Bolt
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 37

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
n AG. Volkswagen AG do
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)olk-sEdition
wage 02.2017 es n
o
yV t gu
db ara
Tightening sequence on bracket for ancillaries rise nte
tho eo
au ra
– Fit ancillary bracket (start bolt -4- first). ss c

ce
e
nl

pt
– Tighten bolts in sequence -1 … 5- in 3 stages as follows:

du

an
itte

y li
erm

ab
1. Tighten bolts hand-tight.

ility
ot p

wit
2. Tighten bolts to 20 Nm.

, is n

h re
hole

spec
3. Turn bolts 90° (1/4 turn) further.

es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
1.2 Removing and installing poly-V belt
te

sd
a

[Link]
iv

o
r
rp

cu
Removing
o

m
f

en
ng

t.
yi Co
Cop py
Caution
t. rig
gh ht
pyri by
Vo
co lksw
by
Danger of destruction due to reverse running direction in the
cted agen
Prote AG.
case of a poly V-belt that has already run.
♦ Before removing the poly V-belt, use a piece of chalk or a
felt pen to mark the running direction.

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation .
– Remove right air hose -arrows-.

38 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Turn tensioner in direction of -arrow- to relieve tension on poly

V-belt.
– Use the locking pin - T10060 A- to lock the tensioner.
– Remove poly V-belt.
Installing
Install in reverse order of removal, observing the following.

Note

Tighten alternator and air conditioner compressor mountings be‐

fore fitting poly V-belt.

– Fit poly V-belt onto crankshaft pulley first, then onto air condi‐
tioner compressor and alternator.

[Link]
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Turn tensioner slightly with ring spanner and remove locking
ce
le
un

pt

pin - T10060 A- .
an
d
itte

y li

– Release tensioner.
erm

ab
ility
ot p

– Check that poly V-belt is properly seated.

wit
is n

h re

– Start engine and check that poly V-belt runs properly.

ole,

spec
urposes, in part or in wh

t to the co
rrectness o

1.3 Removing and installing tensioner for poly V-belt (Passat 2006 ▶, CC)
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 39

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Special tools and workshop

equipment required
♦
♦ Support - 10 - 222 A-
♦ Hook - 10 - 222 A /10- , qty.
2
♦ Shackle - 10 - 222 A /12-
♦ Passat: frame - 10 - 222 A /
1-
♦ CC: Adapter - 10 - 222 A /
8- AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility

[Link]
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi
♦ Pin - T10060 A-
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing
Proceed as follows:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove front part of right wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liner .

40 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– First, undo bolt -1- and then bolts -2…3- and remove pendu‐
lum support.

– Remove bolt -2- at bracket for coolant pump for continued cir‐
culation - V51- .

[Link]
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Vehicles with seat heating:

ce
le
un

pt
– Slacken clip -1- and remove bolt -2-.

an
d
itte

y li
rm

ab
– Detach exhaust silencer for auxiliary heater.
pe

ility
ot

wit
– Fit support bracket - 10 - 222 A- with the following tool parts:
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Passat:
nform
ercia

♦ Rack - 10 - 222 A /1- , qty. 2

m

a
com

♦ Hook - 10 - 222 A /10-

ion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Cylinder block (pulley end) 41

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

CC:
♦ Adapter - 10 - 222 A /8- , qty. 2 AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Hook - 10 - 222 A /10- ed b ara
nte
ris
ho eo
♦ Shackle - 10 - 222 A /12- aut ra
c
ss

ce
e
nl

pt
du

an
Note

itte

y li
erm

ab
ility
♦ The adapters - 10 - 222 A /8- must not be located on the screw

ot p

wit
plates of the wings, as this will otherwise cause damage to
, is n

h re
them. hole

spec
♦ The shackle - 10 - 222 A /12- is needed so the engine is raised
es, in part or in w

t to the co
in its installation position and does not »fall back«.

All:

rrectness of i
– Take up weight of engine with spindle.
l purpos

nf
ercia

– Unscrew bolts -arrows- of engine/gearbox support on the en‐

or

[Link]
gine.

m
m

atio
om

– Lower engine approx. 55 mm.

n in
or c

thi
e

– Remove poly V-belt ⇒ page 38 .

t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Move electrical wiring harness clear -arrow-.

– Remove bolt -1- and take off tensioning device for poly V-belt
from bracket for ancillaries.

Installing
• Torque setting ⇒ page 36 .
Install in reverse order of removal, observing the following.
– Insert tensioner -1- for poly V-belt in ancillary bracket -3- and
tighten bolt -5-.
• Note installation position of support element -2-: fit lug of sup‐
port element in hole on bracket for ancillaries.
• Note position of centring sleeve -4-.
– Adjust assembly mountings ⇒ page 24 .

1.4 Removing and installing tensioner for poly V-belt (Golf, Eos, Scirocco)

42 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Special tools and workshop

equipment required
♦ Support - 10 - 222 A-
♦ Hook - 10 - 222 A /10- n AG. Volkswagen AG do
lkswage es n
♦ Shackle - 10 - 222byAVo/12- ot g
ua
d ran
ir se
♦ Pin - T10060 uth A-
o tee
or
a ac
♦ Torque wrench - V.A.G ss

ce
le

1331-
un

pt
an
d
itte

y li
♦ Golf: frame - 10 - 222 A /13-
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

[Link]
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Eos, Scirocco: Rack - 10 - 222 A /1-

Removing
Proceed as follows:
– If fitted, remove charge air duct to sound generator
⇒ page 447 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .

1. Cylinder block (pulley end) 43

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– First, undo bolt -1- and then bolts -2…3- and remove pendu‐
lum support.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

– Remove bolt -2- at bracket for coolant pump for continued cir‐

h re
ole,

culation - V51- .

spec
urposes, in part or in wh

t to the co
rrectne

[Link]
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
Vehicles with seat heating:
te

sd
iva

o
pr

c
– Slacken clip -1- and remove bolt -2-. um
r
fo

en
ng

t.
– Detach exhaust silencer for auxiliary heater.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf:
– Fit support bracket - 10 - 222 A- with the following tool parts:
♦ Rack - 10 - 222 A /13-
♦ Hook - 10 - 222 A /10-

44 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Eos, Scirocco:
– Fit support bracket - 10 - 222 A- with the following tool parts:
♦ Rack - 10 - 222 A /1-
♦ Hook - 10 - 222 A /10-
♦ Shackle - 10 - 222 A /12-

n AG. Volkswagen AG do
Note lkswage es n
o ot g
byV ua
d ran
ir se
♦ The rack feet - 10 - 222 A /1- must not be placedth on the bolted
o tee
or
on sheet metal of the wings, or these mightssbeau damaged. ac

ce
le
♦ The shackle - 10 - 222 A /12- is needed so the engine is raised

un

pt
an
d
in its installation position and does not »fall back«.
itte

y li
rm

ab
pe

ility
All:
ot

wit
, is n

h re
– Take up weight of engine with spindle.
hole

spec
– Remove poly V-belt ⇒ page 38 .
es, in part or in w

t to the co

[Link]
– Unscrew bolts -arrows- of engine/gearbox support on the en‐
gine.

rrectness of i
– Lower engine approx. 55 mm.
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
op py
– Move electrical wiring harness clear -arrow-. t. C rig
gh ht
pyri by
Vo
– Remove bolt -1- and take off tensioning device for poly V-belt
co lksw
by
cted agen
from bracket for ancillaries. Prote AG.

Installing
• Torque setting ⇒ page 36 .
Install in reverse order of removal, observing the following.
– Insert tensioner -1- for poly V-belt in ancillary bracket -3- and
tighten bolt -5-.
• Note installation position of support element -2-: fit lug of sup‐
port element in hole on bracket for ancillaries.
• Note position of centring sleeve -4-.
– Adjust assembly mountings ⇒ page 28 .

1. Cylinder block (pulley end) 45

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

1.5 Removing and installing tensioner for

poly V-belt (Tiguan)
Special tools and workshop equipment required
♦ Support - 10-222A-

♦ Shackle - 10-222A/12-
♦ Adapter - 10-222A/16-

[Link]
♦ Adapter - 10-222A/18-
♦ Adapter - 10-222A/22-
♦ Adapter - 10-222A/28-
♦ Square tube - T40091/1-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab

♦ Swivel joint - T40091/3-

ility
ot p

wit

Removing
, is n

h re
hole

Proceed as follows:
spec
es, in part or in w

– Remove noise insulation ⇒ General body repairs, exterior;

t to the co

Rep. gr. 50 ; Noise insulation .

– Remove front right wheel housing liner ⇒ General body re‐
rrectness of i

pairs, exterior; Rep. gr. 66 ; Wheel housing liner .

l purpos

– First, undo bolt -1- and then bolts -2…3- and remove pendu‐
lum support.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

46 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Vehicles with all-wheel drive:

– Unscrew heat shield for flexible coupling.

– Mark position of propshaft with flexible coupling relative to

output shaft of bevel box.
– Unbolt propshaft -arrows- and pull off from bevel box.

[Link]
Counterhold at rear final drive when loosening or tightening prop‐
shaft.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li

All:
erm

ab
ility
ot p

– Remove bolt -2- at bracket for coolant pump for continued cir‐
wit
, is n

culation - V51- .
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 47

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017
AG. Volkswagen AG d
Vehicles with seat heating: agen oes
olksw not
V gu
by ara
– Slacken clip -1- and remove bolt -2-. rised
nte
ho eo
ut
– Detach exhaust silencer for auxiliary heater. ss a ra
c

ce
le
All:

un

pt
an
d
itte

y li
– Remove motor cover panel ⇒ page 139 .

rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Fit support bracket - 10 - 222 A- as shown. The rear spindle is

rrectness of i
not required. Attach hooks to support eyes on engine and
support engine and gearbox.
l purpos

– Take up weight of engine with spindle.

nform
mercia

a
com

tion in

[Link]
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Unscrew bolts -arrows- of engine/gearbox support on the en‐

gine.
– Lower engine approx. 55 mm.

– Remove poly V-belt ⇒ page 38 .

– Move electrical wiring harness clear -arrow-.

– Remove bolt -1- and take off tensioning device for poly V-belt
from bracket for ancillaries.

48 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Installing
• Torque setting ⇒ page 36 .
Install in reverse order of removal, observing the following.
– Insert tensioner -1- for poly V-belt in ancillary bracket -3- and
tighten bolt -5-.
• Note installation position of support element -2-: fit lug of sup‐
port element in hole on bracket for ancillaries.
• Note position of centring sleeve -4-.
– Adjust assembly mountings ⇒ page 32 .

1.6 Removing and installing bracket for an‐

cillaries
Removing
Proceed as follows:
– Drain coolant ⇒ page 235 .

[Link]
– Remove poly V-belt ⇒ page 38 .
AG. Volkswagen AG d
agen oes
– If fitted, remove charge air duct
olkto
sw sound generator not
yV gu
⇒ page 447 . se
d b ara
nte
ri
ho eo
– Remove alternator ⇒aut Rep. gr. 27 . ra
c
ss
– Remove electrical connector -1- for control valve for compres‐
ce
e
nl

pt
du

sor of air-conditioning system - N280- .

an
itte

y li
erm

ab
ility
WARNING
ot p

wit
, is n

h re

Danger of injury due to coolant.

hole

spec
es, in part or in w

♦ The air conditioner refrigerant circuit must not be opened.

t to the co

– Unscrew bolts -arrows- for air conditioning compressor.

rrectness of i
l purpos

Caution
nf
ercia

Danger of damage to coolant lines and hoses.

orm
m

♦ Do not stretch, kink or bend refrigerant lines and hoses.

atio
om

n in
or c

thi
te

sd
a

– Fasten air-conditioning compressor together with connected

iv

o
r
rp

cu

coolant hoses to the longitudinal member above.

o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 49

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove bolt -arrow- for dipstick guide tube.

– Unscrew bolts -1 … 5- and detach bracket for ancillary units
from coolant pump housing. n AG. Volkswagen AG do
swage es n
Installing byV
olk ot g
ua
d ran
ir se tee
tho
u or
a ac
Note ss

ce
le
un

pt
♦ If a further tightening angle is specified for certain bolts, these

an
d
itte

y li
must be renewed.

erm

ab
ility
ot p
♦ Renew O-rings and gaskets.

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectnes
– Moisten O-rings -4- with coolant.

s o
cial p

[Link]
in
– Insert connecting piece -2- into coolant pump housing -3-.

form
mer

– Push ancillary bracket -1- onto connecting piece -2-.

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Fit ancillary bracket (start bolt -4- first).

– Tighten bolts in sequence -1 … 5- in 3 stages as follows:
1. Tighten bolts hand-tight.

2. Tighten bolts to 20 Nm.

3. Turn bolts 90° (1/4 turn) further.

The remaining installation steps are carried out in the reverse se‐
quence. Note the following:
♦ Specified torques ⇒ page 36 .
♦ Install A/C compressor ⇒ Rep. gr. 87 .
♦ Install alternator ⇒ Rep. gr. 27 .

1.7 Removing and installing vibration damp‐

er
Special tools and workshop equipment required

50 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Counterhold tool - T10355-

♦ Assembly tool - T10531-

[Link]
n AG. Volkswagen AG do
lkswage es n
Vo ot g
Components of assembly tool - T10531-ed: by ua
ran
ir s tee
o
♦ Support - T10531/1- auth or
ac
ss
♦ Clamping pin - T10531/2-
ce
e
nl

pt
du

an
♦ Turning over tool - T10531/3-
itte

y li
erm

♦ Collar nut - T10531/4- ab

ility
ot p

wit
, is n

h re
hole

Note
spec
es, in part or in w

t to the co

The vibration damper securing bolt -A- is used to secure the vi‐
bration damper -1- and the timing chain sprocket -2- on crankshaft
-3-. Before unscrewing the securing bolt, lock the timing chain
rrectness of i

sprocket in position relative to crankshaft as described below:

l purpos

Removing:
nform
ercia

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 66 ; Noise insulation; Assembly overview – noise in‐
m

at

sulation .
om

ion
c

in t
r

– Remove right wheel housing liner ⇒ General body repairs,

o

his
te

exterior; Rep. gr. 66 ; Wheel housing liner; Removing and

a

do
riv

installing wheel housing liner .

p

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Cylinder block (pulley end) 51

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Vehicles with seat heating:

AG. Volkswagen AG d
agen
– Slacken clip -1- and remove bolt -2-. Volksw
oes
not
gu
by ara
d
– Detach exhaust silencer for auxiliary heater. orise nte
eo
th
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
All:
– Remove bolts -arrows-.

rrectness of i
– Remove air pipe (lift clips -items 1 and 2-).
l purpos

– Remove poly V-belt ⇒ page 38 .

nf
ercia

– Pull locking pin - T10060 A- out of tensioning device for poly

or
V-belt.

m
m

[Link]
atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
– Turn vibration damper to “TDC” position -arrow- using coun‐ Cop py
t. rig
terhold - T10355- . opyri
gh by
Vo
ht
c
• Notch on vibration damper must align with arrow marking on
by lksw
cted agen
Prote
cover for timing chains (bottom).
AG.

• The marking on the cover is located at »4 o'clock position«.

Caution

Initially, the vibration damper securing bolt must only be loos‐

ened by 1/2 turn.

– Loosen vibration damper bolt by 1/2 turn. To do this, use coun‐

ter hold tool - T10355- .
– If vibration damper was turned while loosening bolt, reset TDC
position.

52 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Unscrew the 2 timing chain cover securing bolts -arrows-, as

shown in illustration. Bolts must be renewed.

– Fit support - T10531/1- to vibration damper, as shown in illus‐

tration, and tighten knurled screws -arrows- by hand.
– Unscrew vibration damper bolt completely.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua

[Link]
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
– Check if turning over tool -A- slides easily over clamping
ot

pieces -B-. If necessary, turn tensioning bolt -arrow-.

wit
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
Now, do not turn the tensioning bolt anymore, or the clamping pin
- T10531/2- will be jammed when it is screwed into the crankshaft.

rrectness of i
l purpos

nform
mercia

a
com

tio

– Screw clamping pin - T10531/2- into crankshaft, and tighten it

n in
r

hand-tight with a 12 mm open-end spanner -A-.

te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Cylinder block (pulley end) 53

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Tighten tensioning bolt -A- hand-tight. This will lock the chain
sprocket in position relative to crankshaft.

– Unscrew knurled screws -arrows-. Remove support -

T10531/1- and vibration damper -A-.

AG. Volkswagen AG d
agen oes
olksw not
V gu

[Link]
by ara
d
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
Turning crankshaft without vibration damper

ility
ot p

wit
– Fit turning over tool -A- on clamping pin. Pay attention to tooth‐
, is n

h re
ed contours of sprocket while doing so. In TDC position the
hole

spec
flat section of the tool faces upwards. Tighten turning over tool
es, in part or in w

with flange nut -B-.

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
m

– Now, the crankshaft can be turned on hexagon -arrow-.

o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

54 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Installing vibration damper

– If necessary, remove flange nut -B- and turning over tool -A-
from clamping pin.

G. Volkswagen AG d
– Fit vibration damper in TDC position. Pay attention to teeth oflkswagen A oes
not
chain sprocket -arrow- while doing so. by
Vo gu
ara
ed nte
oris eo
th
au ra
c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility

[Link]
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Fit turning over tool -A- on clamping pin. The hexagon faces
towards vibration damper while doing so. Screw on flange nut

rrectness of i
-B-. Move vibration damper slightly back and forth while doing
l purpos

so, in order to ensure that vibration damper is properly seated

on teeth. Tighten flange nut, until vibration damper cannot be
turned any more.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
– Fit support - T10531/1- to vibration damper, as shown in illus‐ yri
gh by
ht
tration, and tighten knurled screws -arrows- by hand.
op Vo
by c lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 55

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Unscrew flange nut -A-, and loosen clamping pin -B-. Unscrew
clamping pin , and remove it together with turning over tool .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
h
– Screw in newautvibration damper bolt with lubricated O-ring -1-or ac
by hand. ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

[Link]
es, in part or in w

t to the co
rrectness of i
l purpos

– Unscrew knurled screws -arrows-, and remove support -

T10531/1- .
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Tighten vibration damper bolt using counter hold tool -
T10355- .

56 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Screw in new securing bolts -arrows-.

Further assembly is basically a reverse of the dismantling se‐
quence.
Torque settings
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 36

1.8 Renewing oil seal for vibration damper

Special tools and workshop equipment required
♦ Press tool - T10354-

[Link]
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
♦ Thrust washer - T10375-
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

♦ Flange nut - 10531/4- from assembly tool - T10531-

inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 57

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Extractor hook - T40274-

Removing
– Remove vibration damper ⇒ page 50 .
• Clamping pin - T10531/2- is inserted.
– Using extractor hook - T40274- , pull out seal -arrow-.

AG. Volkswagen AG d
agen

[Link]
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
Installing
erm

ab
ility
ot p

– Clean contact surface and sealing surface.

wit
is n

– Slide seal -arrow- onto thrust piece - T10354- . h re

ole,

spec
urposes, in part or in wh

• Closed side of oil seal faces towards thrust piece - T10354- .

t to the co
rrectness o
cial p

f inform
mer

– Slide seal -arrow- with thrust piece - T10354- onto clamping

atio
m

pin - T10531/2- , and fit it to lower timing chain cover.

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

58 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection
wage
nAengine
G. Volks(1.8
wagenand
AG d2.0
oe l engine, chain drive) - Edition 02.2017
ks s no
Vol t gu
by a
– In addition, fit thrust padris-e T10375-
d , and screw on flange nut rante
- 10531/4- . tho eo
s au ra
c
s
– Using open-end spanner, AF 21, tighten flange nut until seal

ce
le
un
has been pressed in as far as stop.

pt
an
d
itte

y li
erm

ab
ility
ot p

Note

wit
is n

h re
ole,

♦ Renew bolt for vibration damper.

spec
urposes, in part or in wh

♦ Renew O-ring.

t to the co
Further assembly is basically a reverse of the dismantling se‐
quence. During this step, observe the following:

rrectne
– Install vibration damper ⇒ page 50 .

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
e

[Link]
t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Cylinder block (pulley end) 59

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

2 Cylinder block, gearbox end

Assembly overview - sealing flange on gearbox side and dual-
mass flywheel/drive plate ⇒ page 60 .
Removing and installing dual-mass flywheel ⇒ page 61 .
Removing and installing drive plate ⇒ page 62
Removing and installing sealing flange on gearbox side
⇒ page 64 . . Volkswage n AG n AG d
wage oes
2.1 Assembly overview - sealing flange on gearbox side and dual-mass fly‐ by
Volks not
gu
ara
ed
wheel/drive plate thoris nte
eo
au ra
c
ss

ce
e
nl

1 - Cylinder block

pt
du

an
itte

y li
❑ Removing and installing
erm

ab
crankshaft

ility
ot p

⇒ page 71 .

wit
, is n

h re
❑ Dismantling and assem‐
hole

bling pistons and con‐

spec
rods ⇒ page 79

[Link]
es, in part or in w

t to the co
2 - Dowel pin
❑ Not installed

rrectness of i
3 - Sealing flange on gearbox
l purpos

side
❑ With seal

nf
ercia

❑ Renew only as com‐

orm
plete unit
m

atio
m

❑ Removing and installing

o

n in
or c

⇒ page 64
thi
te

sd
iva

4 - Bolt
o
r
rp

cu
o

❑ Tightening sequence
f

en
ng

t.
yi
⇒ page 61
Co
Cop py
t. rig
5 - Intermediate plate
gh ht
pyri by
Vo
co
❑ Must seat on dowel
by lksw
cted agen
Prote
sleeves.
AG.

❑ Do not damage or bend

when assembling.
❑ Is fitted onto sealing
flange ⇒ page 61
6 - Bolt
❑ For dual-mass flywheel/
drive plate
❑ 60 Nm + 90° (1/4 turn)
further
❑ Renew
7 - Dual mass flywheel/drive plate
❑ Removing and installing dual-mass flywheel ⇒ page 61
❑ Removing and installing drive plate ⇒ page 62
❑ Drive plate installation position: »collar« points towards engine
❑ Can only be installed in one position, holes are offset.
8 - Dowel pin
❑ Not installed

60 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Sealing flange at gearbox end - tightening sequence

– Tighten bolts -1 to 8- in the sequence shown:
♦ 1. Screw in and tighten bolts by hand.
♦ 2. Tighten bolts to 9 Nm.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
Installing intermediate plate

an
d
itte

y li
rm

ab
– Hook intermediate plate onto sealing flange and slide onto
pe

ility
dowel sleeves -arrows-.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

[Link]
rrectness of i
l purpos

nform
ercia

2.2 Removing and installing dual-mass fly‐

m

a
wheel
com

tion in
r
te o

Special tools and workshop equipment required

thi
s
iva

do
r

♦ Counterhold tool - 3067-

rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove gearbox ⇒ Power transmission; Rep. gr. 37 ; Re‐
moving and installing gearbox .

Caution

In order to avoid destruction of the dual-mass flywheel, you are

not allowed to undo the bolts -B- with a pneumatic/impact
screwdriver. It is only permissible to remove the bolts by hand.

2. Cylinder block, gearbox end 61

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
– When unscrewing bolts -B-, ensure that none of the bolt heads
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged when the bolts are un‐
screwed further.

– Insert counterhold - 3067- in hole on cylinder block -B-.

olkswagen AG
en AG. V
– Unscrew dual-mass flywheel. olkswag does
not
yV gu
db ara
Installing orise nte
h eo
ut ra
Install in the reverse order
ss
a of removal, observing the following: c

ce
e

• Specified torque ⇒ Item 6 (page 60)

nl

pt
du

an
itte

y li
– Use new bolts for securing.

[Link]
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

– Insert counter hold - 3067- in hole on cylinder block -A-.

rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.3 Removing and installing drive plate

Special tools and workshop equipment required

62 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Counterhold tool - VW 558-

♦ Depth gauge AG. Volkswagen AG d

agen oes
olksw not
yV gu
♦ Hexagon bolt M8×40 and ised hexagon nut M8
b ara
nte
or eo
h
– Remove gearboxs a⇒ut Power transmission; Rep. gr. 37 ; Re‐ ra
c
moving and installing
s gearbox .

ce
e
nl

pt
du

Preparing counter hold tool - VW 558- :

an
itte

y li
erm

ab
– Tighten hexagon bolt M8x40 -A- with hexagon nut on clutch

[Link]
ility
ot p

counter-hold tool - VW 558- .

wit
, is n

h re
Loosening and tightening drive plate:
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at

– Insert counter hold - VW 558- in cylinder block and drive plate

om

ion

as shown.
c

in t
or

his
te

Installation position of counter hold: -A- to loosen, -B- to tighten.

a

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Installing drive plate:

– Fit drive plate without washer -A- first.
– Fit used securing bolts -3- and tighten to 30 Nm.

2. Cylinder block, gearbox end 63

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Check dimension between drive plate and cylinder block at

three points and calculate average.

Note

Measure through hole in drive plate to milled surface of cylinder

block. If measuring on the intermediate plate, the plate thickness
must be taken into account.

• Specification measured without intermediate plate: 19.5…

21.1 mm
• Specification measured with intermediate plate: 18.8…
20.4 mm
If the specification is not reached, replace all securing bolts and
tighten.

If specification is not attained:

– Remove drive plate again and fit shim -A-. Tighten bolts -3-
again to 30 Nm. agen
AG. Volkswagen AG d
oes
ksw

[Link]
ol not
V
– Repeat measurement. If the specification is not reached, re‐ ed by gu
ara
place all securing bolts and tighten. horis nte
eo
aut ra
• Specified torque ⇒ Item 6 (page 60) ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
2.4 Removing and installing sealing flange
es, in part or in w

t to the co
on gearbox side

rrectness of i
Note
l purpos

♦ There are 2 versions of the sealing flange. Check which ver‐

sion must be installed.

nform
ercia

♦ Version -A-: Sealing lip -1- faces gearbox (outwards).

m

a
com

tion in
♦ Version -B-: Sealing lip -1- faces engine. This sealing flange
r
te o

also has a dust lip -2-.

thi
s
iva

do
r
rp

cum

Removing and installing version -A- ⇒ page 64 .

fo

en
ng

t.
yi Co
Removing and installing version -B- ⇒ page 67 . ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.4.1 Removing and installing sealing flange

on gearbox side, version A sealing lip
faces outwards
Special tools and workshop equipment required

64 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Assembly sleeve - T20097-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
♦ Hand drill with plastic brush attachment
es, in part or in w

t to the co
♦ Safety glasses
♦ Sealant ⇒ Electronic parts catalogue (ETKA)

rrectness of i
Removing
l purpos

• Gearbox is removed.

[Link]
nf
ercia

• Dual mass flywheel removed ⇒ page 61 or drive plate removed

or
⇒ page 62 .

m
m

atio
m

– Detach intermediate plate from sealing flange and dowel pins

o

n in
or c

-arrows-.

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew bolts -1 to 8-.

– Remove sealing flange.
Installing

Note

♦ Observe use-by date of silicone sealant.

♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.
♦ In order to prevent the lubrication system from being soiled
with sealant residue cover the open section of the sump with
a clean cloth.

Caution

Risk of eye injury caused by sealant residue.

♦ Wear safety goggles.

2. Cylinder block, gearbox end 65

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove sealant residue from cylinder block, e.g. with rotating

plastic brush.
– Clean sealing surfaces. They must be oil and grease free.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
– Cut off nozzle on tube at front marking (∅ of nozzle approx. 2 , is n

h re
hole

mm).

spec
es, in part or in w

t to the co
rrectness of i
l purpos

[Link]
nform
mercia

at
om

ion
c

in t
or

– Apply silicone sealing compound bead, as shown in diagram,

his
ate

to clean sealing surface of sealing flange.

do
priv

cum
for

♦ Thickness of sealant bead: 2 to 3 mm

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Clean crankshaft pins carefully.

– Check assembly sleeve ; it must be free of any deformation or
sharp edges.
– Fit assembly sleeve - T20097- onto crankshaft journal -A-.
– Fit sealing flange over assembly sleeve - T20097- onto crank‐
shaft journal.
– Remove assembly sleeve - T20097- .

66 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Tighten new bolts evenly in the sequence shown.

Stage Bolts Specified torque/turning further angle
1. -1 to 8- Screw in by hand as far as stop
2. -1 to 8- 9 Nm

Note

After installing the sealing flange, wait about 30 minutes for the
sealant to dry. Only then fill with engine oil.

Further assembly is basically a reverse of the dismantling se‐

quence.
Torque settings
♦ ⇒ “2.1 Assembly overview - sealing flange on gearbox side
and dual-mass flywheel/drive plate”, page 60

2.4.2 Removing and installing sealing flange

on gearbox side, version B sealing lip

[Link]
faces engine
Special tools and workshop equipment required
♦ Assembly sleeve - T20097-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab

♦ Hand drill with plastic brush attachment

ility
ot p

wit
, is n

♦ Safety glasses
h re
hole

spec

♦ Sealant ⇒ Electronic parts catalogue (ETKA)

es, in part or in w

t to the co

Removing
• Gearbox is removed.
rrectness of i

• Dual mass flywheel removed ⇒ page 61 or drive plate removed

⇒ page 62 .
l purpos

– Detach intermediate plate from sealing flange and dowel pins

-arrows-.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Cylinder block, gearbox end 67

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Unscrew bolts -1 to 8-.

– Prise off sealing flange.
Installing

Note

♦ Observe use-by date of silicone sealant. . Volkswagen AG

gen AG does
swa
♦ The sealing flange must be installed within 5 minutes of ap‐ y Volk not
gu
plying the silicone sealant. risedb ara
nte
ho eo
♦ In order to prevent the lubrication system from beingaut soiled ra
s c
with sealant residue cover the open section of the sump with
s

ce
le
a clean cloth.
un

pt
an
d
itte

y li
erm

ab
ility
ot p

Caution

wit
is n

h re
ole,

Risk of eye injury caused by sealant residue.

spec
urposes, in part or in wh

♦ Wear safety goggles.

t to the co

[Link]
– Remove sealant remaining on cylinder block with flat scraper

rrectne
or rotating plastic brush.

s
– Clean sealing surfaces. They must be oil and grease free.

s o
cial p

f inform
The sealing lip of the sealing flange must be »shaped« before
mer

installing.

atio
om

n
– Check assembly sleeve ; it must be free of any deformation or
c

i
or

n thi
sharp edges.
te

sd
iva

o
r

– Fit sealing flange onto assembly sleeve as shown.

p

cum
r
fo

en
ng

• The smaller diameter of the assembly sleeve faces towards

t.
yi Co
op
the seal.
C py
t. rig
gh ht
yri by
• Centring cones -1- and -2- face upwards.
op Vo
by c lksw
cted agen
Prote
• Let the sealing flange settle on the assembly sleeve for about
AG.

5 minutes.

– Remove assembly sleeve again from the sealing flange and

turn it over.
– Leading with small diameter, insert assembly sleeve -3- in
sealing flange -1-.
– Make sure that the sealing lips -arrows- are in contact with the
assembly sleeve as shown. Large sealing lip must point to‐
wards engine.

68 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Cut off nozzle on tube at front marking (∅ of nozzle approx.

2 mm).

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

– Apply silicone sealant as shown to clean sealing surface of

y li
rm

ab
sealing flange.
pe

ility
ot

wit
♦ Thickness of sealant bead: 2 to 3 mm.
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
♦ The sealing flange must be installed within 5 minutes after ap‐

[Link]
plying the silicone sealant.

rrectness of i
♦ The bead of sealant must not be thicker than specified, other‐
l purpos

wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.

nform
mercia

a
– Fit sealing flange -1- with assembly sleeve on crankshaft jour‐
com

tion in

nal.
r
te o

thi

– Fit sealing flange -1-over assembly sleeve - T20097- onto

s
iva

do

crankshaft journal.
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove assembly sleeve - T20097- . Large sealing lip -1-

must point towards engine.

2. Cylinder block, gearbox end 69

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Tighten new bolts evenly in the sequence shown.

Stage Bolts Specified torque/turning further angle
1. -1 to 8- Screw in by hand as far as stop
2. -1 to 8- 9 Nm

Note

After installing the sealing flange, wait about 30 minutes for the
sealant to dry. Only then fill with engine oil.

Further assembly is basically a reverse of the dismantling se‐

quence.
Torque settings
♦ ⇒ “2.1 Assembly overview - sealing flange on gearbox side
and dual-mass flywheel/drive plate”, page 60

n AG. Volkswagen AG do
lkswage es n
o ot g
yV

[Link]
d b ua
ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

70 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

3 Crankshaft
Assembly overview - crankshaft ⇒ page 71 .
Tightening sequence - crankshaft ⇒ page 72 .
Removing and installing sender wheel ⇒ page 72 .
Allocation of crankshaft bearing shells ⇒ page 73 .
Pulling needle bearing out of and driving into crankshaft
⇒ page 74 .
Crankshaft dimensions ⇒ page 76 .
AG. Volkswagen AG d
Measuring axial clearance of crankshaft ⇒ page 76 . ksw
agen oes
not
ol
yV gu
Measuring radial clearance of crankshaft ⇒ page 77 . ised b ara
nte
or eo
h
ut
3.1 Assembly overview - crankshaft ss a ra
c

ce
e
nl

pt
du

an
itte

y li
Note
erm

ab
ility
ot p

Secure engine to repair stand using engine and gearbox support

[Link]
wit
, is n

- VAS 6095- when dismantling/assembling engine ⇒ page 18 .

h re
hole

spec
es, in part or in w

t to the co
1 - Cylinder block
❑ If the cylinder block is re‐

rrectness of i
newed, the bearing
shells must be realloca‐
l purpos

ted to cylinder block

⇒ page 73

nf
ercia

2 - Bearing shell for cylinder

orm
block
m

atio
m

❑ With oil groove.

o

n in
or c

❑ Do not interchange

thi
te

sd
a

used bearing shells

iv

o
r
rp

cu
(mark).
o

m
f

en
ng

❑ Marking of crankshaft
t.
yi Co
op
bearing shells C py
ht. rig
⇒ page 73 rig ht
py by
co Vo
by lksw
3 - Crankshaft cted agen
Prote AG.
❑ After removing, place it
down so that the sender
wheel -item 5- is not
damaged and the crank‐
shaft does not rest on
the sender wheel
❑ If the crankshaft is re‐
newed, the bearing
shells must be realloca‐
ted to bearing cap
⇒ page 73
❑ Axial clearance
⇒ page 76
❑ Radial clearance
⇒ page 77
❑ Do not rotate crankshaft
when checking radial
clearance
❑ Crankshaft dimensions
⇒ page 76 .

3. Crankshaft 71
 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
ed ran
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 hor ➤ , Passat 2006 ➤ , ...
is tee
t or
4-cyl. injection engine (1.8 and 2.0 l engine, chain
au drive) - Edition 02.2017 ac
ss

ce
e
❑ Removing and installing ⇒ page 72

nl

pt
du

an
itte

y li
4 - Bearing shell

erm

ab
ility
❑ Without oil groove.

ot p

wit
, is n
❑ Do not interchange used bearing shells (mark).

h re
hole
❑ Marking of crankshaft bearing shells ⇒ page 73

spec
es, in part or in w
5 - Bolt

t to the co
❑ Note tightening sequence ⇒ page 72
❑ Renew

rrectness of i
6 - Bearing cap

l purpos
❑ Bearing cap 1: belt pulley end.
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.

nf
ercia

orm
7 - Bolt
m

atio
m

❑ 10 Nm + 1/4 turn further (90°)

o

n in
or c

thi
e

❑ Renew
t

sd
iva

o
r

❑ Sender wheel must be renewed if bolts are loosened ⇒ page 72

rp

cu
o

m
f

en
ng

8 - Sender wheel
t.
yi Co
op

[Link]
py
❑ For engine speed sender - G28-
t. C rig
gh ht
yri by
❑ Can only be installed in one position, holes are offset. cop Vo
by lksw
cted agen
❑ Always renew sender wheel if securing bolts have been unscrewed
Prote AG.

❑ Removing and installing ⇒ page 72

9 - Thrust washers
❑ For bearing 3
10 - Bolt
❑ Note tightening sequence ⇒ page 72
❑ Renew

Crankshaft tightening sequence

– Tighten crankshaft bolts in the sequence -1 … 5- as follows:
1- Tighten bolts -1 to 10- and -arrows- by hand.
2- Pre-tighten bolts -1 to 10- to 65 Nm.
3- Turn bolts -1 to 10- 90° further using a rigid wrench.
4- Pre-tighten bolts -arrows- to 20 Nm.
5- Turn bolts -arrows- 90° further using a rigid wrench.

3.1.1 Removing and installing sender wheel

– Remove engine.
– Remove crankshaft sealing flange ⇒ page 64 .
– Remove upper part of sump ⇒ page 212 .

72 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove camshaft timing chain and drive chain for balance

shaft ⇒ page 113 .
– Unscrew conrod bearing cap.
– Remove crankshaft bearing cap.
– Remove crankshaft and unscrew sender wheel.
– Renew sender wheel -2- each time bolts -1- are loosened.

n AG. Volkswagen AG do
Note olkswage es n
ot g
byV ua
d ran
ir se
♦ The second time
tho the bolts are tightened, the contact points
tee in
or
the senders awheel
u for the countersunk heads are deformed so ac
far that the bolt heads seat on the crankshaft -3-, -arrows- and
s

ce
e

the sender wheel is »loose« under the bolts.

nl

pt
du

an
itte

y li
♦ Sender wheel can only be installed in one position. The holes
erm

ab
are offset.

ility
ot p

wit
, is n

h re
• Specified torque ⇒ page 71
hole

spec
es, in part or in w

[Link]
3.1.2 Allocation of crankshaft bearing shells

t to the co
(classification)

rrectness of i
Bearing shells of the correct thickness are allocated to the cylin‐
der block at the factory. Coloured dots are used to identify the
l purpos

thickness of the bearing shells.

Which bearing shell is to be inserted at each place in the cylinder nf
ercia

o
block (upper bearing shell) is marked by letters on the lower seal‐
rm
m

ing surface or on the front side of cylinder block.

atio
om

n in
c

Which bearing shell is to be inserted at each place in bearing cap

or

thi
e

(lower bearing shell) is marked by letters on the crankshaft.

t

sd
iva

o
r
rp

cu

The first letter is allocated to bearing cap 1, the second to bearing

o

m
f

cap 2, etc.
en
ng

t.
yi Co
op py
Cylinder block: t. C rig
gh ht
pyri by
The marking on the cylinder block can be found engraved either
co Vo
by lksw
cted
in the sump sealing surface or in the front end (gearbox side) of
agen
Prote AG.
the cylinder block.

3. Crankshaft 73
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Identification on cylinder block is allocated to upper bearing shell

(bearing shell for cylinder block).
– Make a note of the letters and determine the colour marking
for installation with regard to the table.

Crankshaft:

[Link]
Identification on crankshaft is allocated to lower bearing shell
(bearing shell for bearing cap). G. Volkswage nA n AG d
wage oe
– Make a note of the letters and ydetermine
Vol
ks the colour markings not gu
for installation with regard to
ise
dthe table.
b ara
n r tee
ho
ut or
S = ss
a black ac
ce

R = red
le
un

pt
an
d

G = yellow
itte

y li
erm

ab

B = blue
ility
ot p

wit

W = white
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectnes

3.2 Pulling needle bearing out of and driving

s o
cial p

f i

into crankshaft
nform
mer

atio

Only vehicles with a dual clutch gearbox

om

n
c

i
or

Special tools and workshop equipment required

thi
te

sd
va

♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-

i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

74 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Internal puller - VAS 251 635-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
♦ Drift - VW 207 C- thor eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re

[Link]
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Condition:
• The front edges of the inner puller must not be chipped.

nform
ercia

• Gearbox has been removed.

m

at
om

Pulling out needle roller bearing

on
c

in t
or

– Pull out needle bearing -1- with internal puller - VAS 251 635-
his
ate

-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
do
priv

-B- from crankshaft -2-.

um
for

en
ng

t.
yi
– The internal puller must be positioned behind the needle-and-
Co
op py
cage assembly -arrow-.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Crankshaft 75
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .

Installation depth: dimensionen-a-

AG=. V2.0
olkswmm
agen AG

[Link]
wag does
olks not
byV gu
ara
ed
Note tho
ris nte
eo
au ra
c
ss
If the needle bearing is inadvertently driven in too far, it must be
ce
e
nl

renewed because it will be damaged when it is pulled out again.

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

3.3 Crankshaft dimensions

m

at
om

ion
c

in t

(Dimensions in mm)
or

his
ate

do
riv

Honing dimension Main journal ∅ Conrod journal ∅

p

cum
or

1)
f

en
ng

t.
yi Co
Basic dimension 58.00 47.80
Cop py
ht. rig
rig ht
by
1)
py
No provision has yet been made to recondition worn crank‐ co Vo
by lksw
shafts.
cted agen
Prote AG.

3.4 Measuring axial clearance of crankshaft

Special tools and workshop equipment required

76 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

♦ Universal dial gauge holder - VW 387-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
♦ Dial gauge - VAS 6079-

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

[Link]
t to the co
rrectness of i
l purpos

Sequence of operations
nf
ercia

or

– Screw dial gauge - VAS 6079- with universal dial gauge holder
m
m

atio

- VW 387- onto cylinder block and set against crankshaft

om

n in

cheek with 2 mm projection.

or c

thi
te

– Push crankshaft against dial gauge by hand and set dial gauge
sd
iva

to “0”.
r
rp

cu
o

m
f

en
ng

– Press crankshaft away from dial gauge and read value.

t.
yi Co
Cop py
Axial clearance:
t. rig
gh ht
pyri by
Vo
co
• New: 0.07 to 0.23 mm.
by lksw
cted agen
Prote AG.
• Wear limit: 0.30 mm.

3.5 Measuring radial clearance of crank‐

shaft
Special tools and workshop equipment required
♦ Plastigage
Sequence of operations

Note

♦ Do not interchange used bearings.

♦ Bearing shells worn down to nickel layer must be renewed.

– Remove main bearing caps and clean bearing caps and jour‐
nals.
– Place Plastigage onto bearing journal or into bearing shells
according to width of bearing.
• The Plastigage must rest in the middle of the bearing shell.

3. Crankshaft 77
 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Fit main bearing caps and tighten to 60 Nm without rotating

crankshaft.
– Remove main bearing caps again.
– Compare width of Plastigage with measurement scale:
Radial clearance:
• New: 0.017 to 0.037 mm.
• Wear limit: 0.15 mm.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

[Link]
pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

78 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 79
⇒ “4.2 Removing and installing pistons”, page 82
⇒ “4.3 Checking pistons and cylinder bores”, page 83
⇒ “4.4 Separating new conrod”, page 85
⇒ “4.5 Checking radial clearance of conrods”, page 86

4.1 Assembly overview - pistons and conrods

1 - Bolts
❑ Renew after removal
❑ Apply engine oil to
thread and contact sur‐
face
❑ Use old bolts to meas‐
ure radial clearance.
❑ 45 Nm +90°

[Link]
2 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ Conrod bearing cap on‐gen AG. Volkswagen AG d
a
ly fits in one position Vol and
ksw
oes
not
gu
only on the appropriate
d by ara
conrod due ise the break‐
rto nte
tho eo
ing procedure
au (crack‐ ra
c
ss
ing) separating the cap
ce
e
nl

from the conrod

pt
du

an
itte

❑ Mark allocation to cylin‐

y li
erm

ab

der and conrod in colour

ility
ot p

-A-
wit
, is n

❑ Installation position:
h re
hole

Marking -B- faces to‐

spec

wards pulley end.

es, in part or in w

t to the co

❑ Separating new conrod

⇒ page 85 .
rrectness of i

3 - Bearing shells
❑ Fitting position
l purpos

⇒ page 80
❑ Renew worn bearing
nf
ercia

shells
orm
m

atio

❑ Apply engine oil before

om

installing
n in
or c

thi

❑ Axial clearance
te

sd
iva

o
r
rp

cu

♦ New: 0.10 … 0.35 mm

o

m
f

en
ng

t.
♦ Wear limit: 0.40 mm
yi Co
Cop py
❑ Measuring radial clearance ⇒ page 86
t. rig
gh ht
pyri by
Vo
o
4 - Connecting rod
c by lksw
cted agen
Prote AG.
❑ Renew as set only.
❑ Mark allocation to cylinder and to conrod bearing cap
❑ Installation position: Marking -B- faces towards pulley end.
❑ Separating new conrod ⇒ page 85 .
❑ Measuring radial clearance ⇒ page 86

4. Pistons and conrods 79

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

5 - Pressure relief valve

❑ 27 Nm
6 - Oil spray jet
❑ For piston cooling
7 - Retaining ring
❑ Renew after removal
8 - Piston pin
❑ Apply engine oil before installing
9 - Piston
❑ Installing with piston installation sleeve -T40347- ⇒ page 82
❑ Installation position: arrow on piston crown faces towards pulley end
❑ Mark allocation to cylinder
❑ Checking piston and cylinder bore ⇒ page 83 AG. Volkswagen AG d
agen oes
ksw
10 - Compression rings by Vol not
gu
ara
d
❑ Offset gaps by 120° rise nte
tho eo
u
❑ Installation position: “TOP” or “R” marking must face supwards
sa towards piston crown. ra
c

[Link]
❑ ⇒ Fig. ““Installing compression rings”“ , page 81

ce
e
nl

pt
du

an
❑ ⇒ Fig. ““Checking piston ring gap”“ , page 84
itte

y li
erm

ab
❑ ⇒ Fig. ““Checking ring-to-groove clearance”“ , page 84

ility
ot p

❑ ⇒ Fig. ““Allocation of piston rings only in connection with 3-part oil scraper ring”“ , page 81

wit
, is n

h re
11 - Oil scraper ring
hole

spec
❑ 2 or 3 parts, depending on version
es, in part or in w

t to the co
❑ Install in such a way that upper gap of three-part oil scraper ring is offset by 120° relative to adjacent
compression ring
❑ ⇒ Fig. ““Checking piston ring gap”“ , page 84

rrectness of i
❑ ⇒ Fig. ““Checking ring-to-groove clearance”“ , page 84
l purpos

❑ ⇒ Fig. ““Installing oil scraper ring, 3-part”“ , page 81

❑ ⇒ Fig. ““Allocation of piston rings only in connection with 3-part oil scraper ring”“ , page 81

nf
ercia

orm
m

atio
om

n in
c

Bearing shells - installation position

or

thi
te

sd
a

– Position bearing shells in centre of conrod and conrod bearing

iv

o
r
rp

cap when fitting. cu

o

m
f

en
ng

t.
Distance -a- must be identical on both sides.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

80 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Allocation of piston rings only in connection with 3-part oil scraper

ring
1- Compression ring with chamfer -arrow A- on upper inner
side. »TOP« marking and lettering point inwards
2- Compression ring shoulder -arrow B- on lower outer side.
»TOP« marking and lettering point inwards
3- Oil scraper ring, three-part

Installing compression rings

[Link]
• »TOP« marking and lettering point upwards.
• Compression ring -2- should not be opened using piston ring
pliers -VAS 211 003- any further than necessary to just push
it over piston -1-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li

Installing oil scraper ring, 3-part

erm

ab
ility
ot p

– Note installation position of spring:

wit
, is n

h re

• Butts of plates -2, 3- and spring -1- must have an offset of at

hole

spec

least 90° to each other.

es, in part or in w

t to the co

– Install by hand.
Installation sequence:
rrectness of i

1. Insert spring -1- into groove.

l purpos

2. Insert plate -3- in bottom of groove.

3. Insert plate -2- in top of groove.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Pistons and conrods 81

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
CC 2010 ➤ , Eosris2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat
ed
nte 2006 ➤ , ...
o eo
4-cyl. injection autengine (1.8 and 2.0 l engine, chain drive) - Edition
h
r a 02.2017
ss c

ce
le
4.2 Removing and installing pistons

un

pt
an
d
itte

y li
erm

ab
ility
ot p

Note

wit
is n

h re
ole,

If pistons with 3-part oil scraper ring are installed without the pis‐

spec
urposes, in part or in wh

ton installation sleeve - T40347- , the oil scraper ring will be

t to the co
damaged.

Special tools and workshop equipment required

rrectne
♦ Drift - VW 222 A-

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co

[Link]
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Piston installation sleeve - T40347- (not shown)
Removing
– Remove engine, and secure it to engine and gearbox support
- VAS 6095- .
– Remove cylinder head ⇒ page 140 .
– Remove upper part of sump ⇒ page 212 .
– Mark piston installation position and corresponding cylinder
number.
– Mark conrod installation position and corresponding cylinder
number ⇒ Item 4 (page 79) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.

82 Rep. gr.13 - Crankshaft group

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

– Remove circlip from piston pin eye.

– Remove retaining ring -2- from piston pin eye.
– Drive out piston pin -3- using drift - VW 222A- .

Note

If the piston pin is difficult to move, heat the piston to approx. 60°
C.

– Remove piston -1- from conrod -4-.

Installing
Install in the reverse order of removal, observing the following:
• Renew bolts that are tightened with turning further angle after
each removal.
• Arrow on piston crown points to belt pulley end.
– Install oil scraper ring: procedure for 3-part oil scraper ring
⇒ page 81 .

[Link]
– Install compression rings ⇒ page 81 .

– Oil contact surfaces of bearing shells and cylinder wall with

engine oil.
– Carefully push piston -1- into cylinder -arrow- by hand using
piston installation sleeve -T40347- .
– Install conrod bearing cap, noting installation position
⇒ Item 2 (page 79) .
olkswagen AG
en AG. V
– Install cylinder head ⇒ opage
lksw 140 .
ag does
not
V gu
by ara
– Install upper partrisof
ed sump ⇒ page 212 . nte
ho eo
ut
Torque settings
ss
a ra
c
ce
e

♦ ⇒ page 79
nl

pt
du

an
itte

y li
erm

ab

4.3 Checking pistons and cylinder bores

ility
ot p

wit
, is n

Checking piston
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi

Special tools and workshop equipment required

te

sd
iva

o
r
rp

♦ Micrometre 75 - 100 mm - VAS 6071-

cu
o

m
f

en
ng

t.
– Using a micrometer, measure approx. 15 mm from the lower
yi Co
op
edge, perpendicular to the piston pin axis.
C py
ht. rig
rig ht
py by
♦ Difference between actual and nominal diameter max. co Vo
by lksw
cted
0.04 mm.
agen
Prote AG.

4. Pistons and conrods 83

 CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 02.2017

Piston ∅
Basic dimension mm 82.42 1)
• 1)
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear down.

Checking piston ring gap

n AG. Volkswagen AG do
wage es n
– Push ring at right angles
yV
olks to cylinder wall from above ot g down to
approx. 15 mmisefromd b bottom end of cylinder. Push inuusing ara
nte a
piston withouttho rings.
r eo
au ra
c
ss
Piston ring gap in connection New Wear limit

ce
le
un

with two-part oil scraper ring

pt
an
d
itte

y li
compression ring 0.20 … 0.40 m 0.8 mm
rm

ab
m
pe

ility
ot

wit
Oil scraper ring 0.25 … 0.50 m 0.8 mm
, is n

h re
m
hole

spec
es, in part or in w

Piston ring gap in connection New Wear limit

t to the co
with three-part oil scraper ring

[Link]
1st compression ring 0.30 … 0.40 m 0.60 mm

rrectness of i
m
l purpos

2nd compression ring 0.40 … 0.50 m 0.70 mm

m
Oil scraper ring Cannot be Cannot be
nform
ercia

measured measured
m

a
com

tion in

Checking ring-to-groove clearance

r
te o

thi
s
iva

– Clean annular groove of piston before check.

do
r
rp

cum
fo

Ring-to-groove clearance New Wear limit

en
ng

t.
yi
in connection with two-
Co
Cop py
part oil scraper ring
t. rig
gh ht
pyri by
Vo
o
1st compression ring 0.06 … 0.09 mm 0.20 mm
c by lksw
cted agen
Prote AG.
2nd compression ring 0.03 … 0.06 mm 0.15 mm
Oil scraper rings Cannot be measured

Ring-to-groove clearance New Wear limit

in connection with three-
part oil scraper ring
1st compression ring Cannot be measured
2nd compression ring Cannot be measured
Oil scraper rings Cannot be measured
Checking cylinder bores

Note

Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.

Special tools and workshop equipment required

♦ Cylinder gauge - VAS 6078-

84 Rep. gr.13 - Crankshaft group

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
CCut 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009
ho eo
r a ➤ , Passat 2006 ➤ , ...
a
s 4-cyl. injection engine (1.8 and 2.0 l engine, chain
s c drive) - Edition 02.2017

ce
e
nl

pt
du

an
itte

y li
Caution

erm

ab
ility
ot p

wit
The cylinder bore may not be worked on (reboring, honing,
, is n

h re
grinding) may not be carried out using workshop tools! This will
hole
damage the surface of the cylinder bore.

spec
es, in part or in w

t to the co
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.

rrectness of i
♦ Difference between actual and nominal diameter max.
l purpos

0.08 mm
Piston ∅ Cylinder bore ∅

nf
ercia

orm
Basic dimension mm 82.42 1) 82.51
m

atio
om

• 1)

n in
Dimensions without graphite coating (thickness
or c

0.02 mm). The graphite coating wears away.

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py

[Link]
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4.4 Separating new conrod

On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:
– Mark allocation of conrod to cylinder.
– Clamp conrod -1- in a vice below the dashed line using alu‐
minium vice clamps.
– Unscrew both bolts -2- about 5 turns.

– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.

4. Pistons and conrods 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 02.2017

4.5 Checking radial clearance of conrods

Special tools and workshop equipment required
♦ Plastigage
Sequence of operations
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten it using old bolts
⇒ Item 1 (page 79) . When tightening, make sure not to rotate
crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.02 to 0.06 mm

[Link]
• Wear limit: 0.09 mm.
– Renew conrod bolts.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

86 Rep. gr.13 - Crankshaft group