VW Scirocco 2008-2015 - 4-Cyl. Injection Engine (2.0l Engine, Turbocharger) VW R GMBH (CDLA CDLC CDLK) [PDF]

Zitiervorschau

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Workshop Manual

4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH

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Service Department. Technical Information

Service 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 21 - Turbocharging/supercharging 24 - Mixture preparation - injection 26 - Exhaust system 28 - Ignition system

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2019 Volkswagen AG, Wolfsburg

D4B80465DB3

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . Safety precautions when using testers and measuring instruments during a road test . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2 2 3 3 4 4 4 4 4 5 5

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

1 1.1 1.2 1.3 2 2.1

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Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing engine on engine and gearbox support . . . w. a.g.en. A. G. ..V.ol.ks. w. a.g.en. A. G. d. o.e. . . . . . . . . . . s ks Installing engine . . . . . . . . . . . . . . . . . . . . . . . .by. V. o.l . . . . . . . . . . . . . . . . . . . . . n.o.t g. u.a. . . . . . d ra e Assembly mountings . . . . . . . . . . . . . . . .th.or.is. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee.o. . au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c Assembly overview - assembly mountings ss es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

1 1.1 1.2 1.3 1.4 1.5 2 2.1 3 3.1 3.2 3.3 3.4 3.5 3.6

1

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

17 17 19 19 21 23 27 27 28 30 31 34 34 35 35 36 36 39 39 40 41

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 1 1.1 1.2

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Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2 4.3

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents

43 43 45

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Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 51 54 54 55 64 64 65 68 71 75 77 82 82 82

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Removing and installing oilepressure switch agen AGF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 AG. Volksw do ag n kswoil filter housing . . . .e.s n. o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 l Removing and installing o gu yV b d Checking oil pressure and oil pressure switch . . . . .a.ra.nt. . . . . . . . . . . . . . . . . . . . . . . . . . . 94 ise r ee ho Oil circuit s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . 98 s Assembly overview - oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 rrectness of i t to the co nform spec a t i h re o n in wit thi s

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1 1.1 1.2 1.3 2 2.1 2.2 2.3 2.4 3 3.1 4 4.1 4.2

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do c um en

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1 1.1 1.2 1.3 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 4 4.1 4.2 4.3 4.4

105 105 107 112 114 114 115 115 116 117 118 119 119 120 123 123 124 124 126

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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Contents

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 1 1.1 1.2 1.3 2 2.1 2.2 2.3 2.4 2.5

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127 127 129 136 138 138 138 140 141 142

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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5.2 5.3 5.4 6 6.1 7 7.1 7.2

Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AG. Volkswagen Releasing high pressure in fuel system agen . . . . . . . . . . .A.G.d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . ksw no l o Injectors . . . . . . . . . . . . . . .d .by. V. . . . . . . . . . . . . . . . . . . . . . . . t. g.u.ar. . . . . . . . . . . . . . . . . . . . a e ris with injectors . . . . . . . . . . . . . . . . . .n.te.e . . . . . . . . . . . . . . . . Assembly overview - fuelhorail t o au injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . . . Removing and installing ss Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - actuator for structure-borne sound and control unit for structure-borne sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility ab y li an pt ce

1 1.1 2 2.1 2.2 2.3 2.4 3 3.1 3.2 4 4.1 4.2 4.3 4.4 5 5.1

145 145 147 147 148 150 151 154 154 155 157 157 158 160 162 165 165 166 166 167 171 171 174 174 175

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2

Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 177 179 180 181 182 182 183 185 185 185

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 1

Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Contents

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

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Contents

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iv

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Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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1.1 1.2 1.3

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

00 –

Technical data

1

Safety information

(VRL013459; Edition 09.2019) ⇒ “1.1 Safety precautions when working on the cooling system”, page 1 ⇒ “1.2 Safety precautions when working on ignition system”, page 1 ⇒ “1.3 Safety measures when working on fuel supply”, page 2 ⇒ “1.4 Safety measures when working on vehicles with a start/ stop system”, page 2 ⇒ “1.5 Safety precautions when using testers and measuring in‐ struments during a road test”, page 2

1.1

Safety precautions when working on the cooling system

Danger of scalding by hot coolant On a warm engine, the cooling system is under high pressure. Danger of scalding by steam and hot coolant. – Wear protective gloves. – Wear protective goggles. – Reduce excess pressure by covering cap of coolant expan‐ sion tank with cloths and opening it carefully. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

1.2

Safety precautions when working on ignition system

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Risk of injury due to electric shock

The ignition system is under high voltage when the engine is run‐ ning. Touching the ignition system may result in an electric shock.

Risk of damage to components

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– Do not touch or disconnect ignition cables when the engine is running or being turned at starter speed.

Connecting or disconnecting electric cables or washing the en‐ gine while it is running may damage components.

– Switch off the ignition before connecting or disconnecting elec‐ tric cables. – Switch off the ignition before washing the engine.

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1. Safety information

1

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

1.3

Safety measures when working on fuel supply

Danger of accident when fuel is under high pressure The fuel system is pressurised. Injury from fuel spray possible. – Release high pressure in fuel system before opening fuel sys‐ tem.

Danger of fire caused by escaping fuel When the battery is connected and the driver door opens, the door contact switch activates the fuel pump. Escaping fuel can ignite and cause a fire. olksw

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Safety measures when working on vehicles with a start/stop system

If the vehicle’s start/stop system is activated, the engine can start unexpectedly. A message in the dash panel insert indicates whether the start/stop system is activated. – Deactivate start/stop system by switching off the ignition.

1.5

Safety precautions when using testers and measuring instruments during a road test

Risk of injury caused by unsecured testing and measuring instru‐ ments r fo ng

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– Secure testing and measuring instruments on the rear seat.

– Have a second person operate the test and measuring equip‐ ment on the rear seat.

Rep. gr.00 - Technical data

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When the front passenger airbag is triggered in an accident, in‐ sufficiently secured testing and measuring instruments become dangerous projectiles.

2

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Risk of injury due to unexpected motor start

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Identification

⇒ “2.1 Engine number/engine data”, page 3

2.1

Engine number/engine data

The engine number (“code letters” and “serial number”) can be found on the left on the joint between the engine and the gearbox. The engine code is also stamped on the right side of the cylinder head and on the cylinder block. The engine number consists of up to 9 characters (alphanumeric). The first part (maximum 3 characters) makes up the “engine code”, and the second part (6 characters), the “serial number”. If more than 999,999 engines were produced with the same code letters, the first of the six digits is replaced by a letter. In addition, there is a sticker on the toothed belt guard with “engine code” and “serial number”. The engine code is also included on the vehicle data sticker. Vehicles with four digit engine codes Starting with the letter “C”, new four digit engine codes have been introduced. The first 3 places show the mechanical design of en‐ gine and are stamped on the engine as previously. The fourth digit denotes the performance and torque rating of the engine and de‐ pends on the engine control unit. The four-digit engine code can be found on the identification plate, the vehicle data sticker and the engine control unit. CDLC

11.09 ► EU 5 1984

11.09 ► EU 5 1984

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y 188/6000 d b 206/6000 ise r tho 330/2400 350/2500 au s … 5200 … 5000 s 82.5 82.5 92.8 92.8 9.8 9.8 4 4 98 unlea‐ 98 unlea‐ ded1 ded1 Motronic Motronic MED 9.1 MED 9.1 Homoge‐ Homoge‐ neous neous 2 sensors 2 sensors 2 probes 2 probes Yes Yes Yes Yes

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kW at rpm 195/6000 Nm at 350/2500 rpm … 5000 Bore ∅ mm 82.5 Stroke mm 92.8 Compression ratio 9.8 Valves per cylinder 4 RON 98 unlea‐ ded1 Injection, ignition Motronic MED 9.1 Type of mixture formation Homoge‐ neous Knock control 2 sensors Lambda regulation 2 probes Catalytic converter Yes Camshaft timing adjust‐ Yes ment Electronic power control Yes

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Manufactured Exhaust emissions fulfil Displacement cm3

CDLA

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Engine code

2. Identification

3

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3

Repair instructions

⇒ “3.1 Rules for cleanliness”, page 4 ⇒ “3.2 Foreign objects in engine”, page 4 ⇒ “3.3 Contact corrosion”, page 4 ⇒ “3.4 Routing and attachment of lines”, page 4 ⇒ “3.5 Fitting radiator and condensers”, page 5 ⇒ “3.6 Checking vacuum system”, page 5

3.1

Rules for cleanliness

Even small degrees of soiling can lead to defects. Therefore, comply with the following rules for cleanliness when working on the fuel supply system, injection system and turbocharger: ♦ Carefully clean connection points and the surrounding area with engine cleaner or brake cleaner and dry thoroughly before opening. ♦ Seal open pipes and connections immediately with clean plugs for example from the engine bung set - VAS 6122- . ♦ Place removed parts on a clean surface. Cover with lint-free cloths only. ♦ If repair work cannot be performed immediately, carefully cov‐ er or seal components. ♦ Install only clean parts; do not remove new parts from pack‐ aging until immediately before installing. Do not use parts that have been stored outside their packaging (e.g. in tool boxes). AG. Volkswagen AG d ♦ When the system is open, do not work with compressed agen air or oes ksw not l o move the vehicle. gu yV b ed

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is rhoses. ♦ Make sure that no fuel gets onto the fuel Should this tho uimmediately. occur, the fuel hoses must be cleaned a s

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♦ Protect disconnected electrical connectors from dirt and water, and reconnect them only when dry.

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♦ To prevent the ingress of foreign bodies during work on the engine, seal open channels of the intake and exhaust sections with suitable bungs, for example from the engine bung set VAS 6122- .

3.3

Contact corrosion

Contact corrosion can occur if non-approved fasteners are used on the vehicle (bolts, nuts, washers etc.). For this reason, only connecting elements with a special surface coating have been fitted. Furthermore, rubber and plastic components as well as adhe‐ sives are made of non-conductive materials.

Routing and attachment of lines

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♦ Mark fuel lines, vacuum lines, lines for activated charcoal filter system and electrical wiring before removal to prevent them from being interchanged and to ensure that they will be reinstalled in the original positions and correctly connected. If necessary, take a photo or make a sketch.

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3.4

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If there is any doubt about the suitability of parts, a general rule is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .

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3.5

Fitting radiator and condensers

3.6

Checking vacuum system

Special tools and workshop equipment required ♦ Hand operated vacuum pump - VAS 6213-

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Procedure

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Even if installed correctly, the radiator, the condenser and the charge air cooler may have small dents in their fins. This does not mean that these components have been damaged. It is not per‐ missible to renew radiators, condensers or charge air coolers only because of such minor dents.

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– Check all vacuum lines throughout entire vacuum system for: ♦ Cracks ♦ Marten bites ♦ Crushing ♦ Porous areas and other leaks – Check vacuum line to solenoid valve and from solenoid valve to relevant component. – If a fault has been entered in the event memory, make sure to check not only all vacuum lines leading to the specified com‐ ponent, but also those leading to other components. – If pressure cannot be built-up using hand vacuum pump - VAS 6213- or pressure immediately drops again, check hand vac‐ uum pump and connecting hoses for leaks.

3. Repair instructions

5

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

10 –

Removing and installing engine

1

Removing and installing engine

⇒ “1.1 Removing engine”, page 6 ⇒ “1.2 Securing engine on engine and gearbox support”, page 12 ⇒ “1.3 Installing engine”, page 14

1.1

Removing engine

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♦ Engine and gearbox jack - V.A.G 1383 A♦ Stepladder - VAS 5085♦ Engine support - T10012♦ Cable tie

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Rep. gr.10 - Removing and installing engine

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♦ Pliers for spring-type clips - VAS 5024A-

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♦ Torque wrench - V.A.G 1332-

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♦ Torque wrench - V.A.G 1331-

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Special tools and workshop equipment required

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Procedure Note ♦ The engine is removed downwards together with the gearbox. ♦ All cable ties which were opened or cut when the engine was

removed must be replaced with new cable ties in the same positions when engine is installed. Caution

When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines and electrical wiring so that they . Volkswagen AG are in their original positions. gen AG d a lksw

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yV ♦ Ensure that there is sufficient clearance too all moving or db e s i hot components. or

– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . – Unscrew bolts -arrows-. – Remove battery tray.

– Remove plenum chamber cover ⇒ General body repairs, ex‐ terior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing plenum chamber cover .

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– Release feed-through for engine wiring harness -arrow-, and pull it off upwards.

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– Disconnect engine wiring harness from engine control unit J623- .

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– Remove air filter housing ⇒ page 155 .

1. Removing and installing engine

7

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Slide the two clips in the direction of the -arrows- and remove cover from electronics box in engine compartment.

– Unscrew nut -arrow-. – Remove earth wire from longitudinal member. ht rig py Co t.

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– Open cable duct latches on longitudinal member -arrows-.

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Rep. gr.10 - Removing and installing engine

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– Unscrew cable from alternator -A- and cable from battery -Bat fuse box.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Free electrical connector -1- and disconnect. – Open wiring guide bracket located below -2-. – Remove wiring harness leading to engine control unit - J623from wiring duct, and place it on engine. WARNING

Fuel supply line is pressurised. Wear protective goggles and protective clothing to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Release pressure by carefully pulling hose off AG. Volkswagen AG d agen oes connection. n lksw

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– Disconnect breather line -1- and fuel feed liness-2-.

– Separate breather line -2- and pull activated charcoal filter with hoses upwards out of bracket.

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– Remove front right and front left wheel housing liners ⇒ Gen‐ eral body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .

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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .

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– Remove charge air hoses -arrows-.

1. Removing and installing engine

9

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Remove heat shield for drive shaft on right side -arrows-. – Remove right and left drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft . – Remove front exhaust pipe with catalytic converter n AG. Volkswagen AG do es n wage ⇒ page 179 . o olks V by

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ed – Move lock carrier to service position ris ⇒ General body repairs, o h t exterior; Rep. gr. 50 ; Lock carrier; Moving lock carrier to and au back from service position . ss

– Drain coolant ⇒ page 107 .

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Risk of freezing injury from refrigerant When working on the air conditioning system, there is a risk of highly pressurised refrigerant escaping from the system. There is a risk of injury to the skin and parts of the body due to freezing. – Wear protective gloves.

– Wear protective goggles.

– Extract refrigerant, and open the refrigerant circuit immediate‐ ly afterwards. – If more than 10 minutes have passed since the refrigerant was extracted, repeat the extraction process before opening the refrigerant circuit. Due to continued evaporation, pressure will build up in the refrigerant circuit.

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– Remove refrigerant line from condenser.

10

Rep. gr.10 - Removing and installing engine

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– Unscrew bolt -arrow-.

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– Detach refrigerant line from air conditioner compressor.

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– Unscrew bolt -arrow-.

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– Extract refrigerant using air conditioner service station .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -1 to 3-. – Remove pendulum support. – Pull off or disconnect all other electrical connections as nec‐ essary from engine and gearbox and move to one side. – Disconnect all connection, coolant, vacuum and intake hoses from engine. Vehicles with manual gearbox – Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ; Selector mechanism; Removing and installing selector mech‐ anism . – Clamp-off hose for pipe/hose line -A- to slave cylinder using hose clips - 3094- . – Pull out clip -arrow- for pipe/hose line to stop. – Pull pipe/hose line out of slave cylinder breather. Caution

Do not depress clutch pedal any longer. Vehicles with DSG®

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Continued for all vehicles:

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– Unscrew coolant circulation pump - V50- -arrows-.

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1. Removing and installing engine

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y db ise r Insert engine bracket - T10012tho au V.A.G 1383 A- . s s

– Lift engine and gearbox slightly using engine and gearbox jack - V.A.G 1383 A- .

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– Unscrew bolts -arrows-.

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– Unscrew bolts -arrows-. Note ♦ When removing, use the stepladder - VAS 5085- . ♦ Engine and gearbox must be guided carefully when lowering

to prevent damage to bodywork.

– Carefully lower engine with gearbox.

1.2

12

Securing engine on engine and gearbox support

Rep. gr.10 - Removing and installing engine

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– Fit engine bracket - T10012- to engine as shown, and tighten bolt -1- and nut -2- to approx. 20 Nm.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

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♦ Workshop hoist - VAS 6100-

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♦ Lifting tackle - 2024 A-

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Special tools and workshop equipment required

♦ Engine and gearbox support - VAS 6095Procedure Secure engine on engine and gearbox support - VAS 6095- to carry out repairs. – Unbolt gearbox.

1. Removing and installing engine

13

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l. Vengine, olkswageturbocharger) Volkswagen R GmbH - Edition 09.2019

–

n AG d AG agen oes ksw not l o V A- as follows and lift from engine gu y Attach lifting tackle - 2024 b ar d e and gearbox jack - oVAS 6100- using workshop crane - V.A.Gantee ris h t or 1383 A- . ac au ss

Flywheel end: 1st hole in hook rail at position 7

Use securing pins on hooks and locking pins to avoid damage to engine and vehicle. ♦ The positions marked 1…4 on the bar must face towards the V-belt pulley end. ♦ The holes in the hook rails are counted up from the hook. – Secure engine to engine and gearbox support - VAS 6095- .

1.3

Installing engine

Procedure

Install in reverse order of removal, observing the following: c o p yri gh t. C op yi

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When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions:

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♦ Route all the various lines and electrical wiring so that they are in their original positions. ♦ Ensure that there is sufficient clearance to all moving or hot components. – Insert new dowel sleeves in the cylinder block for centring the engine and gearbox. – Hook intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-. Vehicles with manual gearbox – Lightly grease input shaft splines with grease - G 000 100- . – Check clutch and clutch mechanism, and install them ⇒ Rep. gr. 30 ; Clutch mechanism; Repairing clutch release mecha‐ nism . Vehicles with DSG® – Renewing needle bearing in crankshaft ⇒ page 36 . Continued for all vehicles – When installing the engine and gearbox assembly, make sure there is sufficient clearance to the subframe and radiator. – Align engine mountings as follows:

14

Rep. gr.10 - Removing and installing engine

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Caution

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Belt pulley end: 2nd hole in hook rail at position 1

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ There must be a distance -a- of at least 10 mm between engine support and longitudinal member (right side). ♦ The side surface of the engine support -2- should be located parallel to the support arm -1-. – Install pendulum support. – Install right and left drive shafts ⇒ Running gear, axles, steer‐ ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft . – Install front exhaust pipe with catalytic converter ⇒ page 179 . – Screw on refrigerant lines. Vehicles with manual gearbox – Install selector mechanism, and adjust it if necessary ⇒ Rep. gr. 34 ; Selector mechanism; Removing and installing selector mechanism . – Reconnect pipe/hose assembly to slave cylinder breather. Vehicles with DSG® – Install selector lever cable, and adjust it if necessary ⇒ Rep. gr. 34 ; Selector mechanism; Removing and installing selector lever cable . Continued for all vehicles: . Volkswagbody en AG repairs, exterior; Rep. – Install noise insulation AGGeneral n⇒ d es wage s k not gr. 66 ; NoiseVinsulation; Removing andoinstalling noise insu‐ l o gu y b ara lation . ed n

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– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐ moving and installing battery . – Add coolant ⇒ page 107 . – Connect ⇒ Vehicle diagnostic tester. – Read event memory, and delete all entries which may have occurred due to repair work. – Carry out road test.

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– Then carry out vehicle system test and rectify any faults which have occurred. Note

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Specified torques: c o p yri gh t . C op yi

Bolted connection

Specified torque M6 M7 M8 M10 M12

10 Nm 15 Nm 25 Nm 40 Nm 60 Nm

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Nuts and bolts

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h or exte‐ – Installautplenum chamber cover ⇒ General body repairs, ac s s rior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing plenum chamber cover .

1. Removing and installing engine

15

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Assembly mountings

⇒ “2.1 Assembly overview - assembly mountings”, page 16

2.1

Assembly overview - assembly mount‐ ings

Engine mounting Component

Specified torque

Bolt -A-

20 Nm + 90° 1)

Bolt -B-

40 Nm + 90° 1)

Bolt -C-

1)agen A 60 Nm + 90° lksw

Renew after each removal

Bolt -1-

40 Nm + 90° 1) 60 Nm + 90° 1)

Renew after each removal

Component Bolt -ABolt -B-

40 Nm + 90° 1) 100 Nm + 90° 1)

Bolt pendulum support to gearbox and then to subframe. Renew after each removal

16

Rep. gr.10 - Removing and installing engine

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Note

Specified torque

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Pendulum support

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1)

Specified torque

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Bolt -2-

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Component

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Cylinder block (pulley end)

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Crankshaft group

⇒ “1.1 Assembly overview - poly V-belt drive”, page 17

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13 –

Scirocco 2015 ➤ Volkswagen R GmbH - Edition 09.2019

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⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page 19 ⇒ “1.3 Removing and installing poly-V belt”, page 19 ⇒ “1.4 Renewing crankshaft oil seal - belt pulley end”, page 21

⇒ “1.5 Removing and installing sealing flange on pulley end”, page 23

Assembly overview - poly V-belt drive

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1 - Ancillary bracket ❑ Observe tightening se‐ quence ⇒ page 18 agen lksw Vo by

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2 - Bolts ❑ Qty. 2 ❑ 23 Nm

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1.1

3 - Nuts ❑ Qty. 2 ❑ 23 Nm 4 - Alternator ❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator ❑ To facilitate attachment of alternator, knock back threaded bushes for alternator securing bolts slightly. 5 - Bolts ❑ Observe tightening se‐ quence ⇒ page 18 ❑ 40 Nm 6 - Bushes ❑ Qty. 2 7 - Bolts ❑ 25 Nm 8 - Air conditioner compressor ❑ Removing and installing ⇒ Heating, air condi‐ tioning; Rep. gr. 87 ; Air conditioner compressor; Removing and installing air conditioner compressor 9 - Poly V-belt ❑ Mark direction of rotation with chalk or felt pen before removing. ❑ Check for wear

1. Cylinder block (pulley end)

17

12 - Bolts ❑ 23 Nm

13 - Tensioner ❑ Swing with open-end spanner to slacken poly V-belt.

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Rep. gr.13 - Crankshaft group

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18

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Bolt-tightening sequence for ancillary bracket

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11 - Bolts ❑ Renew after removal ❑ 20 Nm +90°

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10 - Pulley

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❑ Do not kink ❑ Removing and installing ⇒ page 19

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise engine, turbocharger) Volkswagen R GmbH Edition 09.2019 r o eo h t u ra a c s s

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

1.2

Assembly overview - sealing flange, belt pulley end

1 - Bolt ❑ Renew after removal ❑ Do not oil ❑ Use counterhold - 3415to loosen and tighten. ❑ 90 Nm +90° 2 - Crankshaft pulley ❑ Contact surface be‐ tween toothed belt pul‐ ley and crankshaft must be free from oil ❑ Can only be fitted in one position 3 - Bolts ❑ 15 Nm 4 - Seal ❑ Do not additionally oil or grease the oil seal seal‐ ing lip. ❑ Renewing ⇒ page 21 5 - Sealing flange ❑ Must seat on dowel pins. ❑ Removing and installing ⇒ page 23 6 - Cylinder block 7 - Bolts ❑ Renew after removal ❑ 60 Nm +90°

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8 - Flywheel/drive plate ❑ Removing and installing flywheel ⇒ page 30 ❑ Removing and installing drive plate ⇒ page 31

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9 - Adapter ❑ Must seat on dowel sleeves. ❑ Do not damage or bend when assembling. 10 - Sealing flange with oil seal ❑ Renew only as complete unit ❑ Removing and installing ⇒ page 28 11 - Diamond-coated washer ❑ Renew after removal

1.3

Removing and installing poly-V belt

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1. Cylinder block (pulley end)

19

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation . – Mark running direction of poly V-belt. – Unlock activated charcoal filter and pull upwards out of bracket with lines connected -arrow-.

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– Swivel tensioning element in direction of -arrow-.

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– Use the locking pin - T10060A- to lock the tensioning element in place. – Remove poly V-belt. Installing Install in reverse order of removal, observing the following: Note ♦ When fitting poly V-belt, check direction of belt rotation and

proper seating of belt in belt pulleys.

♦ Fit poly V-belt over air conditioner compressor last.

20

Rep. gr.13 - Crankshaft group

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♦ Locking pin - T10060A-

1.4

Renewing crankshaft oil seal - belt pulley end

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Special tools and workshop equipment required

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♦ Seal puller - 3203♦ Counter-hold - 3415♦ Assembly tool - T10053♦ Torque wrench - V.A.G 1331♦ Torque wrench - V.A.G 1332-

1. Cylinder block (pulley end)

21

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Removing – Remove toothed belt ⇒ page 55 . – Lock toothed belt pulley using counterhold - 3415- . – Remove crankshaft pulley.

– To guide seal extractor - 3203- , screw centre bolt into crank‐ shaft to stop by hand. – Unscrew inner part of oil seal extractor - 3203- 9 turns (approx. 20 mm) from the outer part and lock in position with the knurled screw.

– Lubricate threaded head of oil seal extractor - 3203- , place it in position and, exerting firm pressure, screw it into the oil seal as far as possible. AG. Volkswagen AG d – Loosen knurled screw and turn inner part against crankshaft agen oes ksw not l until the oil seal is pulled out. o g yV

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Install in reverse order of removal,

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– Remove oil residues from crankshaft journal with a clean cloth.

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– Fit guide sleeve - T10053/1- onto crankshaft journal. – Slide dry oil seal over guide sleeve onto crankshaft journal.

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Rep. gr.13 - Crankshaft group

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22

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH Edition 09.2019 olksw agen AG does not gu ara nte eo ra c

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– Using assembly tool - T10053- and seal as far as stop.

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♦ Contact surface between pulley, diamond-coated washer and

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crankshaft must be free of oil.

♦ Renew the centre bolt after each removal. ♦ Thread and shoulder must be free of oil and grease.

– Fit toothed belt pulley -2- with diamond-coated washer -3-.

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– Tighten new central bolt.

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– Lock toothed belt pulley using counterhold - 3415- .

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– Tighten bolt -1- hand-tight.

Specified torques ♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page 19 ♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54

1.5

Removing and installing sealing flange on pulley end

1. Cylinder block (pulley end)

23

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Special tools and workshop equipment required

rrectness of i t to the co nform spec at i h re o n wit in t his

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♦ Counter-hold - 3415♦ Assembly tool - T10053♦ Torque wrench - V.A.G 1331♦ Torque wrench - V.A.G 1332♦ Hand drill with plastic brush ♦ Silicone sealant - D 176 404 A2♦ Scraper Removing

AG.

Rep. gr.13 - Crankshaft group

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24

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– Turn crankshaft back slightly.

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– Remove toothed belt ⇒ page 55 .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Lock toothed belt pulley using counterhold - 3415- . – Remove crankshaft pulley. – Remove sump ⇒ page 86 . – Unbolt sealing flange. – Remove sealing flange; if necessary, loosen using light blows with a rubber headed hammer. Volkswa AG. agen

swflat scra‐ – Remove sealant residues from cylinder block with olka yV b d per. se

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Note

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– Cover oil seal with a clean cloth.

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If seal is to be renewed, drive it out as follows: – Remove residual sealant on sealing flange using a rotating plastic brush (wear eye protection). – Clean sealing surfaces. They must be oil and grease-free. Installing

Install in reverse order of removal, observing the following:

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Note

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– Apply sealant bead of about 2…3 mm as shown -arrows- to clean sealing surface of sealing flange.

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– Cut off nozzle on tube at front marking (∅ of nozzle approx. 3 mm).

♦ Before applying sealant bead, cover sealing ring with a clean

cloth.

♦ The sealant bead must be no thicker than 2 to 3 mm. Other‐

wise excess sealant may get into the sump and block the strainer in the oil intake pipe.

♦ Observe use-by-date of sealant. ♦ The sealing flange must be installed within 5 minutes after ap‐

plying the silicone sealant.

♦ Use the guide sleeve - T10053/1- to fit the sealing flange with

seal installed.

♦ Leave the sealant to dry for approx. 30 minutes after assem‐

bly. Only then fill with engine oil.

1. Cylinder block (pulley end)

25

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Fit sealing flange immediately and lightly tighten all bolts -arrows-. – Tighten sealing flange bolts diagonally and alternately. – Remove excess sealant. – Install sump ⇒ page 86 . – Install oil seal if necessary ⇒ page 21 . Note ♦ Contact surface between pulley, diamond-coated washer and

crankshaft must be free of oil.

♦ The centre bolt must be renewed. ♦ Thread and shoulder must be free of oil and grease. – Fit toothed belt pulley -2- with

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– Tighten bolt -1- hand-tight.

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– Lock toothed belt pulley using counterhold - 3415- . – Tighten new central bolt. Specified torques

♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page 19 ♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54

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Rep. gr.13 - Crankshaft group

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26

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page 27 ⇒ “2.2 Removing and installing sealing flange on gearbox side”, page 28 ⇒ “2.3 Removing and installing flywheel”, page 30 ⇒ “2.4 Removing and installing drive plate”, page 31

2.1

Assembly overview - cylinder block, gearbox end

1 - Bolt ❑ Renew after removal ❑ Do not oil ❑ Use counterhold - 3415to loosen and tighten. ❑ 90 Nm +90° 2 - Crankshaft pulley ❑ Contact surface be‐ tween toothed belt pul‐ ley and crankshaft must be free from oil ❑ Can only be fitted in one position 3 - Bolts ❑ 15 Nm

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7 - Bolts ❑ Renew after removal ❑ 60 Nm +90°

8 - Flywheel/drive plate ❑ Removing and installing flywheel ⇒ page 30 ❑ Removing and installing drive plate ⇒ page 31 9 - Adapter ❑ Must seat on dowel sleeves. ❑ Do not damage or bend when assembling. r fo ng

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10 - Sealing flange with oil seal ❑ Renew only as complete unit ❑ Removing and installing ⇒ page 28

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6 - Cylinder block

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5 - Sealing flange ❑ Must seat on dowel pins. ❑ Removing and installing ⇒ page 23

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4 - Seal ❑ Do not additionally oil or grease the oil seal seal‐ ing lip. ❑ Renewing ⇒ page 21

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2. Cylinder block, gearbox end

27

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 11 - Diamond-coated washer ❑ Renew after removal

2.2

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Removing and installing sealing flange on gearbox side un le

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Special tools and workshop equipment required

♦ Sealant ⇒ Electronic parts catalogue (ETKA) Removing – Remove flywheel ⇒ page 30 . – Detach intermediate plate from sealing flange and dowel pins -arrows-.

28

Rep. gr.13 - Crankshaft group

AG.

♦ Safety glasses

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♦ Hand drill with plastic brush attachment

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♦ Assembly aid - T10122/1- from fitting tool - T10122B- or fitting tool - T10122C-

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♦ Guide piece - T10122/6- or guide piece - T10122/6A- from fit‐ ting tool - T10122B- or fitting tool - T10122C-

Scirocco 2015 ➤ n AG. Volkswagen AG do wage 4-cylinder injection engine (2.0 l engine, Vturbocharger) Volkswagen eRs nGmbH - Edition 09.2019 ot g olks or ac

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Install in reverse order of removal, observing the following:

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– Remove sealant residue.

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♦ Wear safety goggles.

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Risk of eye injury.

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WARNING

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– In order to prevent the lubrication system from being soiled, cover the open section of the sump with a clean cloth.

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Installing

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– Remove sealing flange.

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– Unscrew bolts -1 … 8-.

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– Clean sealing surfaces. Note

Observe use-by date of silicone sealant. – Cut off nozzle on tube at front marking (∅ of nozzle approx. 2 mm). – Apply silicone sealant -arrow- to clean sealing surface of seal‐ ing flange. •

Thickness of sealant bead: 2 to 3 mm.

2. Cylinder block, gearbox end

29

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Note ♦ Check sealing flange; it must be free of kinks and damage. ♦ The sealing lip must face engine following installation. Other‐

wise, oil leaks may occur.

♦ Install the sealing flange within 5 minutes after application of

the silicone sealant.

– Check guide - T10122/6- -B-; it must be clean and free of sharp edges. – Attach assembly aid - T10122/1- -A- to guide - T10122/6-B-. – Push sealing flange -C-, with outer side leading, onto guide piece - T10122/6- -B-. – Remove assembly aid -A-.

Note

It is not necessary to tighten the bolts -arrows-. – Push sealing flange -B- over guide -A- onto crankshaft journal. – Remove guide -A-. •

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

Specified torques ♦ ⇒ page 27

Removing and installing flywheel Prote cted by

Rep. gr.13 - Crankshaft group

AG.

30

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Special tools and workshop equipment required

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– Put guide -A- with sealing flange -B- onto crankshaft journal.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Counter-hold - 3067-

Removing Caution

The dual-mass flywheel may be destroyed if the bolts -B-are unscrewed with a pneumatic nut runner or impact wrench. Unscrew dual-mass flywheel bolts by hand, without application AG. Volkswagen AG d agen oes ksw not l of any tools. o V g

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– Rotate dual-mass flywheel -A- so that with the holes -arrows-.

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– When removing bolts -B-, make sure that screw heads do not jam on flywheel.

– Insert counterhold - 3067- in hole on cylinder block. – Unscrew flywheel. Installing

Install in reverse order of removal, observing the following:

AG.

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♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page 27

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Specified torques

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– Mark position of flywheel in relation to engine.

Removing and installing drive plate

Special tools and workshop equipment required

2. Cylinder block, gearbox end

31

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Counter-hold - VW 558-

♦ Depth gauge ♦ Hexagon bolt M8 × 45 and two M10 hexagon nuts Removing – Secure counterhold - VW 558- to drive plate with hexagon bolt M8 x 45. When doing this, insert two M10 hexagon nuts in between counterhold and drive plate to act as spacers. Installation position of counterhold: -A- to loosen, -B- to tighten. Installing Install in reverse order of removal, observing the following:

– Fit drive plate using ring with recesses -1-. – Fit bolts -3-, and tighten them to 30 Nm.

Specification: 19.5…21.1 mm Note

Measure through hole in drive plate to milled surface of cylinder block. If specification is not attained:

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Rep. gr.13 - Crankshaft group

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32

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– Check dimension -a- at three points and calculate average.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Remove drive plate again and fit shim -2-. Again tighten bolts -3- to 30 Nm. – Then, tighten bolts to specified torque. Specified torques ♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page 27

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2. Cylinder block, gearbox end

33

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

3

Crankshaft

⇒ “3.1 Assembly overview - crankshaft”, page 34 ⇒ “3.2 Crankshaft dimensions”, page 35 ⇒ “3.3 Allocation of main bearing shells”, page 35 ⇒ “3.4 Removing and installing sender wheel”, page 36 ⇒ “3.5 Renewing needle bearing in crankshaft”, page 36

3.1

Assembly overview - crankshaft Note

♦ Before removing the crankshaft, prepare a suitable surface for storing the crankshaft so that it is not placed

down on the sender wheel ⇒ Item 4 (page 34) and the sender wheel is not damaged.

♦ Secure engine to engine and gearbox support - VAS 6095- to carry out repairs. 1 - Bolts ❑ Renew after removal ❑ Threaded along com‐ plete length. ❑ Only tighten to 65 Nm when measuring crank‐ shaft radial clearance; do not turn further. ❑ 65 Nm +90°

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3 - Bolts ❑ Renew after removal ❑ 10 Nm +90°

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4 - Sender wheel ❑ For engine speed send‐ er - G28❑ Always renew sender wheel if securing bolts have been unscrewed ❑ Can only be installed in one position (holes are offset). ❑ Removing and installing ⇒ page 36

5 - Crankshaft ❑ Axial clearance, new: 0.07…0.23 mm; wear limit: 0.30 mm ❑ Check radial clearance using Plastigage; new: 0.017 … 0.037 mm; wear limit: 0.07 mm ❑ Do not rotate crankshaft when checking radial clearance agen lksw Vo by

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Rep. gr.13 - Crankshaft group

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34

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ❑ Crankshaft dimensions ⇒ page 35 . ❑ Removing and installing needle bearing ⇒ page 36 6 - Thrust washers ❑ For bearing 3 7 - Bearing shell for cylinder block ❑ With oil groove. ❑ Classification for ordering spare parts ⇒ page 35 . ❑ Do not interchange used bearing shells (mark). 8 - Sprocket ❑ For oil pump drive. 9 - Bearing shell for bearing cap ❑ Without oil groove. ❑ Do not interchange used bearing shells (mark).

3.2

Crankshaft dimensions

(Dimensions in mm) Honing dimen‐ sion

Crankshaft main journal ∅

Conrod journal ∅

Basic dimension 54.00 Stage I

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Allocation of main bearing shells

Upper bearing shells of the proper thickness are allocated to the cylinder block in the factory. Coloured dots are used to identify the thickness of the bearing shells. Letters on the lower sealing surface of the cylinder block indicate which bearing thickness is to be used at each position. G B W

= = =

yellow blue white

♦ Arrow points in direction of travel. ♦ If the coloured marks are no longer legible, use blue bearing

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-0.017 47.80 -0.022 AG. Volkswagen AG d -0.042 n -0.037 e g a oes ksw not Vol gu 53.75 -0.017 47.55 -0.022 by ara d e nte is -0.037 -0.042 r o eo h ut ra a 53.50 -0.017 47.30 -0.022 c s s -0.037 -0.042 53.25 -0.017 47.05 -0.022 -0.037 -0.042

♦ Lower crankshaft bearing shells with “yellow” coloured marks AG.

are always supplied as spare parts.

3. Crankshaft

35

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

3.4

Removing and installing sender wheel

Removing – Always renew sender wheel -2- each time bolts -1- are loos‐ ened. Note ♦ The second time the countersunk head bolts are tightened, the

contact points in the sender wheel for the countersunk heads are deformed so far that the bolt head -arrows- seats on the crankshaft -3-, and the sender wheel is loose under the bolt.

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

are offset.

Specified torques ♦ ⇒ “3.1 Assembly overview - crankshaft”, page 34

3.5

Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox Special tools and workshop equipment required ♦ Puller - T10055-

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♦ Centring mandrel - 3176-

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Rep. gr.13 - Crankshaft group

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ or drift - VW 207 C-

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♦ Puller, e.g. KUKKO - 21/2-

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– Pull out needle bearing using commercially available puller, e.g. KUKKO - 21/2- -arrow-, adapter - T10055/3- and puller T10055- . Install in reverse order of removal, observing the following:

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The lettering on the needle bearing must be legible when instal‐ led.

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Installing

AG.

– Drive in needle bearing using drift - VW 207 C- or centring mandrel - 3176- .

3. Crankshaft

37

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

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Rep. gr.13 - Crankshaft group

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Installation depth: dimension -a- = 2 mm.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

4

Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 39 ⇒ “4.2 Separating new conrod”, page 40 ⇒ “4.3 Checking pistons and cylinder bores”, page 41

4.1

Assembly overview - pistons and conrods

1 - Conrod bolt ❑ Renew after removal ❑ Oil threads and contact surface ❑ To measure radial clear‐ ance, tighten to 30 Nm but not further. ❑ 45 Nm +90° 2 - Bolt ❑ with pressure relief valve ❑ Opening pressure: 1.3…1.6 bar ❑ 27 Nm 3 - Oil spray jet ❑ For piston cooling

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4 - Conrod bearing cap ❑ Observe installation po‐ sition ❑ Due to the cracking AG. Volkswagen AG d agen oes method used to sepa‐ ksw not l o V gu y b ara rate the bearingedcap nte is in man‐ r from the conrod o eo h t u ra ufacture, the a caps only c s fit in one sposition and only on the appropriate conrod. ❑ Mark cylinder number -B❑ Installation position: markings -A- face to‐ wards belt pulley end.

5 - Bearing shell ❑ Note installation position ⇒ page 40 ❑ Do not interchange used bearing shells. ❑ Axial clearance, new: 0.10…0.35 mm; wear limit: 0.4 mm ❑ Check radial clearance with Plastigage: new: 0.02…0.06 mm, wear limit: 0.09 mm. Do not rotate crank‐ shaft when checking radial clearance.

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6 - Connecting rod ❑ With industrially cracked conrod cap. ❑ Renew as set only. ❑ Mark cylinder number -B❑ Installation position: markings -A- face towards belt pulley end. ❑ Separating new conrod ⇒ page 40 .

4. Pistons and conrods

39

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 7 - Retaining ring 8 - Piston pin ❑ If difficult to remove, heat piston to 60°C. ❑ Remove and install using drift - VW 222 A- .

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9 - Piston AG. Volkswagen AG d agen oes ksw not l o ❑ Checking ⇒ page 42 V gu by ara d e nte ❑ Mark installation position and cylinder number. is r o eo h ut ra a ❑ Arrow on piston crown points to belt pulley end. c s s ❑ Install using piston ring clamp. ❑ Checking cylinder bores ⇒ page 42 .

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10 - Piston rings ❑ Offset gaps by 120° ❑ Use piston ring pliers to remove and install. ❑ Marking faces to piston crown ❑ Checking ring gap ⇒ page 41 . ❑ Checking ring-to-groove clearance ⇒ page 41 . Installation position of bearing shells

– Position bearing shells in centre of conrod and conrod bearing cap when fitting. Distance -a- must be identical on both sides.

mm

Cylinder bore ∅

82.465 1)

82.51

1)

Dimensions without graphite coating (thickness 0.02 mm). The graphite coating wears away.

4.2

Separating new conrod

On new conrods it is possible that the breaking point is not fully separated. Proceed as follows if the conrod bearing cap cannot be removed by hand: – Mark which cylinder the conrod belongs to ⇒ page 39 .

40

Rep. gr.13 - Crankshaft group

AG.

Basic dimension

Piston ∅

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The cylinder bore may not be worked on (reboring, honing, grinding) may not be carried out using workshop tools! This will damage the surface of the cylinder bore.

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Piston and cylinder dimensions

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Clamp conrod in a vice with aluminium vice clamps. Note ♦ Only clamp the conrod lightly in order to avoid damaging it. ♦ Conrod is clamped below the dashed line. – Unscrew bolts -arrows- around 5 turns.

– Using a plastic hammer, carefully knock against conrod bear‐ ing cap in -direction of arrow- until it is loose.

4.3

Checking pistons and cylinder bores

Special tools and workshop equipment required ♦ Feeler gauge ♦ Micrometre 75 - 100 mm - VAS 6071♦ Cylinder gauge - VAS 6078-

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Compression rings Oil scraper ring

Ring gap New Wear limit mm 0.20 … 0.40 0.8 mm 0.25 … 0.50 0.8

Checking ring-to-groove clearance – Clean annular groove before check.

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Compression rings Oil scraper ring

Clearance New Wear limit mm 0.06 … 0.09 0.20 mm 0.03 … 0.06 0.15

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4. Pistons and conrods

41

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Checking piston Volkswagen AG does not gu ara nte eo ra c

AG. gen – Measure pistons approx 10 mm from the lower edge skirt, aof ksw l o V at 90° to the piston pin axis. by d se

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ri Deviation from nominal dimension: max. 0.04 tho mm

– Take measurements at 3 positions in both lateral direction -A- and longitudinal direction -B-. – Deviation from nominal dimension: max. 0.08 mm Note

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Rep. gr.13 - Crankshaft group

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Do not measure cylinder bores when cylinder block is mounted on a repair stand with engine and gearbox support - VAS 6095- , as measurements may then be incorrect.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

15 –

Cylinder head, valve gear

1

Cylinder head

⇒ “1.1 Assembly overview - cylinder head”, page 43 ⇒ “1.2 Removing and installing cylinder head”, page 45 ⇒ “1.3 Removing and installing cylinder head cover”, page 50 ⇒ “1.4 Checking compression”, page 51

1.1

Assembly overview - cylinder head Note

♦ If an exchange cylinder head is installed, all the contact surfaces between the supporting elements, roller

rocker fingers and the running surfaces of the cam must be oiled before the cylinder head cover is installed.

♦ Do not remove the plastic packing pieces for protecting the open valves until immediately before fitting

cylinder head.

♦ If the cylinder head is renewed, the coolant must also be completely changed.

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9 - Vacuum pump 10 - Bolt ❑ 4 Nm

AG.

8 - Seal ❑ Renew if damaged or leaking

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7 - Bolts ❑ 4 Nm

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6 - Seal ❑ Renew if damaged or leaking

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4 - Valve ❑ For crankcase ventila‐ tion.

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3 - Seal ❑ Renew if damaged or leaking

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2 - Cylinder head cover ❑ Removing and installing ⇒ page 50

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1 - Bolts ❑ Observe tightening se‐ quence ⇒ page 50 ❑ 10 Nm

11 - Inlet camshaft control valve 1 - N205❑ Removing and installing ⇒ page 75

1. Cylinder head

43

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 12 - Seal ❑ Renew after removal 13 - Bolt ❑ 10 Nm 14 - Cable bracket 15 - Seal . Volkswagen AG gen AG does ❑ Renew if damaged or leaking Volkswa not

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18 - Seal ❑ Renew after removal 19 - Transportation shackle 20 - Bolt ❑ 25 Nm

21 - Stud ❑ For intake manifold ❑ 10 Nm 22 - Partition

23 - Cylinder head gasket ❑ Renew after removal ❑ Observe installation position: part number faces cylinder head

AG.

27 - Stud ❑ For tensioning roller ❑ 10 Nm

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26 - Seal

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25 - Hall sender - G40-

28 - Stud ❑ For exhaust manifold ❑ 20 Nm 29 - Cylinder head ❑ Check for distortion ⇒ page 45 . 30 - Cylinder head bolt ❑ Renew after removal ❑ Observe sequence for loosing and tightening ⇒ page 45 ❑ 40 Nm +180°

44

Rep. gr.15 - Cylinder head, valve gear

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16 - Bolts ❑ 10 Nm

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Checking cylinder head for distortion – Use straight edge 500 mm - VAS 6075- and feeler gauge to measure cylinder head for distortion at several points. ♦ Max. permissible distortion: 0.05 mm. – Renew cylinder head if max. distortion is exceeded.

1.2

Removing and installing cylinder head

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Special tools and workshop equipment required

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♦ Drip tray - V.A.G 1306- or drip tray for workshop hoist - VAS 6208♦ Puller - T40039♦ Pliers for spring-type clips - VAS 5024A♦ Insert tool - T10070♦ Torque wrench - V.A.G 13321. Cylinder head

45

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Torque wrench - V.A.G 1331AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo When doing any h repair work, especially in the engine compart‐ ut ra a ment, pay attention to the following due to the cramped condi‐ c s s pe rm itte d

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♦ To avoid damage to lines, ensure sufficient clearance to all moving or hot components.

Removing •

The engine must be no more than warm to touch. Note

♦ All cable ties which were opened or cut during removal must

♦ If engine oil is dirty, change oil. – With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

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– Remove plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and installing ple‐ num chamber bulkhead . AG.

– Remove intake manifold ⇒ page 158 . – Drain coolant ⇒ page 107 . – Remove front right wheel housing liner ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner . – Remove front exhaust pipe with catalytic converter ⇒ page 179 . – Release clip -arrow-. – Pull charge air hose off charge air cooler.

46

Rep. gr.15 - Cylinder head, valve gear

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be renewed at the same points.

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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -arrows-. – Remove charge air pipe. – Pull off or disconnect all other electrical connections from tur‐ bocharger and lay to side.

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– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .

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– Remove turbocharger support.

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– Unscrew bolts -1 and 2-.

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– Remove oil return line from turbocharger.

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– Unscrew bolts -arrows-.

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– Unscrew oil supply line and coolant supply line from turbo‐ . Volkswag en AG AG does charger -arrows-. agen ksw n

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47

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -arrows-. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

– Loosen clamps -1 and 2-. – Pull off coolant hoses.

Prote cted by

– Unscrew bolts -arrows-. – Remove coolant hose. – Remove poly V-belt ⇒ page 19 . – Remove locking pin - T10060A- from tensioning device for poly V-belt. – Remove toothed belt ⇒ page 55 . – Remove cylinder head cover ⇒ page 50 .

48

Rep. gr.15 - Cylinder head, valve gear

AG.

– Move wiring harness aside.

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– Unscrew bolt -arrow-.

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– Pull off or disconnect all the other electrical connections as necessary from the cylinder head and lay open.

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– Remove battery tray.

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Check if all hose and line connections between engine, gearbox and body have been detached. – Remove cylinder head. Installing

Install in reverse order of removal, observing the following: Note

♦ There must be no oil or coolant in the cylinder head bolt pock‐

ets in the cylinder head.

♦ Do not remove new cylinder head gasket from packaging until ♦ Handle new gasket very carefully. Damage will cause leakage.

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– Also prevent dirt and emery cloth particles from getting into coolant.

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– Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.

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– Carefully clean sealing surfaces of cylinder head and cylinder block. Ensure that surfaces are not scored or scratched (if abrasive paper is used, do not use a grade less than 100). – Carefully remove metal particles, emery residue and cloths. – If crankshaft has since been turned, position cylinder number 1 piston to TDC and then turn crankshaft back slightly. – Position new cylinder head gasket; inscription (Part No.) must be legible. – Note centring pins in cylinder block -arrows-. – Fit cylinder head. – Insert cylinder head bolts, and tighten them by hand.

1. Cylinder head

49

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Tighten cylinder head in sequence as follows: Stage 1 2 3

Specified torque 40 Nm Turn 90° further Turn 90° further

– Fill with new coolant ⇒ page 107 . Specified torques ♦ ⇒ “1.1 Assembly overview - cylinder head”, page 43 ♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54 ♦ ⇒ “4.1 Assembly overview - intake manifold”, page 157 ♦ ⇒ “1.1 Assembly overview - silencers”, page 177 AG agenhead Removing and installing cylinder ksw l o V by cover ed ris

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Rep. gr.15 - Cylinder head, valve gear

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50

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– Remove air filter ⇒ page 155 .

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♦ Puller - T40039-

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

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– Unscrew bolts -arrows-.

– Disconnect lines -2, 3 and 4- from cylinder head cover. – Disconnect electrical connectors -1-. – Remove ignition coils ⇒ page 186 .

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– Unscrew line for crankcase breather system with heat shield from turbocharger -1-.

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– Pull off activated charcoal filter line to turbocharger from cyl‐ inder head cover -2-. AG.

– Loosen cylinder head cover working from inside outwards. – Remove cylinder head cover. Installing Install in reverse order of removal, observing the following:

– Tighten cylinder head cover - in several stages - in the tight‐ ening sequence shown. – Ensure that upper toothed belt guard is seated correctly. Specified torques ♦ ⇒ “1.1 Assembly overview - cylinder head”, page 43 ♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54

1.4

Checking compression

1. Cylinder head

51

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1331♦ Compression tester - V.A.G 1763♦ Adapter - V.A.G 1381/5ATest conditions •

The engine oil temperature must be at least 30°C.

•

Voltage supply OK.

Procedure – Remove air filter housing ⇒ page 155 . – Remove ignition coils ⇒ page 186 . – Remove spark plugs using spark plug socket and extension 3122 B- . – Check compression using compression tester - V.A.G 1763and adapter - V.A.G 1381/5A- .

52

Rep. gr.15 - Cylinder head, valve gear

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♦ Puller - T40039-

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♦ Spark plug socket - 3122 B-

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Note

Using the compression tester ⇒ Operating instructions – Have starter actuated by a second mechanic. – Operate starter until tester shows no further pressure in‐ crease. Compression pressures: New

7.0

max. 3.0

– After completing work, read event memory of engine control unit, clear all entries which may have been created during checks and repairs ⇒ Vehicle diagnostic tester. Note

The readiness code must be generated if the event memory has been cleared ⇒ Vehicle diagnostic tester .

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11.0 … 14.0

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53

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt”, page 54 ⇒ “2.2 Removing and installing toothed belt”, page 55

2.1

Assembly overview - toothed belt

1 - Bolt ❑ 10 Nm

11 - O-ring ❑ Renew after removal 12 - Bolt ❑ 25 Nm 13 - Roller 14 - Bolts ❑ 15 Nm 15 - Bolt ❑ 35 Nm 16 - Roller 17 - Sealing flange ❑ Assembly overview ⇒ page 19 ❑ Removing and installing ⇒ page 23 18 - Diamond-coated washer ❑ Renew after removal

54

Rep. gr.15 - Cylinder head, valve gear

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10 - Coolant pump ❑ Removing and installing ⇒ page 115

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9 - Tensioning pulley ❑ Semi-automatic

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8 - Nut ❑ 25 Nm

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7 - Woodruff key ❑ Check for firm seating

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6 - Toothed belt guard

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5 - Bolt ❑ Install with locking fluid ❑ 10 Nm

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4 - Camshaft sprocket ❑ Locked in installation position by Woodruff key.

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3 - Bolt ❑ Renew after removal ❑ Use counterhold - 3036to loosen and tighten. ❑ 50 Nm +180°

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2 - Toothed belt guard

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 19 - Crankshaft pulley ❑ Contact surface between pulley, diamond-coated washer and crankshaft must be free of oil. ❑ Can only be fitted in one position 20 - Bolt ❑ Renew after removal ❑ Do not oil ❑ Use counterhold - 3415- to loosen and tighten. ❑ 90 Nm +90° 21 - Toothed belt ❑ Mark direction of rotation with chalk or felt pen before removing. ❑ Check for wear ❑ Removing and installing ⇒ page 55 22 - Toothed belt guard

24 - Engine support

2.2

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25 - Bolt ❑ 45 Nm

Removing and installing toothed belt

Special tools and workshop equipment required ♦ Bracket - T10339-

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♦ Adapter - 10 - 222 A /18-

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23 - Bolts ❑ Qty. 7 ❑ 8 Nm

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2. Toothed belt drive

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Support bracket - 10 - 222 A-

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Removing

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♦ Adapter - 10 - 222 A /8-

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56

Rep. gr.15 - Cylinder head, valve gear

AG.

– Disconnect breather line -1- and fuel feed line -2-.

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♦ For reasons of safety, before opening the fuel system, re‐ move fuse for the fuel pump control unit - J538- from the fuse holder. This prevents the fuel pump from being acti‐ vated by driver door contact switch. Fuse assignment ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

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♦ Fuel supply line is pressurised. Wear protective goggles and protective clothing to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Then release pressure by carefully pulling hose off connection.

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– Remove air filter housing ⇒ page 155 .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Separate breather line -arrow 2- and pull activated charcoal filter -A- with hoses upwards out of bracket. WARNING

Hot steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover the cap with a cloth and open it carefully. – Depressurise by opening coolant expansion tank and closing it again. – Loosen clamp -arrow-, and pull off coolant hose. – Collect escaping coolant with a cloth.

– Disconnect electrical connector -1-. – Unscrew bolts -arrows-. – Lay coolant expansion tank to one side. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

– Remove tensioner for poly V-belt -A-.

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– Secure bracket - T10339- at the two upper threaded holes.

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– Remove poly V-belt ⇒ page 19 .

2. Toothed belt drive

57

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Position support bracket - 10 - 222 A- with adapter - 10 - 222 A /8- and adapter - 10 - 222 A /18- on longitudinal members.

– Remove toothed belt cover. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation . – Remove front right wheel housing liner ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .

– Unscrew bolts -arrows-. – Remove charge air pipe together with hoses. ht rig py Co t.

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– Set camshaft pulley to “TDC” marking by turning crankshaft. – The mark on the camshaft toothed-belt pulley must align with the arrow on the toothed-belt guard.

58

Rep. gr.15 - Cylinder head, valve gear

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– Unscrew bolts -arrows-.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Remove vibration damper/belt pulley. Note ♦ Ensure that the TDC markings align before removing the vi‐

bration damper.

♦ Do not turn the crankshaft until the TDC position is additionally

marked.

– Unscrew bolts -arrows-.

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The following work step is necessary to raise the engine high enough.

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– Unscrew bolt -3-.

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– Mark TDC position -arrow-.

2. Toothed belt drive

59

AG.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -2 and 3-.

– Unscrew bolts -arrows-. – Remove assembly mounting completely. Caution

When raising engine using support bracket - 10 - 222 A- , en‐ sure that no components or hoses are damaged, over-exten‐ ded or torn off.

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– Lift

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– Unscrew bolts -arrows-. – Remove toothed belt cover downwards from engine. – Remove engine bracket upwards from engine. – Mark direction of rotation of toothed belt. – Turn crankshaft back slightly. c o p yri gh t. C op yi

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– Loosen tensioning roller and remove toothed belt.

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– Unscrew bolts -1 and 2-.

Install in reverse order of removal, observing the following: agen lksw Vo by

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Note ♦ Never rotate the camshaft when the crankshaft is at TDC (risk

of damage to valves/piston crowns).

♦ The engine must be no more than warm to touch.

60

Rep. gr.15 - Cylinder head, valve gear

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Set camshaft and crankshaft to TDC markings. – Fit toothed belt on crankshaft toothed belt pulley (note direc‐ tion of rotation).

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– Fit toothed belt in the sequence: pulley, coolant pump and last onto guide roller -arrow-.

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Ensure proper seating of tensioning roller in cylinder head.

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– Tension toothed belt; to do this, turn Allen key to right -direction of arrow- until notch is positioned above lug (toothed belt over-tensioned). – Relax toothed belt again. – Tension toothed belt until notch and lug are positioned oppo‐ site each other. – Tighten nut. – Turn crankshaft 2 turns in engine direction of rotation until en‐ gine is again at TDC. It is important that the last 45° rotation (1/8 turn) is performed without interruption. – Check toothed belt tension. Specification: indicator and notch must align.

2. Toothed belt drive

61

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Check valve timing; the markings must align -arrows-. If the markings do not align: – Repeat valve timing adjustment. If the markings align: – Bring engine bracket to installation position. – Install toothed belt cover from below.

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

– Tighten bolts -1 and 2-. – Install engine assembly mounting.

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Rep. gr.15 - Cylinder head, valve gear

AG.

– Tighten bolt -3-.

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– Lower engine with support bracket - 10 - 222 A- .

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– Attach engine bracket to cylinder block and tighten bolts handtight.

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– Check valve timing; the markings must align

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– Install vibration damper.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Tighten bolts for engine assembly mounting and engine brack‐ et hand-tight -arrows-; to do so, bring surfaces into contact using support bracket - 10 - 222 A- .

Align engine mountings as follows: There must be a distance -a- of at least 10 mm between engine support and longitudinal member (right side). The side surface of the engine support -2- should be located par‐ allel to the support arm -1-. – Tighten bolts for engine assembly mounting and engine brack‐ et. – Remove support bracket - 10 - 222 A- . – Remove bracket - T10339- and install tensioning device for poly V-belt. – Install poly V-belt. – Reconnect fuel and breather lines; ensure that plug-in con‐ nectors are firmly seated. – Install coolant expansion tank. – Install noise insulation ⇒ General body repairs, exterior; Rep. AG. Volkswagen AG d agen oes gr. 66 ; Noise insulation; Removing and installing noise insu‐ ksw not l o gu lation . yV a db

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– Install air filter.

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– Re-insert fuse for fuel pump control unit - J538- into tho fuse hold‐ au er. s s

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♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54 ♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 17

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2. Toothed belt drive

63

AG.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

3

Valve gear

⇒ “3.1 Assembly overview - valve gear”, page 64 ⇒ “3.2 Removing and installing camshaft”, page 65 ⇒ “3.3 Removing and installing camshaft oil seal”, page 68 ⇒ “3.4 Removing and installing camshaft adjuster”, page 71 ⇒ “3.5 Removing and installing camshaft control valve 1 N205 ”, page 75 ⇒ “3.6 Removing and installing valve stem seals”, page 77

3.1

Assembly overview - valve gear

1 - Bolt ❑ Renew after removal ❑ Use counterhold - 3036to loosen and tighten. ❑ 50 Nm +180° 2 - Camshaft sprocket ❑ Use counterhold - 3036to loosen and tighten. 3 - Seal ❑ Renewing ⇒ page 68 4 - Cylinder head AG. Volkswagen AG d agen oes ksw not l o ❑ Removing and installing gu yV b ara d e ⇒ page 45 nte ris tho

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6 - Valve stem seal ❑ Renewing ⇒ page 77 7 - Valve springs 8 - Upper valve spring plate 9 - Valve cotter 10 - Hydraulic compensation element ❑ Do not interchange ❑ Oil contact surface 11 - Woodruff key ❑ Check for firm seating

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13 - Ladder frame ❑ With integrated camshaft bearings. ❑ Clean sealing surface; reworking not permitted. ❑ Remove sealant residue. AG.

Rep. gr.15 - Cylinder head, valve gear

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64

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12 - Exhaust camshaft ❑ Check radial clearance with Plastigage (roller rocker fingers removed). Wear limit: 0.1 mm. ❑ Runout: max. 0.035 mm

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5 - Valve guide ss au ❑ Checking ⇒ page 82

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 14 - Bolt ❑ Renew after removal ❑ 8 Nm +90° 15 - Camshaft adjuster ❑ Removing and installing ⇒ page 71 16 - Bolt ❑ Use counterhold - 3036- to loosen and tighten. ❑ 20 Nm +45° 17 - Inlet camshaft ❑ Check radial clearance with Plastigage, wear limit: 0.1 mm ❑ Runout: max. 0.035Vmm olkswa AG. agen

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20 - Bolt ❑ 10 Nm

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a 19 s-s Drive chain ❑ Removing and installing ⇒ page 65 ❑ Check for wear

21 - Bolt ❑ 10 Nm 22 - Hall sender - G4023 - Outlet valve ❑ Do not rework. Only lapping in is permitted. ❑ Valve dimensions ⇒ page 82 ❑ Checking valve guides ⇒ page 82

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24 - Inlet valve ❑ Do not rework. Only lapping in is permitted. ❑ Valve dimensions ⇒ page 82 ❑ Checking valve guides ⇒ page 82

25 - Cap ❑ Renew ❑ Removing: pierce centre of cap using screwdriver and lever out. ❑ Installing: do not use sealant, but press in 1…2 mm using thrust piece - 3334- . ht rig py Co t.

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3.2

Removing and installing camshaft

Special tools and workshop equipment required

3. Valve gear

65

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♦ Never rework the sealing surfaces on the bottom of the re‐

taining frame and top of the cylinder head.

♦ The camshaft bearings are integrated into the cylinder head

and the retaining frame. The toothed belt must be relieved of tension before the retaining frame is removed.

♦ Renew camshaft oil seal and sealing cap if retaining frame has

been unfastened.

– Removing camshaft adjuster ⇒ page 71 . – Remove toothed belt ⇒ page 55 . – Loosen securing bolt for camshaft sprocket and unscrew ap‐ prox. 10 mm.

66

Rep. gr.15 - Cylinder head, valve gear

AG.

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Note

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♦ Counter-hold - 3036-

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♦ Two-arm puller - T40001-

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Pull off camshaft pulley using puller - T40001- , hook T40001/6- and hook - T40001/7- . The puller - T40001- is supported by the securing bolt -arrow-. – Remove securing bolt and camshaft pulley. – Remove rear toothed belt guard from cylinder head. – Evenly loosen retaining frame bolts from outside to inside and remove retaining frame. – Carefully lift out camshafts from above and place down on a clean surface. – Remove old sealant from retaining frame groove and from sealing surfaces. olksw

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Note

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♦ The pistons cannot be positioned at TDC. ♦ Ensure that all roller rocker fingers are properly seated on

valve stem ends.

♦ Never rotate the camshaft when the pistons are at TDC. This

could otherwise result in damage to valves and pistons.

♦ Ensure proper seating of the parallel key. – Oil running surfaces of both camshafts.

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– Carefully place camshafts into camshaft bearings of cylinder head. Cams -A- of cylinder 4 must face each other.

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♦ Sealing surfaces must be free of oil and grease.

3. Valve gear

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Apply an even, slightly raised bead of sealant with sealant - D 154 103 A1- into clean retaining frame groove. Note ♦ Do not apply sealant too thickly. If necessary, remove excess

sealant with a lint-free cloth.

♦ The retaining frame must be positioned and bolted on without

interruption because the sealant begins to harden immediately when the sealing surfaces come into contact with each other.

♦ Observe use-by-date of sealant. – Place retaining frame onto cylinder head. – Tighten new bolts gently, from inside outwards. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d approx. 1…2 nte isemm r o eo h t u ra a c s s

– Finally, tighten bolts in the sequence shown.

– Installing toothed belt. – Install camshaft adjuster. – Install cylinder head cover. Specified torques

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– Install camshaft sprocket.

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– Insert Woodruff key in camshaft.

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– Install rear part of toothed-belt guard.

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– Install camshaft oil seal ⇒ page 68 .

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– Drive sealing cap ⇒ Item 25 (page 65) in deep using thrust piece - 3334- .

♦ ⇒ “3.1 Assembly overview - valve gear”, page 64

AG.

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68

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Removing and installing camshaft oil seal

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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Special tools and workshop equipment required

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♦ Seal puller - 2085♦ Adapter - 2085/2♦ Counter-hold - 3036♦ Assembly tool - T10071♦ Two-arm puller - T40001♦ Torque wrench - V.A.G 1332♦ Thrust piece - T10353-

3. Valve gear

69

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Removing

– Remove toothed belt ⇒ page 55 .

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– Loosen securing bolt for camshaft sprocket and unscrew ap‐ prox. 10 mm.

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– Remove securing bolt and camshaft pulley.

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– Lubricate threaded head of oil seal extractor - 2085- , place it in position and, exerting firm pressure, screw it into the oil seal as far as possible. – Loosen knurled screw and turn inner part against camshaft until oil seal is pulled out. Installing Install in reverse order of removal, observing the following: – Remove oil residues from crankshaft journal with a clean cloth. – Tape over groove in taper of camshaft (e.g. using Sellotape).

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Rep. gr.15 - Cylinder head, valve gear

AG.

– Unscrew inner part of oil seal extractor - 2085- 2 turns (approx. 3 mm) from the outer part and lock in position with the knurled screw.

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– To guide seal extractor, screw adapter - 2085/2- into camshaft to stop by hand.

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The puller - T40001- is supported by the securing bolt -arrow-.

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– Pull off camshaft pulley using puller - T40001- , hook T40001/6- and hook - T40001/7- .

– Carefully push oil seal onto camshaft journal.

09.2019

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a s l sengine, turbocharger) Volkswagen R GmbH - Edition

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Press in oil seal to stop using fitting sleeve - T10071- , thrust piece - T10353- and a washer -arrow-, use bolt - T10071/4n AG. Volkswagen AG do es n wage for this. o olks t gu ara nte eo ra c

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– Fit camshaft sprocket. Note

♦ Never rotate the camshaft when the pistons are at TDC. This

could otherwise result in damage to valves and pistons.

♦ Ensure proper seating of the parallel key. Specified torques ♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54

Removing and installing camshaft adjuster ht rig py Co t.

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3.4

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♦ ⇒ “3.1 Assembly overview - valve gear”, page 64

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Insert Woodruff key in camshaft.

3. Valve gear

71

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

♦ Pin wrench - T10020♦ Torque wrench - V.A.G 1332Removing

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♦ Pin - T10115-

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♦ Camshaft clamp - T10252-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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♦ Insert tool - T40080-

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Special tools and workshop equipment required

– Remove high-pressure pump ⇒ page 175 .

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Rep. gr.15 - Cylinder head, valve gear

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72

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– Remove cylinder head cover ⇒ page 50 .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Loosen clamps -1 and 2-. – Pull off coolant hoses. – Unscrew bolt -3-. – Release coolant pipe from heat shield.

– Remove vacuum pump (if fitted).

rrectness of i t to the co nform spec at i h re o n wit in t his

– Unscrew bolts -arrows-.

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– Release cable retainer -arrow-.

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Remove cover from camshaft adjuster.

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– Align marking on camshaft pulley with marking on toothed belt guard; recesses -arrows- now point vertically to each other.

3. Valve gear

73

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Fit camshaft clamp - T10252- as shown and secure -arrows-. lkswagen o yV

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– Loosen securing bolt of camshaft adjuster with specialrised b ho wrench, long reach - T40080- . ut

AG. Volkswagen AG d oes not gu ara nte eo ra c

– Compress chain tensioner -arrow A- and secure with locking pin - T10115- -arrow B-. – Unscrew securing bolt of camshaft adjuster and remove with chain. Installing

74

Rep. gr.15 - Cylinder head, valve gear

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– Hold camshaft adjuster in front of exhaust camshaft so that notch -A- and pin -B- align.

AG.

– Place chain on camshaft adjuster.

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The camshafts are located with the camshaft clamp T10252- .

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Install in reverse order of removal, observing the following:

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Lay chain over intake camshaft sprocket starting at top -arrow- without changing its position.

– Turn intake camshaft slowly in -direction of arrow A- using pin wrench - T10020- until the camshaft adjuster fits onto the camshaft. Note

If pin does not fit into notch, remove chain and fit it again.

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–

AG. Volkswagen AG d agen oes ksw not l o V gu special wrench, Tighten camshaft adjuster bolt. To do this, use by ara d e nte long reach T40080. is r o eo h ut ra a c s s

Specified torques ♦ ⇒ “3.1 Assembly overview - valve gear”, page 64

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Removing and installing camshaft control valve 1 - N205-

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3.5

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– Remove locking pin - T10115- -arrow B-.

3. Valve gear

75

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Special tools and workshop equipment required

– Disconnect electrical connector -1-. – Release wiring harness -2- from retainer. – Unscrew bolt -3-.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

– Remove air filter housing ⇒ page 155 .

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Rep. gr.15 - Cylinder head, valve gear

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76

Prote cted by

Removing

AG.

♦ Pliers for spring-type clips - VAS 5024 A-

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♦ Ratchet insert 1/4" - VAS 6234-

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♦ TORX bit set - V.A.G 1766-

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♦ Torque wrench - V.A.G 1783-

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -arrows-. – Pull camshaft control valve 1 - N205- out of housing. Installing Install in reverse order of removal, observing the following: Note ♦ The inlet camshaft control valve 1 - N205- and housing must

be free of dirt and soiling.

♦ Do not unpack the camshaft control valve 1 - N205- until im‐

mediately prior to installation. Caution

♦ Ensure the inlet camshaft control valve 1 - N205- is pro‐ tected from knocks and impacts. – Coat oil seal with engine oil. Specified torques ♦ ⇒ “3.1 Assembly overview - valve gear”, page 64

3.6

Removing and installing valve stem seals

(With cylinder head installed)

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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3. Valve gear

77

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Special tools and workshop equipment required

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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♦ Spark plug socket - 3122 B-

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

♦ Valve stem seal puller - 3364-

♦ Valve stem seal fitting tool - 3365♦ Adapter - T40012♦ Torque wrench - V.A.G 1331-

♦ Dismantling and assembling device for valve cotters - VAS 5161-

– Remove roller rocker fingers, and place them on a clean sur‐ face making sure that roller rocker fingers are not inter‐ changed.

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Rep. gr.15 - Cylinder head, valve gear

AG.

– Remove spark plugs using spark plug socket and extension 3122 B- .

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– Remove camshafts ⇒ page 65 .

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Removing

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♦ Guide plate for 2.0 l and 3.0 l FSI engine - VAS 5161/19B-

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Secure guide plate for 2.0 l and 3.0 l FSI engine - VAS 5161/19B- with knurled screws - VAS 5161/12- to cylinder head as shown. – Set piston of respective cylinder to “bottom dead centre”.

– Screw adapter - T40012- into spark plug thread and connect compressed air with pressure of at least 6 bar. – Strike tight valve cotters with drift - VAS 5161/3- and a plastic hammer.

– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5into guide plate for 2.0 l and 3.0 l FSI engine - VAS 5161/19B- . – Insert assembly cartridge - VAS 5161/8- into guide plate for 2.0 l and 3.0 l FSI engine - VAS 5161/19B- . – Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- . AG. Volkswagen A n wage olks V by ed ris o th au ss

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On the exhaust side, the pressure fork - VAS 5161/2- must be attached as shown. – Press installation cartridge - VAS 5161/8- down and turn knurled screw of installation cartridge - VAS 5161/8- to right until tips engage in valve cotters. – Move knurled screw back and forth gently, as a result of which valve cotters are pressed apart and taken up in installation cartridge. – Release pressure fork - VAS 5161/2- . – Remove installation cartridge - VAS 5161/8- .

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Note

3. Valve gear

79

ht rig py Co t.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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– Pull off valve stem seals using valve stem seal puller - 3364- .

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Installing Install in reverse order of removal, observing the following:

– To prevent damage to new valve stem seals -B-, attach plastic sleeve -A- to valve stem. – Lubricate sealing lip of valve stem seal -B-, place it in the valve stem seal fitting tool - 3365- and push carefully onto valve guide. – Remove plastic sleeve -A-. – Insert valve spring and valve spring plate. – Install removal and installation device for valve cotters - VAS 5161- as shown.

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Rep. gr.15 - Cylinder head, valve gear

AG.

– Place installation lever on installation device and pull out valve stem seal -arrow-.

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– Insert punch -1- into bore in lower part of puller.

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– Place lower part of valve stem seal puller - 3364- onto valve stem seal.

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– If valve stem seal puller - 3364- cannot be used on account of restricted space, knock out pin -arrow- with a punch and re‐ move the impact extractor attachment.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Inlet side

Exhaust side

Note ♦ If the valve cotters have been removed from

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a the sinstallation c s

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cartridge, they must first be inserted into the insertion device - VAS 5161/18- .

♦ Press assembly cartridge - VAS 5161/8- onto inserting device

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from above and capture valve cotters.

– Press installation cartridge - VAS 5161/8- down with pressure fork - VAS 5161/2- , and pull installation cartridge knurled screw back and forth whilst pulling upwards. – Relieve pressure fork - VAS 5161/2- whilst pulling on knurled screw. – Remove removal and installation device for valve cotters VAS 5161- .

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3. Valve gear

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– Install camshafts ⇒ page 65 .

81

Inlet and exhaust valves

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⇒ “4.1 Valve dimensions”, page 82

⇒ “4.2 Checking valve guides”, page 82

4.1

Valve dimensions

Never rework the inlet and exhaust valves. Only lapping-in is per‐ mitted. Outlet valve 27.90 … 28.10 5.95 101.87 45

Checking valve guides

♦ Universal dial gauge bracket - VW 387-

♦ Dial gauge - VAS 6079-

82

Rep. gr.15 - Cylinder head, valve gear

AG.

Special tools and workshop equipment required

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4.2

mm mm mm ∠°

Inlet valve 33.75 … 33.95 5.98 103.97 45

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Dimension ∅a ∅b c α

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4

09.2019

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Scirocco 2015 ➤ 4-cylinder injection engine

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s (2.0 s l engine, turbocharger) Volkswagen R GmbH - Edition

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Test sequence – Insert new valve in guide. End of valve stem must be at same lkswagen AG only height as guide. On account of differing stem AG. Vodiameters, d agen ksw use inlet valve in inlet guide and exhaust valve in exhaustoes not g l o V y ua b guide. ran ed is or

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– Renew cylinder head.

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If the amount of sideways play is exceeded:

4. Inlet and exhaust valves

83

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

17 – 1

Lubrication

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h Assembly overview sump/oil pump”, page 84 t u ra a c s s

Sump, oil pump

⇒ “1.1

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Assembly overview - sump/oil pump

Note

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1.1

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⇒ “1.3 Engine oil:”, page 88

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⇒ “1.2 Removing and installing oil sump”, page 86

♦ If large quantities of metal chips and abraded material are found during engine repair, this may indicate that

the crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following work must be carried out following the repair:

♦ Thoroughly clean oil channels. ♦ Renew oil spray jets. ♦ Renew engine oil cooler. ♦ Renewing oil filter.

AG.

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Rep. gr.17 - Lubrication

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84

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♦ The oil level must remain below the max. mark - danger of damage to catalytic converter!

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 1 - Bolt ❑ 15 Nm 2 - Oil dipstick ❑ Markings ⇒ page 89 . ❑ The oil level must not be above the max. mark 3 - Piston fitting tool 4 - Guide tube 5 - Adapter 6 - Oil pump with balance shaft module ❑ With 12 bar pressure re‐ lief valve ❑ Removing and installing . Volkswagen AG ⇒ page 100 gen AG d wa olks

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yV 7 - Bolt db ise r ❑ Renew thoafter removal au s ❑ Note different bolt s lengths ⇒ page 100 ❑ 15 Nm +90°

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8 - Bolt ❑ Observe tightening se‐ quence ⇒ page 86 . ❑ 15 Nm 9 - Bolt ❑ To secure charge air pipe. ❑ 8 Nm

11 - Bolt ❑ 15 Nm

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13 - Sprocket

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12 - Oil drain plug ❑ Renew after removal ❑ With captive seal ❑ 30 Nm

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10 - Oil pan ❑ Clean sealing surface before fitting. ❑ Removing and installing ⇒ page 86

14 - Bolt ❑ 10 Nm 15 - Cap 16 - Oil level and oil temperature sender - G26617 - Seal ❑ Renew after removal ❑ Lubricate before installing. 18 - Bolt ❑ Renew after removal

1. Sump, oil pump

85

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ❑ 20 Nm +90° 19 - Chain guard 20 - Chain 21 - Sealing flange ❑ Must seat on dowel sleeves. AG. Volkswagen AG d agen oes ksw not l o ❑ Removing and installing ⇒ page 23 gu yV

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Special tools and workshop equipment required ♦ T-bar and socket, 10 mm - 3185-

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♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA) ♦ Scraper Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation . – Drain engine oil. Note

Please observe disposal instructions!

86

Rep. gr.17 - Lubrication

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♦ Insert tool - T10058-

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

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– Disconnect electrical connector -1-.

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– Unscrew bolts -arrows-.

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– Unscrew bolts -1 and 2-.

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– Unscrew bolts -arrows-.

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– Unscrew bolts -arrows-. – Loosen sump bolts on flywheel end using T-bar and socket, 10 mm - 3185- and remove with special wrench, long reach T10058- . – Remove bolts -1 … 20-. – Remove sump. – Remove sealant residues from cylinder block with a flat scra‐ per.

1. Sump, oil pump

87

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Remove remaining sealant from sump e.g. with rotating plastic brush or similar. Installing Install in reverse order of removal, observing the following: Note ♦ Observe use-by-date of sealant. ♦ The sump must be installed immediately and tightened after

applying silicone sealing compound.

– Cut off nozzle on tube at front marking (∅ of nozzle approx. 3 mm). – Apply silicone sealant to clean sealing surface of sump as shown. Sealant bead must be: ♦ 2…3 mm thick

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♦ Do not make the sealant bead thicker. Otherwise, excess

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sealant will make its way into the sump and block the strainer or sieve in the suction line of the oil pump.

♦ If gearbox is removed, sump must align smoothly with cylinder

block.

♦ If gearbox is installed, sump must rest against gearbox. ♦ Let sealing compound dry for approx. 30 minutes after instal‐

ling oil sump. Only then fill with engine oil.

– Position oil sump immediately and tighten bolts as follows: 1 - Slightly tighten all sump/cylinder block bolts diagonally. 2 - Tighten sump/gearbox bolts slightly. 3 - Tighten all sump/cylinder block bolts slightly and diagonally. 5 - Diagonally tighten all sump/cylinder block bolts. Prote cted by c o p yri gh t. C op yi

♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 84 Sump/gearbox bolt

40 Nm

1.3

Engine oil:

Oil capacities: With oil filter 4.6 l without oil filter 4.1 l. Engine oil specifications ⇒ Maintenance ; Booklet ; Service ta‐ bles .

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Specified torque

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4 - Tighten sump/gearbox bolts.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Change engine oil ⇒ Maintenance ; Booklet ; Engine oil: Drain or extract; renew oil filter and replenish engine oil . Markings on oil dipstick: 1 - Max. mark 2 - Min. mark a - Oil level in max. mark area: Do not replenish engine oil! b - Oil level in middle range: can be topped up with engine oil.

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c - Oil level in min. mark area: Replenish with approx. 0.5 l engine oil!

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1. Sump, oil pump

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Oil filter, oil pressure switch

⇒ “2.1 Assembly overview - oil filter housing, oil pressure switch”, page 90 ⇒ “2.2 Removing and installing oil pressure switch F1 ”, page 92 ⇒ “2.3 Removing and installing oil filter housing”, page 93 ⇒ “2.4 Checking oil pressure and oil pressure switch”, page 94

2.1

Assembly overview - oil filter housing, oil pressure switch Note

♦ If large quantities of metal chips and abraded material are found during engine repair, this may indicate that

the crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following work must be carried out following the repair:

♦ Thoroughly clean oil channels. ♦ Renew oil spray jets. ♦ Renew engine oil cooler. ♦ Renewing oil filter. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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♦ The oil level must remain below the max. mark - danger of damage to catalytic converter!

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 1 - Tube ❑ For crankcase ventila‐ tion.

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2 - Oil pressure switch - F1❑ 1.4 bar, black ❑ With earth wire for oil pressure switch (only with single pin oil pres‐ sure switch). ❑ Checking oil pressure . Volkswagen AG gen AG does switch ⇒ page 94 . Volkswa not gu y b ara d e ❑ Removing and installing nte ris o eo ⇒ page 92 uth ra a c s s ❑ 21 Nm urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

4 - Bracket

5 - Bolt ❑ 15 Nm

6 - Engine oil cooler ❑ Ensure clearance to ad‐ jacent components ❑ Connection diagram for coolant hoses ⇒ page 105 r fo ng

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8 - Oil filter housing ❑ Fully drain using oil drain adapter - T40057❑ Remove and install with oil filter tool - 3417- . ❑ 25 Nm

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3 - Bolt ❑ With earth wire for oil pressure switch (only with single pin oil pres‐ sure switch). ❑ 15 Nm

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9 - Dust cap 10 - Seal ❑ Renew after removal ❑ Coat with oil before inserting ❑ Service tag at top 11 - Oil filter element ❑ Before removing, fully drain oil filter housing ⇒ Maintenance ; Booklet ; Engine oil: draining or extracting; Renewing oil filter and replenishing engine oil ❑ Renew ⇒ Maintenance ; Booklet ; Engine oil: draining or extracting; renewing oil filter and replenishing engine oil 12 - Bolt ❑ Renew after removal ❑ 15 Nm +90° 13 - Baffle plate ❑ Fitting position ⇒ page 92

2. Oil filter, oil pressure switch

91

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 14 - Seal ❑ Renew after removal 15 - Oil filter bracket ❑ With pressure relief valve, approx. 4 bar ❑ Removing and installing ⇒ page 93 Installation position of baffle plate

2.2

Removing and installing oil pressure switch - F1-

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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation . – Loosen clamps -1 and 2-. – Remove charge air hose.

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♦ Jointed

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Remove connector -1- from retainer. – Pull connector -arrow- off oil pressure switch. Vehicles with a 1-pin oil pressure switch:

– Unscrew bolt -B- for

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– Unscrew oil pressure switch with 24 mm articulated wrench T40175Installing

Install in reverse order of removal, observing the following: Specified torques

♦ ⇒ “2.1 Assembly overview - oil filter housing, oil pressure switch”, page 90

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All vehicles:

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– Remove intake manifold ⇒ page 158 . – Remove coolant pipes ⇒ page 120 . – Unscrew bolts -A and B-. – Remove engine oil cooler.

2. Oil filter, oil pressure switch

93

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Release electrical connector -A-.gen AG. Volkswagen AG d wa olks

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Install in reverse order of removal, observing the following:

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– Remove oil filter housing.

Specified torques ♦ ⇒ “2.1 Assembly overview - oil filter housing, oil pressure switch”, page 90

2.4

Checking oil pressure and oil pressure switch

⇒ “2.4.1 Checking oil pressure and oil pressure switch (single pin oil pressure switch)”, page 94 ⇒ “2.4.2 Checking oil pressure and oil pressure switch (2-pin oil pressure switch)”, page 95

Special tools and workshop equipment required

AG.

Rep. gr.17 - Lubrication

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94

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Oil pressure tester - V.A.G 1342♦ Voltage tester - V.A.G 1527 B♦ Adapter set - V.A.G 1594C•

Engine oil level OK.

•

Engine oil temperature at least 80°C (radiator fan must have run once)

Procedure – Remove oil pressure switch - F1- and screw into tester. – Screw tester into oil filter bracket in place of oil pressure switch. – Connect brown wire of tester to earth (-). – Connect voltage tester - V.A.G 1527 B- to battery positive (+) and oil pressure switch using cables from auxiliary measuring set - V.A.G 1594C- ; the LED must remain unlit. – If the LED lights up, renew 1.4 bar oil pressure switch - F1- . If LED does not light up: – Start engine and increase rpm; at pressure of 1.2 to 1.6 bar, LED must light up. Otherwise, renew oil pressure switch. AG. Volkswagen

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If specification is not attained:

Note

Mechanical damage, e.g. to bearings, could also be the cause for oil pressure being too low. If no fault is found: – Renew oil pump ⇒ page 100 . If the specification is exceeded: – Check oil channels. – If necessary, replace oil filter bracket with pressure relief valve.

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– Check strainer in oil intake pipe for soiling.

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a At higher engine ss speeds, the oil pressure must not exceed 7.0 bar.

2. Oil filter, oil pressure switch

95

AG.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

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♦ Oil pressure tester - V.A.G 1342-

♦ Hand multimeter - V.A.G 1526 E-

Engine oil temperature at least 80°C (radiator fan must have run once)

96

Rep. gr.17 - Lubrication

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Engine oil level OK.

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♦ Test instrument adapter/DSO (2-pin) - VAS 5256-

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Procedure – Remove oil pressure switch - F1- and screw into tester. – Screw tester into oil filter bracket in place of oil pressure switch. – Connect test instrument/DSO adapter (2-pin) - VAS 5256- to oil pressure switch – Connect Multimeter - V.A.G 1526E- to test instrument/DSO adapter (2-pin) - VAS 5256- and check for continuity. •

Oil pressure switch must be open at a pressure below 1.2 bar.

– Start engine and increase rpm; oil pressure switch must close at pressure of 1.2…1.6 bar. Otherwise renew oil pressure switch. – Increase engine speed further. At 2000 rpm and an oil tem‐ perature of 80°C, the oil pressure should be between 2.7 to 4.5 bar. At higher engine speeds, the oil pressure must not exceed 7.0 bar. If specification is not attained: – Check strainer in oil intake pipe for soiling. Note

Mechanical damage, e.g. to bearings, could also be the cause for oil pressure being too low. If no fault is found: – If

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– Check oil channels.

– If necessary, replace oil filter bracket with pressure relief valve.

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2. Oil filter, oil pressure switch

97

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

3

Oil circuit

⇒ “3.1 Assembly overview - oil circuit”,

Assembly overview - oil circuit

3 - Oil supply line

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2 - Banjo bolt ❑ 30 Nm

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1 - Seal ❑ Renew after removal

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4 - Turbocharger ❑ Removing and installing ⇒ page 129

11 - Bolt ❑ 23 Nm 12 - Banjo bolt ❑ 35 Nm 13 - Bolt ❑ 9 Nm 14 - Seal ❑ Renew after removal 15 - Seal ❑ Renew after removal 16 - Oil return line 17 - Bolts ❑ 9 Nm 18 - Seal ❑ Renew after removal

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Rep. gr.17 - Lubrication

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10 - Coolant supply line

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9 - Seal ❑ Renew after removal

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8 - Banjo bolt ❑ 35 Nm

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7 - Seal ❑ Renew after removal

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6 - Banjo bolt ❑ 30 Nm

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

4

Balancer shaft module

⇒ “4.1 Assembly overview - balancer shaft module”, page 99 ⇒ “4.2 Removing and installing balance shaft module”, page 100

4.1

Assembly overview - balancer shaft module

1 - Chain guard

11 - O-ring ❑ Renew after removal

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10 - Oil intake tube ❑ Clean strainer if soiled

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9 - Bolt ❑ 8 Nm

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8 - Bolt ❑ 40 Nm

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6 - Bolt ❑ 9 Nm

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5 - Oil pump with balance shaft module ❑ Before installing, ensure that both dowel sleeves for centring are instal‐ led. ❑ Removing and installing ⇒ page 100

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3 - Dowel sleeves

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2 - Chain ❑ Before removing, mark running direction (instal‐ lation position) with paint.

12 - Bolt ❑ Renew after removal ❑ Note different bolt lengths ❑ 15 Nm +90° 13 - Outer rotor ❑ Check running surfaces for scoring. ❑ Marking must be visible. 14 - Inner rotor ❑ Check running surfaces for scoring.

4. Balancer shaft module

99

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16 - Sprocket

17 - Bolt ❑ Renew after removal ❑ 20 Nm +90° 18 - Chain tensioner with tensioning rail ❑ Preload when installing ⇒ page 100 . 19 - Bolt ❑ 15 Nm

Removing and installing balance shaft module

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♦ Pin - T10027-

Removing Note

Oil pump and balance shaft module are combined in one unit. – Remove sump ⇒ page 86 . – Using a small screwdriver, release locking lugs through open‐ ings -arrows-. – Pull off chain guard.

100

Rep. gr.17 - Lubrication

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Special tools and workshop equipment required

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15 - Oil pump cover

4.2

R GmbH - Edition 09.2019

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4-cylinder injection engine (2.0 l

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– Set engine to TDC No. 1 cylinder.

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– Loosen oil pump sprocket bolt; counterhold on centre bolt of vibration damper to do so.

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Check that there is a mark on balance shaft sprocket which aligns with locking hole -arrow-. If there is no mark, mark position using a waterproof pen. The mark is required for reinstalling.

Caution

Do not loosen the balance shaft drive sprocket!

– Relieve tension on chain guide using a screwdriver -arrowand lock using a 3 mm Allen key -1-.

4. Balancer shaft module

101

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Remove oil pump sprocket and detach chain from balance shaft gear assembly.

– Unscrew bolts -1 and 2-. – Remove baffle plate.

– Unscrew balance shaft module bolts working from outside in‐ wards. – Remove balance shaft module. Installing Install in reverse order of removal, observing the following: G. Volkswagen nA wage

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– Preload piston by hand -arrow-.

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Rep. gr.17 - Lubrication

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102

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Press chain guide -in direction of arrow- and lock in place using 3 mm hexagon socket head key -1-. Continuation

– Fit intermediate plate onto dowel sleeves of balance shaft module -arrows-.

– Install oil pump with balance shaft module and intermediate AG. Volkswagen AG d agen oes plate. no lksw Vo by

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– Set engine to TDC No. 1 cylinder.

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103

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Align marking on balance shaft sprocket -arrow- with fixing hole.

–

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Note

The oil pump sprocket can only be installed correctly in one po‐ sition. For installation, only the oil pump may be turned.

– Remove locking pin - T10027- and Allen key -1-. – Secure oil pump sprocket; counterhold on centre bolt of vibra‐ tion damper to do so.

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B - Hexagon head collar bolt M7 × 70 C - Hexagon head collar bolt M7 × 90 D - Hexagon head collar bolt M7 × 55 E - Plug with O-ring Specified torques ♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 84 ♦ ⇒ “4.1 Assembly overview - balancer shaft module”, page 99

104

Rep. gr.17 - Lubrication

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A - Hexagon head collar bolt M7 × 40

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– Install sump ⇒ page 86 .

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

19 –

Cooling

1

Cooling system/coolant

⇒ “1.1 Connection diagram - coolant hoses”, page 105 ⇒ “1.2 Draining and adding coolant”, page 107 ⇒ “1.3 Checking cooling system for leaks”, page 112

1.1

Connection diagram - coolant hoses

1 - Radiator/cooler ❑ Removing and installing ⇒ page 124 ❑ If renewed, refill system with fresh coolant. 2 - Coolant circulation pump V50❑ The flow of the coolant in the run-on phase is opposite to the flow shown. ❑ The function can be checked using final con‐ trol diagnosis ⇒ Vehicle diagnostic tester. 3 - Bypass thermostat ❑ Depending on equip‐ ment

7 - Turbocharger ❑ Removing and installing ⇒ page 129

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6 - Cylinder head/cylinder block ❑ If renewed, refill system with fresh coolant.

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5 - Coolant pump ❑ Removing and installing ⇒ page 115

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4 - Thermostat housing ❑ With thermostat ❑ Checking thermostat ⇒ Vehicle diagnostic tester

9 - Heat exchanger for heater ❑ If renewed, refill system with fresh coolant.

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8 - Expansion tank ❑ When renewing expansion tank and during service operations, ensure that 2 silicate cartridges ⇒ Elec‐ tronic Parts Catalogue are always in expansion tank. Do not remove the silicate cartridges. ❑ With cap ❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/8-

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1. Cooling system/coolant

105

AG.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 10 - Hose ❑ Only for automatic gearbox. 11 - Gear oil cooler ❑ Only for automatic gearbox. 12 - Bypass thermostat ❑ Only for automatic gearbox. 13 - Coolant connection 14 - Engine oil cooler 15 - Intake manifold ❑ Removing and installing ⇒ page 158 16 - Hose ❑ Only for auxiliary radiator 17 - Auxiliary radiator ❑ Optional equipment ❑ Removing and installing ⇒ page 126

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Rep. gr.19 - Cooling

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106

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18 - Hose ❑ Only for auxiliary radiator

Draining and adding coolant

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Special tools and workshop equipment required

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1.2

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4-cylinder injection engine

AG. Volkswagen AG d agen oes Scirocco 2015 ➤ ksw not l o V gu (2.0 l engine, by turbocharger) Volkswagen R GmbH ara - Edition 09.2019 d e nte ris eo ho t u ra a c s s

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♦ Refractometer - T10007 A♦ Drip tray - V.A.G 1306♦ Installation tool for spring-type clips - VAS 5024 A♦ Coolant system charge unit - VAS 6096♦ Adapter - V.A.G 1274/8Draining WARNING

The cooling system is under pressure when the engine is hot! Danger of scalding by steam and hot coolant. Cover filler cap on expansion tank with a cloth and open care‐ fully to release pressure.

1. Cooling system/coolant

107

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Open filler cap on coolant expansion tank. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation . – Release quick-release coupling -arrow-. – Pull coolant hose off radiator.

– Loosen clamp -arrow-. – Place drip tray - V.A.G 1306- underneath. – Pull off coolant hose, and allow coolant to drain out. Filling n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r water for mixing coolant additives. The use o h t or ensures soptimum protection against corro‐ ac au s

Caution

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Rep. gr.19 - Cooling

thi sd o cu m en

108

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Use only distilled of distilled water sion.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Note ♦ The water used for mixing has a major influence on the effec‐

tiveness of the coolant. Because the water quality differs from country to country and even from region to region, the quality of the water to be used in the cooling system has been speci‐ fied by Volkswagen. Distilled water fulfils all requirements. Therefore, always use only distilled water when mixing coolant for topping up or renewing coolant.

♦ Use only coolant additives which conform with the ⇒ Elec‐

tronic parts catalogue (ETKA) . Other coolant additives may reduce corrosion protection substantially. The resulting dam‐ age could lead to loss of coolant and subsequent severe damage to the engine.

olkswagen AG en AG. V ♦ Mixed in the proper proportions, coolant inhibits frost and gcor‐ does swa

k rosion damage as well as scaling. Such additivesbyalso Vol raise dthe cooling e the boiling point of the coolant. For this reason, ris ho system must be filled all-year-round with coolant additives. ut

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s ♦ Because of its high boiling point, the coolant improves engine

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reliability under heavy loads, particularly in countries with trop‐ ical climates. current anti-freeze value.

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♦ ONLY refractometer - T10007A- may be used for determining ♦ Frost protection must be guaranteed down to -25°C as a min‐

imum and, in countries with arctic conditions, down to approx. -36°C. Increasing the frost protection is permissible only if cli‐ matic conditions require stronger frost protection. It may, how‐ ever, be increased only to a maximum of -48°C. Otherwise, the cooling effect will be impaired.

♦ Do not reduce the coolant concentration by adding water even

in warmer seasons and in warmer countries. Frost protection must be guaranteed down to at least -25°C.

♦ Read off anti-freeze figures for respective replenished coolant

additives.

♦ The temperature read off the refractometer - T10007A- corre‐

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♦ Use only a water/coolant additive mixture as a slip agent for

•

Coolant additive (40%) and water (60%) for frost protection to -25°C

•

Coolant additive (50%) and water (50%) for frost protection to -36°C

•

Coolant additive ⇒ Electronic parts catalogue

AG.

Coolant mixture ratio

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coolant hoses.

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♦ Never reuse old coolant.

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sponds the »ice flocculation point«. Flakes of ice may start forming in the coolant below this temperature.

1. Cooling system/coolant

109

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Fill coolant expansion tank of -VAS 6096- with 10 litres of premixed coolant in correct mixture ratio; mixture ratio ⇒ page 109 . – Screw adapter for cooling system tester - V.A.G 1274/8- onto coolant expansion tank. – Attach cooling system charge unit - VAS 6096- to adapter V.A.G 1274/8- . – Feed vent hose -1- into a small container -2-. Note

Exhaust air takes a slight quantity of coolant along with it; this should be collected. – Close valves -A- and -B- (turn lever transverse to direction of flow to do this). – Connect hose -3- to compressed air. •

Pressure: 6 to 10 bar.

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Rep. gr.19 - Cooling

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110

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Open valve -B-; turn lever in direction of flow to do this. •

In cooling system, vacuum is generated by suction jet pump; needle of gauge must move into green area.

– Also briefly open valve -A- (turn lever in direction of flow to do this) so that hose on -VAS 6096- coolant reservoir fills with coolant. – Close valve -A- again. – Leave valve -B- open for a further 2 minutes. •

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– Close valve -B-. – Pull off compressed air hose. •

Volkswagen AG does not gu ara nte eo ra c

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Note

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The needle on the gauge should stop in the green zone. The vacuum level in the cooling system is then sufficient for sub‐ sequent filling.

♦ If the needle does not reach the green zone, repeat the proc‐

ess.

♦ If vacuum drops, cooling system must be checked for leaks. – Open valve -A- slowly. •

Vacuum in cooling system causes coolant to be extracted from -VAS 6096- coolant reservoir and coolant system to be filled.

– Fill coolant up to max. mark.

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– On vehicles with auxiliary heater, switch on auxiliary heater for about 30 seconds.

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– Install noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insu‐ lation .

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– Remove cooling system charge unit - VAS 6096- from coolant expansion tank.

– Set temperature regulator to “HI”. – Switch off air conditioner compressor. To do this, press AC button. •

LED in button should not light up.

– Start engine and run it for max. 2 min. at a speed of approx. 1,500 rpm. – Fill coolant up to the overflow hole of the coolant expansion tank while the engine is running. – Tighten cap of coolant expansion tank until it engages. – Run engine at idling speed until both large coolant hoses on radiator are heated up. – Switch off engine and let it cool off. – Check coolant level. •

When the engine is cold, the coolant level must be between “min.” and max. marking.

1. Cooling system/coolant

111

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 •

The coolant level may be at the max. marking when the engine is warm.

1.3

Checking cooling system for leaks

Special tools and workshop equipment required ♦ Cooling system tester - V.A.G 1274 B-

♦ Adapter for cooling system tester - V.A.G 1274/8-

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

♦ Adapter for cooling system tester - V.A.G 1274/9-

WARNING

The cooling system is under pressure when the engine is hot! Danger of scalding by steam and hot coolant. Cover filler cap on expansion tank with a cloth and open care‐ fully to release pressure.

112

Rep. gr.19 - Cooling

AG.

Procedure

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Engine at operating temperature.

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Test conditions

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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– Screw adapter for cooling system tester - V.A.G 1274/8- onto coolant expansion tank. – Clamp connector - V.A.G 1274 B/1- into adapter for cooling system tester - V.A.G 1274/8- . – Connect connector - V.A.G 1274 B/1- to cooling system tester - V.A.G 1274 B- using supplied hose. – Using hand pump of tester, build up a pressure of approx. 1.0 bar. DANGER!

AG.

Prote cted by

– Find leaks and rectify.

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If the pressure drops:

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Risk of scalding! Before the cooling system tester - V.A.G 1274 B- is disconnected from the connecting hose or the connector - V.A.G 1274 B/1- it is essential that the pressure is first re‐ lieved. To do this, press pressure relief valve on cooling system tester - V.A.G 1274 B- until pressure gauge displays value of »0«.

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– Open filler cap on coolant expansion tank.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

Checking pressure relief valve in filler cap: – Screw cap into adapter for cooling system tester - V.A.G 1274/9- . – Clamp connector - V.A.G 1274 B/1- into adapter for cooling system tester - V.A.G 1274/9- . – Connect connector - V.A.G 1274 B/1- to cooling system tester - V.A.G 1274 B- using supplied hose. – Operate hand pump. •

The pressure relief valve must open at a pressure of 1.4 to 1.6 bar.

1. Cooling system/coolant

113

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Coolant pump, regulation of cooling system

⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 114 ⇒ “2.2 Assembly overview - electric coolant pump”, page 115 ⇒ “2.3 Removing and installing coolant pump”, page 115 ⇒ “2.4 Removing and installing thermostat”, page 116 ⇒ “2.5 Removing and installing coolant temperature sender G62 ”, page 117 ⇒ “2.6 Removing and installing radiator outlet coolant tempera‐ ture sender G83 ”, page 118

2.1

Assembly overview - coolant pump, thermostat

1 - Bolt ❑ 15 Nm

12 - O-ring ❑ Renew after removal 13 - Bolt ❑ 9 Nm

114

Rep. gr.19 - Cooling

pe rm itte d r te o iva r rp fo g n

11 - Coolant hose ❑ With mount for radiator outlet coolant tempera‐ ture sender - G83-

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10 - Retaining clip

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9 - O-ring ❑ Renew after removal

AG.

8 - Radiator outlet coolant tem‐ perature sender - G83❑ Removing and installing ⇒ page 118

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7 - Bolt ❑ 9 Nm

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6 - Front coolant pipe ❑ Removing and installing ⇒ page 120

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5 - O-ring ❑ Renew after removal

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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4 - Thermostat with housing ❑ Removing and installing ⇒ page 116

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3 - O-ring ❑ Renew after removal

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2 - Coolant pump ❑ Removing and installing ⇒ page 115

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 14 - O-ring ❑ Renew after removal

2.2

Assembly overview - electric coolant pump

1 - Nut ❑ 3

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2 - Coolant pipe

3 - Spring-type clip

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4 - Coolant line ❑ To turbocharger 5 - Coolant hose 6 - Bracket 7 - Coolant hose ❑ To cooler opening

9 - Bolt ❑ 5 Nm

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2.3

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10 - Nut ❑ 5 Nm

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8 - Coolant circulation pump V50❑ The function can be checked using final con‐ trol diagnosis ⇒ Vehicle diagnostic tester.

Removing and installing coolant pump

Special tools and workshop equipment required ♦ Drip tray for workshop hoist - VAS 6208-

2. Coolant pump, regulation of cooling system

115

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Pliers for spring-type clips - VAS 5024A-

Removing WARNING

The cooling system is under pressure when the engine is hot! Danger of scalding by steam and hot coolant. Cover filler cap on expansion tank with a cloth and open care‐ fully to release pressure. – Drain coolant ⇒ page 107 . – Remove toothed belt ⇒ page 55 . – Unscrew bolts -1-. – Remove coolant pump -2-. – Remove O-ring -3-. Installing . Volkswag

en AG Install in reverse order of removal, observing agenthe following: AG does ksw

– Renew O-ring.

– Moisten new O-ring

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Specified torques

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Installation position: plug in the housing faces downwards.

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2.4

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♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 114

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Removing and installing thermostat

Removing

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐ nator; Removing and installing alternator .

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AG.

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Rep. gr.19 - Cooling

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116

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– Remove coolant pipes ⇒ page 120 .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Release clip -1-. – Pull off coolant hose -2-.

– Unscrew bolts -arrows-. – Remove thermostat housing together with thermostat from engine. Installing Install in reverse order of removal, observing the following: Note

Renew O-ring. – Check coolant level ⇒ page 107 . Specified torques ♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 114 ♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 119

Removing and installing coolant temper‐ ature sender - G62n AG. Volkswagen AG do e wage

Removing

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WARNING

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2.5

The cooling system is under pressure when the engine is hot! Danger of scalding by steam and hot coolant.

rrectness of i t to the co nform spec at i h re o n wit in t his

Cover filler cap on expansion tank with a cloth and open care‐ fully to release pressure. •

Engine cold.

– Briefly open filler cap for coolant expansion tank in order to reduce pressure in cooling system. – Remove air filter housing ⇒ page 155 .

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2. Coolant pump, regulation of cooling system

117

AG.

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Note

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sender - G62- .

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–

AG. Volkswagen AG d agen oes ksw not l o V Scirocco 2015 ➤ gu by ara d e nte 4-cylinder injection engine (2.0 l engine, 09.2019 isturbocharger) Volkswagen R GmbH - Edition r o eo h ut ra a c ss Disconnect electrical connector -1- at coolant temperature

Place a cloth underneath to catch escaping coolant. – Release clip, and remove coolant temperature sender - G62- . Installing

Install in reverse order of removal, observing the following: Note

Renew O-ring.

– Check coolant level ⇒ page 107 .

Danger of scalding by steam and hot coolant. Cover filler cap on expansion tank with a cloth and open care‐ fully to release pressure. •

Engine cold.

– Briefly open filler cap of coolant expansion tank in order to reduce pressure in cooling system. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation . – Disconnect connector -2- on radiator outlet coolant tempera‐ ture sender - G83- . Note

Place a cloth underneath to catch escaping coolant. – Release clip -1-, and pull off radiator outlet coolant tempera‐ ture sender - G83- . Installing Install in reverse order of removal, observing the following: Note

Renew O-ring. – Check coolant level ⇒ page 107 .

118

Rep. gr.19 - Cooling

AG.

The cooling system is under pressure when the engine is hot!

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WARNING

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Removing

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Removing and installing radiator outlet coolant temperature sender - G83-

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2.6

Coolant pipes

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3

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4-cylinder injection engine (2.0 l engine,

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r Scirocco 2015 ➤e o o h ut ra a turbocharger) Volkswagen R GmbH Edition 09.2019 c s s

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⇒ “3.1 Assembly overview - coolant pipes”, page 119 ⇒ “3.2 Removing and installing coolant pipes”, page 120

Assembly overview - coolant pipes

5 - O-ring ❑ Renew after removal 6 - Union 7 - Bolt ❑ 10 Nm 8 - Retaining clip

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4 - Connection hose

AG.

3 - Coolant pipe

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2 - Bolt ❑ 23 Nm

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1 - Bolt ❑ 40 Nm

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3.1

9 - O-ring ❑ Renew after removal 10 - Radiator outlet coolant G62❑ Removing and installing ⇒ page 117 11 - Connection hose 12 - Connector 13 - Connection hose 14 - Connection hose 15 - Connection hose 16 - Coolant pipe ❑ Removing and installing ⇒ page 120 17 - Bolt ❑ 5 Nm 18 - Connection hose 19 - Coolant pipe ❑ Removing and installing ⇒ page 120 20 - Bolt ❑ 10 Nm 21 - Thermostat housing ❑ With thermostat ❑ Checking thermostat ⇒ Vehicle diagnostic tester ❑ Starts to open at 87°C 22 - Bolt ❑ 15 Nm 3. Coolant pipes

119

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 23 - Coolant pump ❑ Removing and installing ⇒ page 115 24 - Bolt ❑ 15 Nm

3.2

Removing and installing coolant pipes

Special tools and workshop equipment required ♦ Drip tray for workshop hoist - VAS 6208-

♦ Pliers for spring-type clips - VAS 5024A-

– Remove air filter housing ⇒ page 155 . – Remove turbocharger air recirculation valve - N249- -1- with housing and hose ⇒ page 138 .

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Rep. gr.19 - Cooling

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120

thi sd o cu m en

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Removing

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– Unscrew bolt -2-.

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– Disconnect electrical connector -3-. – Unscrew bolt -4-.

– Pull air intake pipe off charge air cooler, and remove it down‐ wards. – Drain coolant ⇒ page 107 .

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– Separate electrical connectors -arrows-.

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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .

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AG.

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– Loosen clamps -arrow-. – Pull off coolant hoses.

– Loosen clamp -A-. – Pull off hose. – Unscrew bolt -B-. – Remove coolant pipe.

3. Coolant pipes

121

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Release connector -A- from retainer. – Loosen clamp -B-. – Pull off hose. – Unscrew bolts -C-. – Remove coolant pipe. Installing Install in reverse order of removal, observing the following: Specified torques

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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Rep. gr.19 - Cooling

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122

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♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 119

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

4

Radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 123 ⇒ “4.2 Removing and installing radiator”, page 124 ⇒ “4.3 Removing and installing radiator fan V7 ”, page 124 ⇒ “4.4 Removing and installing auxiliary radiator”, page 126

4.1

Assembly overview - radiator/radiator fan

1 - Cap ❑ Check using cooling system tester - V.A.G 1274- and adapter for cooling system tester V.A.G 1274/9❑ Pressure relief valve must open at pressure of 1.4 to 1.6 bar 2 - Electrical connector 3 - Bolt ❑ 5 Nm

6 - O-ring ❑ Renew after removal

AG.

11 - Radiator fan - V7❑ Removing and installing ⇒ page 124 ❑ With radiator fan control unit - J293-

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10 - Radiator fan 2 - V177❑ Removing and installing ⇒ page 124

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9 - Bolt ❑ 5 Nm

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8 - Nut ❑ 5 Nm

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7 - Lower coolant hose ❑ To connection for ther‐ mostat.

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5 - Sealing strip ❑ Not fitted

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4 - Expansion tank ❑ When renewing expan‐ sion tank and during service operations, en‐ AG. Volkswagen AG d agen oes sure that 2 silicate car‐ ksw not l o V gu by ara tridges ⇒ Electronic d e nte s i r Parts Catalogue are al‐ o eo h ra ways in expansion tank. s aut c Do not remove the sili‐ s cate cartridges. ❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester V.A.G 1274/8-

4. Radiator, radiator fan

123

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 12 - Electrical connector 13 - Radiator fan support ❑ Removing and installing ⇒ page 124 un le

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14 - Radiator/cooler ❑ Removing and installing ⇒ page 124 ❑ After renewing, renew entire coolant.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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4.2

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15 - Upper coolant hose ❑ To connection on cylinder head.

Removing and installing radiator

Removing – Drain coolant ⇒ page 107 .

– Move lock carrier to service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Moving to and from service position .

– Remove radiator upwards. Installing Install in reverse order of removal, observing the following: – Check coolant level ⇒ page 107 . Specified torques ♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 123

4.3

Removing and installing radiator fan V7-

Special tools and workshop equipment required

124

Rep. gr.19 - Cooling

AG.

– Unscrew bolts -1 and 2-.

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– Pull coolant hoses off radiator.

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– Unscrew bolts -arrows-.

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– Removing fan support ⇒ page 124 .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Tensioning strap - T10038-

Removing – Remove air filter housing ⇒ page 155 . – Unscrew upper fan support bolts -arrows-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .

– Unscrew bolts -2 and 3-.

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4. Radiator, radiator fan

125

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Disconnect electrical connector -1-. – Unscrew lower fan support bolts -arrows-. – Take out fan support from underneath.

– Disconnect electrical connector -1- and move electrical wires clear. – Unscrew nuts -arrows-. – Remove fan. Installing Install in reverse order of removal, observing the following: Specified torques ♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 123

4.4

Removing and installing auxiliary radia‐ tor

Removing – Drain coolant ⇒ page 107 . . Volkswagen AG – Pull coolant hoses -1 and 2- off auxiliary radiator. gen AG d

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– Unscrew nuts -arrows-. – Remove auxiliary radiator -1-. Installing

Install in reverse order of removal, observing the following: – Check coolant level ⇒ page 107 .

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Rep. gr.19 - Cooling

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126

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Auxiliary radiator nuts

Specified torque

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Specified torques

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

21 –

Turbocharging/supercharging

1

Turbocharger

⇒ “1.1

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1.1

Assembly overview - turbocharger

⇒ “1.1.1 Assembly overview – turbocharger, part I”, page 127 ⇒ “1.1.2 Assembly overview – turbocharger, part II”, page 128

1.1.1

Assembly overview – turbocharger, part I

1 - Seal ❑ Renew after removal

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3 - Banjo bolt ❑ 35 Nm

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2 - Nuts ❑ Renew after removal ❑ Lubricate exhaust mani‐ fold studs with high-tem‐ perature paste ⇒ Elec‐ tronic Parts Catalogue (ETKA) ❑ 20 Nm

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⇒ “1.3 Checking vacuum unit for turbocharger”, page 136

5 - Bolt ❑ 9 Nm 6 - Bolt ❑ On coolant return line only fitted with 2 retain‐ ers ❑ 23 Nm 7 - Coolant distribution housing ❑ Gradual introduction of coolant return lines with one retainer 8 - Turbocharger ❑ Removing and installing ⇒ page 129 9 - Bracket 10 - Bolt ❑ Coat bolt with high-temperature paste; ⇒ Electronic Parts Catalogue (ETKA) ❑ 30 Nm 11 - Bolt ❑ Coat bolt with high-temperature paste; ⇒ Electronic Parts Catalogue (ETKA) ❑ 30 Nm

1. Turbocharger

127

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 12 - Bracket 13 - Bolt ❑ 23 Nm

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Assembly overview – turbocharger, part II

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1 - Turbocharger ❑ Can only be renewed to‐ gether with exhaust manifold and vacuum unit as one unit ❑ Removing and installing ⇒ page 129

3 - Seal ❑ Renew after removal

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7 - Intake hose ❑ Note installation posi‐ tion ⇒ page 129 8 - Seal ❑ Renew after removal 9 - To turbocharger air recircu‐ lation valve - N249❑ ⇒ Item 29 (page 140) 10 - Hose clamp 11 - Seal ❑ Note installation posi‐ tion ⇒ page 129 12 - Vacuum unit for turbo‐ charger ❑ Checking ⇒ page 136 13 - Connection 14 - Hose 15 - Seal ❑ Renew after removal

128

Rep. gr.21 - Turbocharging/supercharging

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6 - Crankcase breather line

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5 - Heat shield

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4 - Bolt ❑ 9 Nm

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2 - Line ❑ To activated charcoal fil‐ ter

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 16 - Banjo bolt ❑ 8 Nm 17 - Hose 18 - Bolt ❑ 3 Nm agen 19 - Charge pressure control solenoid valvelk-swN75-

20 - Hose

24 - Bolt ❑ 9 Nm

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1.2

Removing and installing turbocharger

Special tools and workshop equipment required ♦ Pliers for spring-type clips - VAS 5024 A-

1. Turbocharger

129

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Tensioning strap - T10038-

Caution

If a mechanical fault is found on the turbocharger, e.g. a de‐ stroyed compressor impeller, just renewing the turbocharger is not enough. To avoid subsequent damage, the following work must be performed: ♦ Check air filter housing, air filter element and intake hoses for soiling. ♦ Check the whole charge air path and charge air cooler for foreign objects. AG. Volkswagen G d charg‐ If foreign objects are found in the wcharge agen air system,Athe oes s k not l o ed air routing must be cleaned gu y V and the charge air cooler must b ara d be renewed, if necessary. nt ise

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– Loosen clamps -1 and 2-. – Remove intake hose. – Drain coolant ⇒ page 107 . – Remove front right wheel housing liner ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .

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Rep. gr.21 - Turbocharging/supercharging

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– Pull charge air hose -arrow- from charge air cooler.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -arrows-. – Remove charge air pipe.

– Disconnect electrical connectors -1 and 2-. – Unclip wiring harness. – Unscrew bolts -arrows-. – Remove connection from turbocharger.

– Disconnect connector for lambda probe - G39- -arrow-. – Lay wiring harness to one side.

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– Move wiring harness aside.

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– Pull connectors -arrows- off ignition coils.

1. Turbocharger

131

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Loosen clamp -arrow-. – Pull off coolant hose.

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– Loosen clamps -1 and 2-. – Pull off coolant hoses. – Unscrew bolt -3-.

Rep. gr.21 - Turbocharging/supercharging

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132

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– Remove heat shield together with coolant pipe.

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– Unscrew bolts -arrows-.

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– Pull upper coolant hose from heat exchanger -arrow-.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -1-. – Pull crankcase breather -2- off cylinder head cover, and re‐ move it. – Release clip -3- and detach hose. – Unscrew bolt -4-.

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– Unscrew bolts -arrows-.

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– Unscrew both lower front exhaust pipe/turbocharger nuts.

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– Remove heat shield for right drive shaft.

1. Turbocharger

133

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -arrows-.

– Disconnect exhaust system from clamping sleeve -arrows-.

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– Unscrew bolts -arrows-.

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– Unscrew bolts -arrows-.

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– Pull front exhaust pipe from turbocharger and push backwards slightly.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -1 and 2-. – Remove turbocharger support. Note

The following procedure is necessary to provide more space be‐ tween the cylinder head and plenum chamber bulkhead.

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– Unscrew bolts -2 and 3-.

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– Pull off coolant hose.

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– Loosen clamp -arrow-.

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– Using tensioning strap - T10038- , pull engine approx. 20 mm towards rear.

1. Turbocharger

135

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolt -1- for coolant pipe. Note ♦ The clamping strip nuts need not be loosened. ♦ Bolt -1- is only fitted on coolant pipes with 2 retainers. – Unscrew upper nuts -arrows-. – Remove turbocharger and exhaust manifold upwards. Installing Install in reverse order of removal, observing the following: AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d e nte isseals r gaskets, and self-locking nuts. o eo h t u ra a c s s

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– Fill turbocharger with engine oil at oil supply line connection.

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Specified torques ♦ ⇒ “1.1 Assembly overview - turbocharger”, page 127

♦ ⇒ “3.1 Assembly overview - oil circuit”, page 98

1.3

Checking vacuum unit for turbocharger

Special tools and workshop equipment required

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♦ Hand operated vacuum pump - VAS 6213-

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Test conditions ♦ Hose from turbocharger via charge pressure control solenoid valve - N75- to vacuum unit must have through-flow (not blocked). ♦ Charge pressure control solenoid valve - N75- must be OK. Procedure – Remove air filter housing ⇒ page 155 .

136

Rep. gr.21 - Turbocharging/supercharging

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– After installing turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the turbocharg‐ er.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Connect hand vacuum pump - VAS 6213- to vacuum unit -arrow-.

The pressure must not exceed 750 mbar! If the pressure is exceeded, the vacuum unit can be damaged.

– Operate hand vacuum pump - VAS 6213- repeatedly, observ‐ ing linkage. The linkage -A- should start to move at a pressure of approx. 300 mbar and be at its limit stop at a pressure of approx. 700 mbar.

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1. Turbocharger

137

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Charge air system

⇒ “2.1 Schematic overview - charge air system”, page 138 ⇒ “2.2 Assembly overview - charge air system”, page 138 ⇒ “2.3 Assembly overview - charge-air hose connections”, page 140 ⇒ “2.4 Removing and installing charge air cooler”, page 141 ⇒ “2.5 Checking charge air system for leaks”, page 142

2.1

Schematic overview - charge air system

1 - Turbocharger air recircula‐ tion valve - N2492 - Throttle valve module J3383 - Pressure regulating valve for crankcase breather 5 - Vacuum unit for charge pressure control un le pe rm itte d

7 - Turbocharger

16 - Activated charcoal filter solenoid valve 1 - N8017 - Dual non-return valve

19 - Charge air cooler

2.2

Assembly overview - charge air system Caution

The screw-type clips on the charge air pipes must be tightened to 5.5 Nm. If the torque is too low or too high, the charge air hose may slip off the charge air pipe during vehicle operation.

138

Rep. gr.21 - Turbocharging/supercharging

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18 - Charge air pressure send‐ er - G31-

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15 - Oil filter bracket

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14 - Non-return valve

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13 - Vacuum pump

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11 - Air filter

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10 - Air mass meter - G70-

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8 - Brake servo 9 - Non-return valve

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6 - Charge pressure control solenoid valve - N75-

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4 - To activated charcoal filter

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 1 - Bolt ❑ 5 Nm 2 - Mountings ❑ for charge air cooler 3 - Charge air cooler ❑ Removing and installing ⇒ page 141 4 - Hose clamp ❑ 5.5 Nm 5 - Bolt ❑ 10 Nm 6 - Charge air pipe ❑ Fitting hose connec‐ tions with plug-in con‐ nectors ⇒ page 140 7 - Charge air hose ❑ Fitting hose connec‐ tions with plug-in con‐ nectors ⇒ page 140 9 - To intake hose

12 - Charge air pipe 13 - Bolt ❑ 10 Nm 14 - Hose clamp ❑ 5.5 Nm

15 - Charge air hose 16 - Hose clamp ❑ 5.5 Nm

17 - Seal ❑ Renew after removal

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20 - Bolt ❑ 10 Nm

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19 - Bolts ❑ 5 Nm

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18 - Charge air pressure sender - G31-

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2. Charge air system

139

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 21 - Hose clamp 22 - Hose 23 - Hose

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24 - Housing

26 - Bolt ❑ 7 Nm 27 - Seal ❑ Renew after removal 28 - Hose clamp 29 - Hose

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25 - Turbocharger air recirculation valve - N249❑ Fitting position ⇒ page 140

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Installation location of turbocharger air recirculation valve - N249-

Assembly overview - charge-air hose connections Caution

The seal for the push-on coupling can be damaged if the re‐ taining clip is in the locked position during installation. This would result in leaking. Observe assembly instructions.

140

Rep. gr.21 - Turbocharging/supercharging

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Removing – Loosen locking lug -A-. – Release plug-in connector by pulling out retaining clip -arrow-. Installing Install in reverse order of removal, observing the following: – On renewing oil seal in charge air hose groove; ensure that oil seal is seated completely in groove all around and is not twis‐ ted. – Coat sealing surface and oil seal with oil. – Bring retaining clip to release position -1-. – Push charge air hose into coupling as far as stop. – Bring retaining clip to locking position -2- and then press charge air hose again. – Pull on hose to ensure that plug-in connector is properly seat‐ ed and engaged.

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Removing and installing charge air cool‐ er

– Remove bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 ; Front bumper; Removing and installing front bumper cover . – Release clips -arrows-.

– Removing radiator ⇒ page 124 . ht rig py Co t.

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– Remove air ducts from lock carrier ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Assembly overview – lock carrier .

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– Remove air intake hose.

2. Charge air system

141

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -1-. Note

The condenser bolts are difficult to access. With the aid of a 2nd mechanic, lift the charge air cooler out of the radiator mountings. The charge air cooler can now be moved back and forth a little to allow access to the bolts.

– On the right-hand side of the charge air cooler, unscrew bolt -arrow-.

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– Unscrew bolts -arrows-. – Secure condenser to lock carrier with cable ties. – Take out charge air cooler from underneath. Installing

Install in reverse order of removal, observing the following: Specified torques

♦ ⇒ “2.2 Assembly overview - charge air system”, page 138 ♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 123

Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-

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Special tools and workshop equipment required AG.

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♦ Adapter - V.A.G 1687/5Procedure – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front, noise insulation .

142

Rep. gr.21 - Turbocharging/supercharging

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Release securing clip -A-. – Pull hose -B- off charge air pipe.

– Connect adapter - V.A.G 1687/5- onto charge air hose -A- and turn approx. 90° -B-. Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely. – Close valves -3 and 4-.

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– Connect charge air system tester - V.A.G 1687- as shown.

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2. Charge air system

143

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Connect compressed air hose -1- (compressed air supply) to charge air system tester - V.A.G 1687- . Note

If there is water in the inspection glass, drain it via the water drainolkswagen yV plug -6-. db

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– Open valve -3-.

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– Pressure control valve -2-, set pressure to 0.5 bar. Caution

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The pressure must not exceed 0.5 bar. If the pressure is too high this can cause damage to the engine. – Open valve -4-, and wait until test circuit has filled; if neces‐ sary, adjust pressure to 0.5 bar. – Check the charge air system for leaks by listening, touching, with commercially available leak detector spray or using ultra‐ sonic tester - V.A.G 1842- . Note

the engine. Therefore a holding pressure test is not possible.

♦ Depressurise test circuit by detaching coupling from adapter ♦ Hose connections and hoses for charge air system must be

free of oil and grease before assembly.

144

Rep. gr.21 - Turbocharging/supercharging

AG.

V.A.G 1687/5- before removing adapter.

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instructions

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♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating

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♦ A small amount of air escapes through the valves and enters

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

24 –

Mixture preparation - injection

1

Injection system

⇒ “1.1 Releasing high pressure in fuel system”, page 145

1.1

Releasing high pressure in fuel system WARNING

Risk of injury due to fuel which is under very high pressure. ♦ The injection system consists of a high-pressure section (maximum approx. 150 bar) and a low-pressure section (approx. 6 bar).

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♦ Prior to opening the high-pressure section, e.g. when re‐ moving the high-pressure pump, fuel rail, injectors, fuel pipes, or the fuel pressure sender - G247- , the fuel pres‐ sure in the high-pressure system must be reduced to a specified value of approx. 6 bar. The appropriate proce‐ dure is described as follows.

1. Injection system

145

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Disconnect electrical connector -arrow- from fuel pressure regulating valve - N276- . – Allow engine to idle for approx. 10 seconds. Note ♦ When the engine is idling and the electrical connector is pulled

off the fuel pressure regulating valve - N276- , the pressure in the high-pressure system will drop to approx. 6 bar.

♦ When the high-pressure is reduced, the high-pressure system

must be opened, because the fuel pressure can rise by warm‐ ing up.

– Switch off ignition. WARNING

Risk of injury, avoid skin contact with fuel. ♦ Wear eye protection and protective clothing when opening the fuel system. ♦ Wrap a clean cloth around the connection to catch escap‐ ing fuel before opening the high-pressure system. . Volkswagen AG gen AG –

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prox. 6 bar. Catch the escaping fuel.

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Note

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– After completing work, read event memory of engine control unit. Delete all event memory entries which may have occur‐ red by unplugging connector ⇒ Vehicle diagnostic tester.

The readiness code must be generated if the event memory has been cleared ⇒ Vehicle diagnostic tester .

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Rep. gr.24 - Mixture preparation - injection

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146

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Injectors

⇒ “2.1 Assembly overview - fuel rail with injectors”, page 147 ⇒ “2.2 Removing and installing injectors”, page 148 ⇒ “2.3 Removing and installing fuel rail”, page 150 ⇒ “2.4 Renewing seals on injectors”, page 151

2.1

Assembly overview - fuel rail with injectors

1 - Injector -N30- / -N33❑ Removing and installing ⇒ page 148 2 - Bolt ❑ 8 Nm

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3 - Fuel distributor ❑ Removing and ⇒ page 150

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4 - Low pressure fuel hose ❑ To high-pressure pump

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5 - Pressure limiting valve ❑ To remove and install, remove intake manifold ⇒ page 158 ❑ 30 Nm

AG.

9 - High-pressure pipe ❑ Counterhold threaded connection when loos‐ ening union nut. ❑ Before installing, check torque of threaded connection ❑ Install free of tension. ❑ Tighten union nuts to 27 Nm.

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8 - Bracket

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7 - Low pressure pipe ❑ Counterhold pressure limiting valve when loos‐ ening union nut. ❑ Before installing, check torque of pressure limit‐ ing valve ❑ Install free of tension. ❑ Tighten union nut to 22 Nm.

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6 - Panel nut

10 - Bolt ❑ 3 Nm 11 - Electrical connector ❑ For injectors.

2. Injectors

147

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 12 - Electrical connector 13 - Electrical connector 14 - Cable channel 15 - Clip ❑ Attach on lower right sleeve of intake manifold 16 - Electrical connector ❑ for Hall sender - G4017 - Electrical connector ❑ For fuel pressure sender - G247. AG. Volkswagen AG do agen 18 - Bolt ❑ 5 Nm

20 - Connecting union ❑ 30 Nm

2.2

Removing and installing injectors

Special tools and workshop equipment required ♦ Tool set - T10133-

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Puller tool T10133/2 has been modified and is now designated puller T10133/2 A . If the new tool is not yet available in the work‐ shop, perform the modification yourself. Rework puller tool T10133/2 to make puller tool T10133/2 A . Special tools and workshop equipment required ♦ Round file approx. 6 mm – File out a semicircle as illustrated. Tool can be pushed further through semicircle onto injector. Tool has larger contact sur‐ face area as a result.

148

Rep. gr.24 - Mixture preparation - injection

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Note

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19 - Fuel pressure ❑ Coat thread and sealing taper with clean engine oil. ❑ Removing and installing ⇒ page 166 ❑ Checking ⇒ page 167 ❑ 22 Nm

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4-cylinder injection engine (2.0 l engine,

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– For identification purposes, mark the modified tool with the letter “A” after the tool number.

3-

Groove in injector.

4-

Support washer (renew).

5-

O-ring (renew; to install, lightly lubricate with clean engine oil).

6-

Support ring

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Combustion chamber ring seal (Teflon ring seal) - renew; when fitting, do not grease ring or use any other lubricant.

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2-

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Radial compensation element (renew)

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Injector components

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Note

When the injector is fitted, the radial compensation element -1- is clipped into the support ring -6-. To remove the injector, the sup‐ port ring must be removed from the injector so that the puller T10133/2- can be inserted into the groove on the injector -3-. Removing – Remove intake manifold ⇒ page 158 . – Seal intake ports with a clean cloth. – Use a screwdriver to move radial compensation element re‐ taining lugs to side and pull support ring from injector. Note

The retaining hooks of radial compensation element are damaged by this action (retaining hooks bend or break). The radial com‐ pensation element must be renewed before injector is refitted.

2. Injectors

149

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Insert puller -T10133/2A- into groove in injector. – Then, fit removal tool -T10133/16- . – Pull out injector by turning bolt -1-. Installing Install in reverse order of removal, observing the following: Note ♦ Do not oil or grease the Teflon seal on the injector. ♦ It is possible that an open inlet valve hinders cleaning. In this

case, turn engine by hand at crankshaft a spanner. olkswagen Ausing G en AG. V

–

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– Renew O-ring, radial compensation element, support washer and Teflon seal of injector ⇒ page 151 .

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– Insert injector in bore in cylinder head to stop using drift T10133/9- .

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– Ensure injectors are positioned correctly in cylinder head. AG.

Specified torques ♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 147 ♦ ⇒ “4.1 Assembly overview - intake manifold”, page 157

2.3

Removing and installing fuel rail

Removing – Remove intake manifold ⇒ page 158 . – Remove activated charcoal filter hoses.

150

Rep. gr.24 - Mixture preparation - injection

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolt -1-. – Unscrew bolts -arrows-.

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– Loosen union nuts

and 3-.

– Carefully lever off linkage from intake manifold flap motor V157- -4-.

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– Unscrew bolts -5-.

– Remove fuel rail from intake manifold. Installing

Install in reverse order of removal, observing the following: Specified torques

♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 147 ♦ ⇒ “4.1 Assembly overview - intake manifold”, page 157

2.4

Renewing seals on injectors

Special tools and workshop equipment required ♦ Tool set - T10133-

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– Counterhold on pressure limiting valve.

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– Unscrew bolts -arrows-.

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Note

Do not lubricate the Teflon ring. Procedure – Carefully remove old Teflon ring using a suitable tool (e.g. cut open ring using razor blade, or prise open ring with small screwdriver and then pull off forwards). It is essential to ensure that the groove and continuous ridge in groove surface are not damaged. 2. Injectors

151

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Carefully clean injector in area of oil seal -arrow- and remove existing deposits (carbon) with a brass brush. – Carefully cut oil seal open with a knife.

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– Clean oil seal groove.

152

Rep. gr.24 - Mixture preparation - injection

AG.

– Remove assembly cone - T10133/5- and push oil seal into groove with assembly sleeve - T10133/6- .

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– Fit assembly cone - T10133/5- on injector and push oil seal onto injector using assembly sleeve - T10133/6- .

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– Turn assembly sleeve - T10133/6- over and push oil seal onto end of assembly cone - T10133/5- .

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– Position new oil seal on assembly cone - T10133/5- and push oil seal onto assembly cone - T10133/6- as far as possible with assembly sleeve - T10133/5- .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Push calibration sleeve - T10133/7- onto injector to stop and simultaneously turn it slightly (approx. 180°). – Pull calibration sleeve - T10133/7- off again, turning in oppo‐ site direction.

–

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d e nte Push calibration sleeve - T10133/8injector to stop and isonto r o eo h t simultaneously turn it slightly (approx. 180°). u ra a c s s

– Renew O-ring on injector and on support washer.

– Attach support ring back to injector -1-.

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– Clip radial compensation element -2- into support ring.

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– Pull calibration sleeve - T10133/8- off again, turning in oppo‐ site direction.

2. Injectors

153

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

3

Air filter

⇒ “3.1 Assembly overview - air filter housing”, page 154 ⇒ “3.2 Removing and installing air filter housing”, page 155

3.1

Assembly overview - air filter housing

1 - Air mass meter - G70❑ Note installation posi‐ tion ⇒ page 155 ❑ Removing and installing ⇒ page 166 2 - Bolt ❑ 3 Nm

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11 - Intake hose ❑ Observe assembly marking ❑ Check for soiling and leaves in air hose.

154

Rep. gr.24 - Mixture preparation - injection

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10 - Rubber grommet ❑ Observe assembly marking

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9 - Heat shield

AG.

8 - Bolt ❑ 3 Nm

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7 - Air filter lower part ❑ Remove salt residues, dirt and leaves from air filter lower section.

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6 - Filter element ❑ Always use Genuine Part for air filter element ❑ Observe change inter‐ vals ⇒ Maintenance ; Booklet ; Service tables

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5 - Intake air guide

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3 - Upper part of air filter/en‐ gine cover panel ❑ Remove salt residues, dirt and leaves from air filter lower section. ❑ Removing and installing ⇒ page 155

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Installation position of seal -2- of air mass meter - G70- -1-

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Removing and installing air filter hous‐ ing

Special tools and workshop equipment required

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♦ Hose clamp pliers - VAS 6340-

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♦ Torque wrench - V.A.G 1783-

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3.2

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Smooth side of seal must be in contact with air mass meter G70- , see magnified view.

3. Air filter

155

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Removing – Using hose clip pliers - VAS 6340- , loosen spring-type clip -B-. – Pull air duct off engine cover panel -A-.

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– Unclip and lift engine cover panel successively from mounting points -arrow 4-, -arrow 5-, -arrow 6- and finally -arrow 3-. Installing

– Position engine cover panel in installation position and press rubber mountings simultaneously onto retaining pins. Specified torques ♦ ⇒ “3.1 Assembly overview - air filter housing”, page 154

156

Rep. gr.24 - Mixture preparation - injection

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– During installation, ensure that the 4 rubber mountings -arrows- are inserted correctly.

AG.

– Renew rubber mountings.

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The engine cover panel rubber mountings -arrows- may not be lubricated or greased before installation.

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Install in reverse order of removal, observing the following:

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– Unclip hose from attachments -2-.

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– Loosen clips -arrows A.-

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– Unplug electrical connector -2- from air mass

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

4

Intake manifold

⇒ “4.1 Assembly overview - intake manifold”, page 157 ⇒ “4.2 Removing and installing intake manifold”, page 158 ⇒ “4.3 Removing and installing intake manifold flap motor V157 ”, page 160 ⇒ “4.4 Removing and installing throttle valve module J338 ”, page AG. Volkswagen AG d 162 agen o

Assembly overview - intake manifold

2 - Clamp

4 - Stud ❑ 10 Nm

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3 - Bolt ❑ 3 Nm

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1 - Nut ❑ 10 Nm

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4.1

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5 - Seal ❑ Renew after removal

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9 - Bolt ❑ 7 Nm

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8 - Intake manifold flap motor V157- and intake manifold flap potentiometer - G336❑ Removing and installing ⇒ page 160

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7 - Coupling rod

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6 - Intake manifold ❑ With intake manifold flaps ❑ Removing and installing ⇒ page 158

10 - To activated charcoal filter 11 - Hose 12 - Activated charcoal filter solenoid valve 1 - N8013 - Hose 14 - Dual non-return valve 15 - Intake manifold support 16 - Bolt ❑ 25 Nm 17 - Nut ❑ 10 Nm

4. Intake manifold

157

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 18 - Bonded rubber bush 19 - Throttle valve module - J338❑ Including throttle valve drive (electric throttle operation) - G186- , angle sender 1 for throttle valve drive (electric throttle operation) - G187- and angle sender 2 for throttle valve drive (electric throttle operation) - G188- . ❑ Removing and installing ⇒ page 162 20 - Bolt ❑ 7 Nm 21 - Seal ❑ Renew if damaged 22 - Bolt ❑ 5 Nm 23 - Intake air temperature sender - G4224 - Bolt ❑ 10 Nm

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Removing and installing intake manifold

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Removing

– Disconnect all necessary electrical connectors. – Pull vacuum hose between intake manifold and vacuum pump from intake manifold. WARNING

Fuel supply line is pressurised. Wear protective goggles and protective clothing to avoid injury and contact with the skin. Before loosening hose connections, wrap a cloth around the connection. Release pressure by carefully pulling hose off con‐ nection.

AG.

Rep. gr.24 - Mixture preparation - injection

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158

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– Disconnect fuel supply line -2-.

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Observe the safety precautions when releasing fuel pressure in the high-pressure system ⇒ page 145 .

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– Remove throttle valve module - J338- ⇒ page 162 .

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Loosen clamp -2-. – Pull off breather line.

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– Pull off vacuum lines -arrows-.

– Release both fuel lines from high-pressure pump.

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Connections of old high-pressure pumps:

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Connections of new high-pressure pumps: – Release both fuel lines from high-pressure pump.

4. Intake manifold

159

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Release coolant pipe and dipstick guide -arrows- from intake manifold. – Pull dipstick guide in direction of -arrow- upwards off engine.

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– Remove intake manifold support.

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– Unscrew bolts -arrows-.

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– Disconnect connector -arrow- from fuel pressure sender G247- .

rrectness of i t to the co nf o r m spec atio h re n in wit

– Unscrew all bolts from intake manifold.

– Carefully pull intake manifold with fuel rail from cylinder head. Installing

Install in reverse order of removal, observing the following: Specified torques

♦ ⇒ “4.1 Assembly overview - intake manifold”, page 157

4.3

Removing and installing intake manifold flap motor - V157-

160

Rep. gr.24 - Mixture preparation - injection

AG.

– Remove air filter housing ⇒ page 155 .

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Removing

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♦ Assembly tool - T10118-

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Special tools and workshop equipment required

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Unscrew bolts -arrows-.

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– Remove air duct.

– Remove turbocharger air recirculation valve - N249- -1- with housing and hose ⇒ page 138 .

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Note

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– Disconnect following connectors:

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– Pull off vacuum lines -arrows-.

Use assembly tool - T10118- to facilitate opening of connectors which are less accessible ♦ Connector for intake manifold flap motor - V157♦ Electrical connection for activated charcoal filter system sole‐ noid valve 1 - N80♦ Connector for intake manifold pressure sender - G71♦ Connector for throttle valve module - J338♦ Connector for fuel pressure sender for low pressure - G410– Disconnect additional connectors -arrows-. – Loosen cable retainer -A-, and place complete wiring harness to side.

4. Intake manifold

161

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

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– Unscrew nuts -arrows-.

Note

– Remove intake manifold flap motor - V157- from intake mani‐ fold. Prote cted by

If the intake manifold flap motor - V157- or the intake manifold were renewed, the intake manifold flap potentiometer - G336must be adapted to the engine control unit - J623- ⇒ Vehicle diagnostic tester. Specified torques ♦ ⇒ “3.1 Assembly overview - air filter housing”, page 154 ♦ ⇒ “4.1 Assembly overview - intake manifold”, page 157

4.4

Removing and installing throttle valve module - J338-

Removing – Remove air filter housing ⇒ page 155 .

162

Rep. gr.24 - Mixture preparation - injection

AG.

Install in reverse order of removal, observing the following:

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Installing

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The rear bolt -arrow- can only be unscrewed with a ratchet handle. The space between the bolt and the water pipe is very constricted.

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– Unscrew bolts -1 and 2-.

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– Prise coupling rod -arrow- off intake manifold flap motor V157- .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Remove turbocharger air recirculation valve - N249- -1- with housing and hose ⇒ page 138 .

– Loosen clamp -1-.

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– Unscrew bolt -2-. – Remove Rep. gr.

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– Disconnect electrical connector -3-. – Unscrew bolt -4-.

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– Pull air intake pipe off charge air cooler, and remove it down‐ wards. – Unscrew 4 bolts, and remove throttle valve module - J338- . Cleaning throttle valve module - J338Note

♦ Note safety precautions ⇒ page 2 .

♦ Observe rules for cleanliness ⇒ page 4 . ♦ When cleaning the throttle valve housing, take care not to

– Open throttle valve by hand and block open with a suitable object -arrow-.

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Acetone is highly inflammable. Observe accident prevention regulations and safety notes when handling highly inflammable fluids. Do not use compressed air to clean throttle valve. Wear protective goggles and protective clothing to avoid injury and contact with the skin.

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4. Intake manifold

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– Thoroughly clean throttle valve housing, especially around closed throttle valve, using commercially available acetone and a cleaning brush. – Wipe the inside of the throttle valve housing with a lint-free cloth. – Allow acetone to dry off completely. Installing

Install in reverse order of removal, observing the following: – Adapt engine control unit - J623- to throttle valve module ⇒ Vehicle diagnostic tester. Specified torques

♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 147

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Rep. gr.24 - Mixture preparation - injection

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♦ ⇒ “4.1 Assembly overview - intake manifold”, page 157

164

09.2019

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Scirocco 2015 ➤ 4-cylinder injection engine

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition s

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

5

Senders and sensors

⇒ “5.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne sound”, page 165 ⇒ “5.2 Removing and installing air mass meter G70 ”, page 166 ⇒ “5.3 Removing and installing fuel pressure sender G247 ”, page 166 ⇒ “5.4 Checking fuel pressure sender G247 ”, page 167

5.1

Assembly overview - actuator for structure-borne sound and control unit for structure-borne sound

1 - Control unit for structureborne sound - J869❑ Fitting location: in ple‐ num chamber ❑ To remove or install, re‐ move plenum chamber cover ⇒ General body repairs, exterior; Rep. . Volkswagen AG gr. 50 ; Plenum cham‐ gen AG does swa k not l o ber bulkhead; Remov‐ V gu y ara db e ing and installing ple‐ nte is r o eo h num chamber cover ut r

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3 - Nut ❑ 8 Nm

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2 - Bolts ❑ 8 Nm

4 - Bracket ❑ for actuator for struc‐ ture-borne sound R214-

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9 - Bracket ❑ for control unit for structure-borne sound - J869-

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7 - Bolt ❑ 8 Nm

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6 - Bolts ❑ 8 Nm

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5 - Nut ❑ 15 Nm

10 - Nuts ❑ 8 Nm

5. Senders and sensors

165

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

5.2 Removing

Removing and installing air mass meter - G70AG. Volkswagen

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– Release clips -arrows-.

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– Unscrew bolts for air mass meter - G70- . Installing

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– Remove air mass meter - G70- from air filter housing -1-. Install in reverse order of removal, observing the following: Note

If the air filter element is very dirty or wet, dirt or water could reach the air mass meter - G70- and affect the air mass value. This would lead to loss of power, since a smaller injection quantity is calculated.

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– Note installation position of seal ⇒ page 155 .

5.3

Removing and installing fuel pressure sender - G247-

Special tools and workshop equipment required ♦ Assembly tool - T10118-

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Rep. gr.24 - Mixture preparation - injection

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♦ ⇒ “3.1 Assembly overview - air filter housing”, page 154

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Specified torques

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– Check intake port for dirt as far as the air filter element. If con‐ tamination is found, remove salt residues, dirt and leaves from top and bottom part of air filter housing by rinsing out or using a vacuum cleaner if necessary.

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– Check air mass meter and intake hose (engine intake side) for salt residue, soiling and leaves.

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♦ Double hex socket 1/2”, 27mm - VAS

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For reasons of safety, before opening the fuel system, remove fuse for the fuel pump control unit - J538- from the fuse holder. This prevents the fuel pump from being activated by driver door contact switch. Fuse assignment ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

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Fuel supply line is pressurised. Wear protective goggles and protective clothing to avoid injury and contact with the skin. Before loosening hose connections, wrap a cloth around the connection. Release pressure by carefully pulling hose off con‐ nection.

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Observe safety precautions when releasing fuel pressure in the high-pressure system ⇒ page 145

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– Detach coolant pipe and oil dipstick tube from intake manifold -arrows-. – Pull dipstick guide in direction of -arrow- upwards off engine. – Using assembly tool - T10118- , release connector from fuel pressure sender - G247- . – Unscrew fuel pressure sender - G247- using double hexagon socket Unscrew double hexagon socket, 1/2", 27 mm - VAS 5301/7- . Installing Install in reverse order of removal, observing the following: Specified torques ♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 147

5.4

Checking fuel pressure sender - G247-

Special tools and workshop equipment required

5. Senders and sensors

167

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Pressure sensor tester - VAS 6394-

♦ Test adapter - VAS 5570Procedure

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise Unscrew plug -2-. r o eo h t u ra c Screw fuel pressure sender - G247- into testerss-a VAS 6394/1- .

– Remove fuel pressure sender - G247- ⇒ page 166 .

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–

– Moisten tapered seal of adapter - VAS 6294/2- with clean en‐ gine oil and screw into fuel rail.

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Rep. gr.24 - Mixture preparation - injection

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Connect pressure line of tester - VAS 6394/1- to adapter - VAS 6394/2- . – Connect fuel pressure sender -1- and electrical connector of fuel pressure sender using test instrument adapter - VAS 5570- .

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– Reinstall air filter housing, and connect air mass meter - G70- .

5. Senders and sensors

169

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Switch tester - VAS 6394/1- on. Press button -A- once briefly for this. Note ♦ When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.

♦ If the tester - VAS 6394/1- reading is not 0 bar, carry out zero

calibration procedure ⇒ Operating instructions .

– Connect ⇒ Vehicle diagnostic tester to diagnostic connector. – Switch on ignition. – One after other, press following buttons on display of ⇒ Vehicle diagnostic tester: Vehicle self-diagnosis Self-diagnosis ► 01 - Engine electronics ► 011 - Measured values ►

– Select measured value block 1 4 0 and acknowledge with Q. The actual fuel pressure value is shown in display zone 3, meas‐ ured by the fuel pressure sender - G247- . – Start engine. – Compare pressure displayed on tester - VAS 6394/1- with ac‐ tual value displayed on vehicle diagnostic tester . •

A maximum pressure deviation of 5 bar is permissible.

– If the deviation is greater than 5 bar, renew fuel pressure n AG. Volkswagen AG do sender - G247- . e wage

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– Repeat the test with the new fuel pressure sender - G247- and compare both measured values. If measured values again fail to correspond: – Perform line test ⇒ Vehicle diagnostic tester.

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The tester - VAS 6394- is under extreme fuel pressure! With engine running, pull electrical connector off fuel pressure send‐ er - G247- . This reduces fuel pressure to approx. 6 bar. Switch off ignition. Place a cleaning cloth around the fuel pressure sender - G247- , then reduce residual pressure by carefully loosening the fuel pressure sender - G247- .

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

6

Engine (motor) control unit

⇒ “6.1 Removing and installing engine (motor) control unit J623 ”, page 171

6.1

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6.1.1

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s ⇒ “6.1.2 Removing and installing engine (motor) control unit J623 with protective housing”, page 172

Special tools and workshop equipment required ♦ Vehicle diagnostic tester Removing

– Switch on ignition, and select following menu options on⇒ Ve‐ hicle diagnostic tester: ♦ 01 - Engine electronics ♦ Guided Functions ♦ 01 - Renew engine control unit – Switch off ignition.

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– Remove windscreen wiper arms: ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper arms . ht rig py Co t.

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– Remove plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and installing ple‐ num chamber bulkhead . agen lksw Vo by

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– Press retaining frame downwards in direction of -arrow-. – Remove engine control unit - J623- .

6. Engine (motor) control unit

171

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Push catches in direction of -arrow-. – Disconnect electrical connectors: Installing Install in reverse order of removal, observing the following: After a new engine (motor) control unit has been installed, the following work procedure must be carried out: – Switch on ignition, and select following menu options on⇒ Ve‐ hicle diagnostic tester: ♦ 01 - Engine electronics ♦ Guided Functions ♦

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6.1.2

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Special tools and workshop equipment required ♦ Vehicle diagnostic tester Removing

– Switch on ignition, and select following menu options on⇒ Ve‐ hicle diagnostic tester: ♦ 01 - Engine electronics ♦ Guided Functions

♦ 01 - Renew engine control unit – Switch off ignition.

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AG.

– Remove engine control unit - J623- .

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– Press retaining frame downwards in direction of -arrow-.

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– Remove plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and installing ple‐ num chamber bulkhead .

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– Remove windscreen wiper arms: ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper arms .

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– Remove locking bracket.

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– Push catches in direction of -arrow-. – Disconnect electrical connectors: Installing

– Evenly tighten shear bolts until bolt heads shear off.

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♦ Guided Functions

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♦ 01 - Engine electronics

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– Switch on ignition, and select following menu options on⇒ Ve‐ hicle diagnostic tester:

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After a new engine (motor) control unit has been installed, the following work procedure must be carried out:

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Install in reverse order of removal, observing the following:

♦ 01 - Renew engine control unit

6. Engine (motor) control unit

173

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

7

High-pressure pump

⇒ “7.1 Assembly overview - high-pressure pump”, page 174 ⇒ “7.2 Removing and installing high-pressure pump”, page 175

7.1

Assembly overview - high-pressure pump

1 - Plunger ❑ Renew if damaged 2 - O-ring ❑ Renew after removal ❑ Before installing, mois‐ ten lightly with clean en‐ gine oil. 3 - High-pressure pump with fuel pressure regulating valve N276❑ Removing and installing ⇒ page 175 4 - Bolts ❑ 10 Nm 5 - Union nut ❑ When loosening, coun‐ terhold threaded con‐ nection ❑ Before installing, check torque of threaded con‐ nection in high-pressure pump ❑ Install fuel pipe free of tension. ❑ 27 Nm

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6 - High-pressure pipe ❑ Observe safety precau‐ tions when releasing fuel pressure in highpressure system ⇒ page 145

7 - Connecting union ❑ Only renew if loosened. ❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with a »grip edge«. ❑ 30 Nm 8 - Low pressure fuel hose ❑ Secure with spring-type clip.

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Rep. gr.24 - Mixture preparation - injection

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174

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10 - Fuel line ❑ Low pressure

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9 - Banjo bolt with conical sealing seat ❑ Renew after removal ❑ Install fuel pipe free of tension. ❑ When loosening, counterhold threaded connection ❑ 15 Nm

Scirocco 2015 ➤ - Edition 09.2019

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4-cylinder injection

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a (2.0 l engine, turbocharger) Volkswagen R GmbH c engine s s

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11 - Connecting union ❑ Only renew if loosened. ❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with a »grip edge«. ❑ 30 Nm 12 - Threaded connection for high-pressure pipe ❑ Do not loosen threaded connection, only retighten ❑ 40 Nm 13 - Fuel pressure sender for low-pressure - G410❑ 15 Nm 14 - Seal ❑ Renew after removal

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Removing

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Removing and installing high-pressure pump

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7.2

Observe safety precautions when releasing fuel pressure in the high-pressure system ⇒ page 145 Fuel supply line is pressurised. Wear protective goggles and protective clothing to avoid injury and contact with the skin. Before loosening hose connections, wrap a cloth around the connection. Release pressure by carefully pulling hose off con‐ nection. For reasons of safety, before opening the fuel system, remove fuse for the fuel pump control unit - J538- from the fuse holder. This prevents the fuel pump from being activated by driver door contact switch. Fuse assignment ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

Note ♦ Never dismantle the high-pressure pump. ♦ Observe rules for cleanliness ⇒ page 4 . – Remove air filter housing ⇒ page 155 . – Set engine to TDC.

7. High-pressure pump

175

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Disconnect electrical connectors -1 and 2-.

Connections of old high-pressure pumps: – Release both fuel lines from high-pressure pump.

Connections of new high-pressure pumps: – Loosen clamp -1-. – Pull off fuel hose. AG. Volkswagen A

G do gen – Unscrew union nut -3- counterholding lon connection -2- to do es n wa ot g o ks V y so. ua b d r

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Continuation for all versions: – Unscrew bolts -arrows-.

– Carefully pull out high-pressure pump. Note

Under certain circumstances, the plunger ⇒ Item 1 (page 174) may become stuck in the cylinder head. Installing

Install in reverse order of removal, observing the following: – Renew high-pressure pump O-ring and coat slightly with clean engine oil.

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Specified torques

♦ ⇒ “7.1 Assembly overview - high-pressure pump”, page 174

176

Rep. gr.24 - Mixture preparation - injection

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– Check plunger ⇒ Item 1 (page 174) for damage and insert cyl‐ inder head.

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

26 –

Exhaust system

1

Exhaust pipes and silencers

⇒ “1.1 Assembly overview - silencers”, page 177 ⇒ “1.2 Removing and installing front exhaust pipe”, page 179 ⇒ “1.3 Separating exhaust pipes from silencers”, page 180 ⇒ “1.4 Aligning exhaust system free of stress”, page 181 ⇒ “1.5 Installation position of clamp”, page 182 ⇒ “1.6 Checking exhaust system for leaks”, page 182 ⇒ “1.7 Checking exhaust flap”, page 183

1.1

Assembly overview - silencers

1 - Nuts ❑ Renew after removal ❑ 40 Nm 2 - Front exhaust pipe with cat‐ alytic converters Caution

Risk of damage to flexi‐ ble joint. Do ♦ not allow the flexible joint to kink by more than 10°. Install ♦ flexible joint so that it is not under tension. Do ♦ not damage wire mesh on decoupling ele‐ ment.

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3 - Lambda probe after catalyt‐ ic converter - G130❑ Grease only the thread with high-temperature paste - G 052 112 A3- . Do not allow the paste to penetrate into the slots on the probe body. ❑ 55 Nm

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4 - Clamping sleeve ❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 181 ❑ Fitting position ⇒ page 182 ❑ Tighten bolted connections evenly.

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❑ Protect catalytic con‐ verter from damage by knocks and impact ❑ Removing and installing ⇒ page 179 ❑ Aligning exhaust sys‐ tem free of tension ⇒ page 181 .

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1. Exhaust pipes and silencers

177

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 5 - Centre silencer ❑ Centre and rear silencers are one unit as original equipment, but can be renewed separately for repair purposes. ❑ Aligning exhaust system free of tension ⇒ page 181 . ❑ Separate exhaust system ⇒ page 180 6 - Bracket ❑ Riveted onto heat shield 7 - Bolt ❑ 23 Nm 8 - Retainer ❑ Renew if damaged 9 - Rear silencer ❑ Rear silencer and centre silencer are one unit as original equipment, but can be renewed separately for repair purposes. ❑ Aligning exhaust system free of tension ⇒ page 181 . ❑ Separate exhaust system ⇒ page 180 10 - Mounting 11 - Bolt ❑ 23 Nm 12 - Vacuum actuator ❑ Checking ⇒ page 183 13 - Vacuum hose ❑ To vacuum unit ❑ Individual parts of vacuum unit ⇒ page 178

16 - Mounting

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15 - Bolt ❑ 23 Nm

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14 - Nut ❑ 23 Nm

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17 - Seal ❑ Renew after removal

18 - Lambda probe - G39❑ Grease only the thread with high-temperature paste - G 052 112 A3- . Do not allow the paste to penetrate into the slots on the probe body. ❑ 55 Nm Individual parts of vacuum unit

1 - To exhaust flap vacuum unit ⇒ Item 12 (page 178) 2 - Exhaust flap valve - N3213 - Bracket

5 - Coupling point (line to intake manifold)

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Rep. gr.26 - Exhaust system

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178

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Installation location of vacuum unit: in wheel housing at rear left

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4 - Vacuum reservoir

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

1.2

Removing and installing front exhaust pipe

Removing – Remove air filter housing ⇒ page 155 . – Disconnect connector for lambda probe - G39- -arrow-. – Lay wiring harness to one side.

– Unscrew front exhaust pipe/turbocharger nuts -arrows-.

– Unscrew nuts -arrows-. – Pull underbody cover down slightly.

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– Disconnect connector for lambda probe after catalytic con‐ verter - G130- -arrow-. – Lay wiring harness to one side.

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1. Exhaust pipes and silencers

179

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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– Unscrew bolts -arrows-.

– Unscrew nuts -arrows-. – Remove cross member. – Loosen clamp -1- and push to rear. Caution

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Installing

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– Detach front exhaust pipe with catalytic converter. Install in reverse order of removal, observing the following: AG.

Note ♦ Coat studs of turbocharger with high-temperature paste - G

052 112 A3- .

♦ Renew seals, gaskets and self-locking nuts. Align exhaust system free of stress ⇒ page 181 . Specified torques ♦ ⇒ “1.1 Assembly overview - silencers”, page 177

1.3

Separating exhaust pipes from silencers

Special tools and workshop equipment required ♦ Chain-type pipe cutter - VAS 6254-

180

Rep. gr.26 - Exhaust system

do c um en

♦ Do not bend de-coupling elements in front exhaust pipe by more than 10°.

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ or body saw - V.A.G 1523A-

Procedure Note ♦ To allow for individual renewal of the centre and rear silencers,

the connecting pipe has a coupling point.

♦ The coupling point is marked with indentations on the outside

of the exhaust pipe. WARNING

To avoid injury from metal shavings, wear eye protection and protective clothing. – Cut through exhaust pipe at cutting point -arrow 2- using chain pipe cutter - VAS 6254- or body saw - V.A.G 1523A. . Volkswag AG agen

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– Install clamp so that bolt ends do not protrude beyond lower edge of clamp -arrow-. •

Threaded connection faces to rear.

– Aligning exhaust system free of tension ⇒ page 181 . Specified torques

♦ ⇒ “1.1 Assembly overview - silencers”, page 177

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The exhaust system must be aligned when cold.

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Aligning exhaust system free of stress

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1.4

1. Exhaust pipes and silencers

181

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 Procedure – Loosen bolts -3 and 4- on front clamp -1-. – Align front clamp -1- to marking -A- on front exhaust pipe -2(-arrow- points forwards). •

Dimension -a- = 5 mm

•

Do not allow the bolts must be on the right and the ends to protrude beyond the lower edge of the clamp.

– Tighten front clamp bolts -3- hand-tight.

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– Push exhaust system forward until preload on rear silencer retainer is dimension -a- 15…17 mm.

pe rm itte d

– In this position, evenly tighten threaded connections -3 and 4- on front clamp.

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Specified torques

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Installation position of clamps ⇒ page 182 . ♦ ⇒ “1.1 Assembly overview - silencers”, page 177

Installation position of clamp

Installation position of clamp

– Install clamp at angle shown in illustration.

Nuts upwards

1.6

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•

Checking exhaust system for leaks

– Start engine and run it at idling speed. – Seal end exhaust pipes with cloths or plugs, for example, for the duration of the leakage test.

182

Rep. gr.26 - Exhaust system

AG.

Bolted connections to right

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α = approx. 20°

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1.5

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Check (by listening) points of connection between exhaust manifold and the cylinder head, between turbocharger and front exhaust pipe etc. to make sure there are no leaks. – Repair any leaks found.

1.7

Checking exhaust flap

Special tools and workshop equipment required ♦ Hand operated vacuum pump - VAS 6213-

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•

Vacuum pipes and hose connections free of leaks.

•

Vacuum hoses not blocked or porous.

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Test sequence

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– Pull hose off vacuum unit for exhaust flap -A-.

– Connect hand operated vacuum pump - VAS 6213- to vacuum unit -A-.

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1. Exhaust pipes and silencers

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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐ sition -A- for “vacuum”.

183

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Use hand operated vacuum pump - VAS 6213- to generate vacuum and observe linkage. •

Linkage of vacuum unit -1- must move backwards.

– Admit air to hand operated vacuum pump - VAS 6213- . •

Linkage must move forwards.

If the linkage does not move: – Check linkage for freedom of movement and/or check vacuum unit for leaks.

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Rep. gr.26 - Exhaust system

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184

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

2

Emission control

⇒ “2.1 Assembly overview - emission control”, page 185 ⇒ “2.2 Removing and installing catalytic converter”, page 185

2.1

Assembly overview - emission control . Volkswage

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Front exhaust pipe and catalytic converter are combined in one unit ⇒ page 179 .

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2.2

2. Emission control

185

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Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019

28 – 1 ⇒ “1.1

Ignition system

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r Assembly overview - ignition system”, page 186 o h t or u ac a s s Removing and installing ignition coils with output stage”,

Ignition system

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⇒ “1.2 page 186

⇒ “1.3 Test data, spark plugs”, page 188

Assembly overview - ignition system

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1.1

1 - Knock sensor 1 - G61❑ To remove, the coolant thermostat housing must be removed ⇒ page 116 ❑ Gold-plated contacts

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6 - Bolt ❑ 10 Nm 7 - Hall sender - G40❑ Gold-plated contacts 8 - O-ring Component

Specified torque

Engine speed sender - G28-

10 Nm

1.2

Removing and installing ignition coils with output stage

Special tools and workshop equipment required

186

Rep. gr.28 - Ignition system

AG.

5 - Bolt ❑ Specified torque influ‐ ences the function of the knock sensor. ❑ 20 Nm

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4 - Spark plug ❑ Remove and install with spark plug socket and extension - 3122 B❑ Type and electrode gap ⇒ page 188 . ❑ 25 Nm

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3 - Ignition coil with output stage - (N70, N127, N291, N292)❑ Removing and installing ⇒ page 186

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2 - Knock sensor 2 - G66❑ To remove, the oil filter bracket must be re‐ moved ⇒ page 93 ❑ Gold-plated contacts

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 ♦ Puller - T40039-

Removing

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Note

♦ Note safety precautions ⇒ page 1 . ♦ To pull off spark plugs, fit puller - T40039- onto uppermost,

thick rib -arrow- of ignition coils with output stage.

♦ If the lower ribs are used, they could be damaged.

– Disconnect connectors while simultaneously pulling them off in direction of -arrow-.

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– Pull all ignition coils out of spark plug recess using puller T40039- . Installing Installation is carried out in the reverse order. When installing, note the following: Note ♦ When fitting new spark plugs, the ignition coil must be re‐

greased using lubricating paste - G 052 141 A2- This will stop the ignition coil sealing hose from sticking to the spark plug. The lubricating paste must be distributed on the spark plug when inserting on the ignition coil.

♦ New ignition coils with output stage are lubricated when de‐

livered.

♦ The lubricating paste coat must be 1…2 mm thick.

1. Ignition system

187

Scirocco 2015 ➤ 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019 – Apply a thin coat of lubricating paste - G 052 141 A2- around the ignition coil sealing hose -arrow-.

1.3

Test data, spark plugs

Engine code

CDLA and CDLC

Firing order Spark plugs VW/Audi AG. Volkswagen AG d Electrode gap agen oes ksw not l o gu yV Change interval ara db

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Rep. gr.28 - Ignition system

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188

⇒ Electronic parts catalogue (ETKA) 0.7…0.8 mm ⇒ Maintenance ; Booklet ; Service tables ility ab y li an pt ce

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1-3-4-2