VW Golf 4, Jetta - Engine Mechanical, Fuel Injection and Glow Plug - Repair Manual

Service
Repair Manual
Golf 1999 ➤
Jetta 1999 ➤
Jetta Wagon 1999 ➤
Engine Mechanical, Fuel Injection and Glow Plug
Engine ID BEW
Edition 07.2007
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
20 - Fuel Supply
21 - Turbocharger
23 - Diesel Fuel Injection
26 - Exhaust System, Emission Controls
28 - Ignition/Glow Plug System
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Golf 1999 ➤ , Jetta 1999 ➤ , Jetta Wagon 1999 ➤
Engine Mechanical, Fuel Injection and Glow Plug - Edition 07.2007
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Engine, Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Engine and Transmission Mount, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Piston Projection at TDC, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Ribbed Belt and Components Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Toothed Belt and Covers Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Cylinder Block and Components Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Sealing Flange and Drive Plate/Flywheel Assembly Overview . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Piston and Connecting Rod Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Crankshaft Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Piston and Cylinder Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Piston, Rings and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Crankshaft Seal, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4 Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.1 Cylinder Head Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Valvetrain Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Contents i
4.2 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.1 Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3 Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5 Camshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.6 Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.2 Oil Level Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.1 Oil Supply Line Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 Oil Pan and Pump Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.3 Oil Filter Bracket Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2 Engine Oil Capacity and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1 Oil Pressure and Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1 Oil Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.2 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.2 Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.2 Cooling System Components Assembly Overview, Body Side . . . . . . . . . . . . . . . . . . . . . . 87
2.3 Cooling System Components Assembly Overview, Engine Side . . . . . . . . . . . . . . . . . . . . 88
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.1 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 Oil Cooler, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3 Coolant Glow Plug, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.1 Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ii Contents

2.1 Accelerator Mechanism Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.2 Fuel Tank and Attachments Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.3 Fuel Filter Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.1 Fuel Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2 Tandem Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.1 Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.2 Tandem Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.3 Fuel Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.4 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.5 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
21 - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.1 Charge Air Cooler and Components Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.2 Turbocharger and Attachments Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.3 Vacuum Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.1 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.1 Hose Connections with Connector Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

2.1 Component Locations Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Engine Control Module Functions and Components, Adapting . . . . . . . . . . . . . . . . . . . . . . 139
2.3 Intake Manifold Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.4 Pump Injector Unit Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.1 Engine Control Module DTC Memory, Checking and Erasing . . . . . . . . . . . . . . . . . . . . . . 143
4.2 Speed Signal, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.1 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.2 Pump Injector Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.3 Pump Injector Unit O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Contents iii
6.1 Variable Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.1 Front Exhaust Pipe with Catalytic Converter Assembly Overview . . . . . . . . . . . . . . . . . . 155
2.2 Mufflers and Mounts Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.3 EGR System Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.1 Bypass Flap and EGR Cooler, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.2 EGR Vacuum Regulator Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1.1 Visual Characteristics of Ceramic and Metal Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.1 Glow Plug System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.1 Glow Plug, Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.2 Glow Plug, Ceramic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
iv Contents
00 – General, Technical Data

1 General Information
⇒ “1.1 Engine Number“, page 1
1.1 Engine Number

The engine number (engine code and serial number) are located
at the engine/transmission joint -arrow-.
In addition, a sticker with the engine code and serial number is
affixed to the timing belt cover.
The engine code is also included on the vehicle data plate.
The engine number consists of up to nine alphanumeric charac‐
ters. The first part (maximum 3 letters) represents the engine
code, the second (six digit) is the serial number. If more than
999,999 engines with the same engine code are produced, the
first of the six characters is replaced with a letter.
1. General Information 1
2 Specifications
⇒ “2.1 Engine Data“, page 2
2.1 Engine Data

Code letters BEW
Manufactured from 06.03
Emission values in accordance with LEV 1
Displacement liter 1.9
Output kW at RPM 74 at 4000
Torque Nm at RPM 240 at 1800/2400
Bore dia. mm 79.5
Stroke mm 95.5
valves per cylinder 2
Compression ratio 17.5
CZ min. 49
Ignition sequence 1-3-4-2
Catalytic converter yes
Exhaust gas recirculation yes
Turbocharger, G-Charger yes
Charge air cooler yes
Volkswagen Technical Site: http://vwts.ru http://vwts.info
2 Rep. Gr.00 - General, Technical Data

10 – Engine Assembly
⇒ “1.1 Engine, Securing to Assembly Stand“, page 3
⇒ “1.2 Engine and Transmission Mount, Aligning“, page 3
1.1 Engine, Securing to Assembly Stand

Special tools and workshop equipment required
♦ Holding fixture -VW 313-
♦ Engine sling -2024A-
♦ Engine and transmission jack -VAG 1383A-
Secure the engine to the -VW 313- of the assembly stand using
the -VW 540- when performing repair work.
Procedure
– Remove the transmission.
With a Automatic Transmission
– After separating the engine from the transmission, secure the
torque converter to prevent it from falling out.
Continuation for All
– Install the -2024A- as shown and lift the engine from the -
VAG 1383A- using the workshop crane.
Belt pulley side: 2. Bore of the hole rail in position 1
Flywheel side: 4. Bore of the hole rail in position 8
WARNING
Use the securing pins at the hooks and pins.
Note
♦ The peg positions on the -2024A- marked with 1 through 4 face

the belt pulley.
♦ The bores in the hole rail are counted from the hook.
– Secure the engine with the -VW 540 - to the -VW 313- .
Note
Loosen the coolant line on the flywheel side.
1.2 Engine and Transmission Mount, Align‐

ing
♦ Engine support bridge -10-222A-
WARNING
Before loosening the bolts, secure the assembly using the

-10-222A- .
Engine Mount
a = 14.0 mm
b = minimum 10.0 mm
Both bolt heads -1- must be flush with the edge -c-.
Transmission Mount
Edges -a and b- must be parallel to each other.
c = 18 to 20 mm
4 Rep. Gr.10 - Engine Assembly

2 Specifications
⇒ “2.1 Fastener Tightening Specifications“, page 5
2.1 Fastener Tightening Specifications

Component Fastener Size Nm
Bolts and Nuts
M6 10
M8 20
M10 45
M12 60
Engine and Transmission Support -T10012- to Cylinder Block M10 x 25/strength 40
category 8.8
Front Exhaust Pipe to Turbocharger Nut 1 - 25
• 1 Always replace
Right Engine Mount

1- Mount to body 1 40 Nm + 90° (1/4) ad‐
ditional turn
2- Mount bracket to body 25 Nm
3- Mount to engine mount bracket 100 Nm
Left Transmission Mount (with a Manual Transmission)

ditional turn
2- Mount to body 25 Nm
3- Mount to transmission mount 100 Nm
bracket
Left Transmission Mount (with a Automatic Transmission)

ditional turn
2- Mount to body 25 Nm
3- Mount to transmission mount 100 Nm
bracket
2. Specifications 5
Pendulum Support
Installation sequence:
1- Pendulum support to subframe 25 Nm
2- Pendulum support to transmission 50 Nm
3- Pendulum support to transmission 50 Nm

3 Removal and Installation

⇒ “3.1 Engine, Removing“, page 7
⇒ “3.2 Engine, Installing“, page 10
3.1 Engine, Removing

♦ Engine and transmission support -T10012-
♦ Shop crane -VAG 1202A-
♦ Drip tray -VAG 1306-
♦ Torque wrench (5-50 Nm) -VAG 1331-
♦ Spring type clip pliers -V.A.S 5024-
♦ Step ladder -V.A.S 5085-
♦ Grease -G 000 100- (Vehicles with manual transmission)
♦ M10 x 25/8.8 strength category bolt
♦ Cable tie
– The engine is removed downward together with the transmis‐
sion.
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to clearance issues:
♦ Route lines of all types (for example: fuel, hydraulic, Evap‐
orative Emission (EVAP) , coolant, refrigerant, brake or
vacuum) and electrical wires so that the original path is
followed.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.
– All cable ties which are opened or cut off when removing the
engine, must be replaced in the same position when installing
the engine.
– First, check whether a coded radio is installed. If necessary,
obtain the antitheft coding.
– Disconnect the battery ground cable with the ignition switched
off.
– Remove the engine cover. Refer to
⇒ “5.1 Cylinder Head Cover“, page 49 .
– Remove the battery and battery holder.
– Remove the air filter.
– Disconnect the connecting pipe between the charge air cooler
and exhaust pipe at the exhaust pipe.
3. Removal and Installation 7

WARNING
♦ The fuel or fuel lines for the fuel system can become very
hot (danger of scalding)!
♦ In addition, the fuel system is under pressure! Before
opening the system, place a cloth around the connection
and release the pressure by carefully loosening the con‐
nection!
♦ Wear protective goggles and protective gloves when
working on the fuel system!
– Clamp off the fuel supply and return lines at the fuel filter.
With a Manual Transmission 02J
– Remove the slave cylinder. Refer to ⇒ Manual Transmission;
Rep. Gr. 30 ; Description and Operation .
– Disconnect the selector mechanism from the transmission, re‐
fer to ⇒ Manual Transmission; Rep. Gr. 34 ; Removal and
Installation .
– Disconnect the selector lever cable from transmission. Refer
to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and
Installation .
– Remove the noise insulation, along with the left and right
sides. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Description and
Operation .
– Drain the cooling system. Refer to
⇒ “1.2 Draining and Filling“, page 81 .
– Disconnect the electrical connectors from the thermal switch
and the radiator fan.
– Remove the coolant hoses from the radiator.
– Disconnect and lay aside all electrical connectors from the
transmission, alternator, and starter.

– Remove the pendulum support bolts -arrows- in the specified

sequence.
– Remove the front exhaust pipe. Refer to
⇒ “2.1 Front Exhaust Pipe with Catalytic Converter Assembly
Overview “, page 155 .
– Remove the ribbed belt. Refer to
⇒ “5.1 Ribbed Belt“, page 29 .
– Remove the power steering pump from the bracket and lay it
to the side; the hoses remain connected. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 48 ; Description and Oper‐
ation .
– Disconnect all coolant and vacuum connections and discon‐
nect the intake hoses from the engine.
– Disconnect all electrical connections as necessary from en‐
gine and lay the harness aside.
– Remove the right drive axle and disconnect the left drive axle
from the transmission. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Removal and Installation .
– Remove the clamps for the power steering pressure line.
With Air Conditioning (A/C)
WARNING
The air conditioning refrigerant circuit must not be opened.
Note
To prevent damage to the condenser and also to the refrigerant

lines/hoses, ensure that the pipes and hoses are not stretched,
kinked or bent.
To facilitate removal and installation of the engine without having

to open the refrigerant circuit:
– Remove the retaining clamp(s) from the refrigerant lines.
– Remove the A/C compressor. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87 ; Description and Operation .
– Secure the A/C compressor to the tow hook so that the refrig‐
erant lines/hoses are not under a load.
Note
Shield the bumper from damage using adhesive tape.

– Install the -T10012- onto the -VAG 1383A- .

– Install the -T10012- to the cylinder block with a nut and a M10
x 25/ strength category 8.8 bolt and tighten to approximately
40 Nm.
– Lift the engine and transmission slightly using the -
VAG 1383A- .
– Remove the engine mount to engine mount bracket bolts

-arrows- from the top.
Note
Use the -VAS 5085- to remove the bolts.
– Remove the transmission mount to transmission mount brack‐

et bolts -arrows- from above.
– Carefully lower the engine with transmission.
Note
Carefully guide the engine with transmission, when lowering, to

prevent damage to the body.
3.2 Engine, Installing

Installation is performed in the reverse of removal, noting the fol‐
lowing:
– Check the clutch release bearing for wear, replace if neces‐
sary.
– Lightly grease the clutch release bearing, guide sleeve for the
release bearing and the input shaft splines with grease - G 000
100- .
– Check whether the alignment pins for centralizing the engine/
transmission are in the cylinder block, install if necessary.
– When installing the engine/transmission, ensure clearance to
the drive axle.
– Align the engine and transmission mounts. Refer to
⇒ “1.2 Engine and Transmission Mount, Aligning“, page 3 .
Tightening specifications, refer to
⇒ “2.1 Fastener Tightening Specifications“, page 5 .
– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Removal and Installation .

– Install the front exhaust pipe. Refer to

Overview “, page 155 .
With a Manual Transmission 02J
– Install the slave cylinder. Refer to ⇒ Manual Transmission;
– Connect the selector mechanism and, if necessary, adjust the
selector lever cable. Refer to ⇒ Manual Transmission; Rep.
Gr. 34 ; Removal and Installation .
– Install the selector lever cable to the transmission, adjust if
necessary: ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal
and Installation .
– Install the power steering pump. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 48 ; Description and Operation .
– Clamp the connecting pipe between the charge air cooler and
exhaust pipe at exhaust pipe.
– Electrical connections and routing. Refer to ⇒ Electrical
Equipment; Rep. Gr. 97 .
– Install the A/C compressor. Refer to ⇒ Heating, Ventilation Air
Conditioning; Rep. Gr. 87 ; Description and Operation .
– Install the ribbed belt. Refer to
– Install the center noise insulation, along with the left and right
Operation .
– Fill the cooling system. Refer to
– Perform a road test and check the Diagnostic Trouble Code
(DTC) memory. Refer to
⇒ “4.1 Engine Control Module DTC Memory, Checking and
Erasing“, page 143 .
Tightening Specifications
Bolted connections Tightening
specifications
Bolts and Nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
deviation from
Front exhaust pipe to turbocharger 1 25 Nm

4 Special Tools
Special tools and workshop

equipment required
♦ Engine and transmission
support -T10012-
♦ Shop crane -VAG 1202A-


equipment required
♦ Torque wrench (5-50 Nm) -
VAG 1331-
♦ Torque wrench (40-200
Nm) -VAG 1332-
♦ Engine and transmission
jack -VAG 1383A-
♦ Spring type clip pliers -
V.A.S 5024-
♦ Step ladder -V.A.S 5085-
4. Special Tools 13
13 – Crankshaft, Cylinder Block

⇒ “1.1 General Repair Information“, page 14
⇒ “1.2 Piston Projection at TDC, Checking“, page 14
1.1 General Repair Information
Note
If large quantities of metal particles or other deposits (caused, for

example, by partial seizure of the crankshaft or connecting rod
damage) are found in the engine oil, the oil passages must be
cleaned thoroughly and the oil cooler replaced in order to prevent
further damage from reoccurring.
Note
Servicing the clutch. Refer to ⇒ Manual Transmission; Rep. Gr.

30 ; Removal and Installation .
1.2 Piston Projection at TDC, Checking

♦ Measuring bar -VW 382/7-
♦ Magnetic plate 50 mm dia. -VW 385/17-
♦ Dial gauge
Test Sequence
When installing new pistons or working with a partial motor, all of
the pistons must be checked for piston projection at Top Dead
Center (TDC). Depending on the piston projection, install the cor‐
responding cylinder head gasket according to the following table.
Note
To measure the piston projection at TDC, turn the engine in a

clockwise direction.
Piston Projection Identification

Notches/Holes
0.91 to 1.00 mm 1
1.01 to 1.10 mm 2
1.11 to 1.20 mm 3
14 Rep. Gr.13 - Crankshaft, Cylinder Block

Identification of Cylinder Head Gasket

♦ Replacement part number = -arrow 1-
♦ Control code = -arrow 2- (ignore this!)
♦ Holes = -arrow 3-
Note
If varying values occur when measuring the projection, use the

gasket for the largest value.
2 Description and Operation

⇒ “2.1 Ribbed Belt and Components Assembly Overview“,
page 16
⇒ “2.2 Toothed Belt and Covers Assembly Overview“,
page 17
⇒ “2.3 Cylinder Block and Components Assembly Overview“,
page 19
⇒ “2.4 Sealing Flange and Drive Plate/Flywheel Assembly Over‐
view“, page 20
⇒ “2.5 Piston and Connecting Rod Assembly Overview“,
page 21
⇒ “2.6 Crankshaft Assembly Overview“, page 23
2.1 Ribbed Belt and Components Assembly Overview
1 - Ribbed Belt
❑ Mark the direction of ro‐
tation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and instal‐
ling, refer to
⇒ “5.1 Ribbed Belt“,
page 29 .
2 - Bolt, 10 Nm + 90° (1/4) ad‐
ditional turn
3 - Vibration Damper
❑ Only possible to install
in one position - Bores
are offset.
4 - Bolt, 25 Nm
5 - Ribbed Belt Tensioner
❑ To release the tension
on the ribbed belt, pivot
using an open end
wrench. Refer to
⇒ “5.1 Ribbed Belt“,
page 29 .
6 - Generator
7 - Accessory Bracket
❑ For the generator, pow‐
er steering pump and Air
Conditioning (A/C) com‐
pressor.
8 - Bolt, 45 Nm
❑ Observe the tightening
sequence, refer to
⇒ Fig. ““Accessory
Bracket Bolt Tightening Sequence““ , page 17 .
9 - Banjo Bolt, 30 Nm
10 - Seal
❑ Always replace.

11 - Pressure Line
12 - Power Steering Pump
❑ For the power steering.
❑ Removing and installing, refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Description and Op‐
eration .
13 - Power Steering Pump Pulley
Accessory Bracket Bolt Tightening Sequence

Procedure
– Place the accessory bracket on the cylinder block (observe the
fitting sleeve between the bracket and cylinder block).
– Tighten the bracket bolts -A through F- in sequence to 45 Nm
2.2 Toothed Belt and Covers Assembly Overview
1 - Upper Toothed Belt Cover

2 - Toothed Belt
❑ Check for wear.
❑ Do not kink.
ling, tensioning. Refer to
⇒ “5.3 Toothed Belt“,
page 54 .
3 - Nut, 20 Nm + 45° (1/8) ad‐
ditional turn
4 - Tensioning Roller
5 - Bolt, 100 Nm
6 - Bolt, 25 Nm
7 - Camshaft Sprocket
8 - Hub
❑ With sensor wheel.
❑ Use the camshaft gear
counter holder -T10051
- to loosen and tighten.
❑ To remove, use the pull‐
er -T10052- .
ling, refer to
⇒ “5.4 Camshaft“,
page 60 .
9 - Bolt, 10 Nm
❑ Always replace.
2. Description and Operation 17

10 - Rear Toothed Belt Cover

11 - Grommet
❑ Replace if damaged.
12 - Idler Roller
13 - Coolant Pump
❑ Removing and installing, refer to ⇒ “5.2 Coolant Pump“, page 94 .
14 - Crankshaft Toothed Belt Sprocket
15 - Bolt, 120 Nm + 90° (1/4) additional turn
❑ Always replace.
❑ Use the spur belt spreading -3099- to loosen and tighten.
❑ Do not additionally oil or grease the threads or collar.
❑ Additional rotation can occur in several stages.
16 - Bolt, 15 Nm
17 - Nut, 20 Nm
18 - Lower Toothed Belt Cover
19 - Belt Pulley/Vibration Damper
❑ Only possible to install in one position - Bores are offset.
21 - Cover
22 - Center Toothed Belt Cover
23 - Bolt, 45 Nm
24 - Engine Mount Bracket

2.3 Cylinder Block and Components Assembly Overview
1 - Cylinder Block
❑ Sealing flanges and
drive plate/flywheel as‐
sembly overview. Refer
to
⇒ “2.4 Sealing Flange
and Drive Plate/Fly‐
wheel Assembly Over‐
view“, page 20 .
❑ Crankshaft assembly
overview. Refer to
⇒ “2.6 Crankshaft As‐
sembly Overview“, page
23 .
❑ Piston and connecting
rod assembly overview.
Refer to
23 .
2 - Bolt, 3.5 Nm
3 - Bracket
❑ for the vacuum reser‐
voir.
4 - Vacuum Reservoir
5 - Bolt, 15 Nm
6 - Gasket
❑ Always replace.
7 - Oil Filter Bracket
❑ Disassembling and as‐
sembling, refer to
⇒ “2.3 Oil Filter Bracket
Assembly Overview“,
page 73 .
❑ Always replace.
❑ First, tighten the upper left and lower right bolts, and then tighten all four bolts in a diagonal sequence.
9 - Bolt, 15 Nm
10 - Engine Speed (RPM) Sensor -G28-
11 - Connecting Piece
❑ For the thermostat.
12 - O-ring
❑ Always replace.
13 - Coolant Thermostat
❑ Removing and installing, refer to ⇒ “5.1 Coolant Thermostat“, page 94 .
❑ Observe the installed location, refer to ⇒ “5.1 Coolant Thermostat“, page 94 .
❑ Checking: Heat up thermostat in water.
❑ Opening begins approximately 85 °C (185 °F).
❑ Ends approximately 105 °C (221 °F).
❑ Opening lift min. 7 mm.

14 - Bolt, 45 Nm
❑ Observe the tightening sequence, refer to
⇒ Fig. ““Accessory Bracket Bolt Tightening Sequence““ , page 17 .
15 - Accessory Bracket
❑ For the generator, power steering pump and Air Conditioning (A/C) compressor.
16 - Oil Pan
❑ Clean the sealing surface before installing.
❑ Install using silicone sealant -D 176 404 A2 - . Refer to ⇒ “5.2 Oil Pan“, page 78 .
2.4 Sealing Flange and Drive Plate/Flywheel Assembly Overview
1 - Seal
❑ Do not additionally oil or
grease the sealing lip of
the seal.
❑ Before installing, re‐
move any remaining oil
from the crankshaft jour‐
nal with a clean cloth.
❑ Crankshaft seal, belt
pulley side, replacing.
Refer to
⇒ “5.3 Crankshaft Seal,
Belt Pulley Side“,
page 32 .
2 - Sealing Flange
❑ Must be located on the
alignment pins.
ling, refer to
⇒ “5.2 Sealing Flange,
page 30 .
❑ Install using silicone
sealant -D 176 404 A2 - .
Refer to
page 30 .
3 - Cylinder Block
❑ Crankshaft assembly
overview. Refer to
23 .
❑ Piston and connecting
rod assembly overview.
Refer to
⇒ “2.6 Crankshaft Assembly Overview“, page 23 .
4 - Drive Plate/Flywheel
❑ To remove and install flywheel, secure using the flywheel retainer -3067- .
❑ Drive plate removing and installing, refer to ⇒ “5.4 Drive Plate“, page 33 .
❑ Always replace.

6 - Intermediate Plate
❑ Must be located on the alignment pins.
❑ Do not damage or bend when doing assembly work.
7 - Bolt, 15 Nm
8 - Sealing Flange with Seal
❑ Only replaced as a complete unit.
❑ Do not additionally oil or grease the sealing lip of the seal.
❑ Before installing, remove any remaining oil from the crankshaft journal with a clean cloth.
❑ To install, use the provided support sleeve.
❑ Support sleeve may only be removed after the sealing flange has been slid onto the crankshaft end.
2.5 Piston and Connecting Rod Assembly Overview
1 - Piston Rings
❑ Offset gaps by 120 de‐
grees.
❑ Position the oil scraping
ring offset gaps closely
in the wound area of the
spring.
❑ Use the piston ring pli‐
ers for removal and in‐
stallation.
❑ “TOP“ faces toward the
piston crown.
❑ Checking ring gap, refer
to ⇒ page 27 .
❑ Check the piston ring
groove clearance, refer
to ⇒ page 27 .
2 - Piston
❑ With combustion cham‐
ber.
❑ Mark the installed posi‐
tion and cylinder alloca‐
tion.
❑ Installed position and al‐
location, piston/cylin‐
der. Refer to
⇒ page 28 .
❑ Arrow on piston face
points toward the belt
pulley side.
❑ Install with a piston ring
compressor.
❑ If cracked, replace the
piston at the piston pin.
❑ Checking the piston po‐
sition at Top Dead Center (TDC). Refer to ⇒ “1.2 Piston Projection at TDC, Checking“, page 14 .
3 - Piston Pin
❑ If the piston is difficult to move, heat it to 60 °C (140 °F).
❑ Remove and install using the pilot drift -VW 222A- .

4 - Circlip
5 - Connecting Rod
❑ Mark the allocation to the cylinder using a colored mark -A-.
❑ Installed position: Markings -B- point to the belt pulley side.
❑ With cracked bearing cap.
6 - Bearing Shell
❑ Note the installed position.
❑ Note version: Upper bearing shell (to piston) made of wear resistant material, identification: Black line
on contact surface in area of separating point.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells in center.
❑ Ensure seated tightly.
❑ Axial play wear limit: 0.37 mm.
❑ Measure radial clearance with Plastigage: Wear limit: 0.08 mm. Do not turn crankshaft when checking
radial clearance.
7 - Cylinder Block
❑ Cylinder bore, checking. Refer to ⇒ page 27 .
❑ Piston and cylinder dimensions. Refer to ⇒ “3.2 Piston and Cylinder Dimensions“, page 26 .
8 - Connecting Rod Bearing Cap
❑ Due to the separation procedure (cracking) of the connecting rod, the cap only fits in one position and
only to the corresponding connecting rod.
9 - Oil Spray Jet
❑ For piston cooling.
10 - Bolt, 25 Nm
❑ Install without sealant.
❑ Always replace.
❑ Lubricate the threads and contact surface.
❑ Use the old bolts to measure radial play.

2.6 Crankshaft Assembly Overview
1 - Bearing Shells 1, 2, 4 and 5

❑ For the bearing cap
without a oil groove.
❑ For the cylinder block
with a oil groove.
❑ Do not interchange
used bearing shells
(mark).
2 - Bolt, 65 Nm + 90° (1/4) ad‐
ditional turn
❑ Always replace.
❑ Tighten to 65 Nm to
measure radial play, do
not turn further.
3 - Crankshaft Bearing Cap
❑ Bearing cap 1: Belt pul‐
ley side.
❑ Bearing cap 3 with
notches for the thrust
washers.
❑ Retaining tabs of the
bearing shells and cylin‐
der block/bearing caps
must lie above one an‐
other.
4 - Bearing Shell 3
❑ For bearing cap without
a oil groove.
❑ For cylinder block with a
oil groove.
5 - Thrust Washer
❑ For bearing cap 3.
❑ Observe the locating
point.
6 - Sensor Wheel
❑ For the engine speed (RPM) sensor.
❑ replace the sensor wheel every time the bolts are loosened.
❑ Removing and installing, refer to ⇒ Fig. ““Sensor Wheel, Removing and Installing““ , page 24 .
❑ Always replace.
8 - Alignment Pin
❑ Check the projection from the crankshaft. Refer to
⇒ Fig. ““Check Projection of Alignment Pin from Crankshaft““ , page 24 .
9 - Crankshaft
❑ Axial play new: 0.07 to 0.17 mm, Wear limit: 0.37 mm.
❑ Check radial clearance with Plastigage 0.03 to 0.08 mm Wear limit: 0.17 mm.
❑ Do not turn the crankshaft when measuring radial play.
❑ Crankshaft dimensions, refer to ⇒ “3.3 Crankshaft Dimensions“, page 26 .

10 - Thrust Washer
❑ For the cylinder block, bearing 3.
Check Projection of Alignment Pin from Crankshaft

♦ Depth gauge
Test Sequence
– Check the projection -a- of the alignment pin with the sensor
wheel -1- removed, using a depth gauge.
1- Sensor wheel
2- Bolt
3- Fitting pin projection -3- from crankshaft a = 2.5 to 3.0 mm
Sensor Wheel, Removing and Installing
– Always replace the sensor wheel -2- whenever the bolts are
removed -1-. Tightening specification: 10 Nm + 90° (1/4) ad‐
ditional turn.
Note
After tightening a second time, the attachment point of the coun‐

tersunk screws of the sensor wheel are so deformed that the
screw heads lie on the crankshaft -3- -arrows- and the sensor
wheel is loose underneath the screws.

3 Specifications
⇒ “3.2 Piston and Cylinder Dimensions“, page 26
⇒ “3.3 Crankshaft Dimensions“, page 26

Camshaft Hub to Camshaft Bolt - 100
Camshaft Sprocket to Hub Bolt - 25
Center Toothed Belt Cover Bolt 1 - 10
Crankshaft Bearing Cap Bolt 1 - 65 + 90° turn
Connecting Piece to Cylinder Block Bolt - 15
Connecting Rod Bearing Cap Bolt 1 - 30 + 90° turn
Coolant Pump to Cylinder Block Bolt - 15
Crankshaft Toothed Belt Sprocket to Crankshaft Bolt 1 - 120 + 90° turn
Drive Plate/Flywheel Bolt 1 - 60 + 90° turn
Engine Mount Bracket to Cylinder Block Bolt - 45
Engine Speed Sensor Bolt - 15
Generator to Accessory Bracket Bolt - 25
Idler Roller to Cylinder Block Stud Nut - 20
Lower Toothed Belt Cover to Cylinder Block Bolt 1 - 10
Oil Filter Bracket to Cylinder Block Bolt 1 - 15 + 90° turn
Oil Pan Bolt - 15
Oil Spray Jet Bolt - 25
Power Steering Pump to Accessory Bracket Bolt - 25
Power Steering Pump Pressure Line Banjo Bolt - 30
Power Steering Pump Pulley to Power Steering Pump Bolt - 25
Rear Toothed Belt Cover to Cylinder Head Bolt - 25
Ribbed Belt Tensioner to Accessory Bracket Bolt - 25
Sealing Flange to Cylinder Block Bolt - 15
Toothed Belt Tensioning Roller to Cylinder Head Stud Nut - 20 + 45° turn
Upper Toothed Belt Cover Bolt 1 - 10
Vacuum Reservoir to Bracket Bolt - 3.5
Vacuum Reservoir Bracket to Cylinder Block Bolt - 15
Vibration Damper/Belt Pulley to Crankshaft Toothed Belt Sprocket - 10 + 90° turn
Bolt
3. Specifications 25
Accessory Bracket Bolt Tightening Sequence and Specification

– Tighten the bracket bolts -A through F- in sequence to 45 Nm.
3.2 Piston and Cylinder Dimensions

Honing dimension Piston diameter Cylinder bore di‐
ameter
Basic dimension mm 79.47 79.51
1st oversize mm 79.72 79.76
2nd oversize mm 79.97 80.01
3.3 Crankshaft Dimensions

Reconditioning Crankshaft bearing Connecting rod
dimension, di‐ pins - diameter bearing
mensions in mm pins - diameter
Basic dimension -0.022 -0.022
54.00 47.80
-0.042 -0.042
1st oversize -0.022 -0.022
53.75 47.55
-0.042 -0.042
2nd oversize -0.022 -0.022
53.50 47.30
-0.042 -0.042
3rd oversize -0.022 -0.022
53.25 47.05
-0.042 -0.042

4 Diagnosis and Testing

⇒ “4.1 Piston, Rings and Cylinder Bore, Checking“, page 27
4.1 Piston, Rings and Cylinder Bore, Check‐

ing
Piston Ring Gap, Checking
♦ Feeler gauges
Test Sequence
– Install the ring into the lower cylinder bore at a right angle from
above, approximately 15 mm from the cylinder edge.
– Determine the ring gap using the feeler gauge.
Piston ring New Wear limit
dimensions in mm
1. Compression ring 0.20 to 0.40 1.0
Oil scraping ring 0.25 to 0.50 1.0
Piston Ring Groove Clearance, Checking

♦ Feeler gauge
Test Sequence
– Before measuring, clean the ring groove.
– Determine the ring to groove clearance using the feeler gauge.
Piston ring New Wear limit
dimensions in mm
Oil scraping ring 0.03 to 0.06 0.15
Cylinder Bore, Checking

♦ Internal dial gauge 50 to 100 mm
4. Diagnosis and Testing 27

Test Sequence
– Measure diagonally at 3 positions transversely -A- and longi‐
tudinally -B-.
Deviation from nominal size: Max. 0.10 mm.
Note
Cylinder bore must not be measured if cylinder block is secured

to the engine stand with holding fixture -VW 540 - , or else results
may be incorrect.
Installed Position of Piston and Piston/Cylinder Allocation
Pistons in cylinder 1 and 2:

Large valve pocket for the intake valve toward the flywheel side
-arrows-
Pistons in cylinder 3 and 4:
Large valve pocket for the intake valve toward the belt pulley side
-arrows-
Note
♦ On new pistons, the cylinder allocation is stamped on the pis‐

ton face in paint.
♦ Pistons for cylinder 1 and 2: identification 1/2.
♦ Pistons for cylinder 3 and 4: identification 3/4.


⇒ “5.1 Ribbed Belt“, page 29
⇒ “5.2 Sealing Flange, Belt Pulley Side“, page 30
⇒ “5.3 Crankshaft Seal, Belt Pulley Side“, page 32
⇒ “5.4 Drive Plate“, page 33
5.1 Ribbed Belt

♦ Release tool -T10060A-
Removing
– Remove the right noise insulation. Refer to ⇒ Body Exterior;
– Mark the direction of rotation of the ribbed belt.
– Move the tensioner in the -direction of the arrow - to release
the tension on the ribbed belt.
– Secure the tensioner using the -T10060A- .

– Remove the ribbed belt.
Installing
– Installation is performed in reverse order.
Note
♦ Ensure, before installing the ribbed belt, that all ancillaries (al‐
ternator, Air Conditioning (A/C) compressor, power steering
pump) are secured tightly.
♦ Note the previously marked direction of belt rotation and be
sure that it is seated correctly on pulley.
♦ In vehicles without A/C, install the ribbed belt last on the gen‐
erator.
♦ In vehicles with A/C, install the ribbed belt last on the A/C
compressor.
After completing repairs always:

– Start the engine and check the belt running.

Belt routing without A/C.
Belt routing with A/C.
5.2 Sealing Flange, Belt Pulley Side

♦ Spur belt spreading -3099-
♦ Assembly tool -T10053-
♦ Hand drill with plastic brush attachment
♦ Silicone sealant -D 176 404 A2-
♦ Flat scraper
Removing
– Remove the toothed belt. Refer to
⇒ “5.3 Toothed Belt“, page 54 .

– Remove the crankshaft toothed belt sprocket. To do this, lock

the toothed belt sprocket using the -3099- .
Note
When installing the -3099- , place two washers between the

toothed belt sprocket and -3099- .
– Drain the engine oil.

– Remove the oil pan. Refer to ⇒ “5.2 Oil Pan“, page 78 .
– Remove the front sealing flange bolts.
– Remove the sealing flange, and if necessary loosen it by ap‐
plying light strikes from a rubber hammer.
– Remove any sealant residue from the cylinder block with a flat
scraper.
– Remove any sealant residue from the sealing flange using a

rotating plastic brush (wear safety glasses).
– Clean the sealing surfaces. They must be free of oil and
grease.
Installing
Note
♦ Note the expiration date of the sealing compound.

♦ The sealing flange must be installed within 5 minutes after ap‐
plication of silicone sealant.
– Before installing, remove any remaining oil from the end of the
crankshaft with a clean cloth.
– Cut off the nozzle on the tube of sealant at the front mark (di‐
ameter of nozzle approximately 3 mm).
Note
♦ The sealing compound bead must not be thicker than 2 to 3

mm, otherwise excess sealing compound could enter the oil
pan and may block the oil suction pipe strainer. Likewise, it
could drip onto the sealing surface of the crankshaft seal.
♦ Before applying the bead of sealant, cover the sealing surface
of the seal with a clean cloth.

– Apply the silicone sealant as illustrated to the clean sealing

surface of the sealing flange.
– Set the sealing flange in place immediately and lightly tighten
the bolts.
Note
To position the sealing flange with seal installed, use the -

T10053/1- .
– Tighten the sealing flange bolts in a diagonal sequence. Tight‐

ening specification: 15 Nm.
– Install the oil pan. Refer to ⇒ “5.2 Oil Pan“, page 78 .
Note
After installing, allow the sealant to dry for approximately 30 mi‐

nutes. Only after then may the engine oil be added.
Install the toothed belt and adjust the valve timing. Refer to
5.3 Crankshaft Seal, Belt Pulley Side

♦ Seal remover -3203-
Removing
– Remove the crankshaft toothed belt sprocket. To do this, lock
the toothed belt sprocket using the -3099- .
Note
When installing the -3099- , place two washers between the

toothed belt sprocket and -3099- .
– To guide the -3203- , thread a central bolt into the crankshaft

by hand until the stop.
– Loose the inner portion of the -3203- two rotations (approxi‐
mately 3 mm) from the outer portion and lock it with the knurled
screw.

– Lubricate the threaded head of the -3203- , position and with

forced pressure, screw it into the oil seal as far as possible.
– Loosen the knurled screw and turn the inner portion against
the crankshaft until the oil seal is pulled out.
Installing
Note
The sealing lip of the seal may not be additionally oiled or

greased.
– Before installing, remove any remaining oil from the end of the
crankshaft with a clean cloth.
– Position the -T10053/1- on the end of the crankshaft.

– Slide the oil seal over the -T10053/1- onto the crankshaft end.
– Install the seal with -T10053- and -T10053/2 - (M16 x 1.5 x

60), in up to the stop.
– Install the toothed belt. Refer to
5.4 Drive Plate

♦ Flywheel lock adapter -VW 558-
♦ M8 x 45 bolt and two M10 nuts
♦ Depth gauge
Removing
– Secure the -VW 558- to the drive plate with a M8 x 45 bolt.
Install two M10 nuts between the -VW 558- and the drive plate.

Installed location of the -VW 558- : A - to loosen

– Loosen the drive plate bolts.
– Remove the -VW 558- .
– Remove the bolts and remove the drive plate.
Installing
– Set drive plate in place, using the washer with notches -1-.
– Install the -VW 558- to the drive plate with a M8 x 45 bolt. Install
two M10 nuts between the -VW 558- and the drive plate.
Installed location of the -VW 558- : B - to fasten

– Install new bolts -3- and tighten to 30 Nm.
– Check the dimension -a- an three points and calculate the

mean value. Specified value: 19.5 to 21.1 mm
Note
This is measured through the hole in the drive plate to the ma‐
chined surface of the cylinder block.
If the specification is not obtained:

– Remove the drive plate again and install the shim -2-. Tighten
the bolts -3- again to 30 Nm.
– Tighten the bolts -3- to 60 Nm and turn an additional 90° (1/4
rotation, additional rotation may occur in several stages).

6 Special Tools
♦ Measuring bar -VW 382/7-
♦ Magnetic plate 50 mm dia. -VW 385/17-
♦ Release tool -T10060A-
♦ Flywheel lock adapter -VW 558-


equipment required
♦ Seal remover -3203-
VAG 1331-
Nm) -VAG 1332-
6. Special Tools 37
15 – Cylinder Head, Valvetrain

Note
♦ When using an exchanged cylinder head with camshaft in‐

stalled, the contact surfaces between the lifters and cam lobes
must be lubricated before installing the cylinder head cover.
♦ The plastic protectors installed to protect the open valves must
only be removed immediately before installing the cylinder
head.
♦ When the cylinder head is replaced, the coolant must also be
replaced.
Note
♦ Cylinder heads with cracks between the valve seats can con‐
tinue to be used without reducing service life, as long as the
cracks have a Max. width of 0.5 mm.
♦ Do not regrind the valve seats, only lapping the valves is per‐
mitted.
38 Rep. Gr.15 - Cylinder Head, Valvetrain


⇒ “2.1 Cylinder Head Assembly Overview“, page 39
⇒ “2.2 Valvetrain Assembly Overview“, page 42
2.1 Cylinder Head Assembly Overview
1 - Upper Toothed Belt Cover

2 - Toothed Belt
❑ Check for wear.
❑ Do not kink.
ling, tensioning. Refer to
⇒ “5.3 Toothed Belt“,
page 54 .
3 - Bolt, 10 Nm
❑ Always replace.
4 - Bolt, 25 Nm
5 - Bolt, 100 Nm
6 - Camshaft Sprocket
7 - Hub
❑ With sensor wheel.
❑ Use the camshaft gear
counter holder -T10051
- to loosen and tighten.
❑ To remove, use the pull‐
er -T10052- .
ling, refer to
page 60 .
8 - Rear Toothed Belt Cover
9 - Grommet
10 - Camshaft Position (CMP)
Sensor -G40-
❑ For camshaft position.
❑ To remove, remove the grommet -item 9- from the rear toothed belt cover.
11 - Bolt
❑ Observe the sequence for loosening and tightening, refer to ⇒ “5.2 Cylinder Head“, page 50 .
❑ Place the washers -item 4- in the ⇒ “2.2 Valvetrain Assembly Overview“, page 42 , in the cylinder head
before installing.
12 - Cylinder Head Cover
❑ Always clean the sealing surfaces of the cylinder head with a clean cloth before setting in place.
13 - Pressure Regulator Valve
❑ For crankcase ventilation.

14 - to Turbocharger
15 - Cap
❑ Replace gaskets if damaged.
16 - Sealing Sleeve
17 - Bolt, 10 Nm
❑ Observe the tightening sequence. Refer to ⇒ “5.1 Cylinder Head Cover“, page 49 .
18 - Cylinder Head Cover Gasket
❑ Before installing, seal the contact surfaces with sealant -AMV 174 004 01- . Refer to
❑ Only replace together with the cylinder head cover.
19 - Bolt, 20 Nm
20 - Lifting Eye
21 - Pump Injector Unit
❑ Removing and installing, refer to ⇒ “5.2 Pump Injector Unit“, page 145 .
22 - Bolt, 10 Nm
23 - Central Harness Connector
❑ For the pump injector unit.
24 - from Brake Booster
25 - Tandem Pump
❑ For the fuel and vacuum supply.
❑ Checking, refer to ⇒ “4.2 Tandem Pump, Checking“, page 108 .
❑ Removing and installing, refer to ⇒ “5.2 Tandem Pump“, page 111 .
26 - Supply Hose
❑ From the fuel filter.
❑ White or with white markings.
❑ Ensure hose is securely seated.
❑ Secure with spring type clips.
27 - Return Hose
❑ To the fuel filter.
❑ Blue or with blue marking.
❑ Ensure hose is securely seated.
28 - Gasket
❑ Always replace.
29 - Bolt
30 - Cylinder Head
❑ Removing and installing, refer to ⇒ “5.2 Cylinder Head“, page 50 .
❑ After replacing, replace the entire amount of coolant.
31 - Cylinder Head Gasket
❑ Always replace.
❑ Identification, refer to ⇒ Fig. ““Cylinder Head Gasket Identification““ , page 41 .
❑ After replacing, replace the entire amount of coolant.
32 - Glow Plug, 15 Nm
❑ Checking, refer to ⇒ “4.1 Glow Plug, Metal“, page 167 .

33 - Tensioning Roller
34 - Nut, 20 Nm + 45° (1/8) additional turn
Checking Cylinder Head for Distortion
Note
Before installing an already mounted cylinder head, check the

sealing surface for evenness.

♦ Straight edge
♦ Feeler gauge
– Place the straight edge, in both directions one after the other,
diagonally over the sealing surface and check for distortion
using the feeler gauges.
Max. permissible distortion: 0.1 mm
Note
Remanufacturing diesel cylinder heads is not permitted.
Cylinder Head Gasket Identification

♦ Replacement part number = -arrow 1-
♦ Control code = -arrow 2- (ignore this!)
♦ Holes = -arrow 3-
Note
Depending on piston projection, varying cylinder head gasket

thicknesses can be installed. When replacing a head gasket, in‐
stall a head gasket with the same identification.

2.2 Valvetrain Assembly Overview
1 - Bolt, 20 Nm + 90° (1/4) ad‐

ditional turn
❑ Always replace
❑ Observe the sequence
for loosening and tight‐
ening. Refer to
page 60 .
2 - Rocker Lever Shafts
❑ Do not interchange.
3 - Bolt
❑ Observe the sequence
for loosening and tight‐
ening. Refer to
⇒ “5.2 Cylinder Head“,
page 50 .
❑ Before installing, install
the washers -item 4- into
the cylinder head.
4 - Washer
❑ For the cylinder head
bolts
❑ Insert into the cylinder
head before assembling
the bearing caps.
5 - Valve Lifter
❑ Do not interchange.
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Place on running sur‐
face when setting down.
❑ Before installing, check
the axial play of the
camshafts. Refer to ⇒ Fig. ““Camshaft, Checking Axial Play““ , page 43 .
❑ Lubricate the contact surface.
❑ Before removing, remove the bearing caps for the camshaft.
6 - Valve Retainers
7 - Valve Spring Plate
8 - Outer Valve Spring
❑ Removing and installing: Cylinder head removed: Installed with valve spring compressor -2037- . Refer
to ⇒ “5.6 Valve Stem Seals“, page 64 .
9 - Inner Valve Spring
❑ Removing and installing: Cylinder head removed: Installed with valve spring compressor -2037- . Refer
to ⇒ “5.6 Valve Stem Seals“, page 64 .
10 - Valve Stem Seal
❑ Replacing, refer to ⇒ “5.6 Valve Stem Seals“, page 64 .
11 - Valve Guide
❑ Checking, refer to ⇒ “4.2 Valve Guides, Checking“, page 48 .
❑ Removing and installing, refer to ⇒ “5.2 Pump Injector Unit“, page 145 .

13 - Cylinder Head
❑ See notes in ⇒ “1.1 General Repair Information“, page 38 .
14 - Seal
❑ Do not additionally oil or grease the sealing lip of the seal.
❑ Before installing, remove any remaining oil from the camshaft journal with a clean cloth.
❑ To install, tape over the groove on the end of the camshaft with adhesive strip (for example, scotch tape).
❑ Removing and installing, refer to ⇒ “5.5 Camshaft Seal“, page 63 .
15 - Valves
❑ Valve dimensions, refer to ⇒ Fig. ““Valve Dimensions““ , page 44 .
16 - Bearing Shell
❑ Do not interchange used bearing shells (mark).
❑ Make sure retaining tabs are engaged properly in the bearing caps and cylinder head.
17 - Camshaft
❑ Checking axial play, refer to ⇒ Fig. ““Camshaft, Checking Axial Play““ , page 43 .
❑ Removing and installing, refer to ⇒ “5.4 Camshaft“, page 60 .
❑ Checking radial clearance with Plastigage, Wear limit: 0.11 mm.
❑ Run out: Max. 0.04 mm.
18 - Bearing Cap
❑ Installation sequence, refer to ⇒ “5.4 Camshaft“, page 60 .
❑ When installing, coat the separating surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- .
Refer to ⇒ Fig. ““Sealing Separating Surfaces of Bearing Caps 1 and 5““ , page 44 .
❑ Always replace.
Camshaft, Checking Axial Play

♦ Dial gauge holder -VW 387-
♦ Dial gauge
Test Sequence
Measure with valve lifters removed and with first, third and last
bearing caps installed.

Wear limit: Max. 0.15 mm

Sealing Separating Surfaces of Bearing Caps 1 and 5
– Coat the surfaces -1- lightly and evenly with sealant -AMV 174
004 01- .
Note
Make sure that no sealant enters the grooves -arrows-.
Valve Dimensions
Note
Valves must not be reworked. Only lapping is permitted.
Dimension Intake valve Exhaust valve

Diameter a mm 35.95 31.45
Diameter b mm 6.980 6.956
c mm 89.95 89.95
α ° angle 45 45

3 Specifications

Camshaft Hub to Camshaft Bolt - 100
Camshaft Position (CMP) Sensor Bolt 1 - 10
Camshaft Sprocket to Hub Bolt - 25
Central Harness Connector Bolt - 10
Engine Mount to Engine Mount bracket Bolt - 100
Engine Mount Bracket to Bracket/Body Bolt - 25
Engine Mount to Longitudinal Member Bolt 1
M8 20 + 90° turn
M10 40 + 90° turn
Glow Plug - 15
Lifting Eye to Cylinder Head Bolt - 20
Rear Toothed Belt Cover to Cylinder Head Bolt - 20
Ribbed Belt Tension to Accessory Bracket Bolt - 25
Tandem Pump Bolt
– Upper - 20
– Lower - 10
Toothed Belt Tensioning Roller to Cylinder Head Stud Nut - 20 + 45° turn
Upper Toothed Belt Cover Bolt 1 - 10
Vibration Damper/Belt Pulley to Crankshaft Toothed Belt Sprocket - 10 + 90° turn
Bolt
Cylinder Head Cover Bolt Tightening Sequence and Specification

– Tighten the bolts in the sequence shown -1 through 13- to 10
Nm.
Volkswagen Technical Site: http://vwts.ru http://vwts.info 3. Specifications 45

Cylinder Head Bolt Tightening Sequence and Specification

1- Tighten using a torque wrench
Stage 1 = 40 Nm
Stage 2 = 60 Nm
2- Tighten further using a ratchet
Stage 3 = 90° (1/4) additional turn
Camshaft Bearing Cap Bolt Tightening Sequence and Specifica‐

tion
– Install the bearing caps 2 and 4 with new bolts, and tighten to
8 Nm + 90° (1/4) additional turn, alternating in a diagonal se‐
quence.
– Install the bearing caps 5, 1 and 3 with new bolts, and tighten
to 8 Nm + 90° (1/4) additional turn, alternating in a diagonal
sequence.
Rocker Lever Shaft Bolt Tightening Sequence and Specification

– Install the rocker lever shafts and first, tighten the new inner
bolts -II- and then the outer bolts-I- evenly in a diagonal se‐
quence to 20 Nm + 90° (1/4) additional turn.


⇒ “4.1 Compression, Checking“, page 47
⇒ “4.2 Valve Guides, Checking“, page 48
4.1 Compression, Checking
Note
If ceramic sheathed element glow plugs are installed, check the

idle stabilization control before removing the glow plugs, refer to
vehicle diagnosis, testing and information system -VAS 5051- .
Only if one or more cylinder(s) is/are noticeable at this point is the
compression test warranted.

♦ Hinged socket -3220-
♦ Adapter -VAG 1381/12-
♦ Compression tester -VAG 1763-
Test conditions
• Engine oil temperature min. 30 °C (86 °F).
Test Sequence
– Disconnect the central electrical connector -1- for the pump
injector unit.
Note
If ceramic sheathed element glow plugs are installed, always fol‐

low the information for removing and installing them. Refer to
⇒ “4.2 Glow Plug, Ceramic“, page 167 .
– Disconnect the connector strip -2- from the glow plugs.

– Remove all the glow plugs -3- using the -3220- .

– Install the -VAG 1381/12- in place of the glow plugs.

– Check the compression pressure using the -VAG 1763- .
Note
Using tester, refer to ⇒ operating instructions .
– Operate the starter until the tester shows no further pressure

increase.
Compression Pressure
♦ New: 25 to 0.31 bar pressure
♦ Wear limit: 19 bar pressure
♦ Permissible difference between all cylinders: 5 bar
Note
If ceramic sheathed element glow plugs are installed, always fol‐

low the information for removing and installing them. Refer to
⇒ “4.2 Glow Plug, Ceramic“, page 167 .
– Install the glow plugs using the -3220- . Tightening specifica‐

tion: 15 Nm.
– Check the Diagnostic Trouble Code (DTC) memory. Refer to
Note
By disconnecting the central connection for the pump injector unit,

DTCs will be stored. Query the fault memory and erase, if nec‐
essary.
4.2 Valve Guides, Checking

♦ Dial gauge
Test Sequence
– Install the new valve into the guide. The end of the valve stem
must be flush with the guide. Due to the slight difference in
stem dimensions, ensure that only an intake valve is used in
the intake guide and an exhaust valve in the exhaust guide.
– Determine tilt clearance. Wear limit: Max. 1.3 mm
– If the tilt clearance exceeds the wear limit, the cylinder head
must be replaced.


⇒ “5.1 Cylinder Head Cover“, page 49
⇒ “5.2 Cylinder Head“, page 50
⇒ “5.3 Toothed Belt“, page 54
⇒ “5.4 Camshaft“, page 60
⇒ “5.5 Camshaft Seal“, page 63
⇒ “5.6 Valve Stem Seals“, page 64
5.1 Cylinder Head Cover

♦ Sealant -AMV 174 004 01-
Removing
– Remove the oil dipstick.
– Remove the engine cover. First pull the front of the cover up‐
ward with a quick jerk -arrows A- and then pull it forward out
of the rear mounting -arrow B-.
– Insert the oil dipstick.
– Remove the Exhaust Gas Recirculation (EGR) vacuum regu‐
lator solenoid valve.
– If present, remove the noise insulation -arrow-.

– Disconnect the electrical connector from the intake manifold
flap motor and free up the wire over the valve cover.
– Remove the upper toothed belt cover.
– Disconnect the crankcase ventilation hose at the connection
of the rear charge air tube.
– Remove the cylinder head cover bolts and cover.
Installing
Note
If damaged, replace the cylinder head cover gasket and the bolt
seals.
Installation is performed in reverse order. When doing this note

the following:

– Place a drop of sealant -AMV 174 004 01- (approximately 5

mm diameter) on both edges on the sealing surfaces of the
front bearing cover/cylinder head -arrows-.
– Place a drop of sealant -AMV 174 004 01- on both edges on

the sealing surfaces of the rear bearing cover/cylinder head
(approximately 5 mm diameter) -arrows-.
– Hand tighten the cylinder head cover bolts in the sequence

shown -1 through 13-.
Nm.
5.2 Cylinder Head

♦ Hand vacuum pump -VAG 1390-
♦ Hand vacuum pump reservoir -VAG 1390/1-
♦ Engine support -T10014-
♦ Engine support bridge -10-222A- with Adapter -10-222A/13-

Removing
Caution

followed.
nents.
Note
♦ The following description refers to the removal of the cylinder

head with the exhaust manifold/turbocharger, intake manifold
and cooler for the Exhaust Gas Recirculation (EGR) including
the bypass flap still attached.
♦ All cable ties which are opened or cut off when removing cyl‐
inder head, must be replaced in the same position when
installing cylinder head.

– Disconnect the exhaust pipe from the turbocharger.
– Fold the rear seat bench forward.
– Remove the cover plate and disconnect the electrical connec‐
tor -arrow- from the flange.
WARNING
♦ The fuel or fuel lines in fuel system can become very hot
(danger of scalding)!
nection!
– Before removing the cylinder head, siphon any fuel using the
-VAG 1390- together with the -VAG 1390/1- on the tandem
pump. Refer to ⇒ “5.2 Tandem Pump“, page 111 .
– Disconnect all fuel hoses, coolant hoses, vacuum hoses and
intake hoses from the cylinder head.
– Disconnect all electrical wires required from the cylinder head
and set aside.

– Disconnect the electrical connector -1- from the turbocharger

vane position sensor.
– Disconnect the vacuum hose -5-.
– Remove the connecting hose -7- and the rear charge air pipe
-6-
– Remove the oil return line -2- from the connecting piece on the
cylinder block.
– Remove the bolts -3 and 4- and remove the bracket.
– Remove the oil supply line.
– Remove the cylinder head cover. Refer to
– Remove the toothed belt from the camshaft. Refer to
Note
Both lifting eyes for the -10-222A- are located on the cylinder
head, for that reason an additional holder to support the engine
must be secured on cylinder block.
– Install the -T10014 - -as shown- into the threaded hole of the
cylinder block in the area of the coolant pump. Tightening
specification: 20 Nm.
– Using spindle -A-, lift the engine slightly until spindle -B- is un‐
loaded.
– Remove spindle -B-.
– Remove the hub for the camshaft sprocket. Refer to
⇒ “5.4 Camshaft“, page 60 .
– Remove the tensioning roller.

– Follow the sequence shown for loosening the cylinder head

bolts.
– After cleaning the sealing surface, check the cylinder head for
distortion. Refer to
⇒ Fig. ““Checking Cylinder Head for Distortion““ , page 41 .
Installing
Note
♦ Always replace the cylinder head bolts.

♦ Carefully remove any residual sealant from the cylinder head
and cylinder block. Make sure that no long scrapes or scratch‐
es result. When using sand paper, grit must not be below 100.
♦ Carefully remove all grinding and sanding residue.
♦ Blow out the threaded holes for the head bolts thoroughly - to
prevent oil from squirting out, place a cloth over each hole.
♦ Only unpack new cylinder head gasket immediately prior to
installation.
♦ Handle the gasket carefully. Damages to the silicone layer and
in areas of recesses may result in leaks.
– Before installing the cylinder head, make sure the new head
gasket is identical to the old head gasket (there are 3 possible
thicknesses), refer to
⇒ Fig. ““Cylinder Head Gasket Identification““ , page 41 .
– Before installing the cylinder head, position the crankshaft to
the Top Dead Center (TDC) marking.
– Turn back the crankshaft in the opposite direction of engine
rotation, until all pistons stand almost evenly below TDC.
– Set the cylinder head gasket in place.
– Install the cylinder head and hand tighten all ten cylinder head
bolts.
– Tighten the cylinder head bolts in the sequence shown, in four

stages as follows:
1- Tighten using a torque wrench
Stage 1 = 40 Nm
Stage 2 = 60 Nm
2- Tighten further using a ratchet
Note
There is no requirement to retighten the cylinder head bolts after

repairs.

– After tightening the cylinder head bolts turn the camshaft

sprocket so that the lobes for cylinder 1 point upward equally.
Before installing the toothed belt, set the crankshaft to TDC by
turning in engine running direction. Refer to
– Install the hub for the camshaft sprocket. Refer to
– Further installation is performed in reverse order.
Note
If the tandem pump has been removed, check it for interior leak‐
age. Refer to ⇒ page 109 .
– Perform a road test and check the DTC memory. Refer to

5.3 Toothed Belt

♦ Diesel injection pump locking pin -3359-
♦ Toothed belt tensioner -T10020- or two hole pen wrench -
T10004-
♦ Locking pin -T10115-
♦ Crankshaft stop -T10050-
♦ Engine support bridge -10-222A- with bracket for engine
-10-222A/1-
♦ Counter hold tool -T10172- with adapter -T10172/4-

Note
A new toothed belt tensioning roller has been introduced as a

running change. This tensioning roller has an additional hex sock‐
et -arrow-. Use a hex wrench instead of the -T10020- or -T10004-
to tension or to relieve the tension on the toothed belt. The work
sequence does not change.
Removing
Note
Adjustments to the toothed belt may generally only be performed

when the engine is cold, because the indicator position of the
tensioning element changes depending on engine temperature.
– Remove the engine cover. refer to

– Remove the right headlight. Refer to ⇒ Electrical Equipment;
Rep. Gr. 94 ; Removal and Installation .
– Remove the connecting tube between the charge air cooler
and intake connection.
– Carefully cover or seal the open ends.
– Remove the coolant expansion tank. The hoses remain con‐
nected.
– Remove the power steering reservoir and the fuel filter and lay
them to the side; the hoses remain connected.
– Remove the ribbed belt tensioner.
– Remove the center and right noise insulation. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Description and Operation .
– Remove the charge air tube between the charge air cooler and
turbocharger. Refer to
⇒ “2.1 Charge Air Cooler and Components Assembly Over‐
view“, page 121 .
– Carefully cover or seal the open ends.
– Remove the vibration damper/belt pulley.
– Remove the upper toothed belt cover.
– Install the -10-222A- with the -10-222A/1- in place and support

the engine into the installed position.

– Remove the engine mount to longitudinal member and engine

mount to engine mount bracket bolts -arrows- and remove en‐
gine mount completely.
Note
♦ The subframe may only be removed if the engine is supported

by the -10-222A- !
♦ The engine mount bracket may first be loosened only when
the engine mount is removed.
– Lift the engine using the -10-222A- slightly so that both upper
bolts of the engine mount bracket can be loosened.
– Lower the engine using the -10-222A- slightly so that the lower
bolt for the engine mount bracket can be loosened.
– Remove the engine mount bracket downward and out.
– Remove the lower and center toothed belt covers.
– Turn crankshaft to set cylinder 1 at Top Dead Center (TDC).
Note
When doing so, turn the crankshaft so that the marking on the
crankshaft toothed belt sprocket and the tooth segment of the
camshaft sprocket are positioned upward, and the arrow “Z4“
aligns with the mark on the camshaft sensor wheel -arrows-.
– Lock the hub using the - 3359- . To do this, push the - 3359-
through the left sided empty slot in the bore of the cylinder
head.
– Lock the crankshaft toothed belt sprocket using the -T10050- .
Push the -T10050- from the front side of the toothed belt
sprocket into the teeth.
Note
Markings on crankshaft toothed belt sprocket and the -T10050-

must be aligned. The tab of the -T10050- must engage in the bore
of the sealing flange.
– Mark the rotational direction of the toothed belt.

– Loosen the bolts -1- of the camshaft sprocket, until the cam‐
shaft sprocket can be turned in the slots.
– Loosen the nut for the tensioning roller.
– Turn the tensioning roller using the -T10020- or -T10004-

counterclockwise until the toothed belt tensioning roller can be
locked with the -T10115- .
– Turn the tensioning roller clockwise using the -T10020- or -

T10004- all the way until it stops and tighten the nut -1- hand
tight.
– Remove the toothed belt from the coolant pump and then from
the remaining sprockets.
Installing
• Camshaft is secured with the -3359- .
• Crankshaft is locked with -T10050- .
• Tensioning roller secured with the -T10115- and seated on the
right stop.
Note
Adjustments to toothed belt may generally only be performed

when the engine is cold, because the indicator position of the
tensioning roller changes depending on engine temperature.
– Turn the camshaft sprocket in its slots -arrows- to the middle

position.
– Instal the toothed belt onto the crankshaft sprocket, tensioning
roller, camshaft sprocket and idler roller.
– Lastly, install the toothed belt onto the coolant pump sprocket.

Note
Make sure the tensioning roller is properly positioned in the rear

toothed belt guard -arrow-.
– Loosen the nut of the tensioning roller and remove the -

T10115- .
– Carefully turn the tensioning roller clockwise using the -

T10020- or -T10004- until the indicator is located centrally in
the gap of the base plate -arrow-.
Make sure that the nut does not turn along with it.
– Hold the tensioning roller in this position and tighten the nut as
follows, tightening specification: 20 Nm and + 45° (1/8) addi‐
tional turn.
– Install the -T10172- with the -T10172/4- as shown. Push the -

T10172- in the -direction of the arrow- and hold the camshaft
sprocket pre-tensioned.
– In this position, tighten the camshaft sprocket bolts -1- to 25
Nm.
– Remove the -3359- and the -T10050- .
– Continue turning the crankshaft two rotations in direction of
engine rotation until the crankshaft is shortly before TDC for
cylinder 1.
– Lock the hub with the -3359- from the rotating movement in
engine rotation direction.
– Make sure the camshaft can be stopped by the -T10050- .
If the crankshaft cannot be locked:

– Loosen the bolts -1- for the camshaft sprocket.
– Turn the crankshaft against the engine running direction until

the crankshaft stop tab is positioned shortly before the sealing
flange bore -arrow-.
– Now turn the crankshaft in the engine running direction until
the crankshaft stop tab engages the sealing flange.
– Install the -T10172- with -T10172/4- as shown. Push the -

T10172- in the -direction of the arrow- and hold the camshaft
sprocket pre-tensioned.
– In this position, tighten the camshaft sprocket bolts -1- to 25
Nm.
– Remove the -3359- and the -T10050- .
– Continue turning the crankshaft two rotations in direction of
engine rotation until the crankshaft is shortly before TDC for
cylinder 1.
– Check again.
– Install the center and lower toothed belt covers. Refer to
⇒ “2.2 Toothed Belt and Covers Assembly Overview“,
page 17 .
– Install the vibration damper/belt pulley. Tightening specifica‐
tion: 10 Nm + 90° (1/4) additional turn.

– Install the engine mount bracket to the cylinder block and

tighten the bolts -arrows- to 45 Nm.
Note
♦ Before installing the engine mount bracket, install all the bolts
into the bracket.
♦ Before the engine mount can be installed, all bolts -arrows- for
the engine mount bracket must be tightened to the specifica‐
tions.
– Install the engine mount to longitudinal member bolts (replace

the bolts) .
Tightening specification for M8 bolts: 20 Nm + 90° (1/4) additional
turn.
Tightening specification for M10 bolts: 40 Nm + 90° (1/4) addi‐
tional turn.
– Align the subframe, engine side. Refer to
⇒ “1.2 Engine and Transmission Mount, Aligning“, page 3 .
– Install the engine mount to engine mount bracket bolts, by
bringing the contact surfaces into contact using the -10-222A- .
Tightening specification: 100 Nm.
– Install the engine mount bracket to bracket/body bolts. Tight‐
ening specification: 25 Nm.
– Install the connecting tubes for the charge air cooler/turbo‐
charger and charge air cooler/intake connection. Refer to
view“, page 121 .
– Install the front noise insulation. Refer to ⇒ Body Exterior;
– Install the upper toothed belt cover.
– Install the ribbed belt tensioner; tightening specification: 25
Nm.
– Install the ribbed belt. Refer to ⇒ “5.1 Ribbed Belt“, page 29 .
– Install the power steering reservoir and the fuel filter.
– Install the coolant expansion tank. Refer to
⇒ “2.2 Cooling System Components Assembly Overview,
Body Side“, page 87 .
– Install the connecting tube between the charge air cooler and
intake connection. Refer to
view“, page 121 .
– Install the right headlight. Refer to ⇒ Electrical Equipment;
Rep. Gr. 94 ; Removal and Installation .
– Install the engine cover.
5.4 Camshaft
♦ Camshaft gear counter holder -T10051-
♦ Puller -T10052-


♦ Sealant -AMV 174 004 01-
Removing
– Remove the bolts -1- for the camshaft sprocket.
– Remove the camshaft sprocket from the hub.
– Loosen the bolt -1- for the hub.

– To do this, use the -T10051- .
– Loosen the bolt for the hub approximately 2 turns.
– Install the -T10052- and align it to the holes in the hub.

– Steadily tighten the -T10052- to place the hub under tension
until the hub is pulled from the taper on the camshaft.
Note
Hold onto the -T10052- with a wrench.
– Remove the hub from the camshaft.

– Remove the cylinder head cover. Refer to
– Mark the rocker lever shafts with a waterproof marker, to pre‐

vent mixing them and thereby having to perform the base
setting for the pump injector unit -arrows-.
– Remove the rocker lever shafts.
Note
First loosen both outer bolts and then the inner bolts.
– Remove the tandem pump. Refer to

⇒ “5.2 Tandem Pump“, page 111 .

– Remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and

4 alternately and diagonally and remove.
– Remove the camshaft.
Installing
Note
♦ When installing the camshaft, the cam lobes for cylinder 1

must point upward.
♦ Do not interchange run in connecting rod bearing shells
(mark).
♦ When installing the camshaft, make sure the bearing shell re‐
taining tabs are seated properly in the bearing caps and
cylinder head.
♦ Before installing the bearing cap, make sure that washers for
the cylinder head bolts are inserted in the cylinder head.
– Oil the bearing cap contact surfaces.

– Install the bearing caps 2 and 4 with the new bolts, and tighten
to 8 Nm + 90° (1/4) additional turn, alternating in a diagonal
sequence.
– Install the bearing caps 5, 1 and 3 with the new bolts, and
likewise, tighten to 8 Nm + 90° (1/4) additional turn, alternating
in a diagonal sequence.
Note
♦ Seal the separating surfaces of bearing caps 1 and 5 with

sealant -AMV 174 004 01- . Refer to
⇒ Fig. ““Sealing Separating Surfaces of Bearing Caps 1 and
5““ , page 44 .
♦ Bearing cap 5 must seat flush with the outer edge of the cyl‐
inder head, otherwise leaks at the tandem pump may result.
– Install the camshaft seal. Refer to

⇒ “5.5 Camshaft Seal“, page 63 .
– Install the rocker lever shafts and first, tighten the new inner
bolts -II- and then the outer bolts-I- evenly in a diagonal se‐
quence to 20 Nm + 90° (1/4) additional turn.
– Place the hub onto the camshaft.

– Tighten the bolt -1- for the hub to 100 Nm.

– To do this, use the -T10051- .
– Push the camshaft sprocket onto the hub.
Note
The toothed segment -arrow- of the camshaft sprocket must face

upward.
– Align the camshaft sprocket to the center location in the slots.

– Install the bolts -1- into the camshaft sprocket by hand to elim‐
inate play.
– Lock the hub with the - 3359- .
– Instal the toothed belt. Refer to
– Install the cylinder head cover. Refer to
– Install the tandem pump. Refer to
Note
♦ After installing new valve lifters, the engine may not be started
for approximately 30 minutes. The hydraulic adjusting ele‐
ments must seat themselves (otherwise the valves will seat
themselves on the pistons).
♦ After working on the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to
be sure that valves do not strike the pistons.
5.5 Camshaft Seal

♦ Oil seal driver -10-203-
♦ Seal extractor -3240-
♦ M12 x 1.5 x 65 bolt
Removing

– Remove the camshaft sprocket and hub. Refer to

– Loosen the inner portion of the -3240- two rotations (approxi‐
mately 3 mm) from the outer portion and lock with the knurled
screw.
– Lubricate the threaded head of the -3203- , position and with
forced pressure, screw it into the oil seal as far as possible.
– Loosen the knurled screw and turn the inner part against the
camshaft until the seal is removed.
Installing
Note
The sealing lip of the seal may not be additionally oiled or

greased.
– Before installing, remove any remaining oil from the camshaft

journal with a clean cloth.
– Tape over the groove on the taper of the camshaft with adhe‐
sive strip (for example, scotch tape).
– Carefully set the seal onto the camshaft.
– Press the seal in up to the stop using the -10-203- and M12 x
1.5 x 65 bolt.
5.6 Valve Stem Seals

♦ Assembly rod -2036-
♦ Slide hammer -3047A-
♦ Seal driver -3129-
♦ Valve lever -VW 541/1A-
♦ Pressure tool for VW 541/1A and 2037 -VW 541/5-
Removing
(with cylinder head installed)
– Remove the camshaft. Refer to ⇒ “5.4 Camshaft“, page 60 .
– Remove the valve lifters and place on the running surface
when setting down. Be careful not to switch valve lifters.
– Move the piston for the respective cylinder to Top Dead Center
(TDC) position.

– Install the -2036- and adjust to the stud height.

– Remove the valve springs with the -VW 541/1A - and the -
VW 541/5- .
Note
Support the valves on the piston head while doing this.
– Remove the valve shaft seal using the -3047A- .

Installing
– Place the supplied plastic sleeve -A- on each valve stem to

prevent damaging the new valve stem seal -B-.
– Insert he new valve stem oil seal into the -3129- .
– Grease the lip of the valve stem oil seal and carefully slide it
onto the valve guide by hand.

6 Special Tools
♦ Compression tester -VAG 1763-
♦ Adapter -10-222A/13-
♦ Bracket for engine -10-222A/1-
♦ Adapter -T10172/4-
♦ Diesel injection pump locking pin -3359-
♦ Toothed belt tensioner -T10020- or two hole pen wrench -
T10004-
♦ Locking pin -T10115-
♦ Crankshaft stop -T10050-
♦ Camshaft gear counter holder -T10051-
♦ Puller -T10052-
♦ Oil seal driver -10-203-
♦ Seal extractor -3240-
♦ Engine support bridge -10-222A-

♦ Counter hold tool -T10172-

equipment required
VAG 1331-
Nm) -VAG 1332-
♦ Hand vacuum pump -
VAG 1390-
♦ Hand vacuum pump reser‐
voir -VAG 1390/1-
♦ Engine support -T10014-
6. Special Tools 67

equipment required
♦ Assembly rod -2036-
♦ Slide hammer -3047A-
♦ Seal driver -3129-
♦ Valve lever -VW 541/1A-
♦ Pressure tool for VW
541/1A and 2037 -
VW 541/5-

17 – Lubrication
⇒ “1.2 Oil Level Markings“, page 69
Note
♦ If large quantities of metal particles or other deposits (caused,

for example, by partial seizure of the crankshaft or connecting
rod damage) are found in the engine oil, the oil passages must
be cleaned thoroughly and the oil cooler replaced in order to
prevent further damage from reoccurring.
♦ The oil level must not be above the Max. mark - danger of
damage to catalytic converter!
1.2 Oil Level Markings

1 - Max. mark
2 - Min. mark
a - Area above the cross hatched field up to the Max. mark: Do
not add engine oil!
b - Oil level within the cross hatched field: Engine oil can be add‐
ed.
c - Area from the Min. mark up to cross hatched field: Add a Max.
0.5 liter of engine oil!

⇒ “2.1 Oil Supply Line Assembly Overview“, page 70
⇒ “2.2 Oil Pan and Pump Assembly Overview“, page 71
⇒ “2.3 Oil Filter Bracket Assembly Overview“, page 73
2.1 Oil Supply Line Assembly Overview
1 - Oil Supply Line

❑ To the turbocharger.
2 - Union Nut, 22 Nm
❑ When loosening and
tightening, counter hold
the connection.
3 - Seal
❑ Always replace.
5 - Clamp
6 - Bolt, 10 Nm
7 - Bracket
8 - Nut, 25 Nm
❑ Always replace.
9 - Bolt, 10 Nm
10 - Nut, 10 Nm
70 Rep. Gr.17 - Lubrication

2.2 Oil Pan and Pump Assembly Overview
1 - Bolt, 15 Nm
2 - Sealing Flange
❑ With seal.
❑ Must be located on the
alignment pins.
ling, refer to
page 30 .
❑ Install using silicone
sealant -D 176 404 A2 - .
Refer to
page 30 .
❑ Do not additionally oil or
grease the sealing lip of
the seal.
move any remaining oil
from crankshaft journal
with a clean cloth.
❑ Crankshaft seal belt pul‐
ley side, replacing. Re‐
fer to
⇒ “5.3 Crankshaft Seal,
page 32 .
3 - Chain Tensioner with Ten‐
sioning Rail, 15 Nm
❑ When installing, preten‐
sion the spring and hook
in.
4 - Dipstick
❑ Oil level must not be
above the Max. mark!
❑ Marks, refer to ⇒ “1.2 Oil Level Markings“, page 69 .
5 - Inlet Spout
❑ For extracting oil.
6 - Guide Tube
7 - Oil Spray Jet
❑ For piston cooling.
8 - Bolt, 25 Nm
❑ Install without sealant.
9 - Alignment Pins
10 - Bolt, 15 Nm
11 - Suction Line
❑ Clean the strainer if contaminated.
12 - O-ring
❑ Always replace.

13 - Splash Wall
14 - Bolt, 15 Nm
15 - Bolt, 15 Nm
16 - Oil Pan
❑ Clean the sealing surface before installing.
❑ Install using silicone sealant -D 176 404 A2 - . Refer to ⇒ “5.2 Oil Pan“, page 78 .
17 - Seal
❑ Always replace.
18 - Oil Pan Drain Plug, 30 Nm
❑ Replace the plug and seal.
19 - Oil Pump
❑ With pressure relief valve, 12 bar.
❑ Before installing, check to be sure both alignment pins are present (for centering the oil pump/cylinder
block).
❑ Replace if running surfaces and gears are scored.
20 - Oil Pump Sprocket
21 - Bolt, 25 Nm
22 - Chain

2.3 Oil Filter Bracket Assembly Overview
1 - Oil Pressure Switch -F1- ,

20 Nm
❑ 0.7 bar switch: brown or
0.9 bar, switch: gray.
❑ If seal is leaking cut off
and replace.
❑ Checking, refer to
⇒ “4.1 Oil Pressure and
Switch, Checking“,
page 76 .
2 - Gasket
❑ Always replace.
3 - Bolt, 15 Nm + 90° (1/4) ad‐
ditional turn
❑ Always replace.
❑ First, install the upper
left and lower right bolts,
and then tighten all four
bolts in a diagonal se‐
quence.
4 - Oil Filter Bracket
5 - Seal
❑ Always replace.
6 - Oil Supply Line
❑ To the turbocharger.
ling, refer to
⇒ “5.1 Oil Supply Line“,
page 77 .
7 - Banjo Bolt
❑ Tightening specifica‐
tion, refer to-item 4- in
the
⇒ “2.1 Oil Supply Line Assembly Overview“, page 70 .
8 - Oil Filter Cap, 25 Nm
❑ Loosen and tighten using the oil filter wrench -3417- .
9 - O-ring
❑ Always replace.
10 - Oil Filter Element
❑ Note the installed position: top = oben
11 - Bolt, 25 Nm
12 - Gasket
❑ Always replace.
13 - Oil Cooler
❑ Ensure sufficient clearance to surrounding components.
❑ See note in ⇒ “1.1 General Repair Information“, page 69 .
❑ Oil cooler, checking for leaks. Refer to ⇒ “4.2 Oil Cooler, Checking for Leaks “, page 91 .
14 - Gasket
❑ Always replace

❑ Snaps into the tabs of the oil cooler.
15 - Sealing Plug, 10 Nm
❑ If sealing plug is leaking cut off seal and replace.
16 - Locking Bolt
❑ For the pressure relief valve.
❑ Do not loosen.

3 Specifications
⇒ “3.2 Engine Oil Capacity and Specifications“, page 75

Chain Tensioner with Tensioning Rail - 15
Oil Cooler to Oil Filter Bracket Bolt - 25
Oil Filter Bracket to Cylinder Block Bolt 1 - 15 + 90° turn
Oil Filter Cap - 25
Oil Pan to Cylinder Block Bolt - 15
Oil Pan Drain Plug - 30
Oil Pan to Transmission Bolt - 45
Oil Pressure Switch - 20
Oil Pump Sprocket to Oil Pump Bolt - 25
Oil Supply Line Bracket to Exhaust Manifold Stud Nut 1 - 25
Oil Supply Line Clamp Bolt - 10
Oil Supply Line Clamp to Bracket Bolt/Nut - 10
Oil Supply Line to Oil Filter Bracket Banjo Bolt - 25
Oil Supply Line Union Nut to Turbocharger - 22
Oil Spray Jet Bolt - 25
Sealing Flange to Cylinder Block Bolt - 15
Sealing Plug to Oil Filter Bracket - 10
Splash Wall to Cylinder Block Bolt - 15
Suction Line to Oil Pump Bolt - 15
3.2 Engine Oil Capacity and Specifications

For engine oil capacities and specifications refer to the Owners
Manual and/or ServiceNet.

⇒ “4.1 Oil Pressure and Switch, Checking“, page 76
4.1 Oil Pressure and Switch, Checking

♦ Oil pressure gauge -VAG 1342-
♦ Voltage tester -VAG 1527B-
♦ Test adapter kit -VAG 1594A-
Note
Function test and servicing the optical and acoustic oil pressure
indicator. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations ⇒ Vehicle diagnosis, testing and information
system VAS 5051
Test Sequence
– Remove the oil pressure switch and install it into the -
VAG 1342- .
– Thread the -VAG 1342- into the oil filter bracket in place of the
oil pressure switch.
– Connect the brown wire of the -VAG 1342- to ground (-).
– Connect the -VAG 1527B- using auxiliary cables from the -
VAG 1594A- to the battery positive (+) and the oil pressure
switch. Light Emitting Diode (LED) must not light up.
– Start the engine and slowly increase the engine speed.
Oil Pressure Switch Brown
– LED must light up at 0.55 to 0.85 bar positive pressure, oth‐
erwise replace the oil pressure switch.
– Increase engine speed further. At 2000 RPM and an oil tem‐
perature of 80 °C (176 °F), oil pressure must be at least 2.0
bar.
At higher RPMs, the oil pressure must not exceed 7.0 bar. If nec‐
essary, replace the oil filter bracket.
Oil Pressure Switch Gray
– LED must light up at 0.75 to 1.05 bar positive pressure, oth‐
erwise replace the oil pressure switch.
– Increase engine speed further. At 2000 RPM and an oil tem‐
perature of 80 °C (176 °F), oil pressure must be at least 2.0
bar.
At higher RPMs, the oil pressure must not exceed 7.0 bar. If nec‐
essary, replace the oil filter bracket.


⇒ “5.1 Oil Supply Line“, page 77
⇒ “5.2 Oil Pan“, page 78
5.1 Oil Supply Line
Removing
– Remove the noise insulation.
– Place the drip tray -VAG 1306- beneath.
– Remove the air filter housing.
– Remove the union nut -2- and banjo bolt -4- from the oil filter
bracket.
– Remove bolt -6-.
– Remove the union nut -2- from the turbocharger.
– Remove the bolt -9- from the bracket -7-.
– Remove the nut -8- and remove the bracket -7-.
– Remove the oil supply line -1-.

Installing
the following:
WARNING
Installation of the oil supply line must be performed as in the

following description.
– Loosely fasten the bracket -7- with the nut -8- to the exhaust
manifold.
– Hand tighten the union nut -2- and banjo bolt -4- to the oil filter
bracket.
– Hand tighten the union nut -2- to the turbocharger.
– Tighten the union nut -2- and banjo bolt -4- on the oil filter
bracket to specifications.
– Tighten the union nut -2- on the turbocharger to specifications.
– Position the clamp -5- on the oil supply line.
– Tighten bolts -6 and 9- to specifications.
– Tighten the nut -8- to specifications.
5.2 Oil Pan

♦ Hand drill
♦ Protective glasses
♦ Flat scraper
♦ Silicone sealant -D 176 404 A2-
Removing
– Remove the noise insulation, along with the left and right
Operation .
– Drain the engine oil.
Note
Observe disposal regulations!
– Remove the oil pan.

– Loosen the oil pan with light blows from a rubber hammer, if
necessary.
– Remove the sealant residue from the cylinder block with a flat
scraper.

– Remove the sealant residue from the pan with a rotating brush,
for example, a hand drill with a plastic brush attachment (wear
eye protection).
– Clean the sealing surfaces. They must be free of oil and
grease.
Installing
Note
♦ Note the expiration date of the sealing compound.

♦ The oil pan must be installed within 5 minutes after application
of silicone sealant.
– Cut off the nozzle on the tube of sealant at the front mark (di‐
ameter of nozzle approximately 3 mm).
– Apply the silicone sealant -D 176 404 A2- to the clean sealing
surfaces of the oil pan as shown. The sealing compound bead
must be:
♦ 2 to 3 mm thick
♦ and run on the inside of the bolt holes -arrows-
Note
Sealant bead must not be thicker than specified. Otherwise, ex‐

cess sealant could get into oil pan and clog strainer in intake line
of oil pump.
– Apply the silicone sealant -D 176 404 A2- bead as shown to

the clean sealing surface of the oil pan. (The fig. shows the
location of the sealant bead on the cylinder block.)
– Install the oil pan immediately and tighten all oil pan bolts
lightly.
Note
The oil pan must seat flush with the cylinder block.
– Tighten the oil pan bolts in a diagonal sequence to 15 Nm.

– Tighten the oil pan/transmission bolts to 45 Nm.
Note
After installing the oil pan, allow the sealant to dry for approxi‐
mately 30 minutes. Only after then may the engine oil be added.
The rest of the assembly is basically a reverse of the removal

sequence.

6 Special Tools

equipment required
♦ Oil pressure gauge -
VAG 1342-
♦ Voltage tester -
VAG 1527B-
♦ Test adapter kit -
VAG 1594A-

19 – Cooling System
⇒ “1.2 Draining and Filling“, page 81
Caution

followed.
nents.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary release pressure before beginning repair
work.
♦ Hoses are secured with spring type clips. In cases of repair
only use spring type clips.
♦ The spring type clip pliers -VAS 5024- or hose clip pliers -
VAG 1921 - are recommended for installing spring type clips.
♦ When installing coolant hoses route them stress free, so that
they do not come into contact with other components (observe
the markings on the coolant connection and hose).
Perform a cooling system leakage test using the cooling system

tester -VAG 1274- and the adapters - VAG 1274/8- and -
VAG 1274/9- .
1.2 Draining and Filling

♦ Refractometer -T10007-
♦ Spring type clip pliers -VAS 5024-
♦ Cooling system charge unit -VAS 6096-
Draining
– Open the cap for the coolant expansion tank.
WARNING
Cover the cap of expansion tank with a cloth and open care‐
fully, as hot steam may escape when opening.
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Description and Operation .
With a Radiator Drain Plug
– Remove the drain plug -arrow- to drain the coolant from the
radiator.
Without a Radiator Drain Plug
– Pull the coolant hose retaining clip -arrow- off downward and
remove the coolant hose from the radiator quick acting cou‐
pling.
82 Rep. Gr.19 - Cooling System

– In addition, to drain the coolant from the engine, disconnect

the coolant hose at the oil cooler -arrow-.
Note
Observe disposal regulations!
Filling
Note
♦ Only use coolant additive G 12 plus in accordance with TL VW

774 F. Distinguishing feature: violet color
♦ G 12 plus (per TL VW 774 F) may not be mixed with coolant
additive G 12 plus!
♦ G 12 plus and coolant additives marked in accordance with
“TL VW 774 F“ prevent frost and corrosion damage, scaling
and also raise boiling point of coolant. For this reason the sys‐
tem must be filled all year round with frost and corrosion
protection additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Protection against frost must be assured to about -25 °C (-13
°F) (in arctic climatic countries to about -35 °C (-31°F)).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive portion must be at least 40%.
♦ If for climatic reasons a greater frost protection is required, the
amount of G 12 plus can be increased, but only up to 60%
(frost protection to about -40 °C (-40 °F)), as otherwise frost
protection is reduced again and cooling effectiveness is also
reduced.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket is replaced, do not reuse old coolant.
Recommended Mixture Ratios

Frost protection Antifreeze por‐ G 121) Water1) 2)
to tion
-25 °C (-13 °F) 40% 2.4 L 3.6 L
-35 °C (-31 °F) 50% 3.0 L 3.0 L
1) The quantity of coolant can vary depending upon the vehicle equipment.
2) Only use clean tap water.
With a Radiator Drain Plug

– Close the coolant drain plug.
Without a Radiator Drain Plug
– Install the lower coolant hose and secure with the retaining clip
-arrow-.
– Push the coolant hose onto the oil cooler connection and fas‐
ten with the spring type clip.
With -VAS 6096-
– Fill the coolant circuit using the -VAS 6096- . Refer to ⇒ Op‐
erating instructions for cooling system charge unit VAS 6096 .
Without -VAS 6096-
Vehicles With a Max. Mark on the Expansion Tank
– Fill the coolant to the Max mark on the expansion tank.

– Install the expansion tank cap.
– Allow the engine to run until the radiator fan switches on.
– Check yjr coolant level and top off, as necessary. With the en‐
gine at operating temperature, the coolant level must be at the
Max. mark, with the engine cold, it must be between the Min.
and Max. marks.
Vehicles Without a Max. Mark on the Expansion Tank
– Slowly fill the coolant up to top mark of the hatched area on

the expansion tank.
– Install the expansion tank cap.
– Allow the engine to run until the radiator fan switches on.
– Check the coolant level and top off, as necessary:
With the engine at operating temperature, the coolant level must
be at the top mark of the hatched area.
With the engine cold, the coolant level should be located approx‐
imately in the center of the hatched area.


⇒ “2.1 Coolant Hose Connection Diagram“, page 85
⇒ “2.2 Cooling System Components Assembly Overview, Body
Side“, page 87
⇒ “2.3 Cooling System Components Assembly Overview, Engine
Side“, page 88
2.1 Coolant Hose Connection Diagram

⇒ “2.1.1 Manual Transmission“, page 85
⇒ “2.1.2 Automatic Transmission“, page 86
2.1.1 Manual Transmission
1 - Expansion Tank
2 - Intake Manifold
3 - Cooler
❑ For the Exhaust Gas
Recirculation (EGR)
system.
4 - Bypass Flap
5 - Heater Unit Heat Exchang‐
er
6 - Coolant Line
7 - Lower Coolant Hose
8 - Upper Coolant Hose
9 - Radiator
10 - Oil Cooler
11 - Coolant Pump/Thermostat
12 - Cylinder Head/Cylinder
Block

2.1.2 Automatic Transmission
1 - Expansion Tank
2 - Intake Manifold
3 - Cooler
Recirculation (EGR)
system.
4 - Bypass Flap
5 - Heater Unit Heat Exchang‐
er
6 - Coolant Line
7 - Transmission Oil Cooler
10 - Radiator
11 - Oil Cooler
12 - Coolant Pump/Thermostat
13 - Cylinder Head/Cylinder
Block

2.2 Cooling System Components Assembly Overview, Body Side
1 - Radiator
ling, refer to
⇒ “5.3 Radiator“,
page 95 .
❑ After replacing, replace
the entire amount of
coolant.
2 - O-ring
❑ Always replace.
❑ Secured to the radiator
with a retaining clip.
❑ Coolant hose connec‐
tion diagram, refer to
⇒ “2.1 Coolant Hose
Connection Diagram“,
page 85 .
4 - Fan Shroud
5 - Bolt, 5 Nm
6 - Auxiliary Fan
❑ Only on vehicles with
optional equipment.
7 - Fan Ring
8 - Retaining Clip
❑ Check the clip for se‐
cure seating.
9 - Electrical Connector
10 - Fan
11 - to Coolant Pipe
tion diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram“, page 85 .
12 - Expansion Tank
❑ Perform a cooling system leakage test using the cooling system tester -VAG 1274- and the adapter -
VAG 1274/8- . Refer to ⇒ “4.1 Cooling System, Checking for Leaks“, page 91 .
❑ Note the markings, refer to ⇒ “1.2 Draining and Filling“, page 81 .
13 - Expansion Tank Cap
❑ Check using the cooling system tester -VAG 1274 - and the adapter -V.A.G 1274/9- . Refer to
⇒ page 91 .
❑ Pressure relief valve must open at a pressure of 1.4 to 1.6 bar.
14 - Bracket
❑ For the fan electrical connector.
❑ Secured to the radiator with a retaining clip.
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram“, page 85 .
16 - O-ring
❑ Always replace
Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Description and Operation 87

17 - Coolant Fan Control Thermal Switch -F18- , 35 Nm

❑ For the electric fan
❑ Switch temperatures:
♦ 1. Speed On: 92 to 97 °C (197.6 to 206.6 °F) Off: 84 to 91 °C (183.2 to 195.8 °F)
♦ 2. Speed On: 99 to 105 °C (210.2 to 221 °F) Off: 91 to 98 °C (195.8 to 208.4 °F)
18 - Bracket
❑ For the radiator.
❑ Note the different versions.
19 - Bolt, 5 Nm
2.3 Cooling System Components Assembly Overview, Engine Side
1 - Bolt, 15 Nm
2 - Coolant Pump
❑ Check for ease of move‐
ment.
❑ Note the installed posi‐
tion.
ling, refer to
⇒ “5.2 Coolant Pump“,
page 94 .
3 - O-ring
❑ Always replace
4 - from Cylinder Head
5 - to Bypass Flap
6 - from Cooler for Exhaust
Gas Recirculation (EGR)
❑ To the heat exchanger.
7 - from the Bypass Flap
❑ For the cooler for the
EGR.
8 - to Cooler for Exhaust Gas
Recirculation
9 - to Expansion Tank (Top Fit‐
ting)
tion diagram, refer to
⇒ “2.1 Coolant Hose
Connection Diagram“,
page 85 .
10 - Upper Coolant Line
❑ Bolted on the cylinder
head cover.
❑ As a unit with the fuel lines.
11 - O-ring
❑ Always replace.

12 - Engine Coolant Temperature (ECT) Sensor -G62-

❑ With the ECT gauge sensor.
13 - Retaining Clip
❑ Check the clip for secure seating.
14 - from Heat Exchanger
15 - to Radiator (Upper Fitting)
16 - Bolt, 10 Nm
17 - Connecting Piece
❑ Connecting pieces with glow plugs for the auxiliary heater, refer to
⇒ Fig. ““Connecting Piece with Glow Plugs for the Auxiliary Heater““ , page 89 . (not installed on all
vehicles)
❑ Coolant glow plug, checking. Refer to ⇒ “4.3 Coolant Glow Plug, Checking “, page 92 .
18 - Coolant Line
19 - to Radiator (Upper Fitting)
20 - from Expansion Tank (Bottom Fitting)
21 - from Radiator (Lower Fitting)
❑ Coolant hose connection diagram ⇒ “2.1 Coolant Hose Connection Diagram“, page 85 .
22 - Connection
❑ For the thermostat.
23 - Coolant Thermostat
❑ Removing and installing, refer to ⇒ “5.1 Coolant Thermostat“, page 94 .
❑ Observe the installed location, refer to ⇒ “5.1 Coolant Thermostat“, page 94 .
❑ Checking: Heat up the thermostat in water.
❑ Opening begins approximately 85 °C (185 °F).
❑ Ends approximately 105 °C (221 °F).
❑ Opening lift min. 7 mm.
24 - Oil Cooler
❑ Removing and installing, refer to ⇒ “2.3 Oil Filter Bracket Assembly Overview“, page 73 .
❑ Oil cooler, checking for leaks. Refer to ⇒ “4.2 Oil Cooler, Checking for Leaks “, page 91 .
Connecting Piece with Glow Plugs for the Auxiliary Heater

1 - Connecting piece
2 - Bolt, 10 Nm
3 - O-ring, always replace
4 - Heater flange for the glow plugs
5 - Glow plugs, 25 Nm
6 - To the cooler for the Exhaust Gas Recirculation (EGR)

3 Specifications

Connecting Piece to Cylinder Head Bolt - 10
Coolant Fan Control Thermal Switch - 35
Coolant Line Bracket Bolt/Nut - 10
Coolant Pump to Cylinder Block Bolt - 15
Fan Shroud to Radiator Bolt - 5
Glow Plug to Connecting Piece - 25
Radiator to Bracket Bolt - 5
Thermostat Connecting Piece Bolt - 15


⇒ “4.1 Cooling System, Checking for Leaks“, page 91
⇒ “4.2 Oil Cooler, Checking for Leaks “, page 91
⇒ “4.3 Coolant Glow Plug, Checking “, page 92
4.1 Cooling System, Checking for Leaks

♦ Cooling system tester -VAG 1274-
Test Conditions
• Engine at operating temperature
Test Sequence
WARNING
Steam can be released when the cap is removed from the ex‐
pansion tank. Cover the cap with a cloth and open carefully.
– Open the coolant expansion tank cap.

– Install the -VAG 1274- with the -VAG 1274/8- onto the expan‐
sion tank.
– Generate a positive pressure of approximately 1.0 bar using
the -VAG 1274- .
If the pressure drops:
– Look for leaks and correct.
Cap Pressure Relief Valve, Checking
– Install the -VAG 1274- with the -VAG 1274/9- onto the expan‐
sion tank cap.
– Operate the -VAG 1274- .
• The pressure release valve must open at 1.4 to 1.6 bar.
4.2 Oil Cooler, Checking for Leaks

♦ Hose clamps up to 25 mm dia. -3094-
♦ Cooling system tester -VAG 1274-


♦ Spring type clip pliers -VAS 5024A-
♦ Drip tray -VAG 1306- or drip tray for VAS 6100 -VAS 6208-
Requirements
• Cold engine
Test Sequence
– Disconnect the supply and return line from the oil cooler using
the -VAS 3094- .
– Remove the hose clamps -arrows- using the -VAS 5024- .
Note
Catch any coolant running out with the -VAG 1306- or the drip tray
-VAS 6208- .
– Disconnect the coolant hoses from the oil cooler.
– Install the sealing cap -5- on the rear connecting piece on the
oil cooler -4-.
– Install the sealing cap -2- on the expansion tank vent connec‐
tion -1-.
– Install the coolant hose -3- to the oil cooler and the expansion
tank.
– Fill the expansion tank up to the “Max“ mark.
– Install the -VAG 1274- and the -VAG 1274/8- onto the expan‐
sion tank.
– Generate a positive pressure of approximately 1.6 bar using
the -VAG 1274- .
– Watch the pressure drop on the gauge. The pressure must not
fall within 10 minutes.
If the pressure drops:
– Replace the oil cooler. Refer to
⇒ “2.3 Oil Filter Bracket Assembly Overview“, page 73 .
Installation is performed in the reverse order of removal, noting
the following:
– Check the coolant level, top off if necessary. Refer to
4.3 Coolant Glow Plug, Checking

♦ Connector test set -VAG 1594C-
Test Requirements
• Battery voltage a min. 11.5 volts
• Ignition switched off

Test Sequence
Check the electrical activation for the coolant glow plugs. Refer
to ⇒ Wiring diagrams, Troubleshooting & Component locations.
– Disconnect the electrical connectors -1- from the coolant glow
plugs.
– Connect the lead of the -VAG 1527B- to the battery positive
terminal with the adapter clips from the -VAG 1594C- .
– Attach the test lead of the -VAG 1527B- to each coolant glow
plug in succession.
♦ Light Emitting Diode (LED) lights up: Coolant glow plug OK
♦ LED does not light up: Replace the coolant glow plug.


⇒ “5.1 Coolant Thermostat“, page 94
⇒ “5.2 Coolant Pump“, page 94
⇒ “5.3 Radiator“, page 95
5.1 Coolant Thermostat

Removing
Note
Always replace gaskets and seals.

– Disconnect the coolant hose from connecting piece.
– Remove the bolts -1- for the connecting piece -2- and remove
the connecting piece -2- with the coolant thermostat -4-.
– Turn the thermostat to the left -4- 90 degrees (1/4 turn) and
remove it from the connecting piece -2-.
Installing
the following:
– Lubricate the new O-ring -3- with coolant.

– Insert the thermostat -4- into the connecting piece -2- and turn
it to the right 90 degrees (1/4 turn).
Note
The clip of the thermostat must be positioned at approximately a

right angle.
– Install the connecting piece -2- with thermostat -4- into the en‐
gine block.
– Tighten the bolts -1-. Tightening specification: 15 Nm.
5.2 Coolant Pump

(with engine installed)


Removing
Note
♦ Always replace gaskets and seals.

♦ Cover the toothed belt with a cloth to protect it from coolant
before removing the coolant pump.

– Remove the bolts -1- for the coolant pump -2- and carefully
remove the coolant pump.
Installing
the following:
– Lubricate the new O-ring -3- with coolant.

– Install the coolant pump -2- into the cylinder block and tighten
the bolts -1-. Tightening specification: 15 Nm.
Note
The sealing plug of the coolant pump faces downward.

5.3 Radiator

Removing
– Remove the coolant hoses from the radiator.
– Remove the electrical connectors from the thermal switch and
radiator fan.
– Remove the front bumper: Refer to ⇒ Body Exterior; Rep. Gr.
63 ; Removal and Installation .
– Bring the lock carrier into the service position. Refer to ⇒ Body
– Remove the bolts from the radiator and remove the radiator
with fans downward.
WARNING
The Air Conditioning (A/C) refrigerant circuit must not be

opened.
Note
To prevent damage to the condenser and also to the refrigerant

lines/hoses, ensure that the pipes and hoses are not stretched,
kinked or bent.
– Remove the retaining clamp(s) from the refrigerant lines.

– Remove the condenser from the radiator and fasten to the lock
carrier.
Installing
the following:

6 Special Tools
♦ Cooling system charge unit -VAS 6096-
6. Special Tools 97

equipment required
♦ Hose clamps up to 25 mm
dia. -3094-
♦ Cooling system tester -
VAG 1274-
♦ Spring type clip pliers -VAS
5024A-
♦ Drip tray -VAG 1306- or drip
tray for VAS 6100 -VAS
6208-

20 – Fuel Supply
⇒ “1.1 Safety Precautions“, page 99
⇒ “1.2 Clean Working Conditions“, page 99
1.1 Safety Precautions
WARNING
nection!
Caution

followed.
nents.
The fuel pump is activated by switching on the ignition and by the

door contact switch of the driver's door. Therefore for reasons of
safety, the electrical connector -arrow- must be disconnected
from the fuel delivery unit before opening the fuel supply system,
if the battery is not disconnected.
Always observe the following when removing and installing the
fuel level sensor or the fuel delivery unit from full or partially filled
fuel tanks:
♦ Before starting work, switch on the exhaust extraction system
and place an extraction hose close to the installation opening
of fuel tank to extract escaping fuel fumes. If no exhaust ex‐
traction system is available, a radial fan (as long as motor is
not in air flow) with a displacement greater than 15 m3/h can
be used.
♦ Prevent fuel from contacting skin! Wear fuel resistant gloves!
1.2 Clean Working Conditions

When working on the fuel supply/injection system, pay careful at‐
tention to the following “6 rules“ of cleanliness:
♦ Thoroughly clean all connections and the surrounding area
before disconnecting.
♦ Place parts that have been removed on a clean surface and

cover them. Use lint free cloths.
♦ Carefully cover or seal opened components, if repairs are not
performed immediately.
♦ Only install clean components: Only unpack replacement
parts immediately prior to installation. Do not use parts that
have been stored loose (for example, in tool boxes etc.).
♦ When the system is open: Avoid working with compressed air
if possible. Do not move vehicle unless absolutely necessary.
♦ In addition, do not let diesel fuel flow onto coolant hoses. If
necessary, the hoses must be cleaned again immediately.
Replace corroded hoses.
Note
♦ Hose connections are secured with either spring type or clamp

type clips.
♦ Always replace clamp type clips with spring type clips.
♦ Fuel hoses at the engine must only be secured with spring type
clips. The use of clamp or screw type clips is not permissible.
♦ The spring type clip pliers -VAS 5024- or hose clip pliers -
VAG 1921 - are recommended for installing spring type clips.
100 Rep. Gr.20 - Fuel Supply


⇒ “2.1 Accelerator Mechanism Assembly Overview“, page 101
⇒ “2.2 Fuel Tank and Attachments Assembly Overview“,
page 101
⇒ “2.3 Fuel Filter Assembly Overview“, page 104
2.1 Accelerator Mechanism Assembly Overview
1 - Bracket
❑ Black, 6 pin.
3 - Nut, 10 Nm
4 - Throttle Position (TP) Sen‐
sor -G79-
❑ Not adjustable.
❑ The TP sensor trans‐
mits the driver control to
the Engine Control Mod‐
ule (ECM).
❑ Remove the footwell
cover to remove the
sensor.
5 - Bracket
❑ For the footwell cover.
❑ Clipped onto the TP
sensor.
2.2 Fuel Tank and Attachments Assembly

Overview
Note
Make sure the supply or return lines do not come into contact with
the fuel tank during all work on the fuel pump unit or the fuel gauge
(transfer of pump noise).

1 - Cap
❑ With securing clip.
2 - Seal
3 - Bolt, 1 Nm
4 - Tank Flap Unit
❑ With a rubber gasket
and overflow hose.
❑ When installing: push
the rear overflow hose
behind the filler tube
bracket, do not clamp it.
5 - Ground Connection
❑ Ensure the connection
is securely seated.
6 - O-ring
❑ Always replace.
7 - Breather Valve
❑ To remove the valve,
unclip sideways out of
the support.
move the cap -item 1-.
❑ Checking, refer to
⇒ Fig. ““Checking
Breather Valve““ ,
page 104 .
8 - Bolt, 10 Nm
9 - Nut, 6 Nm
10 - Protective Cover
❑ For the filler tube.
11 - Vent Line
❑ Clipped in at the top of the fuel tank.
❑ Ensure the line is securely seated.
12 - Lock Washer
13 - Heat Shield
❑ For the fuel tank.
14 - Fuel Tank Cover
15 - Fuel Tank Cover
16 - Bolt, 25 Nm
17 - Securing Strap
❑ Observe the varying lengths.
18 - Fuel Tank
❑ Support using the engine and transmission jack -VAG 1383A - when removing.
❑ Removing and installing, refer to ⇒ “5.5 Fuel Tank“, page 114 .
19 - Seal
❑ To install, place into the opening of the fuel tank dry.

❑ Lubricate with fuel only when installing the fuel delivery unit.
20 - Fuel Delivery Unit
❑ Note the installed position on the fuel tank. Refer to
⇒ Fig. ““Fuel Delivery Unit Installed Position““ , page 103 .
❑ Removing and installing, refer to ⇒ “5.3 Fuel Delivery Unit“, page 113 .
❑ Check fuel pump, refer to ⇒ “4.1 Fuel Pump, Checking“, page 107 .
❑ With the fuel gauge sender.
❑ Fuel level sensor removing and installing, refer to ⇒ “5.4 Fuel Level Sensor“, page 114 .
❑ Clean strainer if contaminated.
21 - Union Nut
❑ Use the ring nut spanner -3217- for removal and installation.
22 - Supply Line
❑ To the fuel filter.
❑ Black.
❑ Clipped in at the fuel tank.
❑ To remove from the fuel delivery unit, press the release buttons on the connecting piece.
23 - Return Line
❑ From the fuel cooler.
❑ To fitting -R-.
❑ Blue or with blue marking.
❑ Clipped in at the fuel tank.
❑ To remove from the fuel delivery unit, press the release buttons on the connecting piece.
24 - Gravity/Expansion Valve
❑ To remove valve, unclip upward out of the support.
❑ Check valve for flow through, valve vertical: open, valve angled at 45°: Closed
25 - Angle Piece
Fuel Delivery Unit Installed Position

The mark on the fuel deliver unit must align with the mark on the
fuel tank -arrows-.
Blue or blue marked return line -1- to the fitting with identification
“R“.
Black supply line -2- to the fitting with identification “V“.
Note
After installing the fuel delivery unit, check whether the supply,
return and ventilation lines are still clipped in at the fuel tank.

Checking Breather Valve

Lever in rest position: Closed
Lever pushed in direction of arrow: Open
Note
Before installing the breather valve, remove the cap from the fuel
tank.
2.3 Fuel Filter Assembly Overview
1 - Supply Line
❑ From the fuel tank.
❑ White or with white
markings.
❑ Ensure the line is se‐
curely seated.
2 - Return Line
❑ To the fuel cooler.
❑ Blue or with blue mark‐
ing.
❑ Ensure the line is se‐
curely seated.
3 - O-ring
❑ Always replace.
4 - Regulator Valve
❑ Installed position: direc‐
tion of arrow to the fuel
tank.
❑ When changing the fil‐
ter, remove the retaining
clip and remove the reg‐
ulator valve with fuel
lines attached.
❑ When under 15 °C (59 °
F): flow through to filter
is open.
❑ When above 31 °C (87.8
°F): flow through to filter
is closed.
5 - Retaining Clip
❑ Check for secure seat‐
ing.
6 - Return Line
❑ From the tandem pump.
7 - Supply Line
❑ To the tandem pump.

8 - Fuel Filter
❑ Before installing, fill with diesel fuel.
❑ Direction of flow is marked with arrows.
❑ Do not interchange connections.
9 - Gasket
10 - Water Drain Plug
❑ To vent, remove the retaining clip for the regulator valve and remove the regulator valve with fuel lines
attached.
❑ Loosen and allow approximately 100 cm3 of fluid to drain.

3 Specifications

Accelerator Pedal Mechanism Nut - 10
Filler Pipe Protective Cover Nut - 6
Fuel Cooler Nut - 20
Fuel Tank Filler Pipe to Body Bolt - 10
Fuel Tank Securing Strap Bolt - 25
Tandem Pump Bolt
– Upper - 20
– Lower - 10
Tank Flap Unit Bolt - 1


⇒ “4.1 Fuel Pump, Checking“, page 107
⇒ “4.2 Tandem Pump, Checking“, page 108
4.1 Fuel Pump, Checking

♦ Hand multi meter -VAG 1526- or Multi meter -VAG 1715-
♦ Voltage tester -VAG 1527-
Test Conditions
• The fuses must be OK.
• The battery voltage must be at least 11.5 volts.
• All electrical components such as, for example, lights and rear
window defroster must be switched off.
Function and Voltage Supply, Checking
– Remove the cover under the bench seat.
– Briefly operate the starter. the fuel pump must run audibly.
– Switch off the ignition.
If fuel pump does not activate:
– Disconnect the 4 pin electrical connector from the fuel delivery
unit.
– Connect the -VAG 1527- using the cables from the -

VAG 1594- to the outer terminals of the electrical connector.
– Switch on the ignition, Light Emitting Diode (LED) must light
up for approximately 2 seconds.
If the LED does not light up:
– Check the activation of the fuel pump relay and wires for a
open circuit and/or a short circuit. Refer to ⇒ Wiring diagrams,
Troubleshooting & Component locations ⇒ Vehicle diagnosis,
testing and information system VAS 5051
LED lights up (voltage supply OK):
– Remove the fuel delivery unit. Refer to
⇒ “5.3 Fuel Delivery Unit“, page 113 .
– Check whether the electrical wires between fuel delivery unit
flange and fuel pump are connected and have continuity.
If no open circuits are found:
– Replace the fuel delivery unit. Refer to
Current Pickup of Fuel Pump, Checking
– Disconnect the 4 pin electrical connector from the fuel delivery
unit.

– Set the multi meter to measuring range 20A and connect the
adapter cables from the -VAG 1594A- between the harness
connector -1- and the fuel delivery unit connector -1-.
Note
Also, the current clamp of the -VAG 1715 - can be attached to an

adapter cable between the contacts -1- of the connector and the
fuel pump.
– Connect the contacts -4- from the electrical connector and the
fuel delivery unit using an adapter cable from the -
VAG 1594A- .
– Start the engine and run at idle speed.
– Measure the fuel pump current draw: specified value: 3.5 to
4.5 amps.
– If the measured value is outside the specified value:
– Replace the fuel delivery unit. Refer to
4.2 Tandem Pump, Checking

Supply Pressure, Checking
♦ pressure gauge -VAS 5187-
♦ Vehicle diagnosis, testing and information system -VAS
5051B- , -VAS 5052- or -VAS 5053-
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
Test Conditions
• Coolant temperature must be at least 85 °C (185 °F).
• Pump injector unit OK.
• Fuel filter and fuel lines must not be plugged.
Procedure
– Remove the locking bolt -arrow-.

– Install the -VAS 5187- as shown.

– Connect the vehicle diagnostic, testing and information sys‐
tem -VAS 5051- and select operating mode “Vehicle On-Board
Diagnostics (OBD)“.
– Press button “01 - Engine electronics“ on display.
– Press the diagnostic function “08 - Read measuring value
blocks“.
– Enter display group “1“ via the number keypad and confirm
input by pressing the Q button.
– Read the idle RPM in display field “1“.
– Increase the engine speed to 4000 RPM.
– Observe the pressure displayed on the -VAS 5187- .
Specified value: min. 7.5 bar
– Clamp the return line closed between the fuel filter and the
tandem pump with a hose clamp.
– Increase the engine speed to 4000 RPM.
– Observe pressure displayed on -VAS 5187- .
Specified value: min. 7.5 bar
If the specification is now obtained:
The pressure loss is at the pump injector unit.
– Replace the O-rings of the pump injector unit.
– Replace the tandem pump. Refer to
Note
After removing the -VAS 5187- , tighten the locking bolt to 25 Nm.
Always replace the seal.
Internal Leakage, Checking
Note
After reinstalling a tandem pump, for example after replacing or

repairing a cylinder head, or after replacing an engine, the tandem
pump must absolutely be checked for internal leakage between
the fuel and oil side. Fuel or oil leakages can cause damage to
the engine.

♦ Testing unit for turbocharger -V.A.G 1687-
Procedure
– Disconnect the fuel supply hose (white marking) and the fuel
return hose (blue marking) to the tandem pump.
– Seal the fuel return connection on the tandem pump with a
sealing plug; secure the plug with a spring clamp.

Prepare the -VAG 1687- as follows:

– Remove the pressure regulator valve -2- completely and close
the valves -3 and 4-.
– Connect the test connector -5- to the tandem pump fuel supply
connection using a commercially available compressed air
connection and a piece of a fuel hose; use a spring clamp to
secure it.
Note
In order to be able to turn pressure regulator valve -2-, rotary knob

must be pulled upward.
– Connect the pressurized air hose -1- (pressurized air supply)

to the -VAG 1687- .
Note
If water is located in viewing glass, drain it via water drain screw

-6-.
– Open valve -3-.

– Set pressure to 1.0 bar using pressure regulator valve -2-.
Caution
The maximum test pressure is 1.3 bar and must not be excee‐
ded.
– Open the valve -4- and wait until the testing circuit has filled.
If necessary, continue to regulate pressure to 1.0 bar.
– Closes the valve -3-, in order to maintain the pressure and
observe the drop in pressure for 1 minute.
If there is no pressure drop, then the tandem pump can be used
again; if there is a pressure drop, then the tandem pump must be
replaced.


⇒ “5.1 Fuel Cooler“, page 111
⇒ “5.2 Tandem Pump“, page 111
⇒ “5.3 Fuel Delivery Unit“, page 113
⇒ “5.4 Fuel Level Sensor“, page 114
⇒ “5.5 Fuel Tank“, page 114
5.1 Fuel Cooler

Removing
Observe safety precautions, refer to
⇒ “1.1 Safety Precautions“, page 99 .
Observe rules for cleanliness, refer to
⇒ “1.2 Clean Working Conditions“, page 99 .
Note
The fuel cooler is located in the return line to the fuel tank. It is
attached to the underbody of the vehicle.
– Remove the cover -A-.

– Separate the fuel lines at the fuel cooler.
– Remove the nuts -arrows-.
Installing
the following:
♦ Tighten the nuts for the fuel cooler to 20 Nm.
5.2 Tandem Pump
WARNING
The tandem pump must not be disassembled under any cir‐

cumstances because it can cause the vacuum part to malfunc‐
tion. The result would be brake booster failure.

♦ Hand vacuum pump -VAG 1390-
♦ Hand vacuum pump reservoir -VAG 1390/1-
♦ Hose clip pliers -VAG 1921-

Removing
WARNING
nection!
– Disconnect the supply hose -1- (white marking) and return

hose -2- (blue marking) from the fuel filter.
– Install the -VAG 1390- and the -VAG 1390/1- to the return
hose.
– Operate the -VAG 1390- , until no more fuel runs from the re‐
turn hose. Make sure that no fuel is sucked into the -
VAG 1390- .
– Disconnect the brake booster vacuum line -1- from the tandem
pump -4-.
– Remove the supply hose -2- (white marking) from the tandem
pump -4-.
– Remove the bolts -arrows-.
– Remove the tandem pump -4- from the cylinder head.
– Pull the tandem pump -4- slightly upward, disconnect the re‐
turn hose -3- (blue marking) and remove the tandem pump
-4-.
Installing
the following:
Note
♦ Make sure that tandem pump coupling has proper seating in

camshaft.
♦ Tandem pump seals must always be replaced.

– Connect the return hose -3- (blue marking) to the return con‐
nection on the tandem pump.
– Install the tandem pump and tighten the upper bolts to 20 Nm.
– Tighten the lower bolts to 10 Nm.
– Connect the supply hose -2- (white marking) to the supply
connection and the vacuum line -1- from the brake booster to
the tandem pump -4-.
– Connect the supply hose -1- (white marking) to the fuel filter.
– Install the -VAG 1390- with the -VAG 1390/1- to the fuel filter
return hose -2- (blue marking).
– Operate the -VAG 1390- , until fuel runs from the return hose.
Make sure that no fuel is sucked into the -VAG 1390- .
– Connect the return hose -2- (blue marking) to the fuel filter.
5.3 Fuel Delivery Unit

♦ Ring nut spanner -3217-
Removing
– Remove the cover from fuel delivery unit.
– Disconnect the 4 pin electrical connector and the supply and
return lines from the fuel delivery unit.
WARNING
nection!

Note
Press the buttons together on the connections to do so.
– Remove the ring nut using the -3217- .

– Remove the fuel delivery unit and seal out of the opening in
fuel tank.
Note
If the delivery unit is to be replaced then drain old unit before dis‐
posal.
Installing
– Installation of the fuel delivery unit is the reverse order of re‐
moval.
Note
♦ Do not bend the fuel level sender when installing.

♦ Insert the seal for the fuel delivery unit into opening of fuel tank
dry.
♦ Only lubricate the seal with fuel when installing the fuel deliv‐
ery unit.
♦ Ensure the fuel hoses are seated securely.
♦ After installing the fuel delivery unit, check that the supply, re‐
turn and breather lines are still clipped onto the fuel tank.
♦ Note the installed position of the fuel delivery unit: Mark on the
delivery unit flange must align with the mark on the fuel tank
-arrows-.
5.4 Fuel Level Sensor

Removing
– Remove the fuel delivery unit. Refer to
– Disengage the connector prongs of the wires -3 and 4- and
disconnect.
– Pry off the retaining straps -1 and 2- using a screwdriver and
remove the fuel level sensor for towards bottom -arrows-.
Installing
– Install the fuel level sensor in the guides on the fuel delivery
unit and push up until it engages.
5.5 Fuel Tank



Removing
– Open the fuel tank flap.
– Remove the rear subframe. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 42 ; Removal and Installation .
– Remove the rear right wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Removal and Installation .
– Remove the cover fasteners -arrows- and remove the cover
for the fuel tank.
– Drain the fuel tank and clean the fuel filler tube and surround‐
ing area.
– Remove the bolt and remove the fuel flap unit with rubber
gasket.
– Remove the bolts for the filler neck.
– Remove the cover plate and disconnect the electrical connec‐

tor -arrow- from the fuel delivery unit.
WARNING
nection!

– Disconnect the fuel supply line and return lines at the right front
of the fuel tank.
Note
Press the buttons on the fittings -arrows- downward to do this.
– Remove the tensioning straps. Support the fuel tank using the
-VAG 1383A- while doing so.
– Lower the fuel tank.
Installing
the following:
♦ Make sure the ventilation and fuel lines are not kinked when
installed.
♦ Ensure the fuel hoses are securely seated.
♦ Do not interchange the supply and return lines (return line is
blue or has blue marking, supply line is black).
♦ Clip in the supply and return lines at the fuel tank.
Note
After installing the fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.

6 Special Tools
♦ Voltage tester -VAG 1527-
5051B- , -VAS 5052- or -VAS 5053-
♦ pressure gauge -VAS 5187-
♦ Ring nut spanner -3217-
6. Special Tools 117



equipment required
VAG 1331-
♦ Hand vacuum pump -
VAG 1390-
♦ Hand vacuum pump reser‐
voir -VAG 1390/1-
♦ Hose clip pliers -VAG 1921-

21 – Turbocharger
Caution

followed.
nents.
Observe the following if test and measuring instruments are re‐

quired during a test drive:
♦ Test and measuring instruments must be secured in the rear
seat and operated by a 2nd person from this location.
If test and measuring instruments are operated from the front
passenger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive se‐
rious injuries when the airbag is triggered.

When working on turbocharger, carefully observe the following
Rules of Cleanliness:
♦ Transport and protective packaging and sealing caps are to
be removed only immediately prior to installation.
♦ During repairs, clean oil from connections and hose ends.
120 Rep. Gr.21 - Turbocharger


⇒ “2.1 Charge Air Cooler and Components Assembly Overview“,
page 121
⇒ “2.2 Turbocharger and Attachments Assembly Overview“, page
123
⇒ “2.3 Vacuum Hose Connection Diagram“, page 125
2.1 Charge Air Cooler and Components As‐

sembly Overview
Note
♦ All hose connections for the charge air system are secured by
spring type clamps or by connector couplings. For connector
couplings, always note the following points:
♦ Charge air system must be properly sealed.
♦ During repairs, clean the oil from the connections and hose
ends.
♦ Hose connections and charge air system hoses must be free
of oil and grease before installing. Only on connector cou‐
plings, the sealing ring and the sealing surfaces must be lightly
oiled. Refer to
⇒ “5.1 Hose Connections with Connector Couplings“,
page 129 .

1 - Connecting Hose
2 - Connecting Pipe
3 - Connecting Hose
❑ Connecting pipe/intake
connection.
4 - Connecting Hose
❑ Charge air pipe/turbo‐
charger.
5 - Bolt/Nut, 10 Nm
6 - Charge Air Pipe
7 - Charge Air Cooler
8 - O-ring
9 - Charge Air Pressure Sen‐
sor - G31- and Intake Air Tem‐
perature (IAT) Sensor - G42-
10 - Bolt, 5 Nm
11 - Bracket

2.2 Turbocharger and Attachments Assembly Overview
1 - Oil Supply Line

❑ From the oil filter brack‐
et, see -item 6- in the
⇒ “2.3 Oil Filter Bracket
page 73 .
❑ Fill the oil supply line
with oil before installing
it to the connection fit‐
ting.
ling, refer to
⇒ “5.1 Oil Supply Line“,
page 77 .
2 - Union Nut
❑ Tightening specifica‐
tion, see -item 2- in the
⇒ “2.1 Oil Supply Line
page 70 .
3 - Bolt, 22 Nm
4 - Connection, 30 Nm
❑ Always replace.
❑ Coat the threads and
bolt head contact sur‐
face with -G 052 112
A3- .
❑ Fill the oil supply line
with oil before installing
it to the connection fit‐
ting.
5 - Bolt, 10 Nm
❑ Installation position, see
-items 6 and 9- in the
⇒ “2.1 Oil Supply Line
Assembly Overview“, page 70 .
❑ Component location, see -item 4- in the ⇒ “2.1 Oil Supply Line Assembly Overview“, page 70 .
7 - Seal
❑ Always replace.
8 - Intake Manifold
9 - Gasket
❑ Always replace.
10 - Washer
11 - Nut, 25 Nm
❑ Always replace.
12 - Brace
❑ Between the turbocharger and cylinder block.
13 - Bolt, 40 Nm
❑ First tighten all bolts hand tight.

14 - Connecting Pipe
❑ Air filter/turbocharger.
15 - Transition Piece
16 - Turbocharger
❑ Replace as a complete unit with the exhaust manifold.
❑ Removing and installing, refer to ⇒ “5.2 Turbocharger“, page 129 .
17 - Gasket
❑ Always replace.
18 - Connection, 40 Nm
19 - Union Nut, 30 Nm
20 - Oil Return Line
❑ To the cylinder block.
21 - Bolt, 17 Nm
❑ For the turbocharger vane position sensor.
23 - Vacuum Hose
❑ To the wastegate bypass regulator valve.
❑ Connection diagram for vacuum hoses, refer to
⇒ “2.3 Vacuum Hose Connection Diagram“, page 125 .
24 - Bolt, 20 Nm
❑ First tighten all bolts hand tight.
25 - Nut, 20 Nm
❑ Always replace.
26 - Heat Shield
27 - Front Exhaust Pipe
28 - Bracket
❑ For the oil supply line, see -item 1-.
❑ Secure the oil supply line before installing.
29 - Nut, 22 Nm
❑ Always replace.
❑ To the cooler for the Exhaust Gas Recirculation (EGR).
❑ From the cooler for the EGR.

2.3 Vacuum Hose Connection Diagram
1 - Vacuum Diaphragm
Recirculation (EGR)
change over (Bypass
flap).
2 - Intake Manifold Tuning
(IMT) Valve -N156-
❑ For the intake manifold
change over.
3 - Exhaust Gas Recirculation
(EGR) Cooler Switch Over
Valve -N345-
4 - Wastegate Bypass Regula‐
tor Valve -N75-
5 - Non Return Valve
❑ White the connector
leading to the EGR cool‐
er switch over valve
⇒ Item 3 (page 125) ,
wastegate bypass regu‐
lator valve
⇒ Item 4 (page 125) and
to the vacuum reservoir
⇒ Item 6 (page 125) .
6 - Vacuum Reservoir
❑ With the turbocharger
vane position sensor.
❑ For the boost pressure
regulation.
❑ Component of the turbo‐
charger cannot be re‐
placed.
❑ For the intake manifold flap.
9 - Vacuum Connection
❑ Between the tandem pump and the brake booster.

3 Specifications

Charge Air Cooler to Bracket Bolt - 10
Charge Air Cooler Bracket Bolt/Nut - 10
Charge Air Pipe Nut - 10
Charge Air Pressure/Intake Air Temperature Sensor Bolt - 5
Exhaust Gas Recirculation Connecting Pipe to Bypass Flap Bolt - 22
Exhaust Gas Recirculation Connecting Pipe to Intake Manifold Bolt - 22
Exhaust Gas Recirculation Connecting Pipe to Turbocharger Nut 1 - 22
Front Exhaust Pipe to Turbocharge Nut 1 - 25
Lower Intake Manifold to Cylinder Head Bolt - 22
Oil Return Line Connection to Cylinder Block - 40
Oil Return Line to Turbocharger Bolt - 17
Oil Return Line Union Nut to Connection - 30
Oil Supply Line Bracket to Turbocharger/Exhaust Manifold Nut 1 - 20
Oil Supply Line Clamp Bolt - 10
Oil Supply Line Connection to Turbocharger 1 - 30
Oil Supply Line to Oil Filter Bracket Banjo Bolt - 25
Oil Supply Line Union Nut to Turbocharger - 22
Pendulum Support to Subframe Bolt - 25
Turbocharger Brace to Cylinder Block Bolt 2 - 40
Turbocharger/Exhaust Manifold to Cylinder Head Nut 1 - 25
Turbocharger/Exhaust Manifold Heat Shield Nut 1 - 20
Turbocharger to Turbocharger Brace Bolt 2 - 20
• 2 First tighten all bolts hand tight


⇒ “4.1 Charge Air System, Checking for Leaks“, page 127
4.1 Charge Air System, Checking for Leaks

– Remove the intake hose -1- from the air filter.
– Install the -VAG 1687/10- in the intake hose -1- and secure it
with a clamp.
Prepare the -VAG 1687- as follows:
– Unscrew the pressure regulator valve -2- completely and close

the valves -3 and 4-.
Note
In order to be able to turn the pressure regulator valve -2-, the

knob must be pulled upward.

– Connect the -VAG 1687- to the - VAG 1687/10- as shown.
– Connect a compressed air hose -1- (pressurized air supply) to

the -VAG 1687 - .
Note
If water is located in the viewing glass, drain it via the water drain
screw -6-.
– Open the valve -3-.

– Set the pressure to 0.5 bar using the pressure regulator valve
-2-.
Caution
Pressure must not exceed 0.5 bar! A pressure set too high may
damage the engine.
– Open the valve -4- and wait until the testing circuit has filled.
If necessary, continue to regulate pressure to 0.5 bar.
– Check the charge air system for leaking areas by listening,
touch, using leak detection spray or using the ultrasonic meas‐
uring device -VAG 1842- .
Note
♦ Handling instructions of the -VAG 1842 - . Refer to ⇒ Owner's

Manual .
♦ If a poorly sealed area is discovered, observe the notes for
charge air system when repairing. Refer to
view“, page 121 .
♦ Before removing the - VAG 1687/10- , discharge the pressure
in the testing circuit by disconnecting the coupling from the -
VAG 1687/10- .


⇒ “5.1 Hose Connections with Connector Couplings“, page 129
⇒ “5.2 Turbocharger“, page 129
5.1 Hose Connections with Connector Cou‐

plings
Caution
Connector coupling sealing ring can be damaged if the secur‐

ing clamp is in the locked position when installing. This would
result in a leak. Follow assembly instructions.
Removing
– Release the connector coupling by pulling the locking clip
-arrow-. Separate the hose/tube without assistance from tools.
Installing
– When replacing the sealing ring, lay the ring in the charge air
hose groove. Ensure the gasket is completely seated in the
groove all the way around.
– Oil the sealing surfaces and sealing ring.
– Bring the securing clip into the release position -1-.
– Slide the charge air hose in as far as the stop.
– Bring the securing clip into the lock position -2- and then press
the charge air hose back again.
– Check for correct seating and proper locking of the connector
by pulling on the hose.
5.2 Turbocharger
♦ Hose clip pliers -VAS 6340-

Caution
If mechanical damage is found on the turbocharger, for exam‐

ple, a destroyed compression wheel, it is not enough to just
replace the turbocharger. Perform the following steps to pre‐
vent subsequent damage.
♦ Check the air filter housing, the air filter element and the
intake hoses for contamination.
♦ Check the entire charge air circuit and cooler for contam‐
ination.
If contaminants are found in the charge air circuit, the circuit
must be cleaned and the cooler replaced if necessary.
Removing
– Remove the engine cover. refer to
– Disconnect the hose -arrow- leading to the charge pressure
regulation vacuum diaphragm.
– Disconnect the hose -4- leading to the air filter housing

– Disconnect the tube leading to the crankcase ventilation -5-
on the air guide pipe.
– Loosen the spring type clip on the turbocharger.
– Free up the vacuum hoses.
– Remove the bolts -1 and 2- and remove the air guide tube
-3-.
– Remove the oil supply line banjo bolt -arrow- from the oil filter
bracket and also from the coolant pipe.

– Remove the air guide tube -arrows- on the right longitudinal

member.
– Remove the center and right noise insulation. Refer to ⇒ Body
– Remove the heat shield for right drive axle.
– Remove the right drive axle from the transmission flange.
– Remove the exhaust system suspended mount bolts

-arrows- from the subframe.
Note
Decoupling element in the front exhaust pipe must not be bent

more than 10 degrees, otherwise it may be damaged.
– Disconnect the exhaust system at the double clamp.

– Remove the front exhaust pipe.
– Remove the pendulum supports bolt -arrows A- from the sub‐

frame.
– Remove the air guide hose -4-.

– Remove the bolts -2 and 3- and remove the turbocharger
brace.
– Remove the oil return line -1- from the cylinder block.
– Disconnect the electrical connector from the turbocharger
vane position sensor (not shown in the illustration).

– Remove the connecting pipe bolts -arrows- for the Exhaust

Gas Recirculation (EGR) and remove the pipe.
– Remove the oil supply line-arrows- on the turbocharger and

on the exhaust manifold.
– Remove the heat shield from the exhaust manifold.

– Remove the nuts -arrows-.

– Remove the washers.
– Remove the exhaust manifold/turbocharger to the rear.
Installing
the following:
♦ Seals, sealing rings and self locking nuts must always be re‐
placed.
♦ Pay attention to the installation position of the seal for the ex‐
haust manifold/turbocharger.
♦ Add oil to the turbocharger through the oil supply line con‐
necting piece.
♦ Hose connections and charge air system hoses must be free
of oil and grease before installing. Only on connector cou‐
plings, the sealing ring and the sealing surfaces must be lightly
oiled. Refer to
page 129 .
♦ Charge air system must be properly sealed.
♦ All hose connections for the charge air system are secured by
spring type clamps or by connector couplings. For connector
couplings, always note the following points. Refer to
page 129 .
♦ Secure all hose connections using hose clamps appropriate
for the model type. Refer to ⇒ Electronic parts catalog “ET‐
KA“ .
♦ Install the exhaust system and align it free of tension. Refer to
⇒ “2.2 Mufflers and Mounts Assembly Overview“, page 156 .
♦ Install the right drive axle. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Removal and Installation .
♦ Check the oil level. Refer to
⇒ “3.2 Engine Oil Capacity and Specifications“, page 75 .
Caution
After installing the turbocharger, let the engine idle for approx‐
imately 1 minute without increasing the engine speed. This
ensures adequate oil supply to the turbocharger.

Tightening Specifications
Component Nm
Exhaust manifold/turbocharger to cylinder head 25 1)
Heat shield to exhaust manifold/turbocharger 20 1)
Connecting pipe for the Bypass flap 22
EGR to the Exhaust manifold 22 1)
Oil supply line to exhaust turbocharger 22
Brace for turbocharger to cylinder block 40
Turbocharger brace to turbocharger 20
Oil return line to cylinder block 30
Oil supply line to oil filter bracket 25
Pendulum supports to subframe 25
• 1) replace

6 Special Tools
♦ Hose clip pliers -VAS 6340-

23 – Diesel Fuel Injection

Caution

followed.
nents.
To reduce the risk of personal injury and/or damage to the fuel

injection and glow plug system, always observe the following:
♦ Only disconnect and reconnect wires for glow plug and fuel
injection systems, including test leads, when the ignition is
turned off.
♦ If the engine is to be cranked at starting RPM without starting,
for example, for a compression test, disconnect the electrical
connector for the pump injector unit at the cylinder head:
♦ Obtain the radio code for radios with antitheft coding before
disconnecting the battery.
♦ Always switch the ignition off before disconnecting or con‐
necting the battery, as failure to do so may damage the control
module for diesel direct fuel injection system.
If test and measuring equipment is required during road test, note
the following:
♦ Test and measuring instruments must be secured in the rear
seat and operated by a 2nd person from this location.
If test and measuring instruments are operated from the front
passenger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive se‐
rious injuries when the airbag is triggered.

When working on the fuel supply/injection system, pay careful at‐
tention to the following “6 rules“ of cleanliness:
136 Rep. Gr.23 - Diesel Fuel Injection


♦ In addition, do not let diesel fuel flow onto coolant hoses. If
necessary, the hoses must be cleaned again immediately.
Replace corroded hoses.


⇒ “2.1 Component Locations Overview“, page 138
⇒ “2.2 Engine Control Module Functions and Components,
Adapting“, page 139
⇒ “2.3 Intake Manifold Assembly Overview “, page 139
⇒ “2.4 Pump Injector Unit Assembly Overview “, page 140
2.1 Component Locations Overview

Components -A through D- are not shown in the exploded view.
A - Brake Pedal Switch -F47-

❑ In the footwell at the
brake pedal.
B - Brake Light Switch -F-
❑ In tee footwell at the
brake pedal.
C - Throttle Position (TP) Sen‐
sor -G79-
❑ In the footwell, at the ac‐
celerator pedal.
D - Clutch Pedal Switch -F36-
❑ In the footwell on the
clutch pedal.
1 - Intake Manifold Flap
❑ With the intake flap mo‐
tor.
(EGR) Vacuum Regulator Sol‐
enoid Valve -N18- (Electric)
3 - Intake Manifold Tuning
(IMT) Valve -N156-
(EGR) Cooler, Switch Over
Valve -N345-
5 - Wastegate Bypass Regula‐
tor Valve -N75-
6 - Control Module for Diesel
Direct Fuel Injection System -
J248-
❑ Barometric (BARO)
pressure sensor.
❑ Replacing, refer to
⇒ “5.1 Engine Control Module“, page 145 .
7 - Positive Crankcase Ventilation (PCV) Heating Element -N79-
8 - Engine Coolant Temperature (ECT) Sensor -G62-
❑ For the engine control unit.
❑ With the ECT gauge sensor.
❑ If necessary release the pressure in the cooling system before removing.

9 - Mass Air Flow (MAF) Sensor -G70-

❑ For the pump/injector valve (cylinder 1) through pump/injector valve (cylinder 4).
11 - Engine Speed (RPM) Sensor -G28-
12 - Fuel Temperature Sensor -G81-
13 - Connector
❑ For Camshaft Position (CMP) Sensor -G40- , for camshaft position
❑ For the engine speed (RPM) sensor.
15 - Camshaft Position (CMP) sensor -G40-
❑ For camshaft position.
16 - Charge Air Pressure Sensor - G31- with Intake Air Temperature (IAT) Sensor - G42-
2.2 Engine Control Module Functions and

Components, Adapting
5051B- , -VAS 5052- or -VAS 5053-
Procedure
In the -VAS 5051- select “Guided Fault Finding“.
Once all control modules have been checked:
– Press the “Go to“ button
– Select “Function/component selection“
– “Select drivetrain“
– Select “engine code“
– Select “01-Systems capable of On Board Diagnostic (OBD)“
– Select “engine management system“
– Select “Functions“
– Select “Function or component“
2.3 Intake Manifold Assembly Overview

When the engine is switched off, the intake manifold flap is closed
for approximately 3 seconds and then opens again. This reduces
the stop jolt.
Intake manifold change over is switched depending on engine
speed and Throttle Position (TP).

1 - Bolt, 22 Nm
2 - Connecting Pipe
❑ From the cooler for Ex‐
haust Gas Recirculation
(EGR).
3 - Gasket
❑ Always replace.
4 - Upper Intake Manifold
5 - O-ring
❑ Always replace.
6 - EGR Vacuum Regulator
Solenoid Valve -N18- (Electric)
7 - Bolt, 10 Nm
8 - O-ring
❑ Always replace.
9 - Intake Manifold Flap
❑ With the intake manifold
flap motor.
10 - Bolt, 10 Nm
11 - Gasket
❑ Always replace.
12 - Gasket
❑ Replace
13 - Selector Shaft
Note
14 - Variable Intake Manifold

(Lower Intake Manifold)
❑ With shift rod.
❑ Disassembling and assembling, refer to ⇒ “6.1 Variable Intake Manifold“, page 151 .
15 - Bolt, 10 Nm
❑ Observe the tightening sequence, refer to ⇒ “6.1 Variable Intake Manifold“, page 151 .
16 - Bolt, 22 Nm
17 - Bracket
18 - Bolt, 10 Nm
19 - Vacuum Actuator
Note
20 - Vacuum Hose
21 - Intake Manifold Tuning (IMT) Valve -N156-
❑ Connection diagram for vacuum hoses, refer to ⇒ “2.3 Vacuum Hose Connection Diagram“, page 125 .
2.4 Pump Injector Unit Assembly Overview

♦ Note the rules of cleanliness. Refer to

♦ Always replace the sealing rings and O-rings.
1 - Bolt, 20 Nm + 90° (1/4) ad‐

ditional turn
❑ Always replace.
❑ Pay attention to the se‐
quence when loosening
and tightening, refer to
⇒ “5.2 Pump Injector
Unit“, page 145 .
2 - Rocker Lever Shaft
❑ With rocker arm.
ling, refer to
Unit“, page 145 .
3 - Lock Nut, 30 Nm
4 - Adjustment Screw
❑ Always replace.
❑ Adjusting, refer to
Unit“, page 145 .
5 - Ball Pin
❑ Always replace.
ling, refer to
Unit“, page 145 .
7 - O-ring
❑ Replacing, refer to
Unit O-rings“,
page 148 .
8 - O-ring
❑ Replacing, refer to ⇒ “5.3 Pump Injector Unit O-rings“, page 148 .
9 - O-ring
❑ Replacing, refer to ⇒ “5.3 Pump Injector Unit O-rings“, page 148 .
10 - Heat Protection Seal
❑ Always replace.
11 - Circlip
12 - Cylinder Head
13 - Tension Block
❑ Always replace.

3 Specifications

Exhaust Gas Recirculation Connecting Pipe to Intake Manifold Bolt - 22
Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve to In‐ - 10
take Manifold Bolt
Intake Manifold Flap to Intake Manifold Bolt - 10
Lower Intake Manifold to Cylinder Head Bolt - 22
Pump Injector Unit Tension Block Bolt 1 - 12 + 270° turn
Rocker Lever Shaft to Cylinder Head Bolt 1 - 20 + 90° turn
Rocker Lever Shaft Lock Nut - 30
Vacuum Actuator Bracket to Lower Intake Manifold Bolt - 10
Lower (Variable) Intake Manifold to Upper Intake Manifold Bolt

Tightening Sequence and Specification
Nm.


⇒ “4.1 Engine Control Module DTC Memory, Checking and Eras‐
ing“, page 143
⇒ “4.2 Speed Signal, Checking“, page 143
4.1 Engine Control Module DTC Memory,

Checking and Erasing
5051B- , -VAS 5052- or -VAS 5053-
Procedure
– Connect the -VAS 5051- -1- as follows:
– Connect the -VAS 5051/1- or the -VAS 5051/3- -2- to the Data
Link Connector (DLC).
Only when engine does not start:
– Switch the ignition on.
Selecting Operating Mode
– Press button on display for “Vehicle On Board Diagnostic
(OBD)“.
Selecting Vehicle System
– Press button “01 - Engine electronics“ on display.
Display will indicate control module identification and Engine
Control Module (ECM) coding.
Selecting Diagnosis Function
– Press button “02 - Check DTC memory“ on display.
– If no malfunction is stored in engine control module, “0 DTC(s)
detected“ is displayed.
– If malfunctions are stored in the engine control unit, these are
shown one below another on the display.
– Press the ← key.
– Press button “05 - Erase DTC memory“ on display.
– Press function “06 - End output“.
Note
Regenerate the readiness code after erasing the ECM Diagnostic

Trouble Code (DTC) memory. Refer to
Adapting“, page 139 .
4.2 Speed Signal, Checking

Function
Engine speed signal is supplied at terminal 28 of the Engine Con‐
trol Module (ECM). The signal is required, among other things, by

the automatic transmission control module to calculate shift points

and for the tachometer in instrument panel cluster.
♦ Test box 105 pin -VAG 1598/42- with adapter lead, 94 pin -
VAG 1598/39-2-
♦ Connector test set -VAG 1594-
♦ Wiring diagram
Test Sequence
– Remove the windshield wiper arms and plenum chamber cov‐
er. Refer to ⇒ Electrical Equipment; Rep. Gr. 92 ; Removal
and Installation .
– Release the connector from the ECM and pull off.
– Connect the -V.A.G 1598/42 - to the control module wiring
harness.
– Check for an open circuit/short circuit in the wire connection
between the -V.A.G 1598/42 - socket 28 and instrument panel
cluster according to the wiring diagram. Wire resistance: Max.
1.5 Ω. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations ⇒ Vehicle diagnosis, testing and information
system VAS 5051


⇒ “5.1 Engine Control Module“, page 145
⇒ “5.2 Pump Injector Unit“, page 145
⇒ “5.3 Pump Injector Unit O-rings“, page 148
5.1 Engine Control Module

– Before removing the Engine Control Module (ECM), the con‐
trol module identification and with it also the coding of the
previous control module must be checked. Refer to
Removing
– Remove the windshield wiper arms and plenum chamber cov‐
er. Refer to ⇒ Electrical Equipment; Rep. Gr. 92 ; Removal
and Installation .
– Release the connector from the ECM and pull off.
– Press the control module to the right and pull it out.
Installing
– Insert the new control module and press it toward the left.
– Plug in the electrical connector and latch it into place.
– Check the previous coding and code the new control module.
Refer to
Adapting“, page 139 .
5.2 Pump Injector Unit

♦ Socket insert -3410-
♦ Special wrench, long reach -T10054-
♦ Puller -T10055-
♦ Dial gauge
♦ Grease -G 000 100-
Removing
– Remove the upper toothed belt cover, refer to
⇒ “5.3 Toothed Belt“, page 54 , and the cylinder head cover,
refer to ⇒ “5.1 Cylinder Head Cover“, page 49 .
– Rotate the crankshaft until the cam lobe pair for the respective
pump injector unit to be removed face upward simultaneously.

– Loosen the lock nut of the adjustment screw -1- and remove
the adjustment screw.
– Loosen the bolts -2- for the rocker lever shaft from the outside
toward the inside, using the -3410- and remove the rocker
lever shaft.
– Loosen the bolt -3- for the tension block using the -T10054-
and remove the tension block.
– Pry out the electrical connector for pump injector unit using a
screwdriver. In order to avoid tilting, support the opposite side
of connector with light finger pressure.
Observe the cylinder allocation of the pump injector units.

– Install the -T10055- in place of the tension block into the side
slit of the pump injector unit.
– Using careful knocking motions, pull the pump injector unit
upward out of its cylinder head seat.
Installing
Note
♦ Install a new pump injector unit, also replace the correspond‐

ing adjustment bolt in the rocker arm.
♦ For every procedure that requires adjustment of the pump in‐
jector unit, the adjustment screw in the rocker lever and the
ball pin of the pump injector unit must be replaced.
♦ New pump injector units are shipped with O-rings and heat
protection seal.
– Install the pump injector unit again, replace the O-rings and
the heat protection seal. Refer to
⇒ “5.3 Pump Injector Unit O-rings“, page 148 .
– Before installing the pump injector unit, check that the three
O-rings, heat protection seal and securing ring are seated
properly.
Note
O-rings must not be twisted on themselves.
– Lubricate the O-rings and install the pump injector unit with
great care into the cylinder head seat.
– Using uniform pressure, push the pump injector unit into the
cylinder head seat until seated.
– Insert the tension block into the lateral slot of the pump injector
unit.
Note
If the pump injector unit does not stand at a right angle to the
tension block, the bolt can loosen and thereby cause damage to
the pump injector unit/cylinder head.
– Align the pump injector unit as follows.

– Install the new bolt into the tension block so far that the pump
injector unit can still be lightly turned.
– Align the pump injector unit at a right angle to the thrust bearing
of the camshaft.

– Using a caliper gauge (measuring range minimum 400 mm),

check dimension “a“ from the outer edge of the cylinder head
to the round surface of the pump injector unit.
Cylinder Dimension “a“
1 333.0 ±0.8 mm
2 245.0 ±0.8 mm
3 153.6 ±0.8 mm
4 65.6 ±0.8 mm
– Realign the pump injector unit if necessary and tighten the bolt
as follows:
– Tighten the tension block bolt to 12 Nm and turn an additional
270° (3/4 rotation, additional rotation may occur in several
stages).
– Install the rocker lever shaft and tighten the new bolts as fol‐
lows:
– Hand tighten the inner bolts -2-, then the outer bolts -1- equal‐
ly; then tighten in the same sequence to 20 Nm and 90° (1/4
turn).
– Place a dial gauge as shown onto the adjustment screw of the

pump injector unit.
– Rotate the crankshaft in direction of engine rotation until the
rocker arm roller stands at the camshaft point. Roller side
-arrow A- is positioned at the highest point, dial gauge
-arrow B- is positioned at the lowest point
– Remove the dial gauge.
– Now turn the adjustment bolt into the rocker arm until signifi‐
cant resistance is noticeable (pump injector element stands at
stop).
– Turn back the adjustment bolt from stop approximately 180

degrees.
– Hold the adjustment bolt in this position and tighten the lock
nut to 30 Nm.
– Connect the pump injector unit electrical connector and install
the cylinder head cover, refer to
⇒ “5.1 Cylinder Head Cover“, page 49 , and the upper toothed
belt cover, refer to ⇒ “5.3 Toothed Belt“, page 54 .
5.3 Pump Injector Unit O-rings

♦ Assembly sleeve -T10056-

Removing
– Remove the pump injector unit. Refer to
⇒ “5.2 Pump Injector Unit“, page 145 .
– Pry off old O-rings from the pump injector unit extremely care‐
fully.
– Above all, make sure that no burrs develop at the O-ring seat.
Installing
Note
♦ Always use assembly sleeves for installing the O-rings. Not

using them may cause the O-rings to be damaged during in‐
stallation.
♦ O-rings without distinguishing color marks are gradually intro‐
duced. Ensure the correct allocation of O-rings to grooves: ring
strength decreases in direction toward injector.
♦ Avoid rolling movements when sliding on O-rings. O-rings
must not be twisted on itself in the seat of pump injector unit.
– Remove the heat protection seal together with the securing

ring.
– Clean the seating surfaces for the O-rings on the pump injector
unit very carefully.
– Install the -T10056/1- up to the stop on the pump injector unit.
– Slide the upper, thicker O-ring carefully on the assembly
sleeve and into the seat of the pump injector unit.
– Remove the -T10056/1- .

– Slide the center, thinner O-ring carefully on the -T10056/2- and
into seat of the pump injector unit.


– Slide the lower O-ring carefully on the -T10056/3- and into the
seat of the pump injector unit.
– Slide on a new heat protection seal together with securing ring.
– Install the pump injector unit. Refer to
⇒ “5.2 Pump Injector Unit“, page 145 .

6 Disassembly and Assembly

⇒ “6.1 Variable Intake Manifold“, page 151
6.1 Variable Intake Manifold
Note
To prevent the variable intake manifold from warping, tighten it

only in the sequence described.
– Remove the variable intake manifold together with the lower

intake manifold.
– Loosen the bolts.
– Separate the upper and the lower intake manifold; if neces‐
sary, tap is lightly with a rubber mallet to loosen the two parts
from each other.
– Clean the sealing surface.
– Replace the gaskets.
– Assemble the upper and lower intake manifold and hand tight‐
en all the bolts.
– Tighten all the bolts to 10 Nm in the sequence shown.
– Install the variable intake manifold together with the upper in‐
take manifold.
6. Disassembly and Assembly 151

7 Special Tools
5051B- , -VAS 5052- or -VAS 5053-
♦ Test box 105 pin -VAG 1598/42- with adapter lead, 94 pin -
VAG 1598/39-2-
♦ Connector test set -VAG 1594-
♦ Hand multi meter -VAG 1526- or multi meter -VAG 1715-
♦ Assembly sleeve -T10056-


equipment required
♦ Socket insert -3410-
♦ Special wrench, long reach
-T10054-
♦ Puller -T10055-
VAG 1331-

26 – Exhaust System, Emission Controls

Note
♦ Exhaust manifold, removing and installing. Refer to

⇒ “5.2 Turbocharger“, page 129 .
♦ After exhaust system repairs, make sure the exhaust system
is not under stress and that it has sufficient clearance to the
body. If necessary, loosen the double clamps and clamp and
align the exhaust pipe so that sufficient clearance is main‐
tained to the body and support rings carry uniform loads.
♦ Replace self locking nuts.
Note
♦ Activation of the Exhaust Gas Recirculation (EGR) system oc‐

curs from the diesel direct fuel injection Engine Control Module
(ECM) to the mechanical EGR vacuum regular solenoid valve
or to the electrical EGR system.
♦ Every relevant valve position is possible via cyclic activation.
♦ Replace self locking nuts.
♦ Connection diagram for vacuum hoses. Refer to
154 Rep. Gr.26 - Exhaust System, Emission Controls


Overview “, page 155
⇒ “2.2 Mufflers and Mounts Assembly Overview“, page 156
⇒ “2.3 EGR System Assembly Overview“, page 158
2.1 Front Exhaust Pipe with Catalytic Converter Assembly Overview
1 - from Turbocharger
2 - Gasket
❑ Always replace.
3 - Nut, 25 Nm
❑ Always replace.
4 - Front Exhaust Pipe with
Catalytic Converter
5 - to Rear Muffler
6 - Oxygen Sensor Connector
-T6c-
7 - Suspended Mount
8 - Oxygen Sensor -G39-

2.2 Mufflers and Mounts Assembly Overview
1 - Nut, 40 Nm
2 - from Front Exhaust Pipe
with Catalytic Converter
3 - Double Clamp
tion, refer to
⇒ Fig. ““Double Clamp
Installed Position““ ,
page 157 .
4 - Bolt, 25 Nm
5 - Suspended Mount
tion, refer to
⇒ Fig. ““Suspended
Mount Installed Loca‐
tion““ , page 157 .
6 - Suspended Mount
❑ With retaining ring.
7 - Bracket
8 - Suspended Mount
9 - Rear Muffler
❑ Rear muffler, aligning
free of stress, refer to
⇒ page 157 , and
⇒ Fig. ““Installing Muf‐
fler Free of Tension““ ,
page 157 .
10 - Separating Point
❑ For repairs.
❑ Marked by three de‐
pressions around the
circumference of the ex‐
haust pipe.
❑ At the factory, the exhaust pipe and rear mufflers are installed as a single component. Replacement
exhaust pipes and rear mufflers are supplied separately, with a replacement double clamp for connecting
the joint.
❑ Cut through the exhaust pipe using a body repair saw -VAG 1523- for example, at right angles at the
separating point. Refer to ⇒ Fig. ““Separation Point on Exhaust Pipe““ , page 157 .
11 - Nut, 20 Nm
12 - Tunnel Bridge

Double Clamp Installed Position

Procedure
– Position the double clamp approximately 5 mm from mark A
-arrow 1-.
Note
Mark -A- applies to vehicles with a manual transmission and au‐

tomatic transmission.
Suspended Mount Installed Location

Procedure
– Angled side of foot for suspended mount -arrow- faces the
front of the vehicle.
Separation Point on Exhaust Pipe

♦ Body repair saw -VAG 1523-
Procedure
– Cut through the exhaust pipe at a right angle at the separating
point -2-.
– Position the repair double clamp -4- at the edge markings
-arrows 1 and 3- when installing. Tightening specification: 40
Nm.
Installing Muffler Free of Tension
Procedure
– Bolt at exhaust pipe must be parallel to the tunnel bridge (di‐
mension -x- same on the left and right).

2.3 EGR System Assembly Overview
1 - Bracket
❑ For the bypass flap.
2 - Bolt, 22 Nm
3 - Bolt, 5 Nm
4 - Intake Manifold
❑ With the intake flap mo‐
tor.
5 - O-ring
❑ Always replace.
(EGR) Vacuum Regulator Sol‐
enoid Valve -N18- (Electric)
ling, refer to
⇒ “4.2 EGR Vacuum
Regulator Solenoid
Valve“, page 161 .
7 - Bolt, 10 Nm
8 - Gasket
❑ Always replace.
9 - Connecting Pipe
10 - Cooler
Recirculation (EGR)
system.
❑ Removing, refer to
⇒ “4.1 Bypass Flap and
EGR Cooler, Connect‐
ing“, page 160 .
11 - Exhaust Manifold/Turbo‐
charger
12 - Gasket
❑ Always replace.
13 - Nut, 22 Nm
❑ Always replace.
15 - Gasket
❑ Always replace.
16 - Bypass Flap
❑ Guides the exhaust gas via activation through the EGR cooler switch over valve into the EGR cooler.
❑ Vacuum diaphragm connection diagram. Refer to
❑ Connecting, refer to ⇒ “4.1 Bypass Flap and EGR Cooler, Connecting“, page 160 .

3 Specifications

Bypass Flap Bracket to Bypass Flap Rear Bolt - 5
Bypass Flap Bracket to Intake Manifold Bolt - 10
Bypass Flap to Exhaust Gas Recirculation Cooler Bolt 10
Connecting Pipe to Bypass Flap Bolt - 22
Connecting Pipe to Intake Manifold Bolt - 22
Connecting Pipe to Turbocharger/Exhaust Manifold Nut 1 - 22
Double Clamp Nut - 40
Exhaust Gas Recirculation Cooler to Bypass Flap Bolt - 10
Exhaust Gas Recirculation Cooler to Intake Manifold Bolt - 10
Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve to In‐ - 10
take Manifold Bolt
Front Exhaust Pipe with Catalytic Converter to Turbocharger/Ex‐ - 25
haust Manifold Nut 1
Suspended Mount to Subframe Bolt 1 - 25
Suspended Mount to Tunnel Bridge Bolt - 25
Suspended Mount to Underbody Bolt - 25
Tunnel Bridge to Underbody Nut - 20

⇒ “4.1 Bypass Flap and EGR Cooler, Connecting“, page 160
⇒ “4.2 EGR Vacuum Regulator Solenoid Valve“, page 161
4.1 Bypass Flap and EGR Cooler, Connect‐

ing
Note
To prevent damage caused by tension, follow the procedure as

described.
– Install the bypass flap -1- with a new seal -2- and two bolts
-5- to the Exhaust Gas Recirculation (EGR) cooler -3- and
hand-tighten.
– Install the four bolts -4- and tighten them to 10 Nm.
– Hand tighten the EGR cooler -7- with the three bolts -8- to the
intake manifold -6- (the EGR cooler must make contact and
be moveable in the threaded connections).
– Install the bolts -9- and tighten to 10 Nm.
– Tighten the bolts -8- to 10 Nm.

– Hand tighten the connecting pipe -15- with new seals, and the
two bolts -14- and bolt -16-.
– Hand tighten the bracket -12- with bolt -11- and the bolt -13-
to the bypass flap.
– Install the bracket -12- with bolt -10- to the intake manifold and
tighten to 10 Nm.
– Tighten bolt -11- to 22 Nm.
– Tighten bolt -13- to 5 Nm.
– Tight the bolts -14- and -16- to 22 Nm.
– Install the connecting pipe -18- from the EGR cooler -16- to
the turbocharger/exhaust manifold -17- with the seals, bolts
-20- and new nuts -19-.
– Tighten the bolts -20- and nuts -19- to 22 Nm.
4.2 EGR Vacuum Regulator Solenoid Valve
Note
To prevent damage to the exhaust gas recirculation (EGR) valve

when cleaning, do not use any solvent containing cleaners or
fuels or sharp edged tools or any metal tools.

♦ Brush with plastic bristles
♦ Wet and dry vacuum -VAS 5128-
– Disconnect the electrical connector from the EGR vacuum
regulator solenoid valve and remove the bolts.
– Carefully removing the EGR vacuum regulator solenoid valve
from its seat.
– Use a brush with plastic bristles to clean the rusty surfaces;
then remove loose rust with a cloth.

– Line the inner intake manifold with a lint free cloth to protect
against soot particles.
– Clean the exhaust gas return valve seat in the intake manifold
using a brush with plastic bristles and a cloth. Make sure no
rust particles get into the intake manifold.
– Take the cloth out of the intake manifold and clean the intake
manifold with a vacuum cleaner if necessary.
– Replace the sealing ring.
– Carefully place the EGR vacuum regulator solenoid valve in
the seat in the intake manifold, and tighten the bolts to 10 Nm.

5 Special Tools
♦ Body repair saw -VAG 1523-

28 – Ignition/Glow Plug System

⇒ “1.1 Visual Characteristics of Ceramic and Metal Glow Plugs“,
page 164
1.1 Visual Characteristics of Ceramic and

Metal Glow Plugs
A - Ceramic glow plug
Phased stepping on tip (see magnified area)
color coding -arrow-: white
B - Metal glow plug
Color coding -arrow-: green
164 Rep. Gr.28 - Ignition/Glow Plug System

2 Specifications

Glow Plug - 15

⇒ “3.1 Glow Plug System, Checking“, page 166
3.1 Glow Plug System, Checking

♦ Portable multi meter -VAG 1526A-
Test Conditions
• Fuse strip for the glow plugs in the fuse panel/battery OK
• All electrical components such as, for example, lights and rear
window defroster must be switched off.
• Diesel direct fuel injection engine Control Module (ECM) OK
Test Sequence
– Disconnect the electrical connector for the Engine Coolant
Temperature (ECT) sensor.
Note
By disconnecting the connector from the sensor, a “cold“ engine

state is simulated and a corresponding glow plug procedure is
performed when ignition is switched on.
– Disconnect the glow plug connectors from the glow plugs.

– Connect multi meter for voltage measurement between a glow
plug connector and the vehicle ground.
– Switch the ignition on. The battery voltage must be displayed
for approximately 20 seconds.
– If there is no voltage, refer to ⇒ Vehicle diagnosis, testing and
information system VAS 5051 ⇒ Wiring diagrams, Trouble‐
shooting & Component locations.


⇒ “4.1 Glow Plug, Metal“, page 167
⇒ “4.2 Glow Plug, Ceramic“, page 167
4.1 Glow Plug, Metal

♦ Hand multi meter -VAG 1526C- or Multi meter -VAG 1526A-
Requirements
• Fuse strip for the glow plugs in the fuse panel/battery OK
• Ignition switched off.
Test Sequence
– Disconnect the electrical connectors from the glow plugs.
– Connect the voltage test lamp wire to B+ using adapter clips
from the connector test kit.
– Attach the test lead of the voltage test lamp to each glow plug
in succession. Light Emitting Diode (LED) lights up: Glow plug
OK. LED does not light up: Replace the glow plug
Removing
– Remove and install the glow plugs using the -3220- .
Installing
The rest of the assembly is basically a reverse of the removal
sequence.
– Install the glow plugs using the -3220- and tighten to 15 Nm.
4.2 Glow Plug, Ceramic

♦ Hand multi meter -VAG 1526C- or multi meter -VAG 1526A-

WARNING
♦ The ceramic glow plugs

⇒ “1.1 Visual Characteristics of Ceramic and Metal Glow
Plugs“, page 164 , are very sensitive to impacts and bend‐
ing
♦ For this reason, do not use ceramic sheathed element
glow plugs which have dropped (even from a height of
approximately 2 cm) under any circumstances, even if no
visible damage can be detected.
♦ Installation instructions must be performed in sequence,
otherwise there is a danger the plug breaks and will cause
damage to engine.
Test Conditions
• Engine is cold
• Ignition is switched off
Removing
Note
When removing and installing, do not tilt ceramic sheathed ele‐

ment glow plugs; remove the interfering parts.
– Disconnect the electrical connector from ceramic sheathed el‐

ement glow plugs.
– Remove the ceramic sheathed element glow plugs using the
-3220- .
Installing
the following:
– Cylinder head bore and thread must be completely cleaned of
deposits before installing.
Note
Never oil or grease the threads of bore in the cylinder head and
ceramic sheathed element glow plugs.
– Install the ceramic sheathed element glow plugs into cylinder

head by hand using the -3220- .
– Then tighten ceramic sheathed element glow plugs. Tighten‐
ing specification: 15 Nm
WARNING
♦ After installing and before the first engine start with a cold
engine, always perform a resistance test at all ceramic
sheathed element glow plugs.
♦ If the malfunctioning ceramic sheathed element glow plug
is broken, remove all broken pieces from engine, other‐
wise they can cause damage to engine.

♦ Specified value: Max. 1 Ω

– If specified value is exceeded, replace malfunctioning ceramic
sheathed element glow plug.
Volkswagen Technical Site: http://vwts.ru http://vwts.info 4. Removal and Installation 169

5 Special Tools

equipment required
VAG 1331-
♦ Hand multi meter -
VAG 1526C-
♦ Connector test set -
VAG 1594C-
Edition 08.16.2012 FB

VW Golf 4, Jetta - Engine Mechanical, Fuel Injection and Glow Plug - Repair Manual

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Service

Service Department. Technical Information

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.2 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

6.1 Variable Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

00 – General, Technical Data

1.1 Engine Number

2.1 Engine Data

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2 Rep. Gr.00 - General, Technical Data

1.1 Engine, Securing to Assembly Stand

Use the securing pins at the hooks and pins.

♦ The peg positions on the -2024A- marked with 1 through 4 face

Loosen the coolant line on the flywheel side.

1.2 Engine and Transmission Mount, Align‐

Before loosening the bolts, secure the assembly using the

4 Rep. Gr.10 - Engine Assembly

2.1 Fastener Tightening Specifications

Right Engine Mount

Left Transmission Mount (with a Manual Transmission)

Left Transmission Mount (with a Automatic Transmission)

6 Rep. Gr.10 - Engine Assembly

3 Removal and Installation

3.1 Engine, Removing

When doing any repair work, especially in the engine compart‐

3. Removal and Installation 7

8 Rep. Gr.10 - Engine Assembly

– Remove the pendulum support bolts -arrows- in the specified

The air conditioning refrigerant circuit must not be opened.

To prevent damage to the condenser and also to the refrigerant

To facilitate removal and installation of the engine without having

Shield the bumper from damage using adhesive tape.

Continuation for All

3. Removal and Installation 9

– Install the -T10012- onto the -VAG 1383A- .

– Remove the engine mount to engine mount bracket bolts

Use the -VAS 5085- to remove the bolts.

– Remove the transmission mount to transmission mount brack‐

Carefully guide the engine with transmission, when lowering, to

3.2 Engine, Installing

10 Rep. Gr.10 - Engine Assembly

– Install the front exhaust pipe. Refer to

3. Removal and Installation 11

Special tools and workshop

12 Rep. Gr.10 - Engine Assembly

Special tools and workshop

13 – Crankshaft, Cylinder Block

1.1 General Repair Information

If large quantities of metal particles or other deposits (caused, for

Servicing the clutch. Refer to ⇒ Manual Transmission; Rep. Gr.

1.2 Piston Projection at TDC, Checking

To measure the piston projection at TDC, turn the engine in a

Piston Projection Identification

14 Rep. Gr.13 - Crankshaft, Cylinder Block

Identification of Cylinder Head Gasket

If varying values occur when measuring the projection, use the

2 Description and Operation