Avf Code

Workshop Manual
Passat 1997 ➤
Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector
Engine ID AJM
ATJ AVB AVF AWX
Edition 07.2011
Service
Service Department. Technical Information
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Front engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 10
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Sealing flange and flywheel or drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Pulling needle roller bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.6 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Assembly overview - parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Assembly overview - oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder diesel engine with unit injector - Edition 07.2011
Contents i
1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 82
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.7 Removing and installing viscous fan coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.8 Check fuel cooling pump V166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.9 Check radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Assembly overview - removing and installing fuel tank with attached components . . . . . . 102
1.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.5 Fuel and coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.6 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.7 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.8 Removing and installing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.9 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.10 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.11 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.12 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.13 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.14 Adjust accelerator position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.15 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.16 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.1 Assembly overview - turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.2 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.3 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.3 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.4 Assembly overview - intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.5 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.6 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.7 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Reading and clearing engine control unit event memory . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.3 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
ii Contents
1 Parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.1 Assembly overview - four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.2 Assembly overview - front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Checking exhaust gas recirculation valve (mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.1 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Contents iii
iv Contents
00 – Technical data
1 Technical data
Engine number and engine code ⇒ page 1 .
Engine data ⇒ page 1 .
1.1 Engine number
The engine number („code letters“ and „serial number“) can be
found at the joint between engine and gearbox.
The engine number consists of up to nine characters (alphanumeric).
The first part (maximum 3 characters) makes up the
„engine code“, and the second part (6 characters), the „serial
number“. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
Additionally there is a sticker on the toothed belt guard with „engine
code“ and „serial number“.
The engine code is also included on the vehicle data sticker.
1.2 Engine data
Edition 07.2011, Version 8.0
Engine code AJM ATJ AVB AVF
Manufactured 10.98 ► 09.00 01.00 ► 09.00 10.00 ► 10.00 ►
Emissions fulfil D3 standard EU3 standard EU3 standard EU3 standard
Capacity l 1.9 1.9 1.9 1.9
Output kW at
rpm
85/4000 85/4000 74/4000 96/4000
Torque Nm at
rpm
285/1900 310/1900 250/1900 310/1900
Bore ∅ mm 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 18.0 18.0 19.5 19.0
Fuel according
to
DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Catalytic converter yes yes yes yes
Exhaust gas recirculation
yes yes yes yes
Turbocharging/supercharging
yes yes yes yes
Charge air cooling yes yes yes yes
Engine code AWX
Manufactured 10.00 ►
Emissions fulfil EU3 standard
Capacity l 1.9
Output kW at rpm 96/4000
Torque Nm at rpm 285/1750 ...2500
Bore ∅ mm 79.5
1. Technical data 1
Volkswagen Technical Site: http://vwts.ru http://vwts.info
Engine code AWX
Stroke mm 95.5
Compression ratio 19.0
Fuel according to DIN EN 590
Firing order 1-3-4-2
Catalytic converter yes
Exhaust gas recirculation yes
Turbocharging/supercharging yes
Charge air cooling yes
2 Rep. gr.00 - Technical data
10 – Removing and installing engine
1 Removing and installing engine
Special tools and workshop
equipment required
♦ Gearbox support -3147-
♦ Lifting tackle -2024A-
♦ Support bracket -10-222Awith
rack -10-222A/1-
♦ Support clamp -VW 313-
♦ Engine and gearbox support
-VW 540- and engine
and gearbox support supplementary
kit -VW 540/1B-
♦ Workshop hoist -V.A.G
1202/APassat
1997 ➤ , Passat Variant 1997 ➤
1. Removing and installing engine 3
♦ Drip tray -V.A.G 1306-
♦ Torque wrench (5 ... 50
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Support -T10062-
♦ Spring-type clip pliers -VAS
5024A-
♦ Grease -G 000 100-
♦ Cable ties
Modifying support -T10062-
Additional bore must be made in support -T10062- .
– Make bore in centre between two existing bores.
-a- = 8.5 mm
1.1 Notes on removing
Note
♦ First check whether a coded radio is fitted. If so, obtain antitheft
coding.
♦ The engine is removed forwards without gearbox.
– With ignition switched off, disconnect earth strap from battery.
4 Rep. gr.10 - Removing and installing engine
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Remove engine cover.
– Remove connecting pipe between charge air cooler and intake
connection.
– Detach fuel supply hose (with white marking) and return hose
(with blue marking) from fuel lines (clipped to bulkhead) and
use a cloth to absorb any fuel which escapes.
– Remove intake connection with intake manifold flap and exhaust
gas recirculation valve (mechanical).
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper
– Drain coolant ⇒ page 87 .
– Unbolt hydraulic oil cooling pipe of power-assisted steering
-arrows- and place to one side. Do not open hydraulic oil circuit.
– Remove lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front
– Remove poly V-belt ⇒ page 18 .
– Remove inter-connecting, coolant, vacuum and intake hoses
on engine.
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
– Pull off or disconnect all other electrical connections as necessary
from engine and lay to side.
– Pull vacuum and breather hoses off engine.
– Unscrew front exhaust pipe from turbocharger: ⇒ page 155 ,
Removing and installing parts of exhaust system.
– Unbolt coolant expansion tank for cooling system and lay to
side.
– Remove power-assisted steering vane pump from bracket and
place to one side; hoses remain connected; ⇒ Running gear,
axles, steering; Front and four-wheel drive; Rep. gr. 48 ; Vane
pump, reservoir, hydraulic lines for vehicles with 4 or 5-cylinder
engines .
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 10 .
Continuation for all vehicles
– Remove starter: ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter
– Remove upper engine/gearbox securing bolts.
Note
Do not remove one bolt, only loosen.
– Remove left and right engine mounting upper securing bolts.
Vehicles with automatic gearbox
– Separate torque converter from drive plate (3 securing nuts).
Note
After removing the engine, secure the torque converter against
„falling out“.
– Remove stop -1- -arrows-.
– Secure modified support -T10062- in centre hole on right of
sump.
– Tighten original bolt with the 3 original washers (each 4 mm
thick) -arrow- to 30 Nm.
– Raise engine and gearbox with support -T10062- and engine
and gearbox jack -V.A.G 1383 A- until it is possible to remove
lower engine/gearbox securing bolts.
– Remove lower engine/gearbox connecting bolts and lower assembly
again.
– Fit support bracket -10-222 A- with hooks -10-222 A/2- as
shown.
– Attach gearbox support -3147- to the gearbox bell housing bolt
hole (shown in illustration with engine removed).
– Attach lifting tackle -2024 A- as follows and lift slightly with
workshop crane -VAS 6100- .
Belt pulley end: 1st hole of extension -2024 A/1- at position 1
Flywheel end: 3rd hole in hook rail at position 8
WARNING
Use locking pins -arrows- to secure hooks and locating pins.
Note
♦ The holes marked with 1 … 4 of the support bar point to the
belt pulley.
♦ The holes in the hook rails are counted up from the hook.
– Remove upper engine/gearbox securing bolts.
– Lift engine out forwards.
Note
Guide engine carefully when removing to prevent damage to the
bodywork.
When working on the engine, secure it with engine and gearbox
support -VW 540- and engine and gearbox support supplement -
VW 540/1B- to the assembly stand.
1.2 Notes on installing
Installation is carried out in the reverse order. When installing,
note the following:
WARNING
When doing any repair work, especially in the engine compartment,
pay attention to the following due to the cramped conditions:
♦ Route all the various lines (e.g. for fuel, hydraulics, activated
charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original positions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Vehicles with manual gearbox.
– Check clutch release bearing for wear and renew if necessary.
– Lightly grease clutch release bearing and splines on input
shaft with grease -G 000 100- (do not grease release bearing
guide sleeve).
– A needle bearing must be fitted in crankshaft on vehicles with
manual gearbox; insert needle bearing if not yet fitted
⇒ page 28 .
– Use original bolts to secure torque converter to drive plate.
– Before installing engine, rotate torque converter and engine
drive plate so that one hole is in the starter motor aperture.
– Ensure that the intermediate plate is correctly located on engine.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
– Renew engine mounting self-locking nuts.
– Rock engine to align engine mountings stress-free.
– Install power-assisted steering vane pump: ⇒ Running gear,
axles, steering; Front and four-wheel drive; Rep. gr. 48 ; Vane
pump, reservoir, hydraulic lines for vehicles with 4 or 5-cylinder
engines
– Install poly V-belt ⇒ page 18 .
– Install intake connection with intake manifold flap and exhaust
gas recirculation valve (mechanical).
– Install connecting pipe between charge air cooler and intake
connection.
– Screw front exhaust pipe to turbocharger: ⇒ page 155 , Removing
and installing parts of exhaust system.
– Install starter: ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
– Allow stop of torque support to lie on stop buffer of torque
support under its own weight and tighten bolts to 30 Nm
⇒ page 10 .
– Install air conditioner compressor: ⇒ Heating, air conditioning
system; Rep. gr. 87 ; Air conditioner compressor bracket .
– Install lock carrier with attachments: ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front
– Install front bumper: ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper
– Replenish coolant ⇒ page 87 .
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .
– Check headlight adjustment and correct if necessary ⇒ Maintenance
; Booklet Heft 36 .
– You must adapt gearbox control unit for vehicles with automatic
gearbox. ⇒ Self-diagnosis for automatic gearbox 01N;
Rep. gr. 01 ; Perform basic setting
– Carry out a road test and read event memory ⇒ page 151
Reading and clearing event memory of engine control unit.
1.3 Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
Threaded connection Specified torque
M8 20 Nm
M10 45 Nm
M12 60 Nm
Deviations
Stop/torque reaction support 30 Nm
Front exhaust pipe to turbocharger 25 Nm
Starter to gearbox 65 Nm
1.4 Front engine mounting
1 - Cross tube
❑ With torque support
2 - Stop buffer
3 - Stop
❑ Allow to move onto stop
buffer under its own
weight and tighten securing
bolts.
4 - 30 Nm
1.5 Additional information and assembly
work for vehicles with air conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening refrigerant
circuit:
– Remove retaining clamp(s) for refrigerant lines.
– Remove air conditioner compressor ⇒ Heating, air conditioning
system; Rep. gr. 87 ; Air conditioner compressor bracket .
– Secure air conditioner compressor and condenser to body
such that refrigerant lines/hoses are not under tension.
13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦ Finding metal shavings or a large quantity of small metal particles
during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renew oil spray jets
♦ Renew engine oil cooler
♦ Renew oil filter element
Engine overview ⇒ page 12 .
1.1 Assembly overview
12 Rep. gr.13 - Crankshaft group
I ⇒ page 13
II ⇒ page 14
III ⇒ page 15
IV ⇒ page 17
1.1.1 Part I
1 - 25 Nm
2 - Alternator
3 - 25 Nm
4 - Relay lever
5 - Spacer
❑ Note installation position.
6 - Belt pulley
❑ For poly V-belt.
7 - Tensioning element
❑ For poly V-belt.
❑ Removing and installing
poly V-belt
⇒ page 18 .
8 - Bracket for ancillaries
❑ For alternator, poly Vbelt
tensioning element,
radiator fan viscous
coupling and power-assisted
steering vane
pump
9 - 45 Nm
❑ Observe tightening sequence
⇒ page 18 .
10 - 45 Nm
11 - Vane pump
❑ For power-assisted
steering
❑ Removal and installing:
⇒ Running gear, axles,
steering; Front and fourwheel
drive; Rep. gr. 48 ; Vane pump, reservoir, hydraulic lines for vehicles with 4 or 5-cylinder engines
12 - Banjo bolt, 30 Nm
13 - Seal
❑ Renew.
14 - Pressure line
15 - Belt pulley
❑ For vane pump
16 - Bracket
❑ For tensioning element
17 - Belt pulley
❑ For viscous fan coupling.
1. Dismantling and assembling engine 13
18 - Viscous fan coupling
❑ Removing and installing ⇒ page 96
19 - 10 Nm
1.1.2 Part II
1 - Toothed belt guard upper
part
2 - Toothed belt
❑ Mark direction of rotation
before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 37 .
3 - 20 Nm + 1/8 turn (45°) further
4 - Tensioning roller
5 - 100 Nm
6 - 25 Nm
7 - Camshaft pulley
8 - Hub
❑ With sender wheel
❑ Use counterhold tool -
T10051- to loosen and
tighten.
❑ To remove, use puller -
T10052- .
⇒ page 60 , removing
and installing camshaft.
9 - 10 Nm
10 - Rear toothed belt guard
11 - Sealing grommet
❑ Renew if damaged.
12 - Toothed belt tensioner
13 - Guide roller
14 - Coolant pump
15 - Crankshaft toothed belt pulley
16 - 120 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Use counterhold tool -3099- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
❑ Turning further can be done in several stages.
17 - 15 Nm
18 - 20 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
21 - 10 Nm + 1/4 turn (90°) further
22 - Cover
23 - Toothed belt guard centre part
1.1.3 Part III
1 - Cylinder head cover
❑ Before fitting, thoroughly
clean sealing surface
of cylinder head with
clean cloth.
2 - To turbocharger.
3 - Pressure regulating valve
❑ For crankcase ventilation.
4 - Cap
❑ Renew seal if damaged.
5 - Seal
6 - 10 Nm
❑ First hand tighten all
bolts
7 - Gasket for cylinder head
cover
❑ Renew together with
cylinder head cover only.
8 - 20 Nm
9 - Lifting eye
10 - 10 Nm
11 - Central connector
❑ For unit injector
12 - From brake servo
13 - Tandem pump
❑ For fuel and vacuum
supply.
❑ Checking ⇒ page 128 .
14 - 25 Nm
15 - Supply hose
❑ From fuel filter ⇒ page 106 .
❑ White or with white marking.
❑ Check for secure seating.
❑ Secure with spring-type clips.
16 - Return hose
❑ To fuel filter ⇒ page 106 .
❑ Blue or with blue marking.
17 - Gasket
❑ Renew.
18 - Bolt
19 - Bracket
❑ For fuel filter.
20 - Cylinder head
❑ After renewing, renew entire coolant.
21 - Cylinder head gasket
❑ Renew.
❑ Note marking ⇒ page 34 .
22 - 15 Nm
23 - Hall sender -G40-
❑ For camshaft position.
❑ To remove, unbutton sealing grommet from rear toothed belt guard.
24 - Cylinder head bolt
❑ Renew.
❑ Note sequence when loosening and tightening ⇒ page 48 , Removing and installing cylinder head.
❑ Insert washers in cylinder head before installing ⇒ page 54 , Repairing valve gear
25 - Unit injector
1.1.4 Part IV
1 - 45 Nm
2 - Screen
3 - Bracket
❑ For vacuum reservoir
and charge pressure
control solenoid valve -
N75-
4 - Cylinder block
sealing flanges and flywheel/
drive plate
⇒ page 19 .
crankshaft
⇒ page 26 .
❑ Dismantling and assembling
pistons and conrods
⇒ page 30
5 - Bracket
6 - Bolt
7 - 10 Nm
8 - Gasket
❑ Renew.
9 - Oil filter bracket
⇒ page 69 .
10 - 15 Nm + 1/4 turn (90°) further
❑ Renew.
❑ First fit upper left and
lower right bolts and then tighten all four bolts diagonally.
11 - Engine speed sender
12 - Connection
❑ For thermostat.
13 - 15 Nm
14 - O-ring
❑ Renew.
15 - Thermostat
16 - 45 Nm
❑ Observe tightening sequence ⇒ page 18 .
17 - Bracket for ancillaries
❑ For alternator, radiator fan viscous coupling, poly V-belt tensioning element and power-assisted steering
vane pump
18 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D 176 404 A2- ⇒ page 70 .
19 - 15 Nm
❑ Remove and install both rear bolts to gearbox using socket -T10058-
Sequence for tightening ancillary bracket for ancillaries to cylinder
block
– Place ancillary bracket on cylinder block (observe dowel
sleeve between ancillary bracket and cylinder block).
– Tighten ancillary bracket as shown in following tightening sequence:
1 - Tighten bolt -A- to 45 Nm
2 - Tighten bolt -B- to 45 Nm
3 - Tighten bolt -C- to 45 Nm
4 - Tighten bolt -D- to 45 Nm
5 - Tighten bolt -E- to 45 Nm
6 - Tighten bolt -F- to 45 Nm
1.2 Removing and installing poly V-belt
Procedure
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front .
– Mark direction of rotation of poly V-belt.
– Pivot tensioning roller in -direction of arrow- using straight ring
spanner.
– Remove or fit poly V-belt.
Note
When installing poly V-belt, ensure that belt seats correctly in
pulleys.
2 Sealing flange and flywheel or drive
plate
Note
Repairing clutch: ⇒ 6-speed manual gearbox 01E; Rep. gr. 30 ;
Repairing clutch
1 - Seal
❑ Do not additionally oil or
grease the oil seal sealing
lip.
❑ Before installing, remove
oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal - belt pulley end
⇒ page 20 .
2 - Sealing flange
❑ Must seat on dowel
sleeves.
⇒ page 23
❑ Install with silicone sealant
-D 176 404 A2-
⇒ page 23 .
3 - Cylinder block
crankshaft
⇒ page 26 .
pistons and conrods
⇒ page 30
4 - Flywheel/drive plate
❑ When removing and installing
flywheel, lock
with counterhold
-3067- .
drive plate
⇒ page 21 .
5 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
7 - 15 Nm
8 - Sealing flange with oil seal
❑ Renew complete only.
❑ Do not additionally oil or grease the oil seal sealing lip.
2. Sealing flange and flywheel or drive plate 19
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
❑ Only remove supporting sleeve after sealing flange has been slid onto crankshaft journal.
2.2 Renewing crankshaft oil seal - pulley end
equipment required
♦ Toothed belt pulley counterhold
-3099-
♦ Oil seal extractor -3203-
♦ Assembly tool -T10053-
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
2.2.1 Removing
– Remove toothed belt ⇒ page 37 .
– Remove crankshaft toothed belt pulley. To do this, lock toothed
belt pulley using counterhold -3099- .
Note
When bolting on counterhold, place two washers between toothed
belt pulley and counterhold.
– To guide seal extractor -3203- , screw centre bolt into crankshaft
to stop by hand.
– Screw inner part of oil seal extractor -3203- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
– Lubricate threaded head of oil seal extractor -3203- , place it
in position and, exerting firm pressure, screw it into oil seal as
far as possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
2.2.2 Installing
– Remove oil residue from crankshaft journal using clean cloth.
– Fit guide sleeve -T10053/1- onto crankshaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.
– Using press sleeve -T10053- , press in onto stop with central
bolt.
– Install and tension toothed belt ⇒ page 37 .
2.3 Removing and installing drive plate
Special tools and workshop equipment required
♦ Clutch counterhold -VW 558-
♦ Hexagon bolt M8×45 and two M10 hexagon nuts
♦ Vernier gauge
Loosening and tightening drive plate
– Secure clutch counterhold -VW 558- to drive plate with M8x45
hexagon bolt. Insert two M10 hexagon nuts between counterhold
and drive plate.
Position of counterhold:
♦ A - To loosen
♦ B - To tighten
Installing
– Fit drive plate using washer -1- with recesses -arrow-.
– Fit new bolts and tighten to 30 Nm.
– Use vernier gauge to check distance between drive plate and
cylinder block through three outer holes of drive plate. Specification
-a- : 18.9… 20.5.
If specification is not attained:
– Remove drive plate again and fit shim -2-. Tighten bolts to 30
Nm again.
– Tighten bolts to 60 Nm and turn 90° (1/4 turn) further (turning
further can be done in several stages).
2.4 Removing and installing sealing flange - pulley end
equipment required
♦ Toothed belt pulley counterhold
-3099-
♦ Assembly tool -T10053-
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
Not illustrated:
♦ Silicone sealant -D 176 404 A2-
♦ Hand drill with plastic brush attachment
♦ Flat scraper
2.4.1 Removing
– Remove crankshaft toothed belt pulley. To do this, lock toothed
belt pulley using counterhold -3099- .
Note
When bolting on counterhold, place two washers between toothed
belt pulley and counterhold.
– Drain engine oil.
– Remove sump ⇒ page 70 .
– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove residual sealant on sealing flange using a rotating
plastic brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
2.4.2 Installing
Note
♦ Observe expiry date of sealing compound.
♦ The sealing flange must be installed within 5 minutes of applying
the silicone sealant.
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3
mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ Thickness of sealant bead: 2 ... 3 mm -arrows-
Note
♦ Sealant bead should not be thicker because otherwise excess
sealant can enter sump and plug up strainer in oil pump suction
pipe, as well as drip onto crankshaft oil seal.
♦ Before applying sealant bead, cover sealing surface of oil seal
with a clean cloth.
– Apply silicone sealant bead as shown to clean sealing surface
of sealing flange.
– Fit sealing flange immediately and lightly tighten all bolts.
Note
When fitting sealing flange with oil seal installed use guide sleeve
-T10053/1- .
– Tighten sealing flange securing bolts diagonally and alternately.
Specified torque: 15 Nm.
– Install sump ⇒ page 70 .
Note
Sealing compound must dry for approx. 30 minutes after installation.
Only then fill with engine oil.
Installing toothed belt and adjusting valve timing ⇒ page 37 .
3 Crankshaft
1 - Bearing shells 1, 2, 4 and 5
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
2 - 65 Nm + 1/4 turn (90°) further
❑ Renew.
❑ To measure radial clearance,
tighten to 65 Nm
but not further.
3 - Bearing cap
❑ Bearing cap 1: belt pulley
end.
❑ Bearing cap 3 with recesses
for thrust washers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
4 - Bearing shell 3
❑ For bearing cap without
oil groove.
5 - Thrust washer
❑ For bearing cap 3.
❑ Note fixing arrangement.
6 - Needle bearing
❑ Vehicles with manual
gearbox only.
❑ Pulling out and driving in ⇒ page 28 .
7 - Sender wheel
• Remove crankshaft to renew
❑ For engine speed sender -G28- .
❑ Always renew sender wheel if securing bolts have been unscrewed.
8 - 10 Nm + 1/4 turn (90°) further
❑ Renew.
9 - Dowel pin
❑ Check projection from crankshaft ⇒ page 27
10 - Crankshaft
❑ Axial clearance new: 0.07 … 0.17 mm wear limit: 0.37 mm
❑ Check radial clearance with Plastigage, new: 0.03 … 0.08 mm, wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 29 .
❑ Different design for manual and automatic gearboxes; note part number
11 - Thrust washer
❑ For cylinder block, bearing 3.
12 - Bearing shell 3
❑ For cylinder block with oil groove.
Checking dowel pin projection out of crankshaft
♦ Depth gauge
Test procedure
– Use depth gauge to check fitted pin projection -a- with sender
wheel -1- removed.
1 - Sender wheel
2 - Securing bolt
3 - Projection of fitted pin -3- from crankshaft -a- = ∼2.5 … 3.0 mm
Removing and installing sender wheel
– Renew sender wheel -2- each time bolts -1- are loosened.
Specified torque: 10 Nm + 90° (1/4 turn further).
Note
♦ After securing a 2nd time, countersunk head screw bolting
points in sender wheel are deformed such that:
♦ Screw heads are touching crankshaft -3- -arrows-.
♦ Sender wheel is now lying loose under screws.
3. Crankshaft 27
3.2 Pulling needle roller bearing out of and driving into crankshaft
equipment required
♦ Kukko -21/2- and Kukko
-22/1-
♦ or
♦ Puller -10-202-
♦ Centring mandrel -3176-
♦ or
♦ Drift -VW 207CNote
When installing an engine in a vehicle with a manual gearbox,
always check if the needle bearing is installed in rear of crankshaft,
install if necessary.
Removing
– Extract with puller -A-, e.g. Kukko -21/2- and Kukko -22/1- or
puller -10-202- .
Installing
– Drive in using drift -VW 207C- or centring mandrel -3176- .
♦ The lettering on the needle bearing must be visible when installed.
Installation depth of needle bearing
♦ Dimension -a- = 1.5 mm
3.3 Crankshaft dimensions
(Dimensions in mm)
Honing dimension Crankshaft main
journal ∅
Conrod
journal ∅
Basic dimension -0.022
54.00
-0.042
-0.022
47.80
-0.042
Stage I -0.022
53.75
-0.042
-0.022
47.55
-0.042
Stage II -0.022
53.50
-0.042
-0.022
47.30
-0.042
Stage III -0.022
53.25
-0.042
-0.022
47.05
-0.042
3. Crankshaft 29
4 Pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ „TOP“ faces towards
piston crown.
❑ Checking ring gap
⇒ page 32 .
❑ Checking ring-to-groove
clearance ⇒ page 32 .
2 - Piston
❑ With combustion chamber.
❑ Mark installation position
and cylinder number.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 33 .
❑ Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Checking piston projection
at TDC
⇒ page 33 .
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install using
drift -VW 222A- .
4 - Circlip
5 - Conrod
❑ Renew as set only.
❑ Mark with cylinder number -A-.
❑ Installation position: Marking -B- faces towards pulley end.
6 - Bearing shell
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identification:
Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Axial clearance, wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when measuring
radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 32 .
❑ Piston and cylinder dimensions ⇒ page 34 .
8 - Conrod bearing cap
9 - Oil spray jet
❑ For piston cooling.
10 - 25 Nm
❑ Insert without sealant.
11 - Conrod bolt, 30 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil threads and contact surface.
❑ Use old bolt for measuring radial clearance.
4.2 Separating new conrods
4.2.1 Separating new conrods
– Mark cylinder allocation of conrods ⇒ Item 5 (page 30)
– Lightly clamp the conrod in a vice using aluminium vice
clamps, as shown in the illustration.
Note
♦ To prevent damage to the conrod, only clamp conrod in lightly.
♦ Clamp conrod in below the marked line.
– Unscrew the two bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bearing
cap -arrowuntil it is loose.
4. Pistons and conrods 31
4.3 Pistons and cylinders
Checking piston ring gap
– Insert ring at right angles from above and push down into cylinder
approx. 15 mm from bottom end of cylinder.
Piston ring
dimensions in mm
New Wear limit
1st compression ring 0.20 ... 0.40 1.0
2nd compression ring 0.20 ... 0.40 1.0
Oil scraper ring 0.25 ... 0.50 1.0
Checking ring-to-groove clearance
Clean annular groove before check.
Piston ring
dimensions in mm
New Wear limit
1st compression ring 0.06 ... 0.09 0.25
2nd compression ring 0.05 ... 0,.8 0.25
Oil scraper ring 0.03 ... 0.06 0.15
Checking cylinder bores
♦ Inside caliper 50 … 100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Deviation from nominal dimension
max. 0.10 mm
Note
Cylinder bores must not be measured when cylinder block is
mounted on a repair stand with engine and gearbox support -VW
540- , as measurements may then be incorrect.
Piston installation position and allocation of piston to cylinder
Piston in cylinders 1 and 2:
Larger inlet valve recess -arrows- towards flywheel.
Piston in cylinders 3 and 4:
Larger inlet valve recess -arrows- towards belt pulley end.
Note
♦ New piston allocation to cylinders is shown by a coloured
marking on piston crown.
♦ Piston for cylinders 1 and 2: marked 1/2
♦ Piston for cylinders 3 and 4: marked 3/4
4.4 Checking piston projection at TDC
♦ Measuring tool -VW 382/7-
♦ Universal measuring tool -VW 385/17-
4. Pistons and conrods 33
Test procedure
Piston projection at TDC must be measured when installing new
pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Note
Turn engine clockwise to measure piston projection at TDC.
Piston projection Identification
Holes/notches
0.91 mm … 1.00 mm 1
1.01 mm … 1.10 mm 2
1.11 mm … 1.20 mm 3
Cylinder head gasket identification
♦ Part No. = -arrow 1-
♦ Production control code = -arrow 2- (disregard)
♦ Holes = -arrow 3-
Note
If different values are determined during the projection measurement,
use the largest dimension for selecting the gasket.
4.5 Piston and cylinder dimensions
Honing dimension
Piston ∅ Cylinder bore ∅
Basic dimension mm 79.47 79.51
Stage I mm 79.72 79.76
Stage II mm 79.97 80.01
15 – Cylinder head, valve gear
1 Cylinder head
Checking compression ⇒ page 51 .
Note
♦ When installing an exchange cylinder head with fitted camshaft,
the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cover.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
♦ Cracks between the unit injector holes and the valve seats are
not critical and do not justify exchanging the cylinder head.
1 - Toothed belt guard upper
part
2 - Toothed belt
❑ Mark direction of rotation
before removing.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 37 .
3 - 10 Nm
4 - 25 Nm
5 - 100 Nm
6 - Camshaft pulley
7 - Hub
❑ With sender wheel
❑ Use counterhold tool -
T10051- to loosen and
tighten.
❑ To remove, use puller -
T10052- .
8 - Rear toothed belt guard
9 - Sealing grommet
❑ To remove, unbutton
sealing grommet
1. Cylinder head 35
⇒ Item 9 (page 35) from
rear toothed belt guard.
❑ Renew.
❑ Note sequence when loosening and tightening ⇒ page 48 , Removing and installing cylinder head.
❑ Insert washers in cylinder head before installing ⇒ page 54 , Repairing valve gear
12 - Cylinder head cover
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
13 - To turbocharger.
14 - Pressure regulating valve
❑ For crankcase ventilation.
15 - Cap
❑ Renew seal if damaged.
16 - Seal
17 - 10 Nm
❑ First hand tighten all bolts
18 - Gasket for cylinder head cover
❑ Renew together with cylinder head cover only.
19 - 20 Nm
20 - Lifting eye
21 - Unit injector
22 - Central connector
❑ For unit injector
23 - From brake servo
24 - Tandem pump
❑ For fuel and vacuum supply.
❑ Must not be dismantled.
25 - Supply hose
26 - Return hose
❑ To fuel filter ⇒ page 106 .
27 - Gasket
❑ Renew.
28 - Bolt
29 - Bracket
36 Rep. gr.15 - Cylinder head, valve gear
30 - Cylinder head
❑ If renewed, change entire coolant in system
31 - Cylinder head gasket
❑ Renew.
❑ Note marking ⇒ page 37 .
❑ If renewed, change entire coolant in system
32 - Glow plug
❑ 15 Nm
33 - 15 Nm
34 - Tensioning roller
35 - 20 Nm + 1/8 turn (45°) further
Checking cylinder head for distortion
Max. permissible distortion: 0.1 mm.
Note
♦ Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification
♦ Part No. = -arrow 1-
♦ Production control code = -arrow 2- (disregard)
♦ Holes = -arrow 3-
Note
Different thicknesses of cylinder head gasket are fitted depending
on the piston projection. When renewing gasket, install new gasket
with same identification.
1.2 Removing, installing and tensioning
toothed belt
Note
Always perform adjustment work on toothed belts only on cold
engines.
– Remove upper toothed belt guard.
1. Cylinder head 37
– Remove viscous fan coupling fan wheel.
– Unscrew relay lever for poly V-belt from ancillary bracket.
– Remove centre toothed belt guard.
– Remove vibration damper/belt pulley.
– Remove lower toothed belt guard.
– Unscrew fuel cooler coolant lines from engine and pull them
forwards slightly (coolant hoses remain connected).
Determine which tensioning system (hydraulic or friction-damped)
is installed in this vehicle.
Identifying feature: hydraulic tensioning system with belt tension
damper -arrow- (not fitted in friction-damped tensioning systems).
Vehicles with hydraulic belt tensioning system ⇒ page 38
Vehicles with friction-damped tensioning system ⇒ page 43
1.2.1 Vehicles with hydraulic belt tensioning system
equipment required
♦ Diesel injection pump locking
pin -3359-
♦ 2-hole pin wrench -3387-
♦ Crankshaft stop -T10050-
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
♦ Locking plate -T10008-
♦ Drill bit, ∅ 4 mm
Removing
– Turn crankshaft to TDC No. 1 cylinder.
1. Cylinder head 39
Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
aligns with the lug on the hub sender wheel -arrows-.
– Lock hub using diesel injection pump locking pin -3359- . To
do this, slide locking pin through the free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley with crankshaft stop -
T10050- . To do this, slide crankshaft stop -T10050- from face
side of toothed belt pulley into teeth.
Note
The marks on the crankshaft pulley and the crankshaft stop -
T10050- must be aligned. At the same time, the pin of the crankshaft
stop -T10050- must engage in the drilling in the sealing
flange.
– Mark direction of rotation of toothed belt.
– Insert a hexagon key into the hexagon hole onto limit stop and
push the tensioning roller anti–clockwise -direction of arrowuntil
the toothed belt tensioner can be fixed with the locking
plate -T10008- .
Note
If the hexagon key is not inserted deeply enough there is a risk of
it slipping out.
– Loosen tensioning roller securing nut.
– Unscrew and remove securing bolts -1- of toothed belt tensioner
and remove tensioning element.
– Remove toothed belt.
Installing
Note
Always perform adjustment work on toothed belts only on cold
engines.
– Loosen securing bolts -1- of camshaft pulley until the camshaft
pulley can be moved within the elongated holes.
– Turn camshaft pulley clockwise -in direction of arrow- in elongated
holes until stop is reached.
– Now carefully turn eccentric clockwise using pin wrench
-3387- until eccentric lug lies directly before limit stop -B-.
– Fit toothed belt on camshaft belt pulley, tensioning roller,
crankshaft sprocket and finally on coolant pump sprocket.
– Install toothed belt tensioning device.
– Turn eccentric using 2-hole pin wrench -3387- anti-clockwise
(lug of eccentric moves in direction of stop -A-) until locking
plate -T10008- can be pulled out without resistance and dimension
-a- is less than 4 mm.
– Slacken counterforce of tensioning device clockwise (lug of
eccentric thereby moves in direction of stop -B-) until measurement
-a- is reached. Specification -a-: 4 ± 1 mm.
Note
♦ Dimension -a- reduces when the tensioning roller securing nut
is tightened. Therefore adjust generously using ∅ 4 mm drill
bit.
♦ Measurement -a- may be reduced to 1 mm if engine is at operating
temperature.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
1. Cylinder head 41
– Tighten securing bolts -1- of camshaft pulley to 25 Nm.
– Remove locking pin for diesel injection pump -3359- and
crankshaft stop -T10050- .
– Turn crankshaft two rotations in engine direction of rotation
and set again to TDC no. 1 cylinder.
Note
♦ When doing this, the pin of the crankshaft stop -T10050- must
engage in the sealing flange from the rotational movement.
♦ If the crankshaft is turned past TDC No. 1 cylinder and the
crankshaft stop was unable to engage in the sealing flange,
turn the crankshaft back 1/4 turn to set it to TDC No. 1 cylinder
by again turning in the direction of engine rotation. Corrections
to the position by turning against the direction of engine rotation
in order to insert the crankshaft stop are not permissible.
– Once crankshaft stop -T10050- has been inserted, check
whether:
1.) Dimension -a- is attained
2.) Hub can be locked with locking pin for diesel injection pump
-3359- .
If dimension -a- is not attained:
– Tension the tensioning roller again. To do this, counterhold
tensioning roller using 2-hole pin wrench -3387- , loosen securing
nut and slacken counterforce of tensioning device until
measurement -a- is reached. Specification -a-: 4 ± 1 mm.
– Retighten securing nut to 20 Nm and 45° (1/8 further).
If the hub cannot be locked:
– Pull crankshaft stop -T10050- pin out of hole in sealing flange
and turn crankshaft until hub can be locked with diesel injection
pump locking pin -3359- .
– Loosen securing bolts -1- of camshaft pulley.
– Turn crankshaft slightly against direction of engine rotation
until pin of crankshaft stop -T10050- is positioned just before
hole in sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until pin of
crankshaft stop -T10050- engages in sealing flange from rotational
movement.
– Tighten securing bolts of camshaft belt pulley to 25 Nm.
until crankshaft is set to TDC No. 1 cylinder again.
Note
– Repeat check.
– Install lower toothed belt guard and pulley vibration damper.
– Install centre toothed belt guard.
– Bolt relay lever for poly V-belt to ancillary bracket.
– Bolt fuel cooler coolant lines in place and and fit upper belt
guard.
– Install viscous fan coupling fan wheel.
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front .
; Booklet 36 .
WARNING
hot components.
1.2.2 Vehicles with friction-damped tensioning system
1. Cylinder head 43
equipment required
♦ Diesel injection pump locking
pin -3359-
♦ Crankshaft stop -T10050-
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
♦ Locking pin -T10115-
Removing
– Turn crankshaft to TDC No. 1 cylinder.
Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
aligns with the lug on the hub sender wheel -arrows-.
– Lock hub using diesel injection pump locking pin -3359- . To
do this, slide locking pin through the free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley with crankshaft stop -
T10050- . To do this, slide crankshaft stop -T10050- from face
side of toothed belt pulley into teeth.
Note
The marks on the crankshaft pulley and the crankshaft stop -
T10050- must be aligned. At the same time, the pin of the crankshaft
stop -T10050- must engage in the drilling in the sealing
flange.
– Mark direction of rotation of toothed belt.
– Loosen securing bolts -1- of camshaft pulley until the camshaft
pulley can be moved within the elongated holes.
– Turn 2-hole pin wrench -3387- anti-clockwise until toothed belt
tensioning roller can be locked with locking pin -T10115- .
– Now turn pin-wrench clockwise to stop and hand-tighten securing
nut.
1. Cylinder head 45
You can ignore the -arrow-.
– Remove toothed belt first from coolant pump and then from
remaining pulleys.
Installing
Note
♦ Adjustment work on toothed belts must be performed only on
cold engines, as the indicator position on the tensioning element
varies depending on the engine temperature.
♦ The tensioning roller must be locked with locking pin -T10115-
and secured to right limit stop.
– Turn camshaft pulley anti-clockwise -in direction of arrow- in
elongated holes until stop is reached.
– Fit toothed belt to crankshaft toothed belt pulley, tensioning
roller and camshaft pulley.
– Then fit toothed belt on coolant pump toothed belt pulley.
Note
Ensure that tensioning roller seats correctly in rear toothed belt
guard -arrow-.
– Release tension on tensioning roller by turning with 2-hole pin
wrench -3387- against -direction of arrow- and remove locking
pin from tensioning roller.
– Now carefully turn tensioning roller clockwise using pin wrench
-3387- until indicator is in middle of gap in the base plate
-arrow-.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
and set again to TDC no. 1 cylinder.
Note
– Once the crankshaft stop -T10050- has engaged, check
whether the hub can be fixed in place using the locking pin for
diesel injection pump -3359- .
If the hub cannot be locked:
– Pull crankshaft stop -T10050- pin out of hole in sealing flange
and turn crankshaft until hub can be locked with locking pin.
– Loosen securing bolts -1- of camshaft pulley.
1. Cylinder head 47
– Turn crankshaft slightly against direction of engine rotation
until pin of crankshaft stop -T10050- is positioned just before
hole in sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until pin of
crankshaft stop -T10050- engages in sealing flange from rotational
movement.
until crankshaft is set to TDC No. 1 cylinder again.
Note
– Repeat check.
– Install lower toothed belt guard and pulley vibration damper.
– Install centre toothed belt guard.
– Bolt relay lever for poly V-belt to ancillary bracket.
– Bolt fuel cooler coolant lines in place and and fit upper belt
guard.
– Install viscous fan coupling fan wheel.
50 ; Body - front .
; Booklet 36 .
WARNING
hot components.
1.3 Removing and installing cylinder head
equipment required
♦ Guide pins -3070-
Nm) -V.A.G 1332-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
1.3.1 Removing
Note
Before removing toothed belt from camshaft belt pulley, lock
toothed belt tensioning device ⇒ page 37 ; Removing, installing
and tensioning toothed belt.
– Before removing cylinder head, extract fuel from tandem pump
using hand vacuum pump with accessories -V.A.G 1390- and
water drainage container -V.A.G 1390/1- ⇒ page 125 , Removing
and installing tandem pump.
– Remove hub for camshaft sprocket ⇒ page 60 , Removing
1. Cylinder head 49
– Maintain sequence when loosening and tightening cylinder
head bolts.
1.3.2 Installing
Note
♦ Always renew cylinder head bolts.
♦ In cases of repair carefully remove gasket remains from cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces. When using abrasive
paper do not use a grade less than 100.
♦ Carefully remove emery and abrasive remains.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
– Turn crankshaft to TDC marking before fitting cylinder head.
– Turn crankshaft against engine direction of rotation until all
pistons are about the same distance below TDC.
– Position cylinder head gasket.
– To centre, screw guide pins -3070- into outer threaded holes
on intake side.
– Fit cylinder head, screw in 8 remaining cylinder head bolts and
tighten by hand.
– Unscrew guide pins -3070- though screw holes and fit cylinder
head bolts.
– Tighten cylinder head in four stages in sequence shown as
follows:
1 - Tighten initially with torque wrench:
Stage I = 40 Nm
Stage II = 60 Nm
2 - Turn further with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
Note
It is not necessary to retighten cylinder head bolts after repairs.
– After tightening cylinder head, turn camshaft so that cams for
No. 1 cylinder point equally upwards. Before fitting toothed
belt, turn crankshaft in engine direction of rotation
⇒ page 37 , removing, installing and tightening toothed belt.
– Install hub for camshaft sprocket ⇒ page 60 , Removing and
installing camshaft.
1.4 Checking compression
1. Cylinder head 51
equipment required
♦ Hinged socket -3220-
Nm) -V.A.G 1331-
♦ Adapter -V.A.G 1381/12-
♦ Compression tester -V.A.G
1763-
Test prerequisite
• Engine oil temperature min. 30 °C.
Test procedure
– Pull off central connector for unit injectors.
– Remove all glow plugs using hinged socket -3220- .
– Screw in adapter -V.A.G 1381/12- in place of the glow plugs.
– Check compression using compression tester -V.A.G 1763- .
Note
Using compression tester ⇒ Operating instructions.
– Operate starter until tester shows no further pressure increase.
Compression pressures:
New: 25 ... 31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar
– Install glow plugs using hinged socket -3220- , specified torque:
15 Nm.
Note
Disconnecting the central connector for unit injectors causes
faults to be stored. Therefore, read event memory and delete if
necessary.
1. Cylinder head 53
2 Repairing valve gear
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
Assembly overview - valve gear ⇒ page 54 .
2.1 Assembly overview - valve gear
1 - 20 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Note sequence when
loosening and tightening
⇒ page 60 , Removing
and installing
camshaft.
2 - Rocker arm shaft
❑ Do not interchange.
❑ Renew.
❑ Note sequence when
loosening and tightening
⇒ page 48 , Removing
and installing cylinder
head.
❑ Before installing, insert
washers
⇒ Item 4 (page 54) in
cylinder head.
4 - Washer
❑ For cylinder head bolts.
❑ Insert in cylinder head
before installing bearing
caps
5 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve
clearance compensation.
❑ Set down with contact
surface facing downwards.
❑ Before installing, check camshaft axial clearance ⇒ page 55 .
❑ Oil contact surface.
❑ Before removing, remove camshaft bearing caps
6 - Cotters
7 - Valve spring plate
8 - Outer valve spring
❑ Removing and installing: with cylinder head removed: fitted with valve spring compressor -2037- :
⇒ page 59 , renewing valve stem seals
9 - Inner valve spring
❑ Removing and installing: with cylinder head removed: fitted with valve spring compressor -2037- :
⇒ page 59 , renewing valve stem seals
10 - Valve stem seal
❑ Renew. ⇒ page 59 .
11 - Valve guide
12 - Unit injector
❑ Removing and installing: ⇒ page 146 .
13 - Cylinder head
❑ See note ⇒ page 54 .
❑ Reworking valve seats ⇒ page 57 .
14 - Seal
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape).
15 - Valves
❑ Valve dimensions ⇒ page 56
16 - Bearing shell
❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
17 - Camshaft
❑ Checking axial clearance ⇒ page 55 .
❑ Check radial clearance with Plastigage, wear limit: 0.11 mm.
❑ Runout: max. 0.01 mm.
❑ Identification and valve timing ⇒ page 57 .
18 - Bearing cap
❑ Installation sequence ⇒ page 60 , removing and installing camshaft
❑ To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- ⇒ page 56
19 - 8 Nm + 1/4 turn (90°) further
❑ Renew.
Checking camshaft axial clearance
2. Repairing valve gear 55
♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Check with bucket tappets removed and with first, third and last
bearing caps fitted.
Wear limit: max. 0.15 mm
Seal parting surfaces of bearing caps 1 and 5 with sealant -AMV
174 004 01-
– Apply sealant -AMV 174 004 01- thinly and evenly on the surfaces
-1-.
Note
Be careful that no sealant gets into grooves -arrows-.
Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve
∅ a mm 35.95 31.45
∅ b mm 6.980 6.956
c mm 89.95 89.95
α ∠° 45 45
Camshaft identification, valve timing
Identification
♦ Cam base diameter: -a- = 52.8 mm ∅.
♦ Identification by stamped numbers and letters on face of no.
4 cylinder exhaust cam.
No. 4 cylinder -arrow- 038 R
or
858 R
Valve timing at 1 mm valve lift
Inlet opens ATDC 15.8°
Inlet closes ABDC 25.3°
Exhaust opens BBDC 28.2°
Exhaust closes BTDC 18.7°
2.2 Reworking valve seats
♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient
to rework or renew valve seats and valves. There is also a
requirement to check the valve guides for wear. This is particularly
important on high mileage engines.
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking dimensions.
If the reworking dimension is exceeded, the hydraulic
valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as follows:
– Insert valve and press firmly against seat.
Note
If the valve is to be renewed as part of a repair, use a new valve
for the calculation.
– Measure distance -a- between end of valve stem and upper
edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension: inlet valve 43.4 mm, exhaust valve 43.2 mm
Measured distance minus minimum dimension = max. permissible
reworking dimension.
Example:
Measured distance 44.1 mm
Minimum dimension 43.4 mm
= Max. permissible reworking
dimension
0.7 mm
2.2.1 Reworking inlet valve seat
a = ∅ 35.7 mm
b = 1.6 mm
45° = Valve seat angle
Note
The 30° lower valve seat chamfer is necessary to ensure that the
inlet channel flow characteristics are maintained.
2.2.2 Reworking exhaust valve seat
a = ∅ 31.4 mm
b = 2.7 mm
45° = Valve seat angle
2.3 Checking valve guides
♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Rock: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
2.4 Renewing valve stem seals
equipment required
♦ Assembly tool -2036-
♦ Puller -3047A-
♦ Fitting tool -3129-
♦ Valve lever -VW 541/1A-
♦ Thrust piece -VW 541/5-
2.4.1 Removing
(With cylinder head installed)
– Remove camshaft ⇒ page 60 .
– Remove bucket tappets and place them with the contact surface
downwards. When doing this, ensure that the tappets are
not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Fit assembly tool -2036- and adjust mountings to height of
studs.
– Remove valve springs using valve lever -VW 541/1A- and
press tool -VW 541/5- .
Note
The valves are supported by the piston crown.
– Pull off valve stem seals using puller -3047A- .
2.4.2 Installing
– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
damaged.
– Place new valve stem seal in fitting tool -3129- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
2.5 Removing and installing camshaft
equipment required
♦ Counterhold tool -T10051-
♦ Puller -T10052-
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
♦ Sealant -AMV 174 004 01-
2.5.1 Removing
– Remove securing bolts for camshaft toothed belt pulley -1-.
– Pull camshaft toothed belt pulley off hub.
– Loosen hub securing bolt -1-.
– To do this, use counterhold -T10051- .
– Loosen hub securing bolt about 2 turns.
– Fit puller -T10052- and align it with holes in hub.
– Screw securing bolts -1- into hub.
– Apply tension to hub by evenly tightening puller central bolt
-2- until hub releases from taper of camshaft.
Note
When doing this, hold puller with 30 mm spanner.
– Remove hub from taper of camshaft.
– Remove cylinder head cover.
– Remove rocker arm shafts.
Note
♦ First loosen both outer and then inner securing bolts respectively.
♦ Mark rocker arm shafts to prevent interchanging. This will prevent
having to perform basic settings of unit injectors.
– Remove tandem pump ⇒ page 125 .
– First remove bearing caps 5, 1 and 3. Loosen bearing caps 2
and 4 alternately and diagonally.
2.5.2 Installing
Note
♦ When camshaft is installed, No. 1 cylinder cams must point
upwards.
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retaining
lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.
– Oil running surfaces of shell bearings.
– Tighten bearing caps 2 and 4 alternately and diagonally to 8
Nm + 1/4 turn (90°) further (renew).
– Install bearing caps 5, 1 and 3 and also tighten to 8 Nm + 1/4
turn (90°) (renew).
Note
♦ Seal parting surfaces of bearing caps 1 and 5 with sealant -
AMV 174 004 01- ⇒ page 56 .
♦ Bearing cap 5 must be flush with outer edge of cylinder head,
otherwise leaks can occur at the tandem pump.
– Install camshaft oil seal ⇒ page 63 .
– Install rocker arm shafts and tighten securing bolts, first the
inner and then the outer, diagonally and evenly. Specified torque:
20 Nm + 1/4 turn (90°) further (renew).
– Fit hub onto camshaft.
– Tighten hub securing bolt -1- specified torque: 100 Nm.
– To do this, use counterhold -T10051- .
– Push camshaft toothed belt pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be
on top.
– Align camshaft toothed belt pulley at centre of elongated
holes.
– Hand tighten securing bolts -1- to camshaft toothed belt pulley
so that there is no play.
– Lock hub using diesel injection pump locking pin -3359- .
– Install tandem pump ⇒ page 125 .
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. The hydraulic compensation
elements must settle (otherwise valves will strike pistons).
2.6 Removing and installing camshaft oil seal
equipment required
♦ Fitting tool -10-203-
♦ Oil seal extractor -3240-
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
♦ Bolt M12×65
2.6.1 Removing
– Remove camshaft toothed belt pulley and hub ⇒ page 60 ,
Removing and installing camshaft.
– Screw inner part of oil seal extractor -3240- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
– Lubricate threaded head of oil seal extractor -3240- , place it
in position and, exerting firm pressure, screw it into oil seal as
far as possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
2.6.2 Installing
– Remove oil residue from camshaft journal using a clean cloth.
– Tape over groove in camshaft taper (e.g. with adhesive tape).
– Fit oil seal carefully on camshaft.
– Press in oil seal with press piece of fitting tool -10-203- and
bolt M12×65 onto stop.
50 ; Body - front .
; Booklet 36 .
17 – Lubrication
1 Parts of lubrication system
Note
♦ If large quantities of swarf or metal particles (caused, for example,
by partial seizure of the crankshaft or conrod bearings)
are found in the engine oil when performing repairs, clean the
oil passages thoroughly and renew the engine oil cooler in order
to prevent subsequent damage.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter!
Checking oil pressure ⇒ page 75 .
1.1 Engine oil
Oil capacities ⇒ page 66
Engine oil specification ⇒ page 66
Markings on oil dipstick ⇒ page 66
1.1.1 Oil capacities
With oil filter 3.6 l
Without oil filter 3.1 l
1.1.2 Engine oil specifications:
Vehicles without extended service interval:
Only use engine oil conforming to VW standard 50501.
Vehicles with extended service interval:
Only use engine oil conforming to VW standard 50601 or 50700.
1.1.3 Markings on oil dipstick
1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: can be topped-up with engine oil.
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
66 Rep. gr.17 - Lubrication
1.1.4 Sump acoustic cover
Only in vehicles from 09.02
– When fitting, slide cover -A- between sump and engine mounting/
bracket for ancillaries for alternator and fasten with screw
clips -B- in crankcase bores.
1.2 Assembly overview - parts of lubrication
system
Part II: oil filter bracket, exploded view ⇒ page 69
1 - 15 Nm
2 - Sealing flange
❑ With seal.
❑ Must seat on dowel
sleeves.
⇒ page 23
❑ Install with silicone sealant
-D 176 404 A2-
⇒ page 23 .
❑ Do not additionally oil or
grease the oil seal sealing
lip.
❑ Before installing, remove
oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal on belt pulley end
⇒ page 20
3 - Chain tensioner with tensioning
rail, 15 Nm
❑ When installing, pretension
spring and fit.
4 - 25 Nm
❑ Insert without sealant.
5 - Oil spray jet
❑ For piston cooling.
6 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 66 .
7 - Piston fitting tool
❑ Pull out to extract oil.
1. Parts of lubrication system 67
8 - Guide tube
9 - Dowel sleeves
10 - Seal
❑ Renew.
11 - Suction line
❑ Clean strainer if soiled.
12 - Baffle plate
13 - 40 Nm
14 - 15 Nm
15 - Oil sump
❑ Clean sealing surface before fitting.
❑ Remove and install both rear bolts to gearbox using socket -T10058-
❑ For vehicles from 09.02 with acoustic cover ⇒ page 67
16 - Seal
❑ Renew.
17 - Oil drain plug, 30 Nm
❑ If seal is leaking, nip open and renew.
18 - 10 Nm
19 - Protective cap
20 - Oil level/oil temperature sender -G266-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
21 - Chain sprocket for oil pump
22 - Oil pump
❑ With 12 bar pressure relief valve.
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
23 - 25 Nm
❑ Engine code AVF: 20 Nm + 1/4 turn (90°) further
24 - Chain
1.3 Assembly overview - oil filter bracket
1 - Oil pressure switch -F1- , 20
Nm
❑ 0.7 bar switch: brown or
0.9 bar switch: grey
❑ If seal is leaking, nip
open and renew.
2 - Gasket
❑ Renew.
3 - 15 Nm + 1/4 turn (90°) further
❑ Renew.
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
4 - Oil filter bracket
5 - Seal
❑ Renew.
6 - Oil supply line
❑ To turbocharger.
8 - Cap, 25 Nm
❑ Loosen and tighten with
oil filter spanner -3417-
9 - O-ring
❑ Renew.
10 - Oil filter element
❑ Ensure "Top" is uppermost
when fitting
11 - Engine oil cooler
❑ Engine codes AVF, AWX
❑ Ensure clearance to adjacent components.
12 - Plug, 25 Nm
13 - Gasket
❑ Renew.
❑ Engine codes AJM, ATJ, AVB
❑ Ensure clearance to adjacent components.
15 - Gasket
❑ Renew.
❑ Fit into lugs on engine oil cooler.
16 - Plug, 10 Nm
❑ If seal is leaking, nip open and renew.
17 - Plug
❑ For pressure relief valve
❑ Do not loosen.
1.4 Removing and installing oil sump
equipment required
♦ Support bracket -10-222A-
♦ Workshop hoist -V.A.G
1202/A-
Nm) -V.A.G 1331-
♦ Allen key, long reach -
T10058-
Not illustrated:
♦ Cable ties
♦ Hand drill with plastic brush attachment
♦ Silicone sealant -D 176 404 A2-
♦ Eye protection
1.4.1 Removing
Engine codes ATJ, AVF, AWX:
To remove the sump you need to remove the engine: ⇒ page 3 .
Engine codes AJM, AVB:
– Drain engine oil.
– Cut cable tie -arrows-, open bracket for start cable, remove
cable.
– For vehicles from 09.02 remove acoustic cover ⇒ page 67 .
– Remove stop -1- -arrows-.
– Remove bracket -1- for ATF lines -arrows-.
– Pull connector off oil level/temperature sender.
– Mark the fitting position of threaded connections -1- and locating
sleeves -2- below on the left and right engine mounts.
– Unbolt both engine mountings from below.
– Fit support bracket -10-222A- as shown and take up weight of
engine in installation position.
– Tension engine slightly with spindles of support bracket
-10-222A- .
– Support subframe with workshop crane -V.A.G 1202/A- .
Note
To avoid having to perform wheel alignment, the subframe must
only be loosened or lowered at the front end.
– First remove front bolts -2- and -3- on left and right-hand sides
of subframe Then remove bolts -4-.
Vehicles with manual gearbox.
– Loosen left gearbox mounting nut -arrowuntil it is flush with
end of bolt (turned approx. 4 threads).
– Loosen rear left gearbox mounting rear bolt -2- several turns,
remove left gearbox mounting front bolt -1-.
– Loosen rear right gearbox mounting rear bolt -2- several turns,
remove right gearbox mounting front bolt -1-.
– Lower subframe slowly with workshop crane -V.A.G 1202/A- .
– Remove workshop crane -V.A.G 1202/A- , swing anti-roll bar
down.
Note
Use socket -T10058- to loosen and tighten two rear oil sump bolts.
– Remove sump.
– Remove sump, it may be necessary to release sump by tapping
lightly with a rubber head hammer.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump with a rotating brush, e.g.
an electric hand drill with a plastic brush attachment (wear eye
protection).
– Clean sealing surfaces. They must be free of oil and grease.
1.4.2 Installing
Note
♦ When fitting the oil sump to the removed engine, make sure
that the oil sump is aligned flush with the intermediate plate on
the flywheel side, i.e. the sump must protrude 0.8 mm beyond
the cylinder block.
♦ When the engine is installed, the oil sump must be flush with
the gearbox flange.
♦ Observe expiry date of sealing compound.
♦ The sump must be installed within 5 minutes of applying silicone
sealing compound.
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3
mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ 2 ... 3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing
compound will enter the oil sump and may block the oil suction
line strainer.
– Apply silicone sealing compound bead as shown to the clean
sealing surface of the sump. (The figure shows the position of
the sealant bead on the cylinder block.)
– Before fitting oil sump, insert vertical M10 bolts in oil sump.
– Install sump immediately and tighten all sump bolts lightly.
Engine codes ATJ, AVF, AWX:
– Tighten M7 sump bolts diagonally to 15 Nm.
– Tighten M10 bolts of sump/cylinder block to 40 Nm.
– Install engine: ⇒ page 3 .
– Tighten bolts securing sump to gearbox to 45 Nm.
Engine codes AJM, AVB:
– Gently tighten bolts between sump and gearbox.
– Tighten M7 sump bolts diagonally to 15 Nm.
– Tighten M10 bolts of sump/cylinder block to 40 Nm.
– Tighten bolts securing sump to gearbox to 45 Nm.
Note
Let sealing compound dry for approx. 30 minutes after installing
oil sump. Only then fill with engine oil.
Further assembly is basically the reverse of the dismantling sequence.
1.5 Checking oil pressure and oil pressure switch
equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Voltage tester -V.A.G 1527/
B-
♦ Auxiliary measuring set -
V.A.G 159/A- or -V.A.G
1594CNote
Functional check and repair of the optical and acoustic oil pressure
warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test procedure
– Remove oil pressure switch -F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527B- using test cables from
-V.A.G 1594 A- or -V.A.G 1594C- to battery positive (+) and
oil pressure switch. LED must not light up.
– Start engine and increase speed slowly.
Oil pressure switch, brown:
– At 0.55 ... 0.85 bar, the LED must light up; otherwise renew oil
pressure switch.
– Increase engine speed further. At 2000 rpm and an oil temperature
of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
Oil pressure switch, grey:
– At 0.75 ... 1.05 bar, the LED must light up; otherwise renew oil
pressure switch.
– Increase engine speed further. At 2000 rpm and an oil temperature
of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
19 – Cooling
1 Parts of cooling system
Note
♦ When the engine is warm, the cooling system is under pressure.
If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers -VAS 5024A- or hose clip pliers -V.A.G
1921- are recommended for installation of spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Test for leaks in cooling system using cooling system tester -
V.A.G 1274- and adapter for expansion tank -V.A.G 1274/8- and
adapter for sealing cap -V.A.G 1274/9- .
Parts of cooling system - body side ⇒ page 78 .
Parts of cooling system - engine side ⇒ page 82 .
Draining and filling with coolant ⇒ page 87 .
Coolant mixture ratios ⇒ page 87 , draining and filling with coolant.
1.1 Assembly overview - parts of cooling
system, body side
1.1.1 Vehicles up to 01.02
Vehicles from 01.02 ⇒ page 80
78 Rep. gr.19 - Cooling
1 - Coolant hose
❑ From fuel cooler unit
⇒ Item 29 (page 84)
2 - Connection piece
3 - Connecting hose
4 - Coolant hose
❑ To fuel cooler unit
5 - Fuel cooling pump -V166-
❑ Switched on at a temperature
of approx. 70°
C
6 - Secondary cooler for coolant
❑ For fuel
❑ Installation location: in
front of right wheel
housing
❑ To remove, clamp off
coolant hoses
⇒ Item 1 (page 79) and
⇒ Item 4 (page 79) with
hose clip -3094- .
7 - 10 Nm
8 - Rubber grommet
9 - Retaining frame
❑ For secondary cooler for
coolant
10 - Retaining clip
11 - Rubber mounting
12 - Bracket
13 - Radiator fan -V7-
❑ Vehicles with optional equipment only.
14 - Locking bolt
15 - Fan ring
❑ Clipped into air ducting and secured with locking bolt ⇒ Item 14 (page 79) .
16 - 2-pin connector
17 - Cap
❑ Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- .
❑ Test pressure 1.4 ... 1.6 bar.
18 - O-ring
19 - 3 Nm
20 - Coolant expansion tank
❑ Test cooling system for leaks using cooling system tester -V.A.G 1274- and adapter for expansion tank
-V.A.G 1274/8- .
1. Parts of cooling system 79
21 - Coolant hose
❑ From upper coolant pipe ⇒ Item 26 (page 80) .
22 - O-ring
❑ Renew.
23 - Lower coolant hose
❑ To connection for thermostat ⇒ Item 22 (page 84)
❑ Secured to radiator and thermostat connection with a retaining clip.
24 - Junction
25 - Rubber washer
26 - Coolant hose
❑ To shut-off valve ⇒ Item 17 (page 83) .
27 - Connector
❑ Black, 3-pin.
❑ For radiator fan thermal switch
28 - Radiator fan thermal switch -F18- , 35 Nm
❑ For radiator fan.
❑ Switching temperatures: speed 1 on: 92 ... 97°C, off: 84 ... 91°C, speed 2 on: 99 ... 105°C, off: 91 ... 98°
C
29 - Seal
❑ Renew.
30 - Drain plug
❑ Draining and filling with coolant ⇒ page 87 .
31 - Upper coolant hose
❑ Secured to radiator with retaining clip.
32 - Radiator/cooler
❑ With AFT cooler on vehicles with automatic gearbox: ⇒ Automatic gearbox 01V; Rep. gr. 37 ; Dismantling
and assembling gearbox
❑ Cleaning ATF cooler: ⇒ Automatic gearbox 01V; Rep. gr. 37 ; Dismantling and assembling gearbox
33 - Connector
❑ For fuel cooling pump
1.1.2 Vehicles from 01.02
Vehicles up to 01.02 ⇒ page 78
1 - Radiator/cooler
⇒ page 90
❑ After renewing, renew
entire coolant.
❑ With AFT cooler on vehicles
with automatic
gearbox: ⇒ Automatic
gearbox 01V; Rep. gr.
37 ; Dismantling and assembling
gearbox
❑ Cleaning ATF cooler: ⇒
Automatic gearbox 01V;
Rep. gr. 37 ; Dismantling
and assembling
gearbox
2 - Retaining clip
3 - Rubber mounting
4 - Rubber washer
5 - Radiator fan -V7-
❑ Vehicles with optional
equipment only.
❑ Checking: ⇒ page 98 .
6 - Locking bolt
7 - Fan ring
❑ Clipped into air ducting
and secured with locking
bolt
⇒ Item 14 (page 79) .
8 - 10 Nm
9 - 2-pin connector
10 - Cap
❑ Check using cooling system tester -V.A.G 1274- and adapter for cap -V.A.G 1274/9- .
❑ Test pressure 1.4 ... 1.6 bar.
11 - O-ring
12 - 3 Nm
13 - Coolant expansion tank
❑ Test cooling system for leaks using cooling system tester -V.A.G 1274- and adapter for cap -V.A.G
1274/9- .
14 - Coolant hose
15 - O-ring
❑ Renew.
16 - Lower coolant hose
❑ To connection for thermostat ⇒ Item 22 (page 84)
17 - Connector
❑ Black, 3-pin.
❑ For radiator fan thermal switch
18 - Radiator fan thermal switch -F18- , 35 Nm
❑ For radiator fan.
❑ Switching temperatures: speed 1 on: 92 ... 97°C, off: 84 ... 91°C, speed 2 on: 99 ... 105°C, off: 91 ... 98°
C
19 - Seal
❑ Renew.
20 - Drain plug
❑ Draining and filling with coolant ⇒ page 87 .
21 - Upper coolant hose
❑ Secured to radiator with retaining clip.
1.2 Assembly overview - parts of cooling
system, engine side
1 - To top of radiator
❑ ⇒ Item 31 (page 80)
2 - Upper coolant pipe
3 - Coolant hose
❑ To top of expansion tank
4 - O-ring
❑ Renew.
5 - Coolant hose
6 - Coolant temperature sender
-G62-
❑ With coolant temperature
display sender -
G2- .
7 - Retaining clip
8 - O-ring
❑ Renew.
9 - 10 Nm
10 - Connection
equipment only.
❑ With glow plugs for coolant
11 - Coolant hose
❑ To heat exchanger
❑ Secured to connection
with retaining clip
12 - Connection
13 - Cooler unit
❑ For fuel
❑ Do not interchange connections.
❑ Fuel and coolant hose schematic diagram ⇒ page 109
14 - Fuel filter
❑ Observe change intervals.
❑ Fill with diesel before installing.
❑ Tighten by hand.
15 - Vacuum hose
❑ To non-return valve of brake servo ⇒ page 138 , schematic diagram for vacuum hoses
16 - Vacuum unit
17 - Shut-off valve
❑ For fuel cooling system coolant pump
18 - Coolant hose
❑ From junction ⇒ Item 24 (page 80)
19 - Coolant hose
❑ From heat exchanger
❑ Secured to coolant pipe with retaining clip
20 - Lower coolant pipe
21 - 15 Nm
22 - Coolant hose
❑ From bottom of radiator ⇒ Item 23 (page 80)
23 - Connection
❑ For thermostat.
24 - Thermostat
❑ Observe installation position ⇒ page 94 , removing and installing thermostat.
❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7 mm.
25 - 40 Nm
❑ Removing and installing ⇒ page 69 , and ⇒ Item 14 (page 69)
27 - Fan wheel
28 - Coolant pump
❑ Check for ease of movement.
29 - Coolant hose
❑ To secondary cooler for coolant and pump for fuel cooler -V166- ⇒ Item 1 (page 79)
30 - Coolant hose
❑ From secondary cooler for coolant and pump for fuel cooler -V166- ⇒ Item 4 (page 79)
31 - Coolant lines
32 - 25 Nm
1 - To top of radiator
❑ ⇒ Item 31 (page 80)
2 - Upper coolant pipe
3 - Coolant hose
❑ To top of expansion tank
4 - O-ring
❑ Renew.
5 - Coolant hose
-G62-
❑ With coolant temperature
display sender -
G2- .
7 - Retaining clip
8 - O-ring
❑ Renew.
9 - 10 Nm
10 - Connection
equipment only.
❑ With glow plugs for coolant
11 - Coolant hose
❑ To heat exchanger
❑ Secured to connection
with retaining clip
12 - Connection
13 - Coolant hose
❑ From heat exchanger
❑ Secured to coolant pipe with retaining clip
15 - 15 Nm
16 - Coolant hose
❑ From bottom of radiator ⇒ Item 23 (page 80)
17 - Connection
❑ For thermostat.
18 - Thermostat
❑ Observe installation position ⇒ page 94 , removing and installing thermostat.
❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7 mm.
19 - 40 Nm
❑ Removing and installing ⇒ page 69 , ⇒ Item 11 (page 69) and ⇒ Item 14 (page 69)
21 - Fan wheel
22 - 15 Nm
23 - Coolant pump
❑ Check for ease of movement.
1.2.3 Coolant hose schematic diagram
Fuel and coolant hose schematic diagram ⇒ page 109
1 - Radiator/cooler
❑ With AFT cooler on vehicles
with automatic
gearbox
2 - Coolant pump and thermostat
3 - Cylinder head/cylinder
block
4 - Intake manifold
5 - Exhaust gas recirculation
cooler
❑ Only on vehicles with
automatic gearbox
6 - Heat exchanger for heater
unit
8 - Cap
9 - Expansion tank
1.3 Draining and filling coolant
equipment required
♦ Refractometer -T10007-
5024ANot
illustrated:
♦ Cooling system charge unit -VAS 6096-
1.3.1 Draining
– Detach vacuum hose from vacuum unit of shut-off valve (only
in vehicles up to 01.02).
– Open filler cap on coolant expansion tank.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Pull off lower coolant hose retaining clip -arrow- and remove
coolant hose from radiator.
– To drain coolant from engine, also detach coolant hoses from
engine oil cooler -arrows-.
Note
Follow disposal regulations for coolant!
1.3.2 Filling
Note
♦ For vehicles up to and including model year 2007 coolant additive
G 12 plus according to TL VW 774 F and G 12 plus-plus
according to TL VW 774 G can be used.
♦ The coolant additive G 12 plus-plus can be mixed with the
previous coolant additive G 12 plus. Identification: both are
coloured purple.
♦ Coolant additives marked „according to TL VW 774 G“ or „according
to TL VW 774 F“ prevent frost and corrosion damage,
scaling and also raise boiling point of coolant. Therefore, the
cooling system must be filled all year round with coolant additive.
♦ Because of its higher boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection is required down to about -25°C (in countries
with arctic climates: down to about -35°C).
♦ The coolant concentration must not be reduced by adding water
even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
♦ If for climatic reasons greater frost protection is required, the
amount of coolant additive can be increased, but only up to 60
% (frost protection to about -40 °C). Otherwise frost protection
and cooling effectiveness are reduced again.
♦ The refractometer -T10007- is recommended for determining
the current anti-freeze concentration.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket is renewed, do not reuse old coolant.
Recommended mixture ratios:
Frost protection
to
Anti-freeze
quantity
G 121) Water1)
-25 °C
-35 °C
40 %
50 %
3.0 l
3.5 l
4.0 l
3.5 l
1) The quantity of coolant can vary depending upon vehicle equipment.
– Install lower coolant hose and secure.
– Connect coolant hoses to engine oil cooler.
With cooling system charge unit -VAS 6096- :
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096
Without cooling system charge unit -VAS 6096- :
– Screw adapter for expansion tank -V.A.G 1274/8- to expansion
tank and extend it with adapter -V.A.G 1274/10- .
– Release coolant hose on heat exchanger and pull back hose
until bleeder hole in coolant hose -arrow- is no longer blocked
by the connection.
– Fill with coolant until it overflows from bleeder hole in coolant
hose.
– Push coolant hose onto connection and tighten it.
– Close coolant expansion tank.
Only vehicles up to 01.02:
– Connect vehicle diagnosis, testing and information system -
VAS 5051- ⇒ page 151 .
Selecting operating mode:
– Press button on display for „Vehicle self-diagnosis“.
Selecting vehicle system:
– Press „01 - Engine electronics“ button on display.
The control unit identification and coding are displayed on the
engine control unit display.
Select diagnostic function:
– Press „03 - Final control diagnosis“ button on display.
– Press → key until „Relay for fuel cooler“ appears on display.
Relay has to click, and pump for fuel cooler -V166- starts up.
– Wait until next control element is actuated.
– Proceed with final control diagnosis until completed.
– Press ← button.
– Select „06-End output“ function.
– Attach vacuum hose to vacuum unit of shut-off valve.
– Turn off heater controls.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Then run engine at idling speed until radiator bottom hose becomes
hot.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
at the max. mark; when the engine is cold, between the min.
and max. marks.
1.4 Removing and installing radiator
equipment required
Nm) -V.A.G 1331-
5024A-
1.4.1 Removing
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Pull coolant hoses off radiator.
– Pull connectors off thermal switch and radiator fan.
– Remove upper radiator securing clips and take out radiator
forwards.
Vehicles with air conditioning system:
– Observe additional information and installation work
⇒ page 92 .
1.4.2 Installing
note the following:
– Install front bumper: ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
; Booklet 36 .
1.4.3 Additional information and assembly
work for vehicles with air conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or bent.
– Remove retaining clamp(s) for refrigerant lines.
– Unscrew condenser from radiator and pull forward as far as is
possible.
– Pull radiator out between condenser and lock carrier.
– Secure condenser to body so that the refrigerant lines/hoses
are not under tension.
1.5 Removing and installing coolant pump
equipment required
Nm) -V.A.G 1331-
5024A-
1.5.1 Removing
Note
Always renew seals and gaskets.
– Unscrew coolant pump securing bolts -1- and carefully remove
coolant pump -2-.
1.5.2 Installing
Installing
Note
♦ If the new coolant pump contacts the rear toothed belt guard,
the toothed belt guard must be adapted using workshop equipment.
♦ Remove marked surface -arrow-.
♦ For the sake of clarity, the rear toothed belt guard and the
coolant pump are shown removed.
note the following:
– Moisten new O-ring -3- with coolant.
– Insert coolant pump -2- into cylinder block and tighten securing
bolts -1-. Specified torque: 15 Nm
Note
The coolant pump plug faces downwards.
1.6 Removing and installing thermostat
equipment required
Nm) -V.A.G 1331-
5024A-
1.6.1 Removing
Note
Always renew seals and gaskets.
– Pull coolant hose off connection.
– Unscrew securing bolts -1- of connecting flange -2- and remove
connecting flange -2- with thermostat -4-.
– Turn thermostat -4- 1/4 turn (90°) to left and remove from connection
-2-.
1.6.2 Installing
note the following:
– Moisten new O-ring -3- with coolant.
– Insert thermostat -4- in union -2- and turn 1/4 turn (90°) to right.
Note
The brace on the thermostat must be almost vertical.
– Fit connection -2- with thermostat -4- into cylinder block.
– Tighten securing bolts -1-. Specified torque: 15 Nm
1.7 Removing and installing viscous fan
coupling
♦ Torque wrench (5 ... 50 Nm) -V.A.G 1331-
1.7.1 Removing
– Remove viscous fan coupling fan wheel.
– Counterhold belt pulley for visco fan coupling using 2-hole pin
wrench -3212- and unscrew using 8 mm Allen key from bracket
for ancillaries.
1.7.2 Installing
note the following:
– Bolt viscous fan coupling to bracket for ancillaries, tightening
to 45 Nm.
– Bolt fan wheel to viscous fan coupling, tightening to 30 Nm.
1.8 Check fuel cooling pump -V166-
Only on vehicles up to 01.02
♦ Hand-held multimeter -V.A.G 1526/APassat
1997 ➤ , Passat Variant 1997 ➤
♦ Auxiliary measuring set -V.A.G 159/A- or -V.A.G 1594C-
♦ Current flow diagram
Test prerequisites
• Fuse No. S262 OK.
• Fuel cooling pump relay -J445- OK.
Test procedure
– Remove noise insulation: ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; noise insulation .
– Pull 2-pin connector -1- off fuel cooling pump -V166- -2-.
– Connect contacts 1 and 2 of fuel cooling pump to battery using
test cables from auxiliary test set -V.A.G 1594A- or -V.A.G
1594C- . Fuel cooling pump -V166- must start up.
If the fuel cooling pump -V166- does not run:
– Fit new fuel cooling pump -V166- .
– If the fuel cooling pump -V166- runs:
– Locate and eliminate open circuit referring to current flow diagram:
⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If no open circuit is found:
– Check fuel temperature sender -G81- ⇒ page 152 ; Adapting
functions and components
1.9 Check radiator fan -V7- .
♦ Hand-held multimeter -V.A.G 1526/A-
♦ Auxiliary measuring set -V.A.G 159/A- or -V.A.G 1594C-
♦ Current flow diagram
Test prerequisites
• Fuse no. S42 and S51 OK.
• Radiator fan thermal switch -F18- OK.
Test procedure
– Unplug 3-pin connector from radiator fan thermal switch -
F18- .
– Switch on ignition.
– Bypass contact -1- and contact -2- of plug connector using test
cables from auxiliary test set -V.A.G 1594A- or -V.A.G
1594C- . Radiator fan -V7- must start up at speed 1.
– Bypass contact -1- and contact -3- of plug connector using test
cables from auxiliary test set -V.A.G 1594A- or -V.A.G
1594C- . Radiator fan -V7- must start up at speed 2.
If fan speeds 1 or 2 do not run:
– Locate and eliminate open circuit referring to current flow diagram:
⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If no open circuit is found:
– Renew radiator fan -V7- .
20 – Fuel supply system
1 Parts of fuel supply system
Note
♦ Hose connections are secured with either spring-type or
clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Spring-type clip pliers -VAS 5024A- or hose clip pliers -V.A.G
1921- are recommended for installation of spring-type clips.
Repairing fuel filter ⇒ page 106 .
Observe safety precautions ⇒ page 101 .
Observe rules for cleanliness ⇒ page 101 .
Repairing throttle mechanism ⇒ page 122 .
1.1 Safety precautions when working on
fuel supply system
WARNING
hot components.
When removing and installing the fuel gauge sender from a full or
partly full fuel tank the following must be observed:
♦ Even before work commences, the extraction hose of an activated
fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escaping
fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.2 Rules for cleanliness
When working on the fuel supply and injection system, pay careful
attention to the following „6 rules“ for cleanliness:
♦ Thoroughly clean all connections and surrounding areas before
disconnecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
1. Parts of fuel supply system 101
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely necessary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Assembly overview - removing and installing
fuel tank with attached components
1.3.1 Vehicles with four-wheel drive
Front-wheel drive vehicles ⇒ page 105 .
1 - Cap
2 - Seal
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
5 - O-ring
6 - Breather valve
❑ To remove valve unclip
sideways out of support.
❑ Remove cap before installing
⇒ Item 1 (page 102) .
7 - Connecting hose
8 - Gravity valve
upwards out of support.
❑ Check valve for
through-flow, valve vertical:
open, valve tilted
45°: closed
9 - 25 Nm
10 - Fuel tank filler neck
11 - Non-return valve
12 - Connecting hose
13 - Heat shield
❑ For fuel filler neck
102 Rep. gr.20 - Fuel supply system
14 - 10 Nm
15 - Union nut, 60 Nm
❑ Remove and install using union nut tool -3218- .
16 - Connector
❑ Black, 2-pin.
❑ For fuel gauge sender
17 - Flange
❑ Note installation position on fuel tank ⇒ page 106 .
18 - Seal
❑ Moisten with fuel when installing
19 - Breather line
❑ Black
20 - Fuel gauge sender 3 -G237-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
21 - Heat shield
❑ For fuel tank.
22 - Retaining clip
23 - Securing strap
24 - Fuel gauge sender 2 -G169-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
❑ Removing and installing suction jet pump ⇒ page 115
25 - Locking ring, 145 Nm
❑ Remove and install using fuel tank sender unit tool -3087- .
26 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
27 - Flange
❑ Can only be renewed complete with fuel pump
28 - Return line
❑ Clipped onto fuel tank.
29 - Connector
❑ Black, 4-pin.
30 - Supply line
❑ Black
❑ To fuel filter ⇒ Item 2 (page 108) .
31 - Fuel gauge sender -G-
❑ Clipped on reservoir housing in fuel tank.
32 - Fuel pump -G6-
❑ Can only be renewed complete with flange.
❑ Checking fuel pump ⇒ page 117 .
33 - Earth connection
Installation position of flange for fuel pump
Mark on flange -1- must align with mark on fuel tank -2-.
Note
After installing fuel pump flange, check that supply, return and
breather lines are still clipped onto fuel tank.
Checking breather valve
Lever in rest position: closed
Lever pushed in -direction of arrow-: Open
Note
Before installing breather valve remove fuel tank cap.
1.3.2 Front-wheel drive vehicles
1 - Cap
2 - Seal
3 - Securing bolt
4 - Gravity/overflow valve
upwards out of support.
❑ Check valve for
through-flow valve vertical:
open, valve tilted
45°: closed
5 - Elbow
6 - O-ring
7 - Breather valve
sideways out of support.
❑ Remove cap before installing
⇒ Item 1 (page 102) .
8 - Earth connection
9 - Supply line
❑ To fuel filter
⇒ Item 2 (page 108) .
❑ Black
10 - Return line
11 - Fuel gauge sender -G-
❑ Clipped on reservoir housing in fuel tank.
12 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
13 - Union nut, 80 Nm
❑ Remove and install using union nut tool -3217- .
14 - Connector
❑ Black, 4-pin.
15 - Flange
16 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 117 .
17 - Reservoir housing outer part
❑ With suction-jet pump.
❑ Part of fuel tank
18 - Breather line
19 - 25 Nm
20 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
21 - Securing strap
❑ Note different lengths.
22 - Bracket
❑ For securing straps.
23 - 25 Nm
24 - Tank flap unit
❑ With rubber cup.
Installation position of fuel gauge sender
Mark on sender -1- must align with mark on fuel tank -2-.
Note
After installing fuel gauge sender, check whether supply and return
lines are still clipped onto fuel tank.
Checking breather valve
Lever in rest position: closed
Lever pushed in -direction of arrow-: Open
Note
Before installing breather valve remove fuel tank cap.
1.4 Assembly overview - fuel filter
Fuel and coolant hose schematic diagram ⇒ page 109 .
1 - 8 Nm
2 - O-ring
❑ Renew.
3 - Cooler unit
❑ Fuel and coolant hose
schematic diagram
⇒ page 109
4 - Fuel filter flange
❑ Direction of flow is
marked with arrows.
❑ Fuel and coolant hose
schematic diagram
⇒ page 109
5 - Seal
❑ Renew.
6 - Breather bolt, 10 Nm
❑ Loosen to drain water
❑ Loosen to breathe in
event of filter change
7 - Gasket
❑ Renew.
8 - Fuel filter
9 - Water drain screw
❑ Loosen and allow approx. 100 cm3 fluid to drain
❑ Loosen breather bolt ⇒ Item 6 (page 107) to drain water
1 - Return line
❑ To fuel cooler
⇒ page 110
2 - Supply line
❑ From fuel tank
⇒ Item 9 (page 105) .
❑ White or with white
marking.
3 - Retaining clip
4 - Regulating valve
❑ Installation position: arrow
points towards fuel
tank
❑ When changing filter,
remove retaining clip
and take control valve
off complete with fuel
lines
❑ Below + 15 °C: passageway
to filter open
❑ Over + 31 °C: passageway
to filter closed
5 - O-ring
❑ Renew.
6 - Return line
❑ From tandem pump
7 - Fuel line
8 - Fuel temperature sender -G81-
❑ Installation position: arrow points towards tandem pump
10 - Supply line
❑ To tandem pump ⇒ Item 13 (page 15) .
11 - Fuel filter
❑ Direction of flow is marked with arrows.
12 - Gasket
13 - Water drain screw
❑ To bleed remove regulating valve securing clip and remove regulating valve complete with connected
fuel lines.
❑ Loosen and allow approx. 100 cm3 fluid to drain
1.5 Fuel and coolant hose schematic diagram
Vehicles up to 01.02
1 - Return line
❑ To fuel tank.
❑ Clipped into bulkhead
2 - Supply line
❑ From fuel tank.
❑ Clipped into bulkhead
marking.
3 - Charge air pipe
4 - Return line
❑ From tandem pump
❑ Clipped onto bottom
coolant pipe
5 - Supply line
❑ To tandem pump
⇒ Item 13 (page 15) .
marking.
❑ Clipped onto bottom
coolant pipe
❑ Installation position: arrow points towards tandem pump
8 - Fuel filter
9 - Coolant return line
❑ To secondary cooler for coolant ⇒ Item 6 (page 79)
10 - Coolant supply line
❑ To secondary cooler for coolant ⇒ Item 6 (page 79)
11 - Fuel temperature sender -G81-
1.6 Removing and installing fuel cooler
Only in vehicles from 01.02
1.6.1 Removing
Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
– Remove retaining clips -C- and securing bolt -B- and remove
cover -A-.
– Separate fuel lines at fuel cooler.
– Remove securing nuts -arrows-.
1.6.2 Installing
Install in reverse order. In the process, note the following:
♦ Tighten fuel cooler securing nuts to 15 Nm.
1.7 Removing and installing fuel tank
♦ Engine and gearbox jack -V.A.G 1383 A-
1.7.1 Removing
Note
♦ Fuel tank must not be more than 1/4 full.
♦ In four-wheel drive vehicles drain the fuel tank, if necessary,
via the aperture for fuel gauge sender 3 using the fuel extractor
-V.A.G 1433 A- ⇒ Item 20 (page 103) .
♦ Note safety precautions before beginning work ⇒ page 101 .
– First check whether a coded radio is fitted. If so, obtain antitheft
coding.
– Remove rear right wheel housing liner: ⇒ General body repairs,
exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Unscrew securing bolt and remove tank flap unit with rubber
cup.
– Remove filler neck securing bolt.
Vehicles with four-wheel drive
– Remove centre and rear silencer ⇒ page 155 , Removing and
installing parts of exhaust system.
– Remove rear axle: ⇒ Running gear, front- and four-wheel
drive; Rep. gr. 42 ; Repairing rear axle .
– Remove shield for filler neck.
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack -V.A.G 1383 A- .
– Lower engine and gearbox jack -V.A.G 1383 A- just so far that
supply and return lines and connector can be detached from
fuel gauge sender.
– Unclip supply and return lines from fuel tank.
– Lower fuel tank.
1.7.2 Installing
Install in reverse order. In the process, note the following:
♦ Route breather hoses without kinking.
♦ Route fuel hoses without kinking.
♦ Secure fuel hoses with clamp-type clips.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Clip supply and return lines onto fuel tank.
1.8 Removing and installing fuel pump
Vehicles with four-wheel drive only
♦ Fuel pump tool -3307-
♦ Fuel tank sender unit tool -3087-
1.8.1 Removing
Note
♦ Drain the fuel tank, if necessary, via the aperture for fuel gauge
sender 3 using the fuel extractor -V.A.G 1433 A-
⇒ Item 20 (page 103) .
coding.
– Remove rear bench seat.
– Remove right floor cover.
– Pull 4-pin connector and supply and return lines -arrows- off
flange.
– Unscrew locking ring with fuel tank sender unit tool -3087- .
– Pull flange and seal out of opening in fuel tank.
– Unclip fuel gauge sender -G- from reservoir housing in fuel
tank -arrows- and remove.
– Place fuel hose to suction-jet pump in fuel tank.
– Turn fuel pump approx. 15° anti-clockwise onto stop using fuel
pump tool -3307- and remove.
Note
If the fuel pump is to be renewed, drain the old fuel pump before
disposal.
1.8.2 Installing
– Installing the fuel pump is carried out in reverse order of removal.
Note
♦ Do not bend fuel gauge sender -G- when installing.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Note Installation position of fuel pump flange: mark on flange
-1- must align with mark on fuel tank -2-.
– Tighten locking ring. Specified torque: 145 Nm
Note
♦ Do not interchange supply and return hoses (return hose -
blue-).
1.9 Removing and installing suction-jet
pump
Vehicles with four-wheel drive only
♦ Fuel tank sender unit tool -3087-
1.9.1 Function of suction-jet pump
The fuel tank in four-wheel drive vehicles is divided into two
chambers. A suction-jet pump is used to transfer the fuel from the
left chamber into the right chamber, to the fuel pump reservoir
housing. A second suction-jet pump is located in the right chamber
of the fuel tank where it improves the fuel supply to the fuel
pump reservoir housing. The suction-jet pump function according
to a principle of physics using the return flow of fuel via a junction
with pressure limiting valve.
1.9.2 Removing
Note
♦ Drain the fuel tank, if necessary, via the aperture for fuel gauge
sender 3 using the fuel extractor -V.A.G 1433 A-
⇒ Item 20 (page 103) .
coding.
– With the ignition switched off, disconnect battery earth strap.
– Remove fuel pump ⇒ page 112 , Removing and installing fuel
pump
– Now unscrew locking ring of fuel gauge sender 2 -G169- using
fuel tank sender unit tool -3087- on left side of vehicle.
– Lift fuel gauge sender 2 -G169- upwards as far as possible.
– Detach connection to fuel gauge sender 1 from fuel gauge
sender 2 -G169- .
– Unplug connection of fuel gauge sender 2 -G169- from right
flange.
– On right-hand side, pull fuel lines of left suction-jet pump out
of junction and reservoir housing.
– Reach into left chamber of fuel tank and disengage locking
tabs -arrows- at bottom of suction-jet pump -2-.
– Detach fuel gauge sender 2 -G169- -1- from suction-jet pump.
– You can now withdraw suction-jet pump with lines from left
opening of fuel tank.
1.9.3 Installing
– Check suction-jet pump for possible soiling.
– Install suction-jet pump and fuel gauge sender 2 -G169- again
in reverse order.
Note
♦ Please note that the seal has to be placed dry in the fuel tank
opening before installing the fuel tank or fuel gauge sender 2
-G169- .
♦ Always renew seals.
– Tighten locking ring. Specified torque: 145 Nm
– Install fuel pump ⇒ page 112 , Removing and installing fuel
pump
1.10 Checking fuel pump
Test prerequisites
• Battery voltage at least 11.5 V
• Fuses OK.
Checking function and voltage supply
Front-wheel drive vehicles
– Remove cover in luggage compartment floor.
Vehicles with four-wheel drive
– Remove rear bench seat.
– Remove right floor cover.
– Briefly operate starter. Fuel pump must be heard to run.
– Switch off ignition.
If the fuel pump does not start:
– Continue fault finding using relay controlled current circuit tester
-V.A.G 1466/A- : ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
1.11 Removing and installing fuel delivery
unit
equipment required
♦ Union nut tool -3217-
Nm) -V.A.G 1332-
♦ Fuel extractor -
V.A.G 1433 A-
1.11.1 Removing
Note
♦ If necessary, drain fuel tank using fuel extractor -
V.A.G 1433 A- .
coding.
– Remove cover in luggage compartment floor.
– Pull 4-pin connector and supply and return lines -arrows- off
flange.
WARNING
Fuel supply lines are under pressure! Before loosening hose
connections, wrap a cloth around the connection. Then release
pressure by carefully pulling hose off connection.
– Unscrew using unit nut tool -3217- .
– Pull flange and seal out of opening in fuel tank.
– Detach fuel return line -2- and plug for fuel gauge sender from
underside of flange -1-.
– Detach connection of return hose on inside of reservoir housing
in -direction of arrow-.
– Withdraw fuel gauge sender -G- from reservoir housing in fuel
tank while pressing locking tab at same time -arrows-.
– Press release tabs -arrows- and disconnect fuel hose at Yjunction.
– Turn fuel delivery unit approx. 15° anti-clockwise onto stop
with fuel pump tool -3307- and remove with flange.
Note
If delivery unit is to be renewed, drain old delivery unit before disposal.
1.11.2 Installing
– Insert fuel delivery unit into reservoir housing in fuel tank so
that the notch -1- on fuel delivery unit aligns with mark -2- on
reservoir housing.
Note
The reservoir housing is shown without the fuel tank for a clearer
illustration.
– Turn fuel delivery unit approx. 15° clockwise onto stop with fuel
pump tool -3307- . Notch -1- is then aligned with marking -3-
(quick-release coupling).
– Press fuel hose onto Y-junction coupling until locking tabs
-arrows- engage.
– Place Y-junction coupling with fuel hoses into rear right of fuel
tank.
Note
Ensure that the fuel hose from the reservoir housing to the Yjunction
coupling is held in the bracket on the outside of the
reservoir housing.
– Clip fuel return line to inside of reservoir housing.
– Insert fuel gauge sender in guide in reservoir housing and
press down until it engages.
– Plug connector for fuel gauge sender into flange.
Note
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
– Turn flange clockwise in installation location and insert into
fuel tank.
– Mark on flange -1- must align with mark on fuel tank -2-.
– Tighten union nut. Specified torque: 80 Nm
Further assembly is basically the reverse of the dismantling sequence.
Note
♦ Do not interchange supply and return hoses (return hose -
blue- or with blue marking).
♦ Ensure that fuel hose connections are tight.
1.12 Removing and installing fuel gauge
sender
1.12.1 Removing
Note
♦ If necessary, drain fuel tank using fuel extractor -
V.A.G 1433 A- .
– Remove flange ⇒ page 117 , Removing fuel delivery unit.
– Withdraw fuel gauge sender -G- from reservoir housing in fuel
tank while pressing locking tab at same time -arrows-.
1.12.2 Installing
– Insert fuel gauge sender -G- in guide in reservoir housing and
press down until it engages.
– Install flange and carry out further assembly ⇒ page 117 , Removing
and installing fuel delivery unit.
1.13 Assembly overview - accelerator mechanism
1.13.1 Vehicles ► 04.99
Vehicles 05.99 ► ⇒ page 124
1 - 6-pin connector
❑ For accelerator pedal
position sender
2 - 10 Nm
3 - Accelerator position sender
-G79-
❑ Adjusting ⇒ page 124 .
❑ When removing and installing
accelerator position
sender, mounting
bracket
must be removed
❑ To remove, remove
dash panel cover and
pedal cluster cover.
4 - Cable cam
5 - 10 Nm
6 - Operating rod
❑ With adjuster screw
7 - Accelerator pedal stop
❑ On vehicles with manual
gearbox „AG“ is visible
❑ On vehicles with automatic
gearbox „AG“ is
visible
8 - Accelerator
9 - Bearing bracket
❑ Removing and installing:
⇒ Brake systems;
Rep. gr. 46 ; Assembly
overview - brake pedal
(LHD) .
1.13.2 Vehicles 05.99 ►
1 - Bearing bracket
❑ Removing and installing:
⇒ Brake systems;
Rep. gr. 46 ; Assembly
overview - brake pedal
(LHD) .
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator pedal position
sender -G79- and accelerator
pedal position sender 2 -G185-
❑ To remove, remove
dash panel cover and
pedal cluster cover.
❑ If renewed, adapt control
unit for automatic
gearbox: ⇒ Self-diagnosis
for automatic gearbox
01NV; Rep. gr. 01 ;
Perform self-diagnosis
5 - Bracket
❑ For footwell cover
❑ Clipped to accelerator
position sender
1.14 Adjust accelerator position sender
Vehicles ► 04.99
(Accelerator position sender removed)
Procedure
Adjust cable cam:
– In rest position cable cam must be set such that extension of
wrench surface intersects with centre of bore -arrow-.
– Bolt accelerator pedal position sender with pre-fitted cable
cam to mounting bracket.
– Install mounting bracket ⇒ Brake system; Rep. gr. 46 ; Assembly
overview - brake pedal (left-hand drive)
– Reconnect 6-pin connector for sender
Fine adjustment with sender installed:
– Turn accelerator pedal stop to position „HS“ for manual gearbox
(also for vehicles with automatic gearbox)
⇒ Item 7 (page 123) , „HS“ is visible.
– Press accelerator pedal down by hand until accelerator pedal
is in contact with accelerator pedal stop.
Note
On vehicles with automatic gearbox, the kick-down switch pressure
point must be distinctly noticeable before the full throttle stop.
If accelerator stop is not reached or pressure point of kick-down
switch cannot be felt: adjust accelerator stop by turning adjustment
screw on actuator rod.
– Turn accelerator stop by 180° so that lettering „AG“ is visible
⇒ Item 7 (page 123) .
– After adjustment, check accelerator pedal position sender: ⇒
Diagnosis tester VAS 5051; Guided fault finding; Vehicle system
test or VAS 5052; Vehicle self-diagnosis
1.15 Removing and installing tandem pump
DANGER!
The tandem pump may, under no circumstances, be dismantled
as the vacuum part could otherwise malfunction. This
would result in the failure of the brake servo.
equipment required
Nm) -V.A.G 1331-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
♦ Hose clip pliers -V.A.G
1921- or spring-type clip pliers
-VAS 5024A-
1.15.1 Removing
– Pull supply hose -1- (white marking) and return hose -2- (blue
marking) off fuel filter.
– Connect hand vacuum pump with accessories -V.A.G 1390-
and water drainage container -V.A.G 1390/1- to return hose.
– Operate hand vacuum pump until no more fuel comes out of
return hose. Be careful that no fuel is sucked into hand vacuum
pump.
– Unscrew charge air pipe and lay to side.
– Pull vacuum line -1- from brake servo off tandem pump -4-.
– Pull off central connector for unit injectors.
– Pull supply hose -2- (white marking) off tandem pump -4-.
– Remove securing bolts -arrows-.
– Remove tandem pump -4- from cylinder head.
– Pull tandem pump -4- slightly upwards, pull off return hose
-3- (blue marking) and remove tandem pump -4-.
1.15.2 Installing
note the following:
Note
♦ Ensure that tandem pump coupling seats properly in camshaft.
♦ Always replace tandem pump seals.
– Connect return hose -3- (blue marking) to return connection of
tandem pump.
– Install tandem pump and tighten upper securing bolts to
20 Nm.
– Tighten lower securing bolts to 10 Nm.
– Connect supply hose -2- (white marking) to supply connection
and vacuum line -1- from brake servo to tandem pump -4-.
– Attach central connector for unit injectors.
– Install charge air pipe.
– Attach supply hose -1- (white marking) to fuel filter.
and water drainage container -V.A.G 1390/1- to return hose
-2- (blue marking) of fuel filter.
– Operate hand vacuum pump until fuel comes out of return
hose. Be careful that no fuel is sucked into hand vacuum
pump.
– Connect return hose -2- (blue marking) to fuel filter.
Note
Disconnecting the central connector for unit injectors causes
faults to be stored. Therefore, read event memory and delete if
necessary.
1.16 Checking tandem pump
⇒ „1.16.1 Checking delivery pressure“, page 128
⇒ „1.16.2 Checking for internal leaks“, page 130
1.16.1 Checking delivery pressure
♦ Tandem pump tester -VAS 5187-
♦ Banjo bolt -VAS 5187/1A-
♦ Vehicle diagnostic, testing and information system -VAS 5051-
♦ Diagnosis cable, 3 m with voltage supply -VAS 5051/1- or diagnosis
cable, 5 m without voltage supply -VAS 5051/3-
Test prerequisites
• Coolant temperature must be at least 85 °C.
• Unit injectors OK.
• Fuel filter and fuel lines must not be blocked.
• The non-return valve in the fuel supply hose must be OK.
• The fuel gauge sender must be OK.
Procedure
– Unscrew charge air pipe and lay to side.
– Remove screw plug -arrow-.
– Connect tandem pump tester -VAS 5187- as shown.
– Screw charge air pipe back into position.
– Start engine and run at idling speed.
VAS 5051- and select operating mode „Vehicle self-diagnosis“.
Then select engine electronics control unit with the
Address word „01“.
– Press diagnosis function „08-Read measured value block“.
– Enter display group „2“ using number block (key pad) and
confirm entry with Q button.
– Read engine idling speed in display zone „1“.
– Increase engine speed to 4,000 rpm.
– Observe pressure indicated on pressure gauge. Specification:
min. 7.5 bar.
If the specification is not attained:
– Using a hose clip, clamp-off return line between fuel filter and
tandem pump.
– Increase engine speed to 1500 rpm.
– Observe pressure indicated on pressure gauge. Specification:
min. 3.5 bar.
If specification is now obtained:
– Tandem pump is OK. Renew unit injector O-rings
⇒ page 144 .
If the specification is not attained:
– Renew tandem pump ⇒ page 125
– Repeat check.
Note
After removing pressure gauge, tighten plug to 25 Nm. Always
renew seal.
1.16.2 Checking for internal leaks
Note
The tandem pump must be checked for internal leaks between
fuel side and oil side after reinstalling a used tandem pump, e.g.
after renewing or repairing a cylinder head and/or when installing
a "short" engine. When leaking it is possible for the fuel to mix
with the oil which may cause the engine to fail.
♦ Tester -V.A.G 1687-
Procedure
– Pull fuel supply hose (white marking) and fuel return hose
(blue marking) off tandem pump.
– Seal fuel return union on tandem pump with a plug. Secure
sealing plug with a spring-type clip.
Prepare test unit -V.A.G 1687- as follows:
– Unscrew pressure regulating valve -2- and close valves -3-
and -4-.
– Connect test connection -5- to fuel supply union of tandem
pump using a commercially available compressed air connection
and a section of fuel hose. Use a spring-type clip to secure.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect compressed air hose -1- (compressed air source) to
charge air system tester -V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.
– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
Caution
The maximum test pressure is 1.3 bar and this must not be
exceeded.
– Open valve -4- and wait until the test circuit is filled. If necessary
readjust pressure to 1.0 bar.
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
1.1 Assembly overview - turbocharger with
attachments
Note
♦ All hose connections are secured with clamps or retaining
clips.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before screwing on oil supply line, fill turbocharger at connection
with engine oil.
♦ After installing turbocharger run engine for approx. 1 minute
at idling speed, do not rev engine. This ensures that the turbocharger/
compressor is adequately lubricated.
132 Rep. gr.21 - Turbocharging/supercharging
1 - Exhaust manifold
2 - 25 Nm
❑ Renew.
❑ Coat thread of studs
with grease -G 000
500- .
3 - Intake manifold
4 - From charge air cooler
5 - Gasket
❑ Renew.
❑ Coating (beading) towards
intake pipe
6 - 25 Nm
7 - Gasket
8 - Bracket
❑ For heat shield
9 - Washer
10 - Heat shield
❑ Engage in bracket
11 - Vacuum unit
❑ For charge pressure
control.
❑ Integral part of turbocharger
and cannot be
replaced.
12 - Turbocharger
13 - From crankcase breather
14 - From air filter.
15 - Oil return line
❑ To cylinder block.
16 - Gasket
❑ Renew.
17 - Seal
❑ Renew.
19 - Union, 40 Nm
20 - 15 Nm
21 - Oil return line, 25 Nm
❑ To cylinder block.
22 - Bracket
1. Charge air system with turbocharger 133
23 - To charge air cooler
24 - Gasket
❑ Renew.
25 - Front exhaust pipe
26 - Hose
❑ To charge pressure control solenoid valve -N75- .
27 - Connection
28 - 10 Nm
29 - Oil supply line
❑ From oil filter bracket ⇒ Item 6 (page 69) .
❑ Fill connection with engine oil before attaching oil supply line.
30 - Bracket
31 - 10 Nm
1.2 Removing and installing parts of charge
air cooling
Note
♦ All hose connections of charge air system are secured by
spring-type clips or by connector couplings. Always check the
following points with push-on connectors:
♦ Release connection by pulling the locking clip -arrow-.
♦ Pull hose/pipe off without the use of tools.
♦ When installing, ensure the locking lugs -A- engage correctly.
Note
Charge air system must be free of leaks.
1.2.1 Engine codes AJM, ATJ
Engine code AVB ⇒ page 136
Engine codes AVF, AWX ⇒ page 137
1 - Charge air cooler
2 - Connecting hose
3 - 10 Nm
4 - Bush
5 - Rubber grommet
6 - Intake manifold pressure
sender -G71- with intake manifold
temperature sender -G72-
7 - 3 Nm
8 - O-ring
9 - Connecting hose
❑ To intake connecting
pipe
10 - Charge air pipe
❑ From turbocharger
12 - Cross tube
1.2.2 Engine code AVB
2 - Retaining clip
3 - O-ring
❑ Black
❑ Renew.
4 - Connecting hose
5 - 10 Nm
6 - Bush
7 - Rubber grommet
9 - 3 Nm
10 - O-ring
11 - To intake connecting pipe
15 - From turbocharger
16 - Cross tube
18 - O-ring
❑ Black
❑ Renew.
1.2.3 Engine codes AVF, AWX
2 - Retaining clip
3 - O-ring
❑ Black
❑ Renew.
4 - Connecting hose
5 - Rubber grommet
6 - Bush
7 - 10 Nm
8 - O-ring
10 - 3 Nm
11 - To intake connecting pipe
12 - Retaining clip
16 - O-ring
❑ Green
❑ Renew.
17 - From turbocharger
18 - Cross tube
1.3 Vacuum hose schematic diagram
1 - Vacuum unit for shut-off
valve
❑ For fuel cooling system
coolant pump
❑ Only on vehicles up to
01.02
valve (mechanical)
❑ Part of intake connecting
pipe.
❑ Can only be renewed together
with intake connecting
pipe
valve -N18- (electro-pneumatic)
4 - Brake servo
6 - Tandem pump
❑ For fuel and vacuum
supply.
7 - Cylinder head
8 - Intake manifold
9 - Vacuum unit for intake
manifold switchover
10 - Variable intake manifold
flap changeover valve -N239-
11 - Air filter
12 - Charge pressure control
solenoid valve -N75-
❑ White connection to charge pressure control solenoid valve ⇒ Item 12 (page 138) and to vacuum reservoir
14 - Vacuum reservoir
16 - Vacuum unit
❑ For charge pressure control.
❑ Integral part of turbocharger and cannot be replaced.
17 - Turbocharger
When working on the turbocharger, pay careful attention to the
following „5 rules“ for cleanliness:
disconnecting.
lint-free cloths.
tool boxes etc.).
23 – Mixture preparation - injection
1 Repairing diesel direct injection system
The diesel direct injection system control unit is equipped with an
event memory. The event memory must be read before and after
repairs or adjustments ⇒ page 151 ; Reading and clearing event
memory of engine control unit.
1.1 Safety precautions
WARNING
hot components.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front passenger
seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
WARNING
Secure fault reader to rear seat and operate from this position.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or disconnecting
injection or glow plug system wiring or tester cables.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.
When working on the fuel supply and injection system, pay careful
attention to the following „6 rules“ for cleanliness:
140 Rep. gr.23 - Mixture preparation - injection
disconnecting.
lint-free cloths.
tool boxes etc.).
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Overview of fitting locations
Components A to D are not shown in the illustration.
A - Brake pedal switch -F47- (in footwell on brake pedal)
B - Brake light switch -F- (in footwell on brake pedal)
C - Accelerator position sender -G79- (in footwell on accelerator)
⇒ page 122
D - Clutch pedal switch -F36- (in footwell on clutch pedal)
1. Repairing diesel direct injection system 141
-G62-
valve (mechanical)
❑ With intake manifold
flap
3 - Connector
❑ For unit injector -
N240...N243-
4 - Fuel temperature sender -
G81-
6 - Connector
❑ For Hall sender -G40- ,
for camshaft position
7 - Connector
❑ For engine speed sender
-G28- .
8 - Diesel direct injection system
control unit -J248-
❑ With elevation sender -
F96- .
valve -N18- (electro-pneumatic)
10 - Engine speed sender -
G28-
12 - Vacuum unit
❑ For charge pressure control.
13 - Charge pressure control solenoid valve -N75-
14 - Air mass meter -G70-
15 - Variable intake manifold flap changeover valve -N239-
❑ Engine codes AVF, AWX ⇒ page 142
Switchover valve for intake manifold flap -N239- , engine codes
AVF, AWX
1.4 Assembly overview - intake manifold
flap
The intake manifold flap is closed for approx. 3 seconds when
stopping engine and then opens again. This reduces the stop jolt.
2 - 10 Nm
3 - Intake connecting pipe
❑ With exhaust gas recirculation
valve (mechanical)
and intake manifold
flap
valve (mechanical)
5 - O-ring
❑ Renew.
6 - Intake manifold
7 - Gasket
❑ Renew.
8 - Connecting pipe
❑ To exhaust manifold
9 - 25 Nm
10 - Vacuum supply
❑ From vacuum pump
11 - Variable intake manifold
flap changeover valve
12 - Vacuum actuator
13 - Bracket
14 - 10 Nm
1.5 Assembly overview - unit injector
♦ Observe rules for cleanliness ⇒ page 101 .
♦ Always renew seals and O-rings
1 - 20 Nm + 1/4 turn (90°) further
❑ Renew.
2 - Rocker arm shaft
❑ With rocker arms
and installing unit injector
3 - Lock nut
4 - Adjuster screw
❑ Renew when installing a
new unit injector and if
signs of wear can be
seen
❑ Coat contact face with
ball pin of unit injector
with grease -G 000 100-
5 - Unit injector
❑ Check ball pin for signs
of wear, replace if necessary
❑ Coat contact face with
adjuster screw with
grease -G 000 100-
⇒ page 146
6 - O-ring
7 - O-ring
8 - O-ring
9 - Heat shield seal
❑ Renew.
10 - Circlip
11 - Cylinder head
12 - Tensioning block
13 - 12 Nm + 3/4 turn (270°) further
❑ Renew.
1.6 Removing and installing O-rings for unit
injector
♦ Assembly sleeves -T10056-
1.6.1 Removing
– Lever old O-rings very carefully out of unit injector.
– Pay particular attention to ensure that seat of O-ring is not
damaged by burrs.
1.6.2 Installing
Note
♦ Always use the assembly sleeves -T10056- to fit the O-rings.
There is a danger of damaging the O-rings if the sleeves are
not used.
♦ Gradual introduction of O-rings without different coloured
markings. Note the correct allocation of O-rings to grooves:
the thickness of the rings reduces towards injector nozzle.
♦ Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in unit injector.
– Pull heat shield seal off together with securing clip.
– Clean seating surfaces for O-rings on unit injector very carefully.
– Place assembly sleeve -T10056/1- onto stop on unit injector.
– Push the upper, thicker O-ring carefully onto assembly sleeve
and into seat on unit injector.
– Remove assembly sleeve.
– Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.
– Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
– Fit new heat shield seal together with securing clip.
1.7 Removing and installing unit injector
equipment required
♦ Universal dial gauge bracket
-VW 387-
♦ Allen key, long reach
-3410-
♦ Allen key, long reach -
T10054-
♦ Puller -T10055-
Nm) -V.A.G 1331-
Note
With the extended service interval in place, the adjuster screw
-1- and ball pin -2- of the unit injector have been changed. In older
engines without an extended service interval, a mixture is permissible.
1.7.1 Removing
– Remove the upper toothed belt guard and the cylinder head
cover.
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.
– Loosen lock nut of adjuster screws -1- and screw adjuster
screws out until the relevant rocker arm lies against the plunger
spring of the unit injector.
– Remove rocker arm securing bolts -2- (from outwards to inwards)
with socket XZN 10 -3410- and remove rocker arm
shaft.
– Remove tensioning block securing bolt -3- with special
wrench, long reach -T10054- and remove the block.
– Lever connector off unit injector using a screwdriver. Support
opposite side of connector with light finger pressure to prevent
canting.
– Insert puller -T10055- in place of the clamping block in the slot
on the side of the unit injector.
– Pull unit injector out of cylinder head seat by gently tapping
upwards.
1.7.2 Installing
Note
♦ If a new unit injector is installed, the appropriate adjustment
screw in the rocker arm must also be renewed.
♦ Each time work is performed which requires adjustment of the
unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed.
♦ In the older version of the injector unit drive lubricate the contact
surfaces between the ball pin and adjustment screw with
grease -G 000 100- .
♦ New unit injectors are supplied with O-rings and heat shield
seal.
– Heat shield seal and O-rings must be renewed if old unit injector
is reused ⇒ page 144
– Check that the three O-rings and the heat shield seal along
with securing clip are seated correctly before installing unit injector.
Note
The seals must not be twisted.
– Oil the seals and fit the unit injector into the seat in cylinder
head with great care.
– Push the unit injector evenly into the cylinder head onto its limit
stop.
– Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
– Therefore align the unit injector as follows.
– Screw new securing bolt into clamping block, but do not tighten
(it must still be possible to turn the unit injector slightly).
– Now align unit injector at right angles to camshaft mounting
brackets.
– Check dimension „a“ from outer edge of cylinder head to rounded
edge of unit injector with a vernier gauge (measuring
range at least 400 mm).
Note
Gradual introduction of unit injector with new solenoid valve nut.
A mixed installation is permissible providing measurement „a“ is
adhered to.
Unit injector with old solenoid valve nut
Cylinder Dimension „a“
1 332.2 ± 0.8 mm
2 244.2 ± 0.8 mm
3 152.8 ± 0.8 mm
4 64.8 ± 0.8 mm
Unit injector with new solenoid valve nut
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
Continuation for all unit injectors
– Align unit injector, if necessary, and tighten securing bolt as
follows: 12 Nm + 270° (3/4 turn) (further turning can be done
in several stages).
– Fit rocker arm shaft and tighten new securing bolts as follows.
– Tighten inner and then both outer bolts hand-tight. Then, using
same sequence, tighten to 20 Nm and 90° (1/4 turn) further.
– Fit dial gauge onto adjustment screw of unit injector as shown.
– Turn crankshaft in direction of engine rotation until roller of
rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point: dial gauge -arrow Bpositioned
at lowest point
– Remove dial gauge.
– Now turn adjuster screw into rocker arm against spring pressure
of unit injector until firm resistance is felt (unit injector
positioned at stop).
– Turn adjustment screw 180° back off stop.
– Hold adjuster screw in this position and tighten lock nut to 30
Nm.
– Push on unit injector connector and install cylinder head cover
and toothed belt guard.
2 Engine control unit
2.1 Reading and clearing engine control unit
event memory
Procedure
VAS 5051- as follows:
Vehicles ► 09.00
– Pull cover off in direction of arrow.
– Connect connector of 3 m diagnostic cable with voltage supply
-VAS 5051/1- to diagnostic socket.
Vehicles 10.00 ►
2. Engine control unit 151
-VAS 5051/1- or 5 m diagnostic cable without voltage supply
-VAS 5051/3- to diagnostic socket -arrow-.
Only when engine does not start:
Selecting operating mode:
– Press button on display for „Vehicle self-diagnosis“.
Selecting vehicle system:
– Press „01 - Engine electronics“ button on display.
The control unit identification and coding are displayed on the
engine control unit display.
Select diagnostic function:
– Press button „02 - Read event memory“ on display.
– If no fault is stored in engine control unit „0 fault detected“ is
displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press button „05 - event memory“ on display.
2.2 Adapting functions and components
Procedure
VAS 5051- as follows:
Vehicles ► 09.00
– Pull cover off in direction of arrow.
-VAS 5051/1- to diagnostic socket.
Vehicles 10.00 ►
-VAS 5051/1- or 5 m diagnostic cable without voltage supply
-VAS 5051/3- to diagnostic socket -arrow-.
Only when engine does not start:
Select „Guided fault finding“ in Vehicle diagnosis, testing and information
system -VAS 5051- .
When all control units have been read:
– Press „GoTo“ button.
– Select „Function/component selection“.
– Select „Drive“.
– Select „Engine code“.
– Select „01 Systems capable of self-diagnosis“.
– Select „engine control“.
– Select „Functions“.
– Select „Function or component“.
2.3 Removing and installing engine control
unit
– First read control unit identification and hence also the coding
of the installed engine control unit before removing the control
unit ⇒ page 151 ; Reading and clearing event memory of engine
control unit.
2.3.1 Removing
– Switch off ignition.
2. Engine control unit 153
– Remove cover from E-box.
– Unclip fixing bracket of engine control unit.
– Release connectors on engine control unit and pull off connector.
– Remove old control unit and insert new control unit.
– Check the previous coding and code the new control unit
⇒ page 152 ; Adapting functions and components.
26 – Exhaust system
1 Parts of the exhaust system
Note
♦ Removing and installing exhaust manifold ⇒ page 132 , Removing
and installing turbocharger with connected parts.
♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
1.1 Assembly overview - four-wheel drive
vehicles
Front-wheel drive vehicles ⇒ page 157 .
1 - 25 Nm
2 - Mounting
❑ With retaining ring.
3 - 40 Nm
4 - Coach bolt
5 - Repair double clamp
6 - Separating point
❑ Centre and rear silencers
are installed as a
single component during
production. In cases
of repair, the centre and
rear silencer are supplied
separately, with a
double clamp for connecting.
❑ Cut through separating
point on connecting pipe
at right angles using
body saw -V.A.G
1523A- for example
⇒ page 156 .
7 - Rear right silencer
8 - Mounting
9 - Bracket
10 - Rear left silencer
11 - Intermediate pipe
12 - Gasket
❑ Renew.
1. Parts of the exhaust system 155
❑ With catalytic converter.
❑ Engine codes AVB, AVF, AWX: with one-piece exhaust pipe
14 - Turbocharger
15 - Double clamp
16 - Centre silencer
Separating point between centre silencer and rear silencer
♦ e.g. pneumatic sabre saw -V.A.G 1523AProcedure
– Separate connecting pipe between centre silencer and rear
silencer at the point marked with a groove: measurement -aapprox.
244 mm.
156 Rep. gr.26 - Exhaust system
1.2 Assembly overview - front-wheel drive vehicles
1 - Mounting
2 - 25 Nm
3 - Mounting
❑ With retaining ring.
4 - Rear silencer
❑ Centre and rear silencers
are installed as a
single component during
production. In cases
of repair, the centre and
rear silencer are supplied
separately, with a
double clamp for connecting.
❑ Cut through separating
point on connecting pipe
at right angles using
body saw -V.A.G
1523A- for example
⇒ page 157 .
5 - Centre silencer
❑ Engine codes AJM,
ATJ, AVB
6 - Intermediate pipe
7 - Gasket
❑ Renew.
8 - Bolt
❑ With catalytic converter.
❑ Engine codes AVB,
AVF, AWX: with onepiece
exhaust pipe
10 - Turbocharger
11 - Double clamp
12 - Centre silencer
❑ Engine codes AVF, AXW
Separating point between centre silencer and rear silencer
1. Parts of the exhaust system 157
♦ e.g. pneumatic sabre saw -V.A.G 1523AProcedure
– Separate connecting pipe between centre silencer and rear
silencer at point marked with a groove -arrow-.
2 Exhaust gas recirculation system
Note
♦ The exhaust gas recirculation system is activated by the diesel
direct injection system control unit -J248- via exhaust gas recirculation
valve -N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
♦ The cone-shaped plunger in the mechanical exhaust gas recirculation
valve ensures that various cross sectional openings
are possible at different plunger lifts.
♦ Pulsed control enables every conceivable valve position.
2.1 Assembly overview - parts of exhaust
gas recirculation
2.1.1 Vehicles with manual gearbox.
Vehicles with automatic gearbox ⇒ page 161 .
2. Exhaust gas recirculation system 159
2 - 10 Nm
valve (mechanical)
and intake manifold
flap
valve (mechanical)
pipe.
pipe
❑ Check mechanical operation
⇒ page 163 .
5 - O-ring
❑ Renew.
6 - Intake manifold
8 - Gasket
❑ Renew.
9 - 25 Nm
10 - Connecting pipe
2 - 10 Nm
valve (mechanical)
and intake manifold
flap
valve (mechanical)
pipe.
pipe
⇒ page 163 .
5 - O-ring
❑ Renew.
6 - Intake manifold
8 - Gasket
❑ Renew.
9 - 25 Nm
10 - Connecting pipe
2.1.3 Vehicles with automatic gearbox
valve (mechanical)
pipe.
pipe
⇒ page 163 .
3 - 10 Nm
4 - O-ring
❑ Renew.
5 - Intake manifold
6 - 25 Nm
7 - Connecting pipe
8 - Gasket
❑ Renew.
9 - Radiator/cooler
❑ For exhaust gas recirculation.
11 - To heat exchanger
12 - From connection.
valve (mechanical)
and intake manifold
flap
valve (mechanical)
pipe.
pipe
⇒ page 163 .
3 - 10 Nm
4 - O-ring
❑ Renew.
5 - Intake manifold
6 - 25 Nm
7 - Connecting pipe
8 - Gasket
❑ Renew.
9 - Radiator/cooler
❑ For exhaust gas recirculation.
11 - To heat exchanger
12 - From connection.
valve (mechanical)
and intake manifold
flap
2.2 Checking exhaust gas recirculation
valve (mechanical)
♦ Hand vacuum pump with accessories -V.A.G 1390-
Test procedure
– Remove engine cover.
– Remove charge air pipe/intake connecting pipe connecting
hose
– Pull vacuum hose off exhaust gas recirculation valve (mechanical).
to valve.
– Operate pump and observe diaphragm rod.
The diaphragm rod must move in -direction of arrow-.
– Pull hand vacuum pump hose off exhaust gas recirculation
valve (mechanical).
The diaphragm rod must move back to its original position counter
to the -direction of the arrow-.
28 – Glow plug system
1 Checking glow plug system
♦ Hand-held multimeter -V.A.G 1526/A-
♦ Auxiliary measuring set -V.A.G 1594A- or -V.A.G 1594CTest
prerequisites
• Ignition switched off
• Diesel direct injection system control unit -J248- OK.
• Fuse for glow plugs S189 OK.
Test procedure
– Detach connector from coolant temperature sender
⇒ page 141 .
Note
Pulling the connector off sender, simulates engine condition
„cold“ and when switching the ignition on the relevant glow period
is carried out.
– Pull glow plug connectors off glow plugs.
– Connect multimeter to measure voltage between glow plug
connector and earth.
– Switch on ignition. Approx. battery voltage must be displayed
for approx. 20 seconds.
– If no voltage is present: ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
1.1 Checking glow plugs
1. Checking glow plug system 165
♦ Auxiliary measuring set -V.A.G 1594A- or -V.A.G 1594C-
♦ Hinged socket -3220-
♦ Voltage tester -V.A.G 1527/BTest
prerequisites
• Ignition switched off
Test procedure
– Pull glow plug connectors off glow plugs.
– Connect voltage tester -V.A.G 1527/B- cable to battery positive
(+), using clips from auxiliary test set -V.A.G 1594A- or -
V.A.G 1594C- .
– Place test probe of voltage tester -V.A.G 1527/B- on each glow
plug one after the other. Diode lights up: glow plug OK., diode
does not light up: renew glow plug.
– Remove and install glow plugs with hinged socket -3220- .
Specified torque: 15 Nm.
166 Rep. gr.28 - Glow plug system

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