Diagrama Injection Mecanico Jetta 99 Up PDF

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

No reproduction without prior agreement from publisher.
Copyright 2012 Volkswagen AG, Wolfsburg
D3E8002131A
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Mechanical,
Fuel Injection and Glow Plug - Edition 07.2007
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Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Engine, Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine and Transmission Mount, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
3
3.1
3.2
4
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1
1.1
2
2.1
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00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
5
5
7
7
10
12
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

AG.
1
1.1
1.2
2
2.1
2.2
2.3
2.4
2.5
2.6
3
3.1
3.2
3.3
4
4.1
5
5.1
5.2
5.3
5.4
6
General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Projection at TDC, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbed Belt and Components Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed Belt and Covers Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block and Components Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing Flange and Drive Plate/Flywheel Assembly Overview . . . . . . . . . . . . . . . . . . . . . .
Piston and Connecting Rod Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and Cylinder Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Rings and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Seal, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
14
16
16
17
19
20
21
23
25
25
26
26
27
27
29
29
30
32
33
36
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1
1.1
2
2.1
2.2
3
3.1
4
4.1
Cylinder Head Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valvetrain Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
38
38
39
39
42
45
45
47
47
Golf 1999 , Jetta 1999 , Jetta Wagon 1999

Engine Mechanical, Fuel Injection and Glow Plug - Edition 07.2007
4.2
5
5.1
5.2
5.3
5.4
5.5
5.6
6
Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
49
49
50
54
60
63
64
66
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Oil Level Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Supply Line Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Pump Assembly Overview . . . .ag. e.n.A.G.. V. o. lk. s.w.a.ge. n. A. G. d. o. . . . . . . . . . . . . . . . . . . .
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Oil Filter Bracket Assembly Overview by.V.ol.k . . . . . . . . . . . . . . . . . . . .n.ot.g.ua. . . . . . . . . . . . . .
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Specifications . . . . . . . . . . . . . .ho.ri.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nte. e. . . . . . . . . . .
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Fastener Tightening Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . .
ss
Engine Oil Capacity and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure and Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
3.2
4
4.1
5
5.1
5.2
6
69
69
69
70
70
71
73
75
75
75
76
76
77
77
78
80
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Components Assembly Overview, Body Side . . . . . . . . . . . . . . . . . . . . . .
Cooling System Components Assembly Overview, Engine Side . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Glow Plug, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
4
4.1
4.2
4.3
5
5.1
5.2
5.3
6
81
81
81
85
85
87
88
90
90
91
91
91
92
94
94
94
95
97
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1
1.1
1.2
1.3
ii
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Accelerator Mechanism Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank and Attachments Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
olkswagen AG
en AG. V
Diagnosis and Testing . . . . . . . . . . . . . . . . .ol.ks.w.a.g . . . . . . . . . . . . . . d.o.es. n.o. . . . . . . . . . . . .
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Fuel Pump, Checking . . . . . . . . . . . . . s.ed. b.y. . . . . . . . . . . . . . . . . . . . . . . . . . .ua. r.an. . . . . . . . .
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Tandem Pump, Checking . . . . . . . u.th.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.e.or. . . . . .
ac
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Removal and Installation . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tandem Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
101
101
104
106
106
107
107
108
111
111
111
113
114
114
117
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2
2.1
2.2
2.3
3
3.1
4
4.1
4.2
5
5.1
5.2
5.3
5.4
5.5
6
21 - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Air Cooler and Components Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger and Attachments Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose Connections with Connector Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
4
4.1
5
5.1
5.2
6
120
120
120
121
121
123
125
126
126
127
127
129
129
129
135
23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1
1.1
1.2
2
2.1
2.2
2.3
2.4
3
3.1
4
4.1
4.2
5
5.1
5.2
5.3
6
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Module Functions and Components, Adapting . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Injector Unit Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Module DTC Memory, Checking and Erasing . . . . . . . . . . . . . . . . . . . . . .
Speed Signal, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Injector Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Injector Unit O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
136
136
136
138
138
139
139
140
142
142
143
143
143
145
145
145
148
151
iii

6.1
7
Variable Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
AG. Volkswagen . d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

26 - Exhaust System, Emission
agen Controls .AG
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General Information
. . . . . . . . . . . . . . . . . . . . g.u.ar.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GeneraluthRepair
Information . . . . . . . . . . . . . . . . . . te. e.o . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ra
a
ss
Description
and Operation . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Exhaust Pipe with Catalytic Converter Assembly Overview . . . . . . . . . . . . . . . . . .
Mufflers and Mounts Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EGR System Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Flap and EGR Cooler, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EGR Vacuum Regulator Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rrectne
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1
1.1
2
2.1
2.2
2.3
3
3.1
4
4.1
4.2
5
154
154
155
155
156
158
159
159
160
160
161
163
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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Visual Characteristics of Ceramic and Metal Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug, Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug, Ceramic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
2
2.1
3
3.1
4
4.1
4.2
5
164
164
165
165
166
166
167
167
167
170

00
General, Technical Data
General Information
1.1 Engine Number, page 1
1.1
Engine Number
The engine number (engine code and serial number) are located
at the engine/transmission joint -arrow-.
In addition, a sticker with the engine code and serial number is
affixed to the timing belt cover.
The engine code is also included on the vehicle data plate.
The engine number consists of up to nine alphanumeric charac
ters. The first part (maximum 3 letters) represents the engine
code, the second (six digit) is the serial number. If more than
999,999 engines with the same engine code are produced, the
first of the six characters is replaced with a letter.
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1. General Information
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Specifications
2.1 Engine Data, page 2
Engine Data
Code letters
BEW
from 06.03
LEV 1
liter
1.9
kW at RPM
74 at 4000
Nm at RPM
240 at 1800/2400
dia. mm
79.5
mm
95.5
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1-3-4-2
yes
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yes
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Manufactured
Emission values in accordance with
Displacement
Output
Torque
Bore
Stroke
valves per cylinder
Compression ratio
CZ
Ignition sequence
Catalytic converter
Exhaust gas recirculation
Turbocharger, G-Charger
Charge air cooler
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2.1

10
Engine Assembly
General Information
1.1 Engine, Securing to Assembly Stand, page 3

1.2 Engine and Transmission Mount, Aligning, page 3
1.1
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Holding fixture -VW 540 Engine sling -2024Aes, in part or in w

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Secure the engine to the -VW 313- of the assembly stand using
the -VW 540- when performing repair work.
Procedure
Remove the transmission.
With a Automatic Transmission
After separating the engine from the transmission, secure the
torque converter to prevent it from falling out.
Continuation for All
Belt pulley side: 2. Bore of the hole rail in position 1
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Flywheel side: 4. Bore of the hole rail in position 8
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Install the -2024A- as shown and lift the engine from the VAG 1383A- using the workshop crane.
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Engine and transmission jack -VAG 1383A-
Use the securing pins at the hooks and pins.

AG.
Note
The peg positions on the -2024A- marked with 1 through 4 face
the belt pulley.
The bores in the hole rail are counted from the hook.
Secure the engine with the -VW 540 - to the -VW 313- .
Note
Loosen the coolant line on the flywheel side.
1.2
Engine and Transmission Mount, Align

ing
Special tools and workshop equipment required

Engine support bridge -10-222A-
un
le
Before loosening the bolts, secure the assembly using the

-10-222A- .
Engine Mount
a = 14.0 mm
b = minimum 10.0 mm
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c = 18 to 20 mm
Rep. Gr.10 - Engine Assembly
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Edges -a and b- must be parallel to each other.
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Transmission Mount
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Both bolt heads -1- must be flush with the edge -c-.
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Engine Mechanical, Fuel
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Specifications
2.1 Fastener Tightening Specifications, page 5
2.1

Component
Fastener Size
Nm
Bolts and Nuts

M6
M8
M10
M12
Engine and Transmission Support -T10012- to Cylinder Block
M10 x 25/strength
wagen AG 8.8
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Front Exhaust Pipe to Turbocharger Nut
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1
Always replace
Mount to body 1
23-
Mount bracket to body

Mount to engine mount bracket
1
Always replace
40 Nm + 90 (1/4) ad
ditional turn
25 Nm
100 Nm
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Right Engine Mount
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10
20
45
60
40
Left Transmission Mount (with a Manual Transmission)
Always replace
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Mount to body
Mount to transmission mount
bracket
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23-
40 Nm + 90 (1/4) ad
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25 Nm
100 Nm
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1-
Left Transmission Mount (with a Automatic Transmission)

1-
Mount to body 1
23-
Mount to body
Mount to transmission mount
bracket
40 Nm + 90 (1/4) ad
ditional turn
25 Nm
100 Nm
Always replace
2. Specifications

Pendulum Support
Installation sequence:
123-
Pendulum support to subframe

Pendulum support to transmission
Pendulum support to transmission
25 Nm
50 Nm
50 Nm
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Removal and Installation
3.1 Engine, Removing, page 7

3.2 Engine, Installing, page 10
3.1
Engine, Removing

Engine sling -2024A Engine and transmission support -T10012 Holding fixture -VW 313 Holding fixture -VW 540 Shop crane -VAG 1202A Drip tray -VAG 1306 Torque wrench (5-50 Nm) -VAG 1331 Torque wrench (40-200 Nm) -VAG 1332 Engine and transmission jack -VAG 1383A Spring type clip pliers -V.A.S 5024 Step ladder -V.A.S 5085 Grease -G 000 100- (Vehicles with manual transmission)
M10 x 25/8.8 strength category
bolt
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The hengine
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ee transmis
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Cable tie
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Caution
When doing any repair work, especially in the engine compart

ment, pay attention to the following due to clearance issues:
rrectness of i
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nform
spec
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s
Route lines of all types (for example: fuel, hydraulic, Evap

orative Emission (EVAP) , coolant, refrigerant, brake or
vacuum) and electrical wires so that the original path is
followed.
Ensure sufficient clearance to all moving or hot compo
nents.
All cable ties which are opened or cut off when removing the
engine, must be replaced in the same position when installing
the engine.
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First, check whether a coded radio is installed. If necessary,

obtain the antitheft coding.
Disconnect the battery ground cable with the ignition switched

off.
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Remove the engine cover. Refer to

5.1 Cylinder Head Cover, page 49 .
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Remove the battery and battery holder.

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Remove the air filter.
Disconnect the connecting pipe between the charge air cooler

and exhaust pipe at the exhaust pipe.
3. Removal and Installation

WARNING
The fuel or fuel lines for the fuel system can become very
hot (danger of scalding)!
In addition, the fuel system is under pressure! Before
opening the system, place a cloth around the connection
and release the pressure by carefully loosening the con
nection!
Wear protective goggles and protective gloves when
working on the fuel system!
Clamp off the fuel supply and return lines at the fuel filter.
With a Manual Transmission 02J
Remove the slave cylinder. Refer to Manual Transmission;
Rep. Gr. 30 ; Description and Operation .
Disconnect the selector mechanism from the transmission, re
fer to Manual Transmission; Rep. Gr. 34 ; Removal and
Installation .
Disconnect the selector lever cable from transmission. Refer
to Automatic Transmission; Rep. Gr. 37 ; Removal and
Installation .
Remove the noise insulation, along with the left and right
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Drain the cooling system. Refer to auth

1.2 Draining and Filling, page 81ss .
Disconnect the electrical connectors from the thermal switch

and the radiator fan.
rrectness of i
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spec
at
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Remove the coolant hoses from the radiator.

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

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

to open the refrigerant circuit:
Remove the retaining clamp(s) from the refrigerant lines.
Remove the ribbed belt. Refer to
Remove the A/C compressor. Refer to Heating, Ventilation
and Air Conditioning; Rep. Gr. 87 ; Description and Operation .
Note
Shield the bumper from damage using adhesive tape.

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Secure the A/C compressor to the tow hook so that the refrig
erant lines/hoses are not under a load.

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

-arrows- from the top.
Note
Use the -VAS 5085- to remove the bolts.
Carefully lower the engine with transmission.

Note
Carefully guide the engine with transmission, when lowering, to

prevent damage to the body.
3.2
Engine, Installing
Installation is performed in the reverse of removal, noting the fol

lowing:
Lightly grease the clutch release bearing, guide sleeve for the
release bearing and the input shaft splines with grease - G 000
100- .
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Check whether the alignment pins for centralizing the engine/

transmission are in the cylinder block, install if necessary.
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When installing the engine/transmission, ensure clearance to

the drive axle.
Align the engine and transmission mounts. Refer to
1.2 Engine and Transmission Mount, Aligning, page 3 .
Tightening specifications, refer to
2.1 Fastener Tightening Specifications, page 5 .
Install the drive axles. Refer to Suspension, Wheels, Steer
ing; Rep. Gr. 40 ; Removal and Installation .
10
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Check the clutch release bearing for wear, replace if neces

sary.
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Remove the transmission mount to transmission mount brack

et bolts -arrows- from above.
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Install the front exhaust pipe. Refer to
Overview , page 155 .
With a Manual Transmission 02J
Install the slave cylinder. Refer to Manual Transmission;
Connect the selector mechanism and, if necessary, adjust the
selector lever cable. Refer to Manual Transmission; Rep.
Gr. 34 ; Removal and Installation .
Install the selector lever cable to the transmission, adjust if
necessary: Automatic Transmission; Rep. Gr. 37 ; Removal
and Installation .
Install the power steering pump. Refer to Suspension,
Wheels, Steering; Rep. Gr. 48 ; Description and Operation .
Clamp the connecting pipe between the charge air cooler and
exhaust pipe at exhaust pipe.
Volkswa
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Electrical connections and routing. Refer
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Equipment; Rep. Gr. 97 .
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his
Install the ribbed belt. Refer to

Install the center noise insulation, along with the left and right
sides. Refer to Body Exterior; Rep. Gr. 50 ; Description and
Operation .
Fill the cooling system. Refer to
1.2 Draining and Filling, page 81 .
Perform a road test and check the Diagnostic Trouble Code
(DTC) memory. Refer to
4.1 Engine Control Module DTC Memory, Checking and
Erasing, page 143 .
Tightening Specifications
Tightening
specifications
Prote
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by
Front exhaust pipe to turbocharger 1
10 Nm
20 Nm
45 Nm
60 Nm
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deviation from
M6
M8
M10
M12
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With Air Conditioning (A/C) thori

au
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Install the A/C compressor.
Refer to Heating, Ventilation Air
Conditioning; Rep. Gr. 87 ; Description and Operation .
25 Nm
Always replace
11

Special Tools
Special tools and workshop

equipment required
Engine sling -2024A Engine and transmission
support -T10012 Holding fixture -VW 313 Holding fixture -VW 540 Shop crane -VAG 1202A-
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Drip tray -VAG 1306-

Torque wrench (5-50 Nm) VAG 1331un

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Step ladder -V.A.S 5085-
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Spring type clip pliers V.A.S 5024-
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Engine and transmission

jack -VAG 1383A-
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Torque wrench (40-200

Nm) -VAG 1332-
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equipment required
4. Special Tools
13

13
Crankshaft, Cylinder Block
General Information
1.1 General Repair Information, page 14

1.2 Piston Projection at TDC, Checking, page 14
1.1
General Repair Information

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

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

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

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Measuring bar -VW 382/7s
Test Sequence
Note
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his
When installing new pistons or working with a partial motor, all of

the pistons must be checked for piston projection at Top Dead
Center (TDC). Depending on the piston projection, install the cor
responding cylinder head gasket according to the following table.
To measure the piston projection at TDC, turn the engine in a

clockwise direction.
1
2
3
Rep. Gr.13 - Crankshaft, Cylinder Block
AG.
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0.91 to 1.00 mm
1.01 to 1.10 mm
1.11 to 1.20 mm
Identification
Notches/Holes
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Identification of Cylinder Head Gasket
Replacement part number = -arrow 1 Control code = -arrow 2- (ignore this!)
Holes = -arrow 3Note
If varying values occur when measuring the projection, use the

gasket for the largest value.
rrectness of i
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Description and Operation
2.1 Ribbed Belt and Components Assembly Overview,

page 16
2.2 Toothed Belt and Covers Assembly Overview,
page 17
2.3 Cylinder Block and Components Assembly Overview,
page 19
2.4 Sealing Flange and Drive Plate/Flywheel Assembly Over
view, page 20
2.5 Piston and Connecting Rod Assembly Overview,
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2.6 Crankshaft Assembly Overview, page e23
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Ribbed Belt and Components Assembly Overview
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2.1
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1 - Ribbed Belt
Mark the direction of ro
tation before removing.
Check for wear.
Do not kink.
Removing and instal
ling, refer to
5.1 Ribbed Belt,
page 29 .
2 - Bolt, 10 Nm + 90 (1/4) ad
ditional turn
7 - Accessory Bracket
For the generator, pow
er steering pump and Air
Conditioning (A/C) com
pressor.
8 - Bolt, 45 Nm
Observe the tightening
sequence, refer to
Fig. Accessory
Bracket Bolt Tightening Sequence , page 17 .
9 - Banjo Bolt, 30 Nm
10 - Seal
Always replace.
16
AG.
6 - Generator
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5 - Ribbed Belt Tensioner

To release the tension
on the ribbed belt, pivot
using an open end
wrench. Refer to
5.1 Ribbed Belt,
page 29 .
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4 - Bolt, 25 Nm
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3 - Vibration Damper
Only possible to install
in one position - Bores
are offset.

11 - Pressure Line
12 - Power Steering Pump
For the power steering.
Removing and installing, refer to Suspension, Wheels, Steering; Rep. Gr. 48 ; Description and Op
eration .
13 - Power Steering Pump Pulley
Accessory Bracket Bolt Tightening Sequence
Procedure
Place the accessory bracket on the cylinder block (observe the
fitting sleeve between the bracket and cylinder block).
Tighten the bracket bolts -A through F- in sequence to 45 Nm
pe
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Toothed Belt and Covers Assembly Overview
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1 - Upper Toothed Belt Cover
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2 - Toothed Belt
Check for wear.
Do not kink.
Removing and instal
ling, tensioning. Refer to
5.3 Toothed Belt,
page 54 .
AG.
8 - Hub
With sensor wheel.
Use the camshaft gear
counter holder -T10051
- to loosen and tighten.
To remove, use the pull
er -T10052- .
Removing and instal
ling, refer to
5.4 Camshaft,
page 60 .
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7 - Camshaft Sprocket
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6 - Bolt, 25 Nm
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5 - Bolt, 100 Nm
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4 - Tensioning Roller
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3 - Nut, 20 Nm + 45 (1/8) ad
ditional turn
9 - Bolt, 10 Nm
Always replace.
2. Description and Operation
17

10 - Rear Toothed Belt Cover
11 - Grommet
Replace if damaged.
12 - Idler Roller
13 - Coolant Pump
Removing and installing, refer to 5.2 Coolant Pump, page 94 .
14 - Crankshaft Toothed Belt Sprocket
15 - Bolt, 120 Nm + 90 (1/4) additional turn
Always replace.
Use the spur belt spreading -3099- to loosen and tighten.
Do not additionally oil or grease
the threads or collar.
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18 - Lower Toothed Belt Cover

21 - Cover
22 - Center Toothed Belt Cover

23 - Bolt, 45 Nm
24 - Engine Mount Bracket
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18
rrectness of i
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19 - Belt Pulley/Vibration Damper

Only possible to install in one position - Bores are offset.
do
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16 - Bolt, 15 Nm rised
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17 - Nut, 20 sNm
sa

2.3
Cylinder Block and Components Assembly Overview
1 - Cylinder Block
Sealing flanges and
drive plate/flywheel as
sembly overview. Refer
to
2.4 Sealing Flange
and Drive Plate/Fly
wheel Assembly Over
view, page 20 .
Crankshaft assembly
overview. Refer to
2.6 Crankshaft As
sembly Overview, page
23 .
Piston and connecting
rod assembly overview.
Refer to
2.6 Crankshaft As
23 .
2 - Bolt, 3.5 Nm
3 - Bracket
for the vacuum reser
voir.
4 - Vacuum Reservoir
56-
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Always replace.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
7 - Oil Filter Bracket

Disassembling and as
sembling, refer to
2.3 Oil Filter Bracket
Assembly Overview,
page 73 .

Always replace.
First, tighten the upper left and lower right bolts, and then tighten all four bolts in a diagonal sequence.
9 - Bolt, 15 Nm
10 - Engine Speed (RPM) Sensor -G2811 - Connecting Piece
For the thermostat.
do
c
um
en
12 - O-ring
Always replace.
13 - Coolant Thermostat
Removing and installing, refer to 5.1 Coolant Thermostat, page 94 .
Observe the installed location, refer to 5.1 Coolant Thermostat, page 94 .
Checking: Heat up thermostat in water.
Opening begins approximately 85 C (185 F).
Ends approximately 105 C (221 F).
Opening lift min. 7 mm.
19
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14 - Bolt, 45 Nm
Observe the tightening sequence, refer to
Fig. Accessory Bracket Bolt Tightening Sequence , page 17 .
15 - Accessory Bracket
For the generator, power steering pump and Air Conditioning (A/C) compressor.
16 - Oil Pan
Clean the sealing surface before installing.
Install using silicone sealant -D 176 404 A2 - . Refer to 5.2 Oil Pan, page 78 .
Sealing Flange and Drive Plate/Flywheel Assembly Overview
es, in part or in w
l purpos
hole
ercia
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4 - Drive Plate/Flywheel
To remove and install flywheel, secure using the flywheel retainer -3067- .
Drive plate removing and installing, refer to 5.4 Drive Plate, page 33 .
Always replace.
20
thi
sd
o
cu
m
en
3 - Cylinder Block
Crankshaft assembly
overview. Refer to
2.6 Crankshaft As
23 .
Piston and connecting
rod assembly overview.
Refer to
2.6 Crankshaft Assembly Overview, page 23 .
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
2 - Sealing Flange
Must be located on the
alignment pins.
Removing and instal
ling, refer to
5.2 Sealing Flange,
Belt Pulley Side,
page 30 .
Install using silicone
sealant -D 176 404 A2 - .
Refer to
5.2 Sealing Flange,
Belt Pulley Side,
page 30 .
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1 - Seal
Do not additionally oil or
grease the sealing lip of
the seal.
Before installing, re
move any remaining oil
from the crankshaft jour
nal with a clean cloth.
Crankshaft seal, belt
pulley side, replacing.
Refer to
5.3 Crankshaft Seal,
Belt Pulley Side,
page 32 .
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2.4

6 - Intermediate Plate
Must be located on the alignment pins.
Do not damage or bend when doing assembly work.
7 - Bolt, 15 Nm
8 - Sealing Flange with Seal
Only replaced as a complete unit.
Do not additionally oil or grease the sealing lip of the seal.
Before installing, remove any remaining oil from the crankshaft journal with a clean cloth.
To install, use the provided support sleeve.
Support sleeve may only be removed after the sealing flange has been slid onto the crankshaft end.
2.5
Piston and Connecting Rod Assembly Overview
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1 - Piston Rings
Offset gaps by 120 de
grees.
Position the oil scraping
ring offset gaps closely
in the wound area of the
spring.
Use the piston ring pli
ers for removal and in
stallation.
TOP faces toward
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Checking
nte
ris ring gap, refer
o
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to uthpage 27 .
ra
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Check the piston ring
groove clearance, refer
to page 27 .
do
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hole
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2 - Piston
With combustion cham
ber.
Mark the installed posi
tion and cylinder alloca
tion.
Installed position and al
location, piston/cylin
der. Refer to
page 28 .
Arrow on piston face
points toward the belt
pulley side.
Install with a piston ring
compressor.
If cracked, replace the
piston at the piston pin.
Checking the piston po
sition at Top Dead Center (TDC). Refer to 1.2 Piston Projection at TDC, Checking, page 14 .
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3 - Piston Pin
If the piston is difficult to move, heat it to 60 C (140 F).
Remove and install using the pilot drift -VW 222A- .
21
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4 - Circlip
5 - Connecting Rod
Mark the allocation to the cylinder using a colored mark -A-.
Installed position: Markings -B- point to the belt pulley side.
With cracked bearing cap.
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6 - Bearing Shell
Note the installed position.
Note version: Upper bearing shell (to piston) made of wear resistant material, identification: Black line
on contact surface in area of separating point.
Do not interchange used bearing shells.
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Insert bearing shells in center.
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Ensure seated tightly.
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Axial play wear limit: 0.37 mm.
a
c
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s
Measure radial clearance with Plastigage: Wear limit: 0.08 mm. Do not turn crankshaft when checking
radial clearance.
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22
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Always replace.
Lubricate the threads and contact surface.
Use the old bolts to measure radial play.
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10 - Bolt, 25 Nm
Install without sealant.
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9 - Oil Spray Jet

For piston cooling.
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8 - Connecting Rod Bearing Cap

Due to the separation procedure (cracking) of the connecting rod, the cap only fits in one position and
only to the corresponding connecting rod.
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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s
7 - Cylinder Block
Cylinder bore, checking. Refer to page 27 .
Piston and cylinder dimensions. Refer to 3.2 Piston and Cylinder Dimensions, page 26 .

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

For the bearing cap
without a oil groove.
For the cylinder block
with a oil groove.
Do not interchange
used bearing shells
(mark).
2 - Bolt, 65 Nm + 90 (1/4) ad
ditional turn
Always replace.
Tighten to 65 Nm to
measure radial play, do
not turn further.
4 - Bearing Shell 3
For bearing cap without
a oil groove.
For cylinder block with a
oil groove.
5 - Thrust Washer
For bearing cap 3.
Observe the locating
point.
rrectness of i
t to the co
nform
spec
at
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3 - Crankshaft Bearing Cap

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Bearing cap
ut 3 with
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washers.
Retaining tabs of the
bearing shells and cylin
der block/bearing caps
must lie above one an
other.
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Always replace.
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6 - Sensor Wheel
For the engine speed (RPM) sensor.
Replace if damaged.
replace the sensor wheel every time the bolts are loosened.
Removing and installing, refer to Fig. Sensor Wheel, Removing and Installing , page 24 .
8 - Alignment Pin
Check the projection from the crankshaft. Refer to
Fig. Check Projection of Alignment Pin from Crankshaft , page 24 .
9 - Crankshaft
Axial play new: 0.07 to 0.17 mm, Wear limit: 0.37 mm.
Check radial clearance with Plastigage 0.03 to 0.08 mm Wear limit: 0.17 mm.
Do not turn the crankshaft when measuring radial play.
Crankshaft dimensions, refer to 3.3 Crankshaft Dimensions, page 26 .
23

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

Depth gauge
Test Sequence
Check the projection -a- of the alignment pin with the sensor
wheel -1- removed, using a depth gauge.
1-
Sensor wheel
2-
Bolt
3-
Fitting pin projection -3- from crankshaft a = 2.5 to 3.0 mm
Sensor Wheel, Removing and Installing

Always replace the sensor wheel
-2- whenever the bolts are
n AG. Volkswagen AG do + 90 (1/4) ad
removed -1-. Tightening
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wagespecification: 10 Nm
s
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24
rrectness of i
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at
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es, in part or in w
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After tightening a second time, the attachment point of the coun

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

Specifications

3.2 Piston and Cylinder Dimensions, page 26
3.3 Crankshaft Dimensions, page 26
3.1

Component
Fastener Size
Nm
100
25
10
65 + 90 turn
15
30 + 90 turn
15
120 + 90 turn
60 + 90 turn
45
15
25
20
10
15 + 90 turn
15
25
25
30
25
25
25
15
20 + 45 turn
10
3.5
15
10 + 90 turn
Camshaft Hub to Camshaft Bolt

Camshaft Sprocket to Hub Bolt
Center Toothed Belt Cover Bolt 1
Crankshaft Bearing Cap Bolt 1
Connecting Piece to Cylinder Block Bolt
1
Connecting Rod Bearing Cap Bolt

Coolant Pump to Cylinder Block Bolt
Crankshaft Toothed Belt Sprocket to Crankshaft Bolt
Drive Plate/Flywheel Bolt 1

Engine Mount Bracket to Cylinder Block Bolt
Engine Speed Sensor Bolt
Generator to Accessory Bracket Bolt
Idler Roller to Cylinder Block Stud Nut
Lower Toothed Belt Cover to Cylinder Block Bolt 1
Upper Toothed Belt Cover Bolt 1

Vacuum Reservoir to Bracket Bolt
Vacuum Reservoir Bracket to Cylinder Block Bolt
Vibration Damper/Belt Pulley to Crankshaft Toothed Belt Sprocket
Bolt
Always replace
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rrectness of i
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Oil Filter Bracket to Cylinder Block Bolt 1

Oil Pan Bolt
Oil Spray Jet Bolt
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Power Steering Pump
Pressure
Line
Banjo
Bolt
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Power Steering
u
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Rear Toothed
Belt Cover to Cylinder Head Bolt
Ribbed Belt Tensioner to Accessory Bracket Bolt
Sealing Flange to Cylinder Block Bolt
Toothed Belt Tensioning Roller to Cylinder Head Stud Nut
3. Specifications
25

Accessory Bracket Bolt Tightening Sequence and Specification
Tighten the bracket bolts -A through F- in sequence to 45 Nm.
Piston and Cylinder Dimensions
Honing dimension
Basic dimension
1st oversize
2nd oversize
mm
mm
mm
79.47
79.72
79.97
79.51
79.76
80.01
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Crankshaft bearing hoConnecting
rod
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pins - diameter s aut
bearing
c
s
2nd oversize
3rd oversize
-0.022
47.80
-0.042
-0.022
47.55
-0.042
-0.022
47.30
-0.042
-0.022
47.05
-0.042
Prote
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26
rrectness of i
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1st oversize
-0.022
54.00
-0.042
-0.022
53.75
-0.042
-0.022
53.50
-0.042
-0.022
53.25
-0.042
AG.
Basic dimension
pins - diameter
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Reconditioning
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Crankshaft Dimensions
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3.3
Piston diameter Cylinder bore di

ameter
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3.2

Diagnosis and Testing
4.1 Piston, Rings and Cylinder Bore, Checking, page 27
4.1
Piston, Rings and Cylinder Bore, Check

ing
Piston Ring Gap, Checking

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

Feeler gauge
Test Sequence
Before measuring, clean the ring groove.
0.25
0.25
0.15

Internal dial gauge 50 to 100 mm
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Cylinder Bore, Checking
0.06 to 0.09
0.05 to 0.08
0.03 to 0.06
rrectness of i
t to the co
nform
spec
at
i
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1. Compression ring
2. Compression ring
Oil scraping ring
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Determine the ring to groove clearance usingbthe
y V feeler gauge.
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Piston ring
Newaut
Wear limit
ra
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dimensions in mm
s
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4. Diagnosis and Testing
27
AG.
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Test Sequence
Measure diagonally at 3 positions transversely -A- and longi
tudinally -B-.
Deviation from nominal size: Max. 0.10 mm.
Note
Cylinder bore must not be measured if cylinder block is secured

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

Large valve pocket for the intake valve toward the flywheel side
-arrowsPistons in cylinder 3 and 4:
un
le
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Note
On new pistons, the cylinder allocation is stamped on the pis
rrectness of i
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nform
spec
a
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Large valve pocket for the intakedvalve
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Pistons for cylinder 1 and 2: identification 1/2.
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28
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Pistons for cylinder 3 and 4: identification 3/4.

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5.1 Ribbed Belt, page 29
5.2 Sealing Flange, Belt Pulley Side, page 30

5.3 Crankshaft Seal, Belt Pulley Side, page 32
5.1
rrectness of i
t to the co
nform
spec
at
i
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wit
in t
his
5.4 Drive Plate, page 33
Ribbed Belt

Release tool -T10060ARemoving
Remove the right noise insulation. Refer to Body Exterior;

Mark the direction of rotation of the ribbed belt.
Move the tensioner in the -direction of the arrow - to release
the tension on the ribbed belt.
do
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Secure the tensioner using the -T10060A- .

Remove the ribbed belt.
Installing
Installation is performed in reverse order.
Note
Ensure, before installing the ribbed belt, that all ancillaries (al
ternator, Air Conditioning (A/C) compressor, power steering

pump) are secured tightly.
Note the previously marked direction of belt rotation and be
sure that it is seated correctly on pulley.
In vehicles without A/C, install the ribbed belt last on the gen
erator.
In vehicles with A/C, install the ribbed belt last on the A/C
compressor.
After completing repairs always:

Start the engine and check the belt running.
29

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

Spur belt spreading -3099 Assembly tool -T10053
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Torque wrench (5-50 Nm)b-VAG
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Nm)
-VAG
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Hand drill with plastic
brush attachment
Flat scraper
Removing
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30
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Remove the toothed belt. Refer to

5.3 Toothed Belt, page 54 .
rrectne
s
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form
spec
atio
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Silicone sealant -D 176 404 A2-

Remove the crankshaft toothed belt sprocket. To do this, lock
the toothed belt sprocket using the -3099- .
Note
When installing the -3099- , place two washers between the

toothed belt sprocket and -3099- .
Drain the engine oil.
Remove the oil pan. Refer to 5.2 Oil Pan, page 78 .
Remove the front sealing flange bolts.
Remove the sealing flange, and if necessary loosen it by ap
plying light strikes from a rubber hammer.
AG. Volkswagen AG d
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Remove any sealant
from the cylinderoeblock
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Clean the sealing surfaces. They must be free of oil and

grease.
Installing
Note
Note the expiration date of the sealing compound.

The sealing flange must be installed within 5 minutes after ap
plication of silicone sealant.
Before installing, remove any remaining oil from the end of the
crankshaft with a clean cloth.
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Note
thi
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Cut off the nozzle on the tube of sealant at the front mark (di
ameter of nozzle approximately 3 mm).
rrectness of i
t to the co
nf
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m
spec
atio
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residue from the sealing flange

rotating plastic brush (wear safety glasses).
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Removess any
sealant
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The sealing compound bead must not be thicker than 2 to 3
mm, otherwise excess sealing compound could enter the oil

pan and may block the oil suction pipe strainer. Likewise, it
could drip onto the sealing surface of the crankshaft seal.
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Before applying the bead of sealant, cover the sealing surface
of the seal with a clean cloth.
31

Apply the silicone sealant as illustrated to the clean sealing
surface of the sealing flange.
Set the sealing flange in place immediately and lightly tighten
the bolts.
Note
To position the sealing flange with seal installed, use the T10053/1- .
Tighten the sealing flange bolts in a diagonal sequence. Tight
ening specification: 15 Nm.
Install the oil pan. Refer to 5.2 Oil Pan, page 78 .
Note
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After installing, allow the sealant to dry for approximately

nutes. Only after then may the engine oil be added.
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5.3
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Install the toothed belt and adjust the valve timing. Refer to
Crankshaft Seal, Belt Pulley Side
Seal remover -3203 Assembly tool -T10053 Torque wrench (5-50 Nm) -VAG 1331 Torque wrench (40-200 Nm) -VAG 1332Removing
Remove the crankshaft toothed belt sprocket. To do this, lock

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

by hand until the stop.
Loose the inner portion of the -3203- two rotations (approxi
mately 3 mm) from the outer portion and lock it with the knurled
screw.
32
AG.
When installing the -3099- , place two washers between the

toothed belt sprocket and -3099- .
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Spur belt spreading -3099-
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Lubricate the threaded head of the -3203- , position and with
forced pressure, screw it into the oil seal as far as possible.
Loosen the knurled screw and turn the inner portion against
the crankshaft until the oil seal is pulled out.
Installing
Note
The sealing lip of the seal may not be additionally oiled or

greased.
Before installing, remove any remaining oil from the end of the
crankshaft with a clean cloth.
Position the -T10053/1- on the end of the crankshaft.
Slide the oil seal over the -T10053/1- onto the crankshaft end.
Install the seal with -T10053- and -T10053/2 - (M16 x 1.5 lxkswagen
o
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60), in up to the stop.
db
Drive Plate
rrectness of i
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spec
a
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5.4
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Install the toothed belt. Refer to

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

Install two M10 nuts between the -VW 558- and the drive plate.
do
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33
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olkswagen AG
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Installed location of the -VW 558- o: lkAsw-ato
loosen
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Loosen the drive plate bolts.
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Remove the -VW 558ss .
Installing
Set drive plate in place, using the washer with notches -1-.
AG.
Install new bolts -3- and tighten to 30 Nm.
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Installed location of the -VW 558- : B - to fasten
Check the dimension -a- an three points and calculate the

mean value. Specified value: 19.5 to 21.1 mm
Note
This is measured through the hole in the drive plate to the ma

chined surface of the cylinder block.
If the specification is not obtained:
34
ht
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Co
t.
r
fo
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Install the -VW 558- to the drive plate with a M8 x 45 bolt. Install
two M10 nuts between the -VW 558- and the drive plate.
rrectne
s
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f
i
t to the co
n
form
spec
atio
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Remove the bolts and remove the drive plate.

Remove the drive plate again and install the shim -2-. Tighten
the bolts -3- again to 30 Nm.
Tighten the bolts -3- to 60 Nm and turn an additional 90 (1/4
rotation, additional rotation may occur in several stages).
rrectness of i
t to the co
nf
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spec
atio
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Special Tools

Measuring bar -VW 382/7-
Magnetic plate 50 mm dia. -VW 385/17-
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36
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Flywheel lock adapter -VW 558-
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Release tool -T10060A-
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equipment required
Spur belt spreading -3099 Seal remover -3203-
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Torque wrench (5-50 Nm) VAG 1331-
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Assembly tool -T10053-
6. Special Tools
37

15
1
Cylinder Head, Valvetrain

General Information
Note
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When using an exchanged cylinder head with camshaft in
stalled, the contact surfaces between the lifters and cam lobes
must be lubricated before installing the cylinder head cover.
The plastic protectors installed to protect the open valves must
only be removed immediately before installing the cylinder

head.
When the cylinder head is replaced, the coolant must also be
replaced.
Note
tinue to be used without reducing service life, as long as the

cracks have a Max. width of 0.5 mm.
AG.
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Rep. Gr.15 - Cylinder Head, Valvetrain
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38
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Do not regrind the valve seats, only lapping the valves is per
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Cylinder heads with cracks between the valve seats can con

2.1 Cylinder Head Assembly Overview, page 39

2.2 Valvetrain Assembly Overview, page 42
Cylinder Head Assembly Overview
1 - Upper Toothed Belt Cover
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7 - Hub
With sensor wheel.
Use the camshaft gear
counter holder -T10051
- to loosen and tighten.
To remove, use the pull
er -T10052- .
Removing and instal
ling, refer to
5.4 Camshaft,
page 60 .
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6 - Camshaft Sprocket
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5 - Bolt, 100 Nm
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4 - Bolt, 25 Nm
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3 - Bolt, 10 Nm
Always replace.
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2 - Toothed Belt
Check for wear.
Do not kink.
Removing and instal
ling, tensioning. Refer to
5.3 Toothed Belt,
page 54 .
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2.1
8 - Rear Toothed Belt Cover

9 - Grommet
Replace if damaged.
10 - Camshaft Position (CMP)
Sensor -G40 For camshaft position.
To remove, remove the grommet -item 9- from the rear toothed belt cover.
11 - Bolt
Observe the sequence for loosening and tightening, refer to 5.2 Cylinder Head, page 50 .
Place the washers -item 4- in the 2.2 Valvetrain Assembly Overview, page 42 , in the cylinder head
before installing.
12 - Cylinder Head Cover
Always clean the sealing surfaces of the cylinder head with a clean cloth before setting in place.
13 - Pressure Regulator Valve
For crankcase ventilation.
39

14 - to Turbocharger
15 - Cap
Replace gaskets if damaged.
16 - Sealing Sleeve
Replace if damaged.
17 - Bolt, 10 Nm
Observe the tightening sequence. Refer to 5.1 Cylinder Head Cover, page 49 .
20 - Lifting Eye
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19 - Bolt, 20 Nm
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18 - Cylinder Head Cover Gasket

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Before installing, seal the contact surfaces with sealant
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Only replace together with the cylinder head
cover.
ss
22 - Bolt, 10 Nm
23 - Central Harness Connector
For the pump injector unit.
24 - from Brake Booster
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21 - Pump Injector Unit

Removing and installing, refer to 5.2 Pump Injector Unit, page 145 .
25 - Tandem Pump
For the fuel and vacuum supply.
Checking, refer to 4.2 Tandem Pump, Checking, page 108 .
Removing and installing, refer to 5.2 Tandem Pump, page 111 .
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28 - Gasket
Always replace.
29 - Bolt
30 - Cylinder Head
Removing and installing, refer to 5.2 Cylinder Head, page 50 .
After replacing, replace the entire amount of coolant.
31 - Cylinder Head Gasket
Always replace.
Identification, refer to Fig. Cylinder Head Gasket Identification , page 41 .
After replacing, replace the entire amount of coolant.
32 - Glow Plug, 15 Nm
Checking, refer to 4.1 Glow Plug, Metal, page 167 .
40
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27 - Return Hose
To the fuel filter.
Blue or with blue marking.
Ensure hose is securely seated.
Secure with spring type clips.
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26 - Supply Hose
From the fuel filter.
White or with white markings.
Ensure hose is securely seated.

33 - Tensioning Roller
34 - Nut, 20 Nm + 45 (1/8) additional turn
Checking Cylinder Head for Distortion
Note

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

Cylinder Head Gasket Identification
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Control code = -arrow 2- (ignore this!)
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Replacement part number = -arrow 1-
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Before installing an already
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ir seevenness.
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Note
Depending on piston projection, varying cylinder head gasket

thicknesses can be installed. When replacing a head gasket, in
stall a head gasket with the same identification.
41

2.2
Valvetrain Assembly Overview
1 - Bolt, 20 Nm + 90 (1/4) ad
ditional turn
Always replace
Observe the sequence
for loosening and tight
ening. Refer to
5.4 Camshaft,
page 60 .
2 - Rocker Lever Shafts
Do not interchange.
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7 - Valve Spring Plate
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6 - Valve Retainers
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5 - Valve Lifter
Do not interchange.
With hydraulic valve
clearance compensa
tion.
Place on running sur
face when setting down.
Before installing, check
the axial play of the
camshafts. Refer to Fig. Camshaft, Checking Axial Play , page 43 .
Lubricate the contact surface.
Before removing, remove the bearing caps for the camshaft.
rrectne
s
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4 - Washer
For the cylinder head
bolts
Insert into the cylinder
head before assembling
the bearing caps.
un
le
3 - Bolt
Observe the sequence
for loosening and tight
ening. Refer to
5.2 Cylinder Head,
page 50 .
Before installing, install
the washers -item 4- into
the cylinder head.
8 - Outer Valve Spring

Removing and installing: Cylinder head removed: Installed with valve spring compressor -2037- . Refer
to 5.6 Valve Stem Seals, page 64 .
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9 - Inner Valve Spring

Removing and installing: Cylinder head removed: Installed with valve spring compressor -2037- . Refer
to 5.6 Valve Stem Seals, page 64 .
10 - Valve Stem Seal
Replacing, refer to 5.6 Valve Stem Seals, page 64 .
11 - Valve Guide
Checking, refer to 4.2 Valve Guides, Checking, page 48 .
Removing and installing, refer to 5.2 Pump Injector Unit, page 145 .
42

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

Dial gauge holder -VW 387 Dial gauge
Test Sequence
Measure with valve lifters removed and with first, third and last
bearing caps installed.
43
Wear limit: Max. 0.15 mm
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Sealing Separating Surfaces of Bearing Caps 1 and 5

Coat the surfaces -1- lightly and evenly with sealant -AMV 174
004 01- .
Note
Make sure that no sealant enters the grooves -arrows-.
Valve Dimensions
Note
Valves must not be reworked. Only lapping is permitted.
35.95
6.980
89.95
45
31.45
6.956
89.95
45
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Exhaust valve
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44
mm
mm
mm
angle
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Diameter a
Diameter b
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Intake valve
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Dimension
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Injection and Glow Plug - Edition 07.2007

Specifications
3.1

Component
Fastener Size
Nm
100
10
25
10
100
25
Camshaft Hub to Camshaft Boltagen AG. Volkswagen AG do
Engine Mount to Engine Mount bracket Bolt

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

Tighten the bolts in the sequence shown -1 through 13- to 10
Nm.
3. Specifications
45
un
le
Tighten using a torque wrench
Stage 1 = 40 Nm
Stage 2 = 60 Nm
2-
Tighten further using a ratchet
Stage 3 = 90 (1/4) additional turn

Camshaft Bearing Cap Bolt Tightening Sequence and Specifica

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

Install the rocker lever shafts and first, tighten the new inner
bolts -II- and then the outer bolts-I- evenly in a diagonal se
quence to 20 Nm + 90 (1/4) additional turn.
46
ht
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py
Co
t.
Install the bearing caps 5, 1 and 3 with new bolts, and tighten
to 8 Nm + 90 (1/4) additional turn, alternating in a diagonal
sequence.
rrectne
s
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o
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i
t to the co
n
form
spec
atio
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Cylinder
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Engine Mechanical,
is Fuel Injection and Glow Plug - Edition 07.2007
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Head Bolt Tightening
Sequence and Specification

4.1 Compression, Checking, page 47

4.2 Valve Guides, Checking, page 48
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Note
un
le
Compression, Checking
If ceramic sheathed element glow plugs are installed, check the

idle stabilization control before removing the glow plugs, refer to
vehicle diagnosis, testing and information system -VAS 5051- .
Only if one or more cylinder(s) is/are noticeable at this point is the
compression test warranted.
Hinged socket -3220-
Torque wrench (5-50 Nm) -VAG 1331 Adapter -VAG 1381/12-
Compression tester -VAG 1763Test conditions
AG.
Disconnect the central electrical connector -1- for the pump

injector unit.
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Test Sequence
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Engine oil temperature min. 30 C (86 F).
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4.1
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Note
If ceramic sheathed element glow plugs are installed, always fol

low the information for removing and installing them. Refer to
4.2 Glow Plug, Ceramic, page 167 .
Disconnect the connector strip -2- from the glow plugs.
Remove all the glow plugs -3- using the -3220- .
47
AG. Volkswagen AG d
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Golf 1999 , Jetta 1999 , Jetta Wagon 1999 ed b
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Engine Mechanical, Fuel Injection and Glow Plugth-o Edition 07.2007
eo
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Check the compression pressure using the -VAG 1763- .

Note
Using tester, refer to operating instructions .
Operate the starter until the tester shows no further pressure

increase.
Compression Pressure
New: 25 to 0.31 bar pressure
Wear limit: 19 bar pressure
Permissible difference between all cylinders: 5 bar
r
fo
ng
Note
By disconnecting the central connection for the pump injector unit,

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

Dial gauge holder -VW 387 Dial gauge
Test Sequence
Install the new valve into the guide. The end of the valve stem
must be flush with the guide. Due to the slight difference in
stem dimensions, ensure that only an intake valve is used in
the intake guide and an exhaust valve in the exhaust guide.
Determine tilt clearance. Wear limit: Max. 1.3 mm
If the tilt clearance exceeds the wear limit, the cylinder head
must be replaced.
48
Prote
cted
by
Check the Diagnostic Trouble Code (DTC) memory. Refer to

Erasing, page 143 .
AG.
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Install the glow plugs using the -3220- . Tightening specifica

tion: 15 Nm.
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If ceramic sheathed element glow plugs are installed, always fol

low the information for removing and installing them. Refer to
4.2 Glow Plug, Ceramic, page 167 .
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Note
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spec
atio
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Install the -VAG 1381/12- in place of the glow plugs.

5.1 Cylinder Head Cover, page 49

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

Torque wrench (5-50 Nm) -VAG 1331 Sealant -AMV 174 004 01-
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Remove
is the oil dipstick.
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Remove
the
engine
cover.
First
pull
the
front
of
the
cover
s
s
Removing
up
ward with a quick jerk -arrows A- and then pull it forward out
of the rear mounting -arrow B-.
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Insert the oil dipstick.
If present, remove the noise insulation -arrow-.
rrectness of i
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spec
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wit
Remove the Exhaust Gas Recirculation (EGR) vacuum regu

lator solenoid valve.
Disconnect the electrical connector from the intake manifold

flap motor and free up the wire over the valve cover.
Remove the upper toothed belt cover.
Remove the cylinder head cover bolts and cover.

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Disconnect the crankcase ventilation hose at the connection

of the rear charge air tube.
If damaged, replace the cylinder head cover gasket and the bolt
seals.
Installation is performed in reverse order. When doing this note
the following:
49

Place a drop of sealant -AMV 174 004 01- (approximately 5
mm diameter) on both edges on the sealing surfaces of the
front bearing cover/cylinder head -arrows-.
Place a drop of sealant -AMV 174 004 01- on both edges on

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

sequence
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shown -1 through 13-.
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Tighten the bolts in the sequence
shown -1 through 13- to 10
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Cylinder Head

Drip tray -VAG 1306 Torque wrench (5-50 Nm) -VAG 1331 Torque wrench (40-200 Nm) -VAG 1332 Hand vacuum pump reservoir -VAG 1390/1 Engine support -T10014-
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Engine support bridge -10-222A- with Adapter -10-222A/13-
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Hand vacuum pump -VAG 1390-

Removing
Caution

followed.
nents.
Note
The following description refers to the removal of the cylinder
head with the exhaust manifold/turbocharger, intake manifold

and cooler for the Exhaust Gas Recirculation (EGR) including
the bypass flap still attached.
All cable ties which are opened or cut off when removing cyl
inder head, must be replaced in the same position when

installing cylinder head.
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Drain the cooling system. Refer to
Vol
1.2 Draining and Filling, page 81 .ed by
Disconnect the exhaust pipe
Remove the cover plate and disconnect the electrical connec

tor -arrow- from the flange.
WARNING
The fuel or fuel lines in fuel system can become very hot
(danger of scalding)!
nection!
Disconnect all fuel hoses, coolant hoses, vacuum hoses and

intake hoses from the cylinder head.
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Disconnect all electrical wires required from the cylinder head

and set aside.
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Before removing the cylinder head, siphon any fuel using the
-VAG 1390- together with the -VAG 1390/1- on the tandem
pump. Refer to 5.2 Tandem Pump, page 111 .
rrectne
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Fold the rear seat bench forward.
51

Disconnect the electrical connector -1- from the turbocharger
vane position sensor.
Disconnect the vacuum hose -5-.
Remove the connecting hose -7- and the rear charge air pipe
-6 Remove the oil return line -2- from the connecting piece on the
cylinder block.
Remove the bolts -3 and 4- and remove the bracket.
Remove the cylinder head cover. Refer to
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Remove the toothed belt from the camshaft.

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Remove the oil supply line.
rrectness of i
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spec
a
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wit
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Both lifting eyes for the -10-222A- are located on the cylinder
head, for that reason an additional holder to support the engine
must be secured on cylinder block.
Install the -T10014 - -as shown- into the threaded hole of the
cylinder block in the area of the coolant pump. Tightening
specification: 20 Nm.
Using spindle -A-, lift the engine slightly until spindle -B- is un
loaded.
Remove spindle -B-.
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52
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Remove the tensioning roller.
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Remove the hub for the camshaft sprocket. Refer to

5.4 Camshaft, page 60 .

Follow the sequence shown for loosening the cylinder head
bolts.
After cleaning the sealing surface, check the cylinder head for
distortion. Refer to
Fig. Checking Cylinder Head for Distortion , page 41 .
Installing
Note
Always replace the cylinder head bolts.
Carefully remove any residual sealant from the cylinder head
and cylinder block. Make sure that no long scrapes or scratch

es result. When using sand paper, grit must not be below 100.
Carefully remove all grinding and sanding

residue.
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Blow out the threaded holesbfor
y V the head bolts thoroughly - tot gua
ed place a cloth over each hole.
prevent oil from squirtingrisout,
Only unpack new
Handle the gasket carefully. Damages to the silicone layer and
in areas of recesses may result in leaks.
rrectness of i
t to the co
nf
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spec
atio
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n in
wit
Before installing the cylinder head, make sure the new head
gasket is identical to the old head gasket (there are 3 possible
thicknesses), refer to
Fig. Cylinder Head Gasket Identification , page 41 .
Before installing the cylinder head, position the crankshaft to
the Top Dead Center (TDC) marking.
Turn back the crankshaft in the opposite direction of engine
rotation, until all pistons stand almost evenly below TDC.
Set the cylinder head gasket in place.
Install the cylinder head and hand tighten all ten cylinder head
bolts.
Tighten the cylinder head bolts in the sequence shown, in four
stages as follows:
Tighten using a torque wrench
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Tighten further using a ratchet
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Stage 2 = 60 Nm
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Stage 1 = 40 Nm
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head gasket immediately prior to
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Note
There is no requirement to retighten the cylinder head bolts after

repairs.
53

After tightening the cylinder head bolts turn the camshaft
sprocket so that the lobes for cylinder 1 point upward equally.
Volkswagen Ato
Before installing the toothed belt, set
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by
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5.3 Toothed Belt, page
ed 54 .
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Further installation is performed in reverse order.
rrectness of i
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at
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Note
If the tandem pump has been removed, check it for interior leak
age. Refer to page 109 .
Perform a road test and check the DTC memory. Refer to
Erasing, page 143 .
5.3
Toothed Belt

Diesel injection pump locking pin -3359 Toothed belt tensioner -T10020- or two hole pen wrench T10004Prote
cted
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Crankshaft stop -T10050-
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Torque wrench (40-300 Nm) -VAG 1332-
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Engine support bridge -10-222A- with bracket for engine

-10-222A/1 Counter hold tool -T10172- with adapter -T10172/4-
54
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Locking pin -T10115-
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Install the hub for the
au camshaft sprocket. Refer to
s
5.4 Camshaft,s page 60 .

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

running change. This tensioning roller has an additional hex sock
et -arrow-. Use a hex wrench instead of the -T10020- or -T10004to tension or to relieve the tension on the toothed belt. The work
sequence does not change.
Removing
Note
Adjustments to the toothed belt may generally only be performed

when the engine is cold, because the indicator position of the
tensioning element changes depending on engine temperature.
Remove the engine cover. refer to
Remove the right headlight. Refer to Electrical Equipment;
Rep. Gr. 94 ; Removal and Installation .
Remove the connecting tube between the charge air cooler
and intake connection.
Carefully cover or seal the open ends.
Remove the coolant expansion tank. The hoses remain con
nected.
Remove the power steering reservoir and the fuel filter and lay
them to the side; the hoses remain
geconnected.
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Remove the ribbed belt.seRefer
to
db
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5.1 Ribbed Belt, tpage
29 .
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Remove the charge air tube between the charge air cooler and
turbocharger. Refer to
2.1 Charge Air Cooler and Components Assembly Over
view, page 121 .
Carefully cover or seal the open ends.
Remove the vibration damper/belt pulley.
Remove the upper toothed belt cover.
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Install the -10-222A- with the -10-222A/1- in place and support

the engine into the installed position.
rrectne
s
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t to the co
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spec
atio
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Remove the center and right noise insulation. Refer to Body

Exterior; Rep. Gr. 50 ; Description and Operation .
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ss belt tensioner.
Remove the ribbed
55
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G. Volkswagenmember
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Remove the engine mount
ton Alongitudinal
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swa
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mount to engine mount
bracket
bolts
-arrowsand
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Note
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or
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The subframe may only be removed if the engine is supported
The engine mount bracket may first be loosened only when
the engine mount is removed.
Lift the engine using the -10-222A- slightly so that both upper
bolts of the engine mount bracket can be loosened.
Lower the engine using the -10-222A- slightly so that the lower
bolt for the engine mount bracket can be loosened.
Remove the engine mount bracket downward and out.
Remove the lower and center toothed belt covers.
Turn crankshaft to set cylinder 1 at Top Dead Center (TDC).
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When doing so, turn the crankshaft so that the marking on the
crankshaft toothed belt sprocket and the tooth segment of the
camshaft sprocket are positioned upward, and the arrow Z4
aligns with the mark on the camshaft sensor wheel -arrows-.
Lock the hub using the - 3359- . To do this, push the - 3359through the left sided empty slot in the bore of the cylinder
head.
Lock the crankshaft toothed belt sprocket using the -T10050- .
Push the -T10050- from the front side of the toothed belt
sprocket into the teeth.
Note
Markings on crankshaft toothed belt sprocket and the -T10050must be aligned. The tab of the -T10050- must engage in the bore
of the sealing flange.
Mark the rotational direction of the toothed belt.
56
do
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en
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
by the -10-222A- !

Loosen the bolts -1- of the camshaft sprocket, until the cam
shaft sprocket can be turned in the slots.
Loosen the nut for the tensioning roller.
Turn the tensioning roller using the -T10020- or -T10004counterclockwise until the toothed belt tensioning roller can be
locked with the -T10115- .
Turn the tensioning roller clockwise using the -T10020- or T10004- all the way until it stops and tighten the nut -1- hand
tight.
Remove the toothed belt from the coolant pump and then from
the remaining sprockets.
Installing
Camshaft is secured with the -3359- .
Crankshaft is locked with -T10050- .
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Note
Adjustments to toothed belt may generally only be performed

when the engine is cold, because the indicator position of the
tensioning roller changes depending on engine temperature.
Turn the camshaft sprocket in its slots -arrows- to the middle
position.
Instal the toothed belt onto the crankshaft sprocket, tensioning
roller, camshaft sprocket and idler roller.
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Lastly, install the toothed belt onto the coolant pump sprocket.
rrectne
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form
spec
atio
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Tensioning roller secured with the -T10115and
seated
on
the
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right stop.
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57
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Note
Make sure the tensioning roller is properly positioned in the rear

toothed belt guard -arrow-.
Loosen the nut of the tensioning roller and remove the T10115- .
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Make sure that the nut does not turn along with it.
Hold the tensioning roller in this position and tighten the nut as
follows, tightening specification: 20 Nm and + 45 (1/8) addi
tional turn.
Install the -T10172- with the -T10172/4- as shown. Push the T10172- in the -direction of the arrow- and hold the camshaft
sprocket pre-tensioned.
In this position, tighten the camshaft sprocket bolts -1- to 25
Nm.
Prote
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Continue turning the crankshaft two rotations in direction of

engine rotation until the crankshaft is shortly before TDC for
cylinder 1.
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Lock the hub with the -3359- from the rotating movement in
engine rotation direction.
Make sure the camshaft can be stopped by the -T10050- .
If the crankshaft cannot be locked:
58
ht
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Remove the -3359- and the -T10050- .
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Carefully turn the tensioning roller clockwise using the T10020- or -T10004- until the indicator is located centrally in
the gap of the base plate -arrow-.
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Loosen the bolts -1- for the camshaft sprocket.
Turn the crankshaft against the engine running direction until

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

T10172- in the -direction of the arrow- and hold the camshaft
sprocket pre-tensioned.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
In this position, tighten the camshaft sprocket bolts -1- to 25

Nm.
Remove the -3359- and the -T10050- .
Continue turning the crankshaft two rotations in direction of

engine rotation until the crankshaft is shortly before TDC for
cylinder 1.
Check again.
Install the center and lower toothed belt covers. Refer to

2.2 Toothed Belt and Covers Assembly Overview,
page 17 .
Install the vibration damper/belt pulley. Tightening specifica
tion: 10 Nm + 90 (1/4) additional turn.
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Install the engine mount bracket to the cylinder block and
tighten the bolts -arrows- to 45 Nm.
Note
Before installing the engine mount bracket, install all the bolts
into the bracket.
Before the engine mount can be installed, all bolts -arrows- for
the engine mount bracket must be tightened to the specifica

tions.
Install the engine mount to longitudinal member bolts (replace

the bolts) .
Tightening specification for M8 bolts: 20 Nm + 90 (1/4) additional
turn.
Tightening specification for M10 bolts: 40 Nm + 90 (1/4) addi
tional turn.
Align the subframe, engine side. Refer to
1.2 Engine and Transmission Mount, Aligning, page 3 .
Install the engine mount to engine mount bracket bolts, by
bringing the contact surfaces into contact using the -10-222A- .
Tightening specification: 100 Nm.
Install the engine mount bracket to bracket/body bolts. Tight
ening specification: 25 Nm.
Install the connecting tubes for the charge air cooler/turbo
charger and charge air cooler/intake connection. Refer to
olkswagen AGOver
AG. VAssembly
2.1 Charge Air Cooler and Components
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view, page 121 .
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Install the front noise insulation.
Refer to Body Exterior;
ho
ut
Rep. Gr. 50 ; Description
and Operation .
a
s
ara
nte
e
Install the ribbed belt tensioner; tightening specification: 25

Nm.
Install the ribbed belt. Refer to 5.1 Ribbed Belt, page 29 .
Install the power steering reservoir and the fuel filter.
Install the coolant expansion tank. Refer to
2.2 Cooling System Components Assembly Overview,
Body Side, page 87 .
Install the connecting tube between the charge air cooler and
intake connection. Refer to
view, page 121 .
Install the right headlight. Refer to Electrical Equipment;
Rep. Gr. 94 ; Removal and Installation .
Install the engine cover.
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Camshaft
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60
AG.
Puller -T10052-
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Install the upper toothed belt cover.
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Torque wrench (40-200 Nm) -VAG 1332 Sealant -AMV 174 004 01Removing
Remove the bolts -1- for the camshaft sprocket.
Loosen the bolt -1- for the hub.

To do this, use the -T10051- .
Install the -T10052- and align it to the holes in the hub.
do
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Loosen the bolt for the hub approximately 2 turns.
rrectness of i
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spec
a
t
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Remove the camshaft

sprocket
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Steadily tighten the -T10052- to place the hub under tension

until the hub is pulled from the taper on the camshaft.
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Note
Hold onto the -T10052- with a wrench.

Remove the hub from the camshaft.
Remove the cylinder head cover. Refer to
Mark the rocker lever shafts with a waterproof marker, to pre
vent mixing them and thereby having to perform the base
setting for the pump injector unit -arrows-.
Remove the rocker lever shafts.
Note
First loosen both outer bolts and then the inner bolts.
Remove the tandem pump. Refer to
5.2 Tandem Pump, page 111 .
61

Remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and
4 alternately and diagonally and remove.
Remove the camshaft.
Installing
Note
When installing the camshaft, the cam lobes for cylinder 1
must point upward.
Do not interchange run in connecting rod bearing shells
(mark).
When installing the camshaft, make sure the bearing shell re
taining tabs are seated properly in the bearing caps and

cylinder head.
Before installing the bearing cap, make sure that washers for
the cylinder head bolts are inserted in the cylinder head.
Oil the bearing cap contact surfaces.

Install the bearing caps 2 and 4 with. Vthe
new bolts, and tighten
olkswagen AG
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geturn,
to 8 Nm + 90 (1/4) additional
indoaesdiagonal
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Note
sealant -AMV 174 004 01- . Refer to

Fig. Sealing Separating Surfaces of Bearing Caps 1 and
5 , page 44 .
Bearing cap 5 must seat flush with the outer edge of the cyl
inder head, otherwise leaks at the tandem pump may result.
Install the camshaft seal. Refer to

5.5 Camshaft Seal, page 63 .
Install the rocker lever shafts and first, tighten the new inner
bolts -II- and then the outer bolts-I- evenly in a diagonal se
quence to 20 Nm + 90 (1/4) additional turn.
Place the hub onto the camshaft.
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Seal the separating surfaces of bearing caps 1 and 5 with
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Install the bearing
ho caps 5, 1 and 3 with the new bolts, and e o
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likewise, tighten
to 8 Nm + 90 (1/4) additional turn, alternating r ac
ss
in a diagonal sequence.

Tighten the bolt -1- for the hub to 100 Nm.
To do this, use the -T10051- .
Push the camshaft sprocket onto the hub.

Note
The toothed segment -arrow- of the camshaft sprocket must face

upward.
Align the camshaft sprocket to the center location in the slots.
Install the bolts -1- into the camshaft sprocket by hand to elim
inate play.
Lock the hub with the - 3359- .
Instal the toothed belt. Refer to
Install the cylinder head cover. Refer to
Install the tandem pump. Refer to
for approximately 30 minutes. The hydraulic adjusting ele

ments must seat themselves (otherwise the valves will seat
themselves on the pistons).
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After working on the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to

be sure that valves do not strike the pistons.
5.5
Camshaft Seal

Oil seal driver -10-203 Seal extractor -3240-
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63

Remove the camshaft sprocket and hub. Refer to
5.4 Camshaft, page 60 .
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Loosen the inner portion of the -3240gtwo
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Installing
The sealing lip of the seal may not be additionally oiled or

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

Assembly rod -2036 Slide hammer -3047A Seal driver -3129 Valve lever -VW 541/1A Pressure tool for VW 541/1A and 2037 -VW 541/5Removing
(with cylinder head installed)
Remove the camshaft. Refer to 5.4 Camshaft, page 60 .
Remove the valve lifters and place on the running surface
when setting down. Be careful not to switch valve lifters.
Move the piston for the respective cylinder to Top Dead Center
(TDC) position.
64
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Loosen the knurled screw and turn the inner part against the
camshaft until the seal is removed.
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Lubricate the threadeds ahead
of the -3203- , position and with
s
forced pressure, screw
it into the oil seal as far as possible.

Install the -2036- and adjust to the stud height.
Remove the valve springs with the -VW 541/1A - and the VW 541/5- .
Note
Support the valves on the piston head while doing this.
Place the supplied plastic sleeve -A- on each valve stem to

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

Hinged socket -3220 Adapter -VAG 1381/12 Compression tester -VAG 1763 Adapter -10-222A/13 Bracket for engine -10-222A/1 Adapter -T10172/4 Diesel injection pump locking pin -3359 Toothed belt tensioner -T10020- or two hole pen wrench T10004 Locking pin -T10115 Crankshaft stop -T10050 Camshaft gear counter holder -T10051 Puller -T10052 Oil seal driver -10-203-
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Engine support bridge -10-222A-
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Seal extractor -3240-

Counter hold tool -T10172-

equipment required
Drip tray -VAG 1306 Torque wrench (5-50 Nm) VAG 1331 Torque wrench (40-200
Nm) -VAG 1332 Hand vacuum pump VAG 1390 Hand vacuum pump reser
voir -VAG 1390/1-
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-T10014-oris
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6. Special Tools
67
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equipment required
Assembly rod -2036-
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Pressure tool for VW

541/1A and 2037 VW 541/5-
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Slide hammer -3047A- by V
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Seal driver -3129-uth
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s 541/1AValve lever -VW

17
Lubrication
General Information

1.2 Oil Level Markings, page 69
1.1

Note
If large quantities of metal particles or other deposits (caused,
for example, by partial seizure of the crankshaft or connecting

rod damage) are found in the engine oil, the oil passages must
be cleaned thoroughly and the oil cooler replaced in order to
prevent further damage from reoccurring.
The oil level must not be above the Max. mark - danger of
damage to catalytic converter!
1.2
Oil Level Markings
1 - Max. mark
2 - Min. mark
a - Area above the cross hatched field up to the Max. mark:
Do
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b - Oil level within the cross hatched field: Engine
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c - Area from the Min. mark up to cross hatched field: Add a Max.
0.5 liter of engine oil!
69
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2.1 Oil Supply Line Assembly Overview, page 70
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Assembly Overview,
page 73
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2.2 Oil Pan and Pump Assembly Overview,
kpage
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Oil Supply Line Assembly Overview

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2.1
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spec
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wit
1 - Oil Supply Line

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

2.2
Oil Pan and Pump Assembly Overview
1 - Bolt, 15 Nm
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4 - Dipstick
Oil level must not be
above the Max. mark!
Marks, refer to 1.2 Oil Level Markings, page 69 .
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3 - Chain Tensioner with Ten

sioning Rail, 15 Nm
When installing, preten
sion the spring and hook
in.
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2 - Sealing Flange
With seal.
Must be located on the
alignment pins.
Removing and instal
ling, refer to
5.2 Sealing Flange,
Belt Pulley Side,
page 30 .
Install using silicone
sealant -D 176 404 A2 - .
Refer to
5.2 Sealing Flange,
Belt Pulley Side,
page 30 .
Do not additionally oil or
grease the sealing lip of
the seal.
move any remaining oil
from crankshaft journal
with a clean cloth.
Crankshaft seal belt pul
ley side, replacing. Re
fer to
5.3 Crankshaft Seal,
Belt Pulley Side,
page 32 .
5 - Inlet Spout
For extracting oil.
6 - Guide Tube
7 - Oil Spray Jet
For piston cooling.
8 - Bolt, 25 Nm
Install without sealant.
9 - Alignment Pins
10 - Bolt, 15 Nm
11 - Suction Line
Clean the strainer if contaminated.
12 - O-ring
Always replace.
71

13 - Splash Wall
14 - Bolt, 15 Nm
15 - Bolt, 15 Nm
16 - Oil Pan
Clean the sealing surface before installing.
Install using silicone sealant -D 176 404 A2 - . Refer to 5.2 Oil Pan, page 78 .
17 - Seal
Always replace.
18 - Oil Pan Drain Plug, 30 Nm
Replace the plug and seal.
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72
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22 - Chain
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21 - Bolt, 25 Nm
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20 - Oil Pump Sprocket
rrectness of i
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spec
a
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i
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wit
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s
19 - Oil Pump
With pressure relief valve, 12 bar.
Before installing, check to be sure both alignment pins are present (for centering the oil pump/cylinder
block).
Replace if running surfaces and gears are scored.
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3 - Bolt, 15 Nm + 90 (1/4) ad
ditional turn
Always replace.
First, install the upper
left and lower right bolts,
and then tighten all four
bolts in a diagonal se
quence.
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2 - Gasket
Always replace.
rrectness of i
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a
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i
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wit
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s
1 - Oil Pressure Switch -F1- ,

20 Nm
0.7 bar switch: brown or
0.9 bar, switch: gray.
If seal is leaking cut off
and replace.
Checking, refer to
4.1 Oil Pressure and
Switch, Checking,
page 76 .
es, in part or in w
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Oil Filter Bracket Assembly Overview
ht
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2.3
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Engine
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Golf a1999
, Jetta 1999 , Jetta Wagon 1999 e or a
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Mechanical,ssFuel Injection and Glow Plug - Edition 07.2007
4 - Oil Filter Bracket

5 - Seal
Always replace.
6 - Oil Supply Line
To the turbocharger.
Removing and instal
ling, refer to
5.1 Oil Supply Line,
page 77 .
7 - Banjo Bolt
Tightening specifica
tion, refer to-item 4- in
the
2.1 Oil Supply Line Assembly Overview, page 70 .
8 - Oil Filter Cap, 25 Nm
Loosen and tighten using the oil filter wrench -3417- .
9 - O-ring
Always replace.
10 - Oil Filter Element
Note the installed position: top = oben
11 - Bolt, 25 Nm
12 - Gasket
Always replace.
13 - Oil Cooler
Ensure sufficient clearance to surrounding components.
See note in 1.1 General Repair Information, page 69 .
Oil cooler, checking for leaks. Refer to 4.2 Oil Cooler, Checking for Leaks , page 91 .
14 - Gasket
Always replace
73

Snaps into the tabs of the oil cooler.
15 - Sealing Plug, 10 Nm
es n
wage
If sealing plug is leaking cut off sealVand
ot g
olks replace.
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16 - Locking Bolt
ho
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For the pressure relief valve.
ss
Do not loosen.

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Tightening
Specifications, page 75
a
c
s
s
Specifications
3.1 Fastener
Chain Tensioner with Tensioning Rail

Oil Cooler to Oil Filter Bracket Bolt
Oil Filter Bracket to Cylinder Block Bolt 1
Oil Filter Cap
Oil Pan to Cylinder Block Bolt
Oil Pan Drain Plug
Oil Pan to Transmission Bolt
Oil Pressure Switch
Oil Pump Sprocket to Oil Pump Bolt
Prote
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3.2
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Oil Supply Line Bracket to Exhaust Manifold Stud Nut 1

Oil Supply Line Clamp Bolt
Oil Supply Line Clamp to Bracket Bolt/Nut
Oil Supply Line to Oil Filter Bracket Banjo Bolt
Oil Supply Line Union Nut to Turbocharger
Oil Spray Jet Bolt
Sealing Flange to Cylinder Block Bolt
Sealing Plug to Oil Filter Bracket
Splash Wall to Cylinder Block Bolt
Suction Line to Oil Pump Bolt
Fastener Size
Nm
15
25
15 + 90 turn
25
15
30
45
20
25
25
10
10
25
22
25
15
10
15
15
rrectness of i
t to the co
nf
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spec
atio
h re
n in
wit
Component
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3.1
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3.2 Engine Oil Capacity and Specifications, page 75
Always replace
Engine Oil Capacity and Specifications
For engine oil capacities and specifications refer to the Owners

Manual and/or ServiceNet.
3. Specifications
75

4.1 Oil Pressure and Switch, eChecking,

gen AG76
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4.1
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Oil Pressure and Switch, Checking
Special tools
required
Voltage tester -VAG 1527B-
Note
Function test and servicing the optical and acoustic oil pressure
indicator. Refer to Wiring diagrams, Troubleshooting & Com
ponent locations Vehicle diagnosis, testing and information
system VAS 5051
Test Sequence
Remove the oil pressure switch and install it into the VAG 1342- .
Thread the -VAG 1342- into the oil filter bracket in place of the
oil pressure switch.
Connect the brown wire of the -VAG 1342- to ground (-).
Connect the -VAG 1527B- using auxiliary cables from the VAG 1594A- to the battery positive (+) and the oil pressure
switch. Light Emitting Diode (LED) must not light up.
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Start the engine and slowly increase the engine speed.

AG.
Oil Pressure Switch Brown
LED must light up at 0.55 to 0.85 bar positive pressure, oth

erwise replace the oil pressure switch.
Increase engine speed further. At 2000 RPM and an oil tem
perature of 80 C (176 F), oil pressure must be at least 2.0
bar.
At higher RPMs, the oil pressure must not exceed 7.0 bar. If nec
essary, replace the oil filter bracket.
Oil Pressure Switch Gray
LED must light up at 0.75 to 1.05 bar positive pressure, oth
erwise replace the oil pressure switch.
Increase engine speed further. At 2000 RPM and an oil tem
perature of 80 C (176 F), oil pressure must be at least 2.0
bar.
At higher RPMs, the oil pressure must not exceed 7.0 bar. If nec
essary, replace the oil filter bracket.
76
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Test adapter kit -VAG 1594A-
do
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Oil pressure gauge -VAG 1342-

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

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

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

Torque wrench (5-50 Nm) -VAG 1331 Hand drill
Protective glasses
Flat scraper
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Remove the noise insulation, along with the left and right
sides. Refer to Body Exterior; Rep. Gr. 50 ; Description and
Operation .
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Removing
un
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Silicone sealant -D 176
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A2ss
Drain the engine oil.

Note
Observe disposal regulations!

Remove the oil pan.
Loosen the oil pan with light blows from a rubber hammer, if
necessary.
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78
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Remove the sealant residue from the cylinder block with a flat
scraper.

Remove the sealant residue from the pan with a rotating brush,
for example, a hand drill with a plastic brush attachment (wear
eye protection).
Clean the sealing surfaces. They must be free of oil and
grease.
Installing
Note
Note the expiration date of the sealing compound.
agen
The oil pan must be installed within 5 minutes after application
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of silicone sealant.
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Cut off the nozzle on the tube of sealant at the sfront
mark (di
ameter of nozzle approximately 3 mm).
AG. Volkswagen AG d
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2 to 3 mm thick
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Apply the silicone sealant -D 176 404 A2- to the clean sealing
surfaces of the oil pan as shown. The sealing compound bead
must be:
and run on the inside of the bolt holes -arrowsNote
Sealant bead must not be thicker than specified. Otherwise, ex

cess sealant could get into oil pan and clog strainer in intake line
of oil pump.
AG.
The oil pan must seat flush with the cylinder block.
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Install the oil pan immediately and tighten all oil pan bolts
lightly.
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Apply the silicone sealant -D 176 404 A2- bead as shown to

the clean sealing surface of the oil pan. (The fig. shows the
location of the sealant bead on the cylinder block.)
Tighten the oil pan bolts in a diagonal sequence to 15 Nm.

Tighten the oil pan/transmission bolts to 45 Nm.
Note
After installing the oil pan, allow the sealant to dry for approxi
mately 30 minutes. Only after then may the engine oil be added.
The rest of the assembly is basically a reverse of the removal
sequence.
79

Special Tools


equipment required
Oil pressure gauge VAG 1342 Voltage tester VAG 1527B Test adapter kit VAG 1594A-
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80
rrectness of i
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spec
atio
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AG.
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Cooling System
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General Information
b
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Volkswagen AG
does
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19
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1.2 Draining and Filling, page 81
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1.1
Caution

followed.
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sure. If necessary release pressure before beginning repair

work.
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When the engine is warm the cooling system is under pres
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Note
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nents.
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Hoses are secured with spring type clips. In cases of repair
only use spring type clips.
The spring type clip pliers -VAS 5024- or hose clip pliers -
VAG 1921 - are recommended for installing spring type clips.
When installing coolant hoses route them stress free, so that
they do not come into contact with other components (observe

the markings on the coolant connection and hose).
Perform a cooling system leakage test using the cooling system

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

Refractometer -T10007 Drip tray -VAG 1306 Spring type clip pliers -VAS 5024 Cooling system charge unit -VAS 6096Draining
Open the cap for the coolant expansion tank.
WARNING
Cover the cap of expansion tank with a cloth and open care
fully, as hot steam may escape when opening.
81

Remove the noise insulation. Refer to Body Exterior; Rep.
Gr. 50 ; Description and Operation .
With a Radiator Drain Plug
Remove the drain plug -arrow- to drain the coolant from the
radiator.
Without a Radiator Drain Plug
Pull the coolant hose retaining clip -arrow- off downward and
remove the coolant hose from the radiator quick acting cou
pling.
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Rep. Gr.19 - Cooling System
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82
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In addition, to drain the coolant from the engine, disconnect
the coolant hose at the oil cooler -arrow-.
Note
Observe disposal regulations!

Filling
Note
. Volkswagen AG
gen AG
does
not
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with coolant
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a
Only use coolant additive G 12 plus in accordance
ksw with TL VW
Vol
774 F. Distinguishing feature: violet colored by

is
or
th
G 12 plus (per TL VW 774 F) may not
au be mixed
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additive G 12 plus!
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G 12 plus and coolant additives marked in accordance with
rrectness of i
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a
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TL VW 774 F prevent frost and corrosion damage, scaling

and also raise boiling point of coolant. For this reason the sys
tem must be filled all year round with frost and corrosion
protection additives.
Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop

ical climates.
Protection against frost must be assured to about -25 C (-13
F) (in arctic climatic countries to about -35 C (-31F)).
The coolant concentration must not be reduced by adding wa
ter even in warmer seasons and in warmer countries. The

coolant additive portion must be at least 40%.
If for climatic reasons a greater frost protection is required, the

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gasket is replaced, do not reuse old coolant.
-25 C (-13 F)
-35 C (-31 F)
40%
50%
G 121)
Water1) 2)
2.4 L
3.0 L
3.6 L
3.0 L
AG.
Antifreeze por
tion
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Recommended Mixture Ratios
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If radiator, heat exchanger, cylinder head or cylinder head
do
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amount of G 12 plus can be increased, but only up to 60%

(frost protection to about -40 C (-40 F)), as otherwise frost
protection is reduced again and cooling effectiveness is also
reduced.
1) The quantity of coolant can vary depending upon the vehicle equipment.
2) Only use clean tap water.
With a Radiator Drain Plug

Close the coolant drain plug.
Without a Radiator Drain Plug
83

Install the lower coolant hose and secure with the retaining clip
-arrow-.
es, in part or in w
l purpos
hole
ercia
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With -VAS 6096-
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Push the coolant hose onto the oil cooler

ten with the spring type clip.
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connection
and fas
Without -VAS 6096-
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m
spec
atio
h re
n in
wit
Fill the coolant circuit using the -VAS 6096- . Refer to Op

erating instructions for cooling system charge unit VAS 6096 .
Vehicles With a Max. Mark on the Expansion Tank
Fill the coolant to the Max mark on the expansion tank.

Install the expansion tank cap.
Allow the engine to run until the radiator fan switches on.
c
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Prote
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Allow the engine to run until the radiator fan switches on.
Check the coolant level and top off, as necessary:
With the engine at operating temperature, the coolant level must
be at the top mark of the hatched area.
With the engine cold, the coolant level should be located approx
imately in the center of the hatched area.
84
AG.
Install the expansion tank cap.
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Slowly fill the coolant up to top mark of the hatched area on

the expansion tank.
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Vehicles Without a Max. Mark on the Expansion Tank
thi
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Check yjr coolant level and top off, as necessary. With the en
gine at operating temperature, the coolant level must be at the
Max. mark, with the engine cold, it must be between the Min.
and Max. marks.

2.1 Coolant Hose Connection Diagram, page 85

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

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

2.1.2
Automatic Transmission
1 - Expansion Tank
2 - Intake Manifold
3 - Cooler
For the Exhaust Gas
Recirculation (EGR)
system.
4 - Bypass Flap
5 - Heater Unit Heat Exchang
er
6 - Coolant Line
7 - Transmission Oil Cooler
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10 - Radiator uth
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11 - Oil Cooler
12 - Coolant Pump/Thermostat
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86
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his
13 - Cylinder Head/Cylinder
Block
, Jetta Wagon 1999

Plug - Edition 07.2007
1 - Radiator
Removing and instal
ling, refer to
5.3 Radiator,
page 95 .
After replacing, replace
the entire amount of
coolant.
2 - O-ring
Always replace.
r
fo
ng
AG.
Prote
cted
by
6 - Auxiliary Fan
Only on vehicles with
optional equipment.
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5 - Bolt, 5 Nm
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4 - Fan Shroud
ht
rig
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Co
t.

Secured to the radiator
with a retaining clip.
Coolant hose connec
tion diagram, refer to
2.1 Coolant Hose
Connection Diagram,
page 85 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
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um
en
ole,
cial p
is n
mer
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Cooling System Components Assembly Overview, Body Side

ility
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2.2
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Golf
1999
,
Jetta
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ac
a
ss
7 - Fan Ring
8 - Retaining Clip
Check the clip for se
cure seating.
9 - Electrical Connector
10 - Fan
11 - to Coolant Pipe
Coolant hose connec
tion diagram, refer to 2.1 Coolant Hose Connection Diagram, page 85 .
12 - Expansion Tank
Perform a cooling system leakage test using the cooling system tester -VAG 1274- and the adapter VAG 1274/8- . Refer to 4.1 Cooling System, Checking for Leaks, page 91 .
Note the markings, refer to 1.2 Draining and Filling, page 81 .
13 - Expansion Tank Cap
Check using the cooling system tester -VAG 1274 - and the adapter -V.A.G 1274/9- . Refer to
page 91 .
Pressure relief valve must open at a pressure of 1.4 to 1.6 bar.
14 - Bracket
For the fan electrical connector.
Secured to the radiator with a retaining clip.
Coolant hose connection diagram, refer to 2.1 Coolant Hose Connection Diagram, page 85 .
16 - O-ring
Always replace
87

17 - Coolant Fan Control Thermal Switch -F18- , 35 Nm
For the electric fan
Switch temperatures:
1. Speed On: 92 to 97 C (197.6 to 206.6 F) Off: 84 to 91 C (183.2 to 195.8 F)
2. Speed On: 99 to 105 C (210.2 to 221 F) Off: 91 to 98 C (195.8 to 208.4 F)
18 - Bracket
For the radiator.
Note the different versions.
19 - Bolt, 5 Nm
2.3
Cooling System Components Assembly Overview, Engine Side
1 - Bolt, 15 Nm
2 - Coolant Pump
Check for ease of move
ment.
Note the installed posi
tion.
Removing and instal
ling, refer to
5.2 Coolant Pump,
page 94 .
3 - O-ring
Always replace
4 - from Cylinder Head
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5 - to Bypass Flap
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6 - from Cooler for Exhaust

Gas Recirculation (EGR)
To the heat exchanger.
7 - from the Bypass Flap
For the cooler for the
EGR.
8 - to Cooler for Exhaust Gas

Recirculation
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9 - to Expansion Tank (Top Fit

ting)
Coolant hose connec
tion diagram, refer to
2.1 Coolant Hose
Connection Diagram,
page 85 .
AG.
Prote
cted
by
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88
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11 - O-ring
Always replace.
do
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um
en
10 - Upper Coolant Line

Bolted on the cylinder
head cover.
As a unit with the fuel lines.

12 - Engine Coolant Temperature (ECT) Sensor -G62 With the ECT gauge sensor.
13 - Retaining Clip
Check the clip for secure seating.
14 - from Heat Exchanger
15 - to Radiator (Upper Fitting)
16 - Bolt, 10 Nm
17 - Connecting Piece
Connecting pieces with glow plugs for the auxiliary heater, refer to
Fig. Connecting Piece with Glow Plugs for the Auxiliary Heater , page 89 . (not installed on all
vehicles)
Coolant glow plug, checking. Refer to 4.3 Coolant Glow Plug, Checking , page 92 .
18 - Coolant Line
19 - to Radiator (Upper Fitting)
20 - from Expansion Tank (Bottom Fitting)
21 - from Radiator (Lower Fitting)
Coolant hose connection diagram 2.1 Coolant Hose Connection Diagram, page 85 .
22 - Connection
es n
wage
For the thermostat.
o
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nform
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a
t
i
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thi
s
24 - Oil Cooler
Removing and installing, refer to 2.3 Oil Filter Bracket Assembly Overview, page 73 .
Oil cooler, checking for leaks. Refer to 4.2 Oil Cooler, Checking for Leaks , page 91 .
Connecting Piece with Glow Plugs for the Auxiliary Heater
1 - Connecting piece
2 - Bolt, 10 Nm
4 - Heater flange for the glow plugs
5 - Glow plugs, 25 Nm
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23 - Coolant
tee
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ho
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page 94 .
c
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Observe the installed location, refer to 5.1 Coolant Thermostat, page 94 .
Checking: Heat up the thermostat in water.
Opening begins approximately 85 C (185 F).
Ends approximately 105 C (221 F).
Opening lift min. 7 mm.
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6 - To the cooler for the Exhaust Gas Recirculation (EGR)
89
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Specifications
3.1
Component
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90
Nm
10
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10
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5
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5
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Connecting Piece to Cylinder Head Bolt

Coolant Fan Control Thermal Switch
Coolant Line Bracket Bolt/Nut
Coolant Pump to Cylinder Block Bolt
Fan Shroud to Radiator Bolt
Glow Plug to Connecting Piece
Radiator to Bracket Bolt
Thermostat Connecting Piece Bolt
Fastener Size
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Specifications, page 90
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4.1 Cooling System, Checking for Leaks, page 91

4.2 Oil Cooler, Checking for Leaks , page 91
4.3 Coolant Glow Plug, Checking , page 92
4.1
Cooling System, Checking for Leaks
Special tools and workshop equipment
Test Conditions
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Adapter -VAG 1274/9-
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Cooling system tester -VAG 1274-
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Engine at operating temperature
Test Sequence
WARNING
Steam can be released when the cap is removed from the ex

pansion tank. Cover the cap with a cloth and open carefully.
Open the coolant expansion tank cap.
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Cap Pressure Relief Valve, Checking
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the -VAG 1274- .
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Install the -VAG 1274- with the -VAG 1274/8- onto the expan
sion tank.
Install the -VAG 1274- with the -VAG 1274/9- onto the expan
sion tank cap.
Operate the -VAG 1274- .
The pressure release valve must open at 1.4 to 1.6 bar.
4.2
Oil Cooler, Checking for Leaks

Refractometer -T10007 Hose clamps up to 25 mm dia. -3094 Cooling system tester -VAG 12744. Diagnosis and Testing
91

Adapter -VAG 1274/8 Spring type clip pliers -VAS 5024A Drip tray -VAG 1306- or drip tray for VAS 6100 -VAS 6208 Torque wrench (5-50 Nm) -VAG 1331Cold engine
Test Sequence
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Requirements
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Disconnect the supply and return line from the oil cooler using
the -VAS 3094- .
Remove the hose clamps -arrows- using the -VAS 5024- .
Note
Catch any coolant running out with the -VAG 1306- or the drip tray
-VAS 6208- .
Disconnect the coolant hoses from the oil cooler.
Install the sealing cap -5- on the rear connecting piece on the
oil cooler -4-.
Generate a positive pressure of approximately 1.6 bar using

the -VAG 1274- .
Watch the pressure drop on the gauge. The pressure must not
fall within 10 minutes.
If the pressure drops:
Replace the oil cooler. Refer to
2.3 Oil Filter Bracket Assembly Overview, page 73 .
Installation is performed in the reverse order of removal, noting
the following:
Check the coolant level, top off if necessary. Refer to
4.3
Coolant Glow Plug, Checking

Connector test set -VAG 1594C Voltage tester -VAG 1527BTest Requirements
Battery voltage a min. 11.5 volts
Ignition switched off
92
AG.
Install the -VAG 1274- and the -VAG 1274/8- onto the expan
sion tank.
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Fill the expansion tank up to the Max mark.
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Install the coolant hose -3- to the oil cooler and the expansion
tank.
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Install the sealing cap -2- on the expansion tank vent connec
tion -1-.

Test Sequence
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Check the electrical activation for the coolant glow plugs.
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Disconnect the electrical connectors -1- from
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glow
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Connect the lead of the -VAG 1527B- to the battery positive

terminal with the adapter clips from the -VAG 1594C- .
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Attach the test lead of the -VAG 1527B- to each coolant glow
plug in succession.
Light Emitting Diode (LED) lights up: Coolant glow plug OK
LED does not light up: Replace the coolant glow plug.
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93
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5.1 Coolant Thermostat, page 94

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

Refractometer -T10007 Drip tray -VAG 1306 Torque wrench (5-50 Nm) -VAG 1331 Spring type clip pliers -VAS 5024Removing
Note
Always replace gaskets and seals.

Disconnect the coolant hose from connecting piece.
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Remove the bolts -1- for the connecting piece -2- and remove
the connecting piece -2- with the coolant thermostat -4-.
Installing
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Turn the thermostat to the left -4- 90 degrees (1/4 turn) and
remove it from the connecting piece -2-.
the following:
Lubricate the new O-ring -3- with coolant.
The clip of the thermostat must be positioned at approximately a

right angle.
5.2
Coolant Pump
(with engine installed)
94
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Tighten the bolts -1-. Tightening specification: 15 Nm.
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Install the connecting piece -2- with thermostat -4- into the en
gine block.
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Insert the thermostat -4- into the connecting piece -2- and turn
it to the right 90 degrees (1/4 turn).

Refractometer -T10007 Drip tray -VAG 1306 Torque wrench (5-50 Nm) -VAG 1331 Spring type clip pliers -VAS 5024Removing
Note
Always replace gaskets and seals.
Cover the toothed belt with a cloth to protect it from coolant
before removing the coolant pump.

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

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

Radiator
AG.
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Drip tray -VAG 1306-
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Refractometer -T10007-
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AG. Volkswagen AG d
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Spring type clip pliers -VAS 5024-
95

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Remove the coolant hoses from the radiator.
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Remove the electrical connectors from the thermal switch and
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Remove the front bumper: Refer to Body Exterior; Rep. Gr.

63 ; Removal and Installation .
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Bring the lock carrier into the service position. Refer to Body
Remove the bolts from the radiator and remove the radiator
with fans downward.
With Air Conditioning (A/C)
WARNING
The Air Conditioning (A/C) refrigerant circuit must not be

opened.

the following:
96
Prote
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Remove the condenser from the radiator and fasten to the lock
carrier.
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Remove the retaining clamp(s) from the refrigerant lines.
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To prevent damage to the condenser and also to the refrigerant

lines/hoses, ensure that the pipes and hoses are not stretched,
kinked or bent.
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Engine
Mechanical,
Fuel
Injection
and Glow
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Special Tools
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Cooling system charge unit -VAS 6096 Adapter -VAG 1274/9-
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Connector test set -VAG 1594C-
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Voltage tester -VAG 1527B-
6. Special Tools
97

equipment required
Refractometer -T10007 Hose clamps up to 25 mm
dia. -3094 Cooling system tester VAG 1274 Adapter -VAG 1274/8-
olkswagen AG
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Spring type clip pliers -VAS
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98
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Drip tray -VAG 1306au
s
tray for VAS 6100
-VAS
s
6208-

20
Fuel Supply
General Information
1.1 Safety Precautions, page 99

1.2 Clean Working Conditions, page 99
1.1
Safety Precautions
WARNING
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The fuel or fuel lines for the fuel rsystem
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nection!
Caution
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The fuel pump is activated by switching on the ignition and by the

door contact switch of the driver's door. Therefore for reasons of
safety, the electrical connector -arrow- must be disconnected
from the fuel delivery unit before opening the fuel supply system,
if the battery is not disconnected.
do
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nents.
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Always observe the following when removing and installing the

fuel level sensor or the fuel delivery unit from full or partially filled
fuel tanks:
Before starting work, switch on the exhaust extraction system
and place an extraction hose close to the installation opening
of fuel tank to extract escaping fuel fumes. If no exhaust ex
traction system is available, a radial fan (as long as motor is
not in air flow) with a displacement greater than 15 m3/h can
be used.
Prevent fuel from contacting skin! Wear fuel resistant gloves!
1.2
Clean Working Conditions
When working on the fuel supply/injection system, pay careful at

tention to the following 6 rules of cleanliness:
Thoroughly clean all connections and the surrounding area
before disconnecting.
99

Place parts that have been removed on a clean surface and
cover them. Use lint free cloths.
Carefully cover or seal opened components, if repairs are not
performed immediately.
Only install clean components: Only unpack replacement
parts immediately prior to installation. Do not use parts that
have been stored loose (for example, in tool boxes etc.).
When the system is open: Avoid working with compressed air
if possible. Do not move vehicle unless absolutely necessary.
In addition, do not let diesel fuel flow onto coolant hoses. If
necessary, the hoses must be cleaned again immediately.
Replace corroded hoses.
1.3

Note
Hose connections are secured with either spring type or clamp
type clips.
Always replace clamp type clips with spring type clips.

Fuel hoses at the engine must only be secured with spring type
clips. The use of clamp or screw type clips is not permissible.
The spring type clip pliers -VAS 5024- or hose clip pliers -
VAG 1921 - are recommended for installing spring type clips.
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Rep. Gr.20 - Fuel Supply
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100
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. Volkswage
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Engine Mechanical,
Fuel
and
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doe Plug - Edition 07.2007
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2.2 Fuel Tank and Attachments Assembly Overview,

page 101
2.3 Fuel Filter Assembly Overview, page 104
4 - Throttle Position (TP) Sen

sor -G79 Not adjustable.
The TP sensor trans
mits the driver control to
the Engine Control Mod
ule (ECM).
Remove the footwell
cover to remove the
sensor.
5 - Bracket
For the footwell cover.
Clipped onto the TP
sensor.
2.2
AG.
3 - Nut, 10 Nm
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1 - Bracket
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Accelerator Mechanism Assembly Overview
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2.1 Accelerator Mechanism Assembly Overview, page 101
Fuel Tank and Attachments Assembly

Overview
Note
Make sure the supply or return lines do not come into contact with
the fuel tank during all work on the fuel pump unit or the fuel gauge
(transfer of pump noise).
101

1 - Cap
With securing clip.
2 - Seal
Replace if damaged.
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3 - Bolt, 1 Nm
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When installing: push

the rear overflow hose
behind the filler tube
bracket, do not clamp it.
5 - Ground Connection
Ensure the connection
is securely seated.
6 - O-ring
Always replace.
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10 - Protective Cover
For the filler tube.
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9 - Nut, 6 Nm
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8 - Bolt, 10 Nm
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7 - Breather Valve
To remove the valve,
unclip sideways out of
the support.
move the cap -item 1-.
Checking, refer to
Fig. Checking
Breather Valve ,
page 104 .
11 - Vent Line
Clipped in at the top of the fuel tank.
Ensure the line is securely seated.
12 - Lock Washer
13 - Heat Shield
For the fuel tank.
14 - Fuel Tank Cover
15 - Fuel Tank Cover
16 - Bolt, 25 Nm
17 - Securing Strap
Observe the varying lengths.
18 - Fuel Tank
Support using the engine and transmission jack -VAG 1383A - when removing.
Removing and installing, refer to 5.5 Fuel Tank, page 114 .
19 - Seal
Replace if damaged.
To install, place into the opening of the fuel tank dry.
102

Lubricate with fuel only when installing the fuel delivery unit.
20 - Fuel Delivery Unit
Note the installed position on the fuel tank. Refer to
Fig. Fuel Delivery Unit Installed Position , page 103 .
Removing and installing, refer to 5.3 Fuel Delivery Unit, page 113 .
Check fuel pump, refer to 4.1 Fuel Pump, Checking, page 107 .
With the fuel gauge sender.
Fuel level sensor removing and installing, refer to 5.4 Fuel Level Sensor, page 114 .
Clean strainer if contaminated.
21 - Union Nut
Use the ring nut spanner -3217- for removal and installation.
22 - Supply Line
To the fuel filter.
Black.
Clipped in at the fuel tank.
To remove from the fuel delivery unit, press the release buttons on the connecting piece.
23 - Return Line
From the fuel cooler.
To fitting -R-.
Blue or with blue marking.
AG. Volkswagen AG d
Clipped in at the fuel tank.
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To remove from the fuel delivery unit,thpress
the release buttons on the connectingteepiece.
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25 - Angle Piece
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24 - Gravity/Expansion Valve
To remove valve, unclip upward out of the support.
Check valve for flow through, valve vertical: open, valve angled at 45: Closed
Fuel Delivery Unit Installed Position
The mark on the fuel deliver unit must align with the mark on the
fuel tank -arrows-.
Blue or blue marked return line -1- to the fitting with identification
R.
Black supply line -2- to the fitting with identification V.
Note
do
c
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en
After installing the fuel delivery unit, check whether the supply,
return and ventilation lines are still clipped in at the fuel tank.
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103
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Checking Breather Valve
Lever in rest position: Closed
Lever pushed in direction of arrow: Open
Note
Before installing the breather valve, remove the cap from the fuel
tank.
2.3
Fuel Filter Assembly Overview
1 - Supply Line
From the fuel tank.
White or with white
markings.
Ensure the line is se
curely seated.
2 - Return Line
To the fuel cooler.
Blue or with blue mark
ing.
Ensure the line is se
curely seated.
3 - O-ring
Always replace.
6 - Return Line
From the tandem pump.
7 - Supply Line
To the tandem pump.
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104
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5 - Retaining Clip
Check for secure seat
ing.
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4 - Regulator Valve
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When changing
the
fil
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ac
a
ter, remove
ss
clip and remove the reg
ulator valve with fuel
lines attached.
When under 15 C (59
F): flow through to filter
is open.
When above 31 C (87.8
F): flow through to filter
is closed.

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

Filler Pipe Protective Cover Nut
Fuel Cooler Nut
Fuel Tank Filler Pipe to Body Bolt
Fuel Tank Securing Strap Bolt
Tandem Pump Bolt
Upper
Lower
Tank Flap Unit Bolt
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3.1

4.1 Fuel Pump, Checking, page 107

4.2 Tandem Pump, Checking, page 108
4.1
Fuel Pump, Checking
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Voltage tester -VAG 1527-
un
le
The fuses must be OK.
The battery voltage must be at least 11.5 volts.
All electrical components such as, for example, lights and rear
window defroster must be switched off.
Function and Voltage Supply, Checking

Remove the cover under the bench seat.
Briefly operate the starter. the fuel pump must run audibly.
r
fo
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If fuel pump does not activate:
Disconnect the 4 pin electrical connector from the fuel delivery

unit.
AG.
Switch on the ignition, Light Emitting Diode (LED) must light

up for approximately 2 seconds.
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Connect the -VAG 1527- using the cables from the VAG 1594- to the outer terminals of the electrical connector.
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Switch off the ignition.
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Test Conditions
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Hand multi meter -VAG 1526- or Multi meter -VAG 1715-
If the LED does not light up:

Check the activation of the fuel pump relay and wires for a
open circuit and/or a short circuit. Refer to Wiring diagrams,
Troubleshooting & Component locations Vehicle diagnosis,
testing and information system VAS 5051
LED lights up (voltage supply OK):
Remove the fuel delivery unit. Refer to
5.3 Fuel Delivery Unit, page 113 .
Check whether the electrical wires between fuel delivery unit
flange and fuel pump are connected and have continuity.
If no open circuits are found:
Replace the fuel delivery unit. Refer to
Current Pickup of Fuel Pump, Checking
Disconnect the 4 pin electrical connector from the fuel delivery
unit.
107

lkswagPlug
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G. Vo
Engine Mechanical, Fuel Injection
and
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wit
Also, the current clamp of the -VAG 1715 - can be attached to an

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

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Supply Pressure, Checking
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pressure gauge -VAS 5187-
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Vehicle diagnosis, testing and information system -VAS

5051B- , -VAS 5052- or -VAS 5053 Diagnosis cable -VAS 5051/1- or -VAS 5051/3Test Conditions
Coolant temperature must be at least 85 C (185 F).
Pump injector unit OK.
Fuel filter and fuel lines must not be plugged.
Procedure
Remove the locking bolt -arrow-.
108
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Set the multi meter to measuring
range 20A and connect the
nte
ise
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adapter cables from the
ut -VAG 1594A- between the harness
ra
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s
connector -1- and the
fuel
delivery
unit
connector
-1-.
s

Install the -VAS 5187- as shown.
Connect the vehicle diagnostic, testing and information sys
tem -VAS 5051- and select operating mode Vehicle On-Board
Diagnostics (OBD).
Press button 01 - Engine electronics on display.
Press the diagnostic function 08 - Read measuring value
blocks.
Enter display group 1 via the number keypad and confirm
input by pressing the Q button.
Read the idle RPM in display field 1.
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Increase the engine speed to 4000 RPM. lkswagen A

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Observe the pressure displayed on ithe
se -VAS 5187- .
Specified value: min. 7.5 bar
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Clamp the return line closed between the fuel filter and the
tandem pump with a hose clamp.
Increase the engine speed to 4000 RPM.
Observe pressure displayed on -VAS 5187- .
Specified value: min. 7.5 bar
If the specification is now obtained:

The pressure loss is at the pump injector unit.
Replace the O-rings of the pump injector unit.
Replace the tandem pump. Refer to
r
fo
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After removing the -VAS 5187- , tighten the locking bolt to 25 Nm.
Always replace the seal.
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Internal Leakage, Checking
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Note
After reinstalling a tandem pump, for example after replacing or

repairing a cylinder head, or after replacing an engine, the tandem
pump must absolutely be checked for internal leakage between
the fuel and oil side. Fuel or oil leakages can cause damage to
the engine.
Testing unit for turbocharger -V.A.G 1687Procedure
Disconnect the fuel supply hose (white marking) and the fuel
return hose (blue marking) to the tandem pump.
Seal the fuel return connection on the tandem pump with a
sealing plug; secure the plug with a spring clamp.
109

Prepare the -VAG 1687- as follows:
Remove the pressure regulator valve -2- completely and close
the valves -3 and 4-.
Connect the test connector -5- to the tandem pump fuel supply
connection using a commercially available compressed air
connection and a piece of a fuel hose; use a spring clamp to
secure it.
Note
In order to be able to turn pressure regulator valve -2-, rotary knob

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

to the -VAG 1687- .
un
le
Set pressure to 1.0 bar using pressure regulator valve -2-.

Caution
rrectne
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spec
atio
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Open valve -3-.
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If water is located
in viewing glass, drain it via water drain screw
ut
ra
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-6-.
The maximum test pressure is 1.3 bar and must not be excee
ded.
Open the valve -4- and wait until the testing circuit has filled.
If necessary, continue to regulate pressure to 1.0 bar.
Closes the valve -3-, in order to maintain the pressure and
observe the drop in pressure for 1 minute.
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110
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If there is no pressure drop, then the tandem pump can be used

again; if there is a pressure drop, then the tandem pump must be
replaced.

5.1 Fuel Cooler, page 111

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

Torque wrench (5-50 Nm) -VAG 1331Removing
Observe safety precautions, refer to
1.1 Safety Precautions, page 99 .
Observe rules for cleanliness, refer to
1.2 Clean Working Conditions, page 99 .
Note
The fuel cooler is located in the return line to the fuel tank. It is
attached to the underbody of the vehicle.
Remove the cover -A-.
Separate the fuel lines at the fuel cooler.
Remove the nuts -arrows-.
Installing
Installation is performed in reverse
the following:
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Tandem Pump
WARNING
The tandem pump must not be disassembled under any cir

cumstances because it can cause the vacuum part to malfunc
tion. The result would be brake booster failure.
Torque wrench (5-50 Nm) -VAG 1331 Hand vacuum pump -VAG 1390-
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Hose clip pliers -VAG 1921-
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Hand vacuum pump reservoir -VAG 1390/1-
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spec
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5.2
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Tighten the nuts for the fuel cooler to 20 Nm.
111

Removing
WARNING
nection!
Disconnect the supply hose -1- (white marking) and return
hose -2- (blue marking) from the fuel filter.
Install the -VAG 1390- and the -VAG 1390/1- to the return
hose.
Operate the -VAG 1390- , until no more fuel runs from the re
turn hose. Make sure that no fuel is sucked into the VAG 1390- .
Disconnect the brake booster vacuum line -1- from the tandem
pump -4-.
Remove the supply hose -2- (white marking) from the tandem
pump -4-.
Remove the bolts -arrows-.
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Pull the tandem pump -4- slightly upward, disconnect the
ir sere
tee
o
th
or
turn hose -3- (blue marking) and remove the tandem upump
ac
a
-4-.
ss
Remove the tandem pump -4- from the cylinder head.
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Installing
es, in part or in w
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Note
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his

the following:
Make sure that tandem pump coupling has proper seating in
camshaft.
Tandem pump seals must always be replaced.
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112

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

Ring nut spanner -3217 Torque wrench (40-200 Nm) -VAG 1332Removing
es, in part or in w
l purpos
hole
ercia
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rrectness of i
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at
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his
Remove the cover from fuel delivery unit.

Disconnect the 4 pin electrical connector and the supply and
return lines from the fuel delivery unit.
WARNING
nection!
do
c
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en

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113
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Note
Press the buttons together on the connections to do so.

Remove the ring nut using the -3217- .
Remove the fuel delivery unit and seal out of the opening in
fuel tank.
Note
If the delivery unit is to be replaced then drain old unit before dis
posal.
Installing
Installation of the fuel delivery unit is the reverse order of re
moval.
Note
Do not bend the fuel level sender when installing.
Insert the seal for the fuel delivery unit into opening of fuel tank
dry.
Only lubricate the seal with fuel when installing the fuel deliv
ery unit.
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unit, check that
the
supply,
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clipped onto
ut the fuel tank.
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Ensure the fuel hoses are seated securely.

After installing the fuel delivery
turn and breather lines are still
un
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Note the installed position of the fuel delivery unit: Mark on the
rrectness of i
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spec
a
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wit
thi
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5.4
es, in part or in w
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hole
ercia
, is n
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com
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d
delivery unit flange must align with the mark on the fuel tank
-arrows-.
Fuel Level Sensor
Removing
Remove the fuel delivery unit. Refer to

Disengage the connector prongs of the wires -3 and 4- and
disconnect.
Pry off the retaining straps -1 and 2- using a screwdriver and
remove the fuel level sensor for towards bottom -arrows-.
Installing
114
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Fuel Tank
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Install the fuel level sensor in the guides on the fuel delivery
unit and push up until it engages.

Engine and transmission jack -VAG 1383ARemoving
Open the fuel tank flap.
Remove the rear subframe. Refer to Suspension, Wheels,
Steering; Rep. Gr. 42 ; Removal and Installation .
Remove the rear right wheel housing liner. Refer to Body
Exterior; Rep. Gr. 66 ; Removal and Installation .
Remove the cover fasteners -arrows- and remove the cover
for the fuel tank.
Drain the fuel tank and clean the fuel filler tube and surround
ing area.
Remove the bolt and remove the fuel flap unit with rubber
gasket.
Remove the bolts for the filler neck.
Remove the cover plate and disconnect the electrical connec

tor -arrow- from the fuel delivery unit.
rrectness of i
t to the co
nform
spec
at
i
h re
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wit
in t
his

nection!
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do
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es, in part or in w
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hole
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ut for the fuel system can become very
ra
The fuel or fuel lines
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115
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Disconnect the fuel supply line and return lines
at
the
right
front
s
wa
Golf 1999 , Jetta 1999 , Jetta Wagon 1999 V
olks
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Engine Mechanical, Fuel Injection and GlowisePlug - Edition 07.2007
Note
un
le
Press the buttons on the fittings -arrows- downward to do this.

Remove the tensioning straps. Support the fuel tank using the
-VAG 1383A- while doing so.
Lower the fuel tank.
Installing

the following:
Make sure the ventilation and fuel lines are not kinked when
installed.
Ensure the fuel hoses are securely seated.
Prote
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Clip in the supply and return lines at the fuel tank.
116
AG.
After installing the fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
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Do not interchange the supply and return lines (return line is

blue or has blue marking, supply line is black).
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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v
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p
of the fuel tank.
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Special Tools

Test adapter kit -VAG 1594A Voltage tester -VAG 1527 Vehicle diagnosis, testing and information system -VAS
5051B- , -VAS 5052- or -VAS 5053 Diagnosis cable -VAS 5051/1- or -VAS 5051/3 Hand multi meter -VAG 1526- or Multi meter -VAG 1715-
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pressure gauge -VAS 5187-
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Ring nut spanner -3217-
6. Special Tools
117

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Engine and transmission jack -VAG
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118
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Testing unit for turbocharger -V.A.G 1687-

equipment required
Torque wrench (5-50 Nm) VAG 1331 Hand vacuum pump VAG 1390 Hand vacuum pump reser
voir -VAG 1390/1-
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Hose clip pliers -VAG 1921-
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119
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21
Turbocharger
General Information

1.1
Safety Precautions
Caution

olkswagen AG
orative Emission (EVAP) , coolant, refrigerant,
brake
n AG. Vor
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wage path is
not
vacuum) and electrical wires so that theVoriginal
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Ensure sufficient clearance to all
au moving or hot compo
ss
nents.
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wit
Observe the following if test and measuring instruments are re

quired during a test drive:
Test and measuring instruments must be secured in the rear
seat and operated by a 2nd person from this location.
If test and measuring instruments are operated from the front
passenger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive se
rious injuries when the airbag is triggered.
1.2
When working on turbocharger, carefully observe the following

Rules of Cleanliness:
During repairs, clean oil from connections and hose ends.

120
Rep. Gr.21 - Turbocharger
AG.
Transport and protective packaging and sealing caps are to

be removed only immediately prior to installation.
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2.1 Charge Air Cooler and Components Assembly Overview,

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

sembly Overview

Note
All hose connections for the charge air system are secured by
spring type clamps or by connector couplings. For connector

couplings, always note the following points:
Charge air system must be properly sealed.

During repairs, clean the oil from the connections and hose
ends.
Hose connections and charge air system hoses must be free
of oil and grease before installing. Only on connector cou

plings, the sealing ring and the sealing surfaces must be lightly
oiled. Refer to
5.1 Hose Connections with Connector Couplings,
page 129 .
rrectness of i
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at
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121
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1 - Connecting Hose
2 - Connecting Pipe
10 - Bolt, 5 Nm
11 - Bracket
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9 - Charge Air Pressure Sen

sor - G31- and Intake Air Tem
perature (IAT) Sensor - G42-
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122
Prote
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8 - O-ring
Replace if damaged.
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7 - Charge Air Cooler
AG.
6 - Charge Air Pipe
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5 - Bolt/Nut, 10 Nm
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4 - Connecting Hose
Charge air pipe/turbo
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3 - Connecting Hose
Connecting pipe/intake
connection.

2.2
Turbocharger and Attachments Assembly Overview
1 - Oil Supply Line

From the oil filter brack
et, see -item 6- in the
Assembly Overview,
page 73 .
Fill the oil supply line
with oil before installing
it to the connection fit
ting.
Removing and instal
ling, refer to
5.1 Oil Supply Line,
page 77 .
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2 - Union Nut
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Assembly Overview,
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page 70 . ss
3 - Bolt, 22 Nm
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4 - Connection, 30 Nm
Always replace.
Coat the threads and
bolt head contact sur
face with -G 052 112
A3- .
Fill the oil supply line
with oil before installing
it to the connection fit
ting.
5 - Bolt, 10 Nm
Installation position, see
-items 6 and 9- in the
2.1 Oil Supply Line
Assembly Overview, page 70 .
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Component location, see -item 4- in the 2.1 Oil Supply Line Assembly Overview, page 70 .
AG.
9 - Gasket
Always replace.
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8 - Intake Manifold
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7 - Seal
Always replace.
10 - Washer
11 - Nut, 25 Nm
Always replace.
12 - Brace
Between the turbocharger and cylinder block.
13 - Bolt, 40 Nm
First tighten all bolts hand tight.
123

14 - Connecting Pipe
Air filter/turbocharger.
15 - Transition Piece
16 - Turbocharger
Replace as a complete unit with the exhaust manifold.
Removing and installing, refer to 5.2 Turbocharger, page 129 .
17 - Gasket
Always replace.
18 - Connection, 40 Nm
19 - Union Nut, 30 Nm
20 - Oil Return Line
To the cylinder block.
21 - Bolt, 17 Nm
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For the turbocharger vane position sensor.
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23 - Vacuum Hose
To the wastegate bypass regulator valve.
Connection diagram for vacuum hoses, refer to
2.3 Vacuum Hose Connection Diagram, page 125 .
24 - Bolt, 20 Nm
First tighten all bolts hand tight.
25 - Nut, 20 Nm
Always replace.
26 - Heat Shield
27 - Front Exhaust Pipe
124
AG.
From the cooler for the EGR.
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To the cooler for the Exhaust Gas Recirculation (EGR).
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29 - Nut, 22 Nm
Always replace.
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28 - Bracket
For the oil supply line, see -item 1-.
Secure the oil supply line before installing.

Vacuum Hose Connection Diagram
pe
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7 - Vacuum Diaphragm
With the turbocharger
vane position sensor.
For the boost pressure
regulation.
Component of the turbo
charger cannot be re
placed.
AG.
6 - Vacuum Reservoir
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5 - Non Return Valve

White the connector
leading to the EGR cool
er switch over valve
Item 3 (page 125) ,
wastegate bypass regu
lator valve
Item 4 (page 125) and
to the vacuum reservoir
Item 6 (page 125) .
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4 - Wastegate Bypass Regula

tor Valve -N75-
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3 - Exhaust Gas Recirculation

(EGR) Cooler Switch Over
Valve -N345-
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2 - Intake Manifold Tuning

(IMT) Valve -N156 For the intake manifold
change over.
un
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For the Exhaust Gas
Recirculation (EGR)
change over (Bypass
flap).
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2.3
For the intake manifold flap.
9 - Vacuum Connection
Between the tandem pump and the brake booster.
125

Specifications
3.1

Component
Fastener Size
Nm
Charge Air Cooler to Bracket Bolt

Charge Air Cooler Bracket Bolt/Nut
Charge Air Pipe Nut
Charge Air Pressure/Intake Air Temperature Sensor Bolt
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Exhaust Gas Recirculation Connecting Pipe to Bypass Flapsw
Bolt
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Exhaust Gas Recirculation Connecting Pipe to IntakeedManifold
Bolt
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Exhaust Gas Recirculation Connecting Pipe to Turbocharger
Nut
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Oil Supply Line Bracket to Turbocharger/Exhaust Manifold Nut 1

Oil Supply Line Clamp Bolt
ac
25
22
40
17
30
20
10
30
Turbocharger Brace to Cylinder Block Bolt 2
25
22
25
40
Turbocharger/Exhaust Manifold to Cylinder Head Nut 1
25
Turbocharger/Exhaust Manifold Heat Shield Nut 1
20
Turbocharger to Turbocharger Brace Bolt 2
20
First tighten all bolts hand tight
126
Prote
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Always replace
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Oil Supply Line Connection to Turbocharger 1

Oil Supply Line to Oil Filter Bracket Banjo Bolt
Oil Supply Line Union Nut to Turbocharger
Pendulum Support to Subframe Bolt
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Front Exhaust Pipe to Turbocharge Nut 1

Lower Intake Manifold to Cylinder Head Bolt
Oil Return Line Connection to Cylinder Block
Oil Return Line to Turbocharger Bolt
Oil Return Line Union Nut to Connection
10
10
10
5
22
22
22

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

Testing unit for turbocharger -V.A.G 1687 Adapter -VAG 1687/10 Remove the intake hose -1- from the air filter.
Install the -VAG 1687/10- in the intake hose -1- and secure it
with a clamp.
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Unscrew the pressure regulator valve -2- completely and close

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

knob must be pulled upward.
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Prepare the -VAG 1687- as follows:
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127
AG.
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Connect the -VAG 1687- to the - VAG 1687/10- as shown.
Connect a compressed air hose -1- (pressurized air supply) to

the -VAG 1687 - .
Note
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Open the valve -3-.
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If water is located in the viewing

screw -6-.
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Set the pressure to 0.5 bar using the pressure regulator valve
-2-.
rrectness of i
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nf
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spec
atio
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n in
wit
Caution
Pressure must not exceed 0.5 bar! A pressure set too high may
damage the engine.
Open the valve -4- and wait until the testing circuit has filled.
If necessary, continue to regulate pressure to 0.5 bar.
Check the charge air system for leaking areas by listening,
touch, using leak detection spray or using the ultrasonic meas
uring device -VAG 1842- .
If a poorly sealed area is discovered, observe the notes for

Prote
cted
by
Before removing the - VAG 1687/10- , discharge the pressure
in the testing circuit by disconnecting the coupling from the VAG 1687/10- .
128
AG.
charge air system when repairing. Refer to

view, page 121 .
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Manual .
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Handling instructions of the -VAG 1842 - . Refer to Owner's
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5.2 Turbocharger, page 129
5.1
Hose Connections with Connector Cou

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

ing clamp is in the locked position when installing. This would
result in a leak. Follow assembly instructions.
Release the connector coupling by pulling the locking clip

-arrow-. Separate the hose/tube without assistance from tools.
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Installing
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Removing
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5.1 Hose Connections with Connector Couplings, page 129
, Jetta Wagon 1999

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Engine
Mechanical,
Fuel
Injection
and Glow
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When replacing the sealing ring, lay the ring in the charge air
hose groove. Ensure the gasket is completely seated in the
groove all the way around.
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Oil the sealing surfaces and sealing ring.
Bring the securing clip into the release position -1-.

Slide the charge air hose in as far as the stop.
Bring the securing clip into the lock position -2- and then press
the charge air hose back again.
Check for correct seating and proper locking of the connector
by pulling on the hose.
5.2
Turbocharger

Hose clip pliers -VAS 6340-
129
es, in part or in w
l purpos
hole
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Golf 1999 , Jetta 1999 se,d Jetta Wagon 1999
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Caution
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
If mechanical damage is found on the turbocharger, for exam

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

Disconnect the tube leading to the crankcase ventilation -5on the air guide pipe.
Loosen the spring type clip on the turbocharger.
Free up the vacuum hoses.
Remove the bolts -1 and 2- and remove the air guide tube
-3-.
Remove the oil supply line banjo bolt -arrow- from the oil filter
bracket and also from the coolant pipe.
130
ht
rig
py
Co
t.
Disconnect the hose -arrow- leading to the charge pressure

regulation vacuum diaphragm.
thi
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Remove the engine cover. refer to


Remove the air guide tube -arrows- on the right longitudinal
member.
Remove the center and right noise insulation. Refer to Body
Remove the heat shield for right drive axle.
Remove the right drive axle from the transmission flange.
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Note
Decoupling element in the front exhaust pipe must not be bent

more than 10 degrees, otherwise it may be damaged.
Disconnect the exhaust system at the double clamp.
Remove the front exhaust pipe.
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Remove the pendulum supports bolt -arrows A- from the sub

frame.
rrectne
s
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form
spec
atio
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Remove the exhaust system suspended mount bolts

-arrows- from the subframe.
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Remove the air guide hose -4-.

Remove the bolts -2 and 3- and remove the turbocharger
brace.
Remove the oil return line -1- from the cylinder block.
Disconnect the electrical connector from the turbocharger
vane position sensor (not shown in the illustration).
131

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Remove the connecting pipe bolts -arrows- for the Exhaust

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

on the exhaust manifold.
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132
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Remove the heat shield from the exhaust manifold.

Remove the nuts -arrows-.
Remove the washers.
Remove the exhaust manifold/turbocharger to the rear.
Installing
the following:
Seals, sealing rings and self locking nuts must always be re
placed.
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Pay attention to the installation position Vof
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haust manifold/turbocharger.
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Add oil to the turbocharger through
the oil supply line con
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necting piece.
rrectness of i
t to the co
nform
spec
at
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his
Hose connections and charge air system hoses must be free

of oil and grease before installing. Only on connector cou
plings, the sealing ring and the sealing surfaces must be lightly
oiled. Refer to
page 129 .
Charge air system must be properly sealed.
All hose connections for the charge air system are secured by
spring type clamps or by connector couplings. For connector
couplings, always note the following points. Refer to
page 129 .
Secure all hose connections using hose clamps appropriate
for the model type. Refer to Electronic parts catalog ET
KA .
AG.
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Check the oil level. Refer to

3.2 Engine Oil Capacity and Specifications, page 75 .
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Install the right drive axle. Refer to Suspension, Wheels,

Steering; Rep. Gr. 40 ; Removal and Installation .
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Install the exhaust system and align it free of tension. Refer to

2.2 Mufflers and Mounts Assembly Overview, page 156 .
After installing the turbocharger, let the engine idle for approx
imately 1 minute without increasing the engine speed. This
ensures adequate oil supply to the turbocharger.
133
25 1)
Heat shield to exhaust manifold/turbocharger
20 1)
22
Bypass flap
Exhaust manifold
25
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134
Prote
cted
by
Oil supply line to exhaust turbocharger

Brace for turbocharger to cylinder block
Turbocharger brace to turbocharger
Oil return line to cylinder block
Oil supply line to oil filter bracket
Pendulum supports to subframe
1) replace
22 1)
22
40
20
30
25
AG.
Connecting pipe for the

EGR to the
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spec
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Exhaust manifold/turbocharger to cylinder head
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Tightening Specifications
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Golf 1999 , Jetta 1999 , Jetta Wagon 1999ris
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Engine Mechanical, Fuel Injection and Glow aPlug
- Edition 07.2007
u
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Special Tools

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Testing unit for turbocharger -V.A.G 1687-
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Hose clip pliers -VAS 6340-
6. Special Tools
135
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23
Diesel Fuel Injection
General Information

1.1
Safety Precautions
Caution

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orative Emission (EVAP) , coolant,
brake
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Only disconnect and reconnect wires for glow plug and fuel
injection systems, including test leads, when the ignition is
turned off.
If the engine is to be cranked at starting RPM without starting,
for example, for a compression test, disconnect the electrical
connector for the pump injector unit at the cylinder head:
Obtain the radio code for radios with antitheft coding before
disconnecting the battery.
Always switch the ignition off before disconnecting or con
necting the battery, as failure to do so may damage the control
module for diesel direct fuel injection system.
If test and measuring equipment is required during road test, note
the following:
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If test and measuring instruments are operated from the front

passenger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive se
rious injuries when the airbag is triggered.
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1.2
When working on the fuel supply/injection system, pay careful at

tention to the following 6 rules of cleanliness:
136
Rep. Gr.23 - Diesel Fuel Injection
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Test and measuring instruments must be secured in the rear

seat and operated by a 2nd person from this location.
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To reduce the risk of personal injury and/or damage to the fuel

injection and glow plug system, always observe the following:
ee
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Ensure sufficientsclearance
to all moving or hot compo
au
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nents.

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In addition, do not let diesel fuel flow onto coolant hoses. If

necessary, the hoses must be cleaned again immediately.
Replace corroded hoses.
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137
AG.
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2.1 Component Locations Overview, page 138

2.2 Engine Control Module Functions and Components,
Adapting, page 139
2.3 Intake Manifold Assembly Overview , page 139
2.4 Pump Injector Unit Assembly Overview , page 140
2.1
Component Locations Overview
Components -A through D- are not shown in the exploded view.

A - Brake Pedal Switch -F47 In the footwell at the
brake pedal.
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B - Brake Light Switch -F In tee footwell at the

brake pedal.
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C - Throttle Position (TP) Sen

sor -G79 In the footwell, at the ac
celerator pedal.
D - Clutch Pedal Switch -F36 In the footwell on the
clutch pedal.
1 - Intake Manifold Flap

With the intake flap mo
tor.

(EGR) Vacuum Regulator Sol
enoid Valve -N18- (Electric)
AG.
6 - Control Module for Diesel

Direct Fuel Injection System J248 Barometric (BARO)
pressure sensor.
Replacing, refer to
5.1 Engine Control Module, page 145 .
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5 - Wastegate Bypass Regula

tor Valve -N75-
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(EGR) Cooler, Switch Over
Valve -N345-
7 - Positive Crankcase Ventilation (PCV) Heating Element -N798 - Engine Coolant Temperature (ECT) Sensor -G62 For the engine control unit.
With the ECT gauge sensor.
If necessary release the pressure in the cooling system before removing.
138
thi
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3 - Intake Manifold Tuning

(IMT) Valve -N156-
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9 - Mass Air Flow (MAF) Sensor -G70-
For the pump/injector valve (cylinder 1) through pump/injector valve (cylinder 4).
11 - Engine Speed (RPM) Sensor -G2812 - Fuel Temperature Sensor -G81-
13 - Connector
For Camshaft Position (CMP) Sensor -G40- , for camshaft position
For the engine speed (RPM) sensor.
15 - Camshaft Position (CMP) sensor -G40 For camshaft position.
Engine Control Module Functions and

Components, Adapting
AG.
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5051B- , -VAS 5052- or -VAS 5053-
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16 - Charge Air Pressure Sensor - G31- with Intake Air Temperature (IAT) Sensor - G42-
rrectne
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Diagnosis cable -VAS 5051/1- or -VAS 5051/3Procedure

In the -VAS 5051- select Guided Fault Finding.
Once all control modules have been checked:
Press the Go to button
Select Function/component selection
Select drivetrain
Select engine code
Select 01-Systems capable of On Board Diagnostic (OBD)
Select engine management system
Select Functions
Select Function or component
2.3
Intake Manifold Assembly Overview
When the engine is switched off, the intake manifold flap is closed
for approximately 3 seconds and then opens again. This reduces
the stop jolt.
Intake manifold change over is switched depending on engine
speed and Throttle Position (TP).
139

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

Disassembling and assembling, refer to 6.1 Variable Intake Manifold, page 151 .
16 - Bolt, 22 Nm
17 - Bracket
18 - Bolt, 10 Nm
19 - Vacuum Actuator
Note
20 - Vacuum Hose
rrectne
s
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spec
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15 - Bolt, 10 Nm
Observe the tightening sequence, refer to 6.1 Variable Intake Manifold, page 151 .
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Pump Injector Unit Assembly Overview
Prote
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140
AG.
Note the rules of cleanliness. Refer to

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21 - Intake Manifold Tuning (IMT) Valve -N156 Connection diagram for vacuum hoses, refer to 2.3 Vacuum Hose Connection Diagram, page 125 .

Always replace the sealing rings and O-rings.
1 - Bolt, 20 Nm + 90 (1/4) ad
ditional turn
Always replace.
Pay attention to the se
quence when loosening
and tightening, refer to
5.2 Pump Injector
Unit, page 145 .
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3 - Lock Nut, 30 Nm
4 - Adjustment Screw
Always replace.
Adjusting, refer to
5.2 Pump Injector
Unit, page 145 .
5 - Ball Pin
Always replace.
Removing and instal
ling, refer to
5.2 Pump Injector
Unit, page 145 .
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7 - O-ring
Replacing, refer to
5.3 Pump Injector
Unit O-rings,
page 148 .
rrectne
s
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t to the co
n
form
spec
atio
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2 - Rocker Lever Shaft Volkswa

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With rocker arm.
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Removingaand
instal
s
s
ling, refer to
5.2 Pump Injector
Unit, page 145 .
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8 - O-ring
Replacing, refer to 5.3 Pump Injector Unit O-rings, page 148 .
AG.
Prote
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by
9 - O-ring
Replacing, refer to 5.3 Pump Injector Unit O-rings, page 148 .
10 - Heat Protection Seal
Always replace.
11 - Circlip
12 - Cylinder Head
13 - Tension Block
Always replace.
141

Specifications
3.1

Component
Fastener Size
Nm
Exhaust Gas Recirculation Connecting Pipe to Intake Manifold Bolt

Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve to In
take Manifold Bolt
Intake Manifold Flap to Intake Manifold Bolt
Lower Intake Manifold to Cylinder Head Bolt
22
10
10
22
12 + 270 turn
20 + 90 turn
30
10
Pump Injector Unit Tension Block Bolt 1

Rocker Lever Shaft to Cylinder Head Bolt 1
Rocker Lever Shaft Lock Nut
Vacuum Actuator Bracket to Lower Intake Manifold Bolt
Always replace
Lower (Variable) Intake Manifold to Upper Intake Manifold Bolt

Tightening Sequence and Specification
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142
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Tighten the bolts in the sequence shown -1 through 8- to 10by Volk

ed
Nm.
ris

4.1 Engine Control Module DTC Memory, Checking and Eras

ing, page 143
4.2 Speed Signal, Checking, page 143
olkswagen AG
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4.1
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Engine Control Module
DTC Memory,
Vol
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Checking and
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Procedure
rrectness of i
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spec
at
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his
Diagnosis cable -VAS 5051/1- or -VAS 5051/3 Connect the -VAS 5051- -1- as follows:
Connect the -VAS 5051/1- or the -VAS 5051/3- -2- to the Data
Link Connector (DLC).
Only when engine does not start:
Switch the ignition on.
Selecting Operating Mode
Press button on display for Vehicle On Board Diagnostic
(OBD).
Selecting Vehicle System
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Display will indicate control module identification and Engine

Control Module (ECM) coding.
AG.
Press button 02 - Check DTC memory on display.
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Selecting Diagnosis Function
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Press button 01 - Engine electronics on display.
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5051B- , -VAS 5052- or -VAS 5053-
or
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a equipment required
ss
If no malfunction is stored in engine control module, 0 DTC(s)

detected is displayed.
If malfunctions are stored in the engine control unit, these are
shown one below another on the display.
Press the key.
Press button 05 - Erase DTC memory on display.
Press function 06 - End output.
Note
Regenerate the readiness code after erasing the ECM Diagnostic

Trouble Code (DTC) memory. Refer to
2.2 Engine Control Module Functions and Components,
Adapting, page 139 .
4.2
Speed Signal, Checking
Function
Engine speed signal is supplied at terminal 28 of the Engine Con
trol Module (ECM). The signal is required, among other things, by
143

AG. Volkswagen AG d
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the automatic transmission control module to calculate shift
olkspoints
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and for the tachometer in instrument panel cluster.sed
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Test box 105 pin -VAG 1598/42- with adapter lead, 94 pin VAG 1598/39-2 Connector test set -VAG 1594 Wiring diagram
Test Sequence
rrectness of i
t to the co
nform
spec
at
i
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his
Hand multi meter -VAG 1526- or Multi meter -VAG 1715-
Remove the windshield wiper arms and plenum chamber cov

er. Refer to Electrical Equipment; Rep. Gr. 92 ; Removal
and Installation .
Release the connector from the ECM and pull off.
Connect the -V.A.G 1598/42 - to the control module wiring
harness.
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144
do
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Check for an open circuit/short circuit in the wire connection

between the -V.A.G 1598/42 - socket 28 and instrument panel
cluster according to the wiring diagram. Wire resistance: Max.
1.5 . Refer to Wiring diagrams, Troubleshooting & Com
ponent locations Vehicle diagnosis, testing and information
system VAS 5051

5.1 Engine Control Module, page 145

5.2 Pump Injector Unit, page 145
5.3 Pump Injector Unit O-rings, page 148
5.1
Engine Control Module
Before removing the Engine Control Module (ECM), the con

trol module identification and with it also the coding of the
previous control module must be checked. Refer to
Erasing, page 143 .
Removing
Remove the windshield wiper arms and plenum chamber cov
er. Refer to Electrical Equipment; Rep. Gr. 92 ; Removal
and Installation .
Release the connector from the ECM and pull off.
Press the control module to the right and pull it out.
Installing
Insert the new control module and press it toward the left.
Plug in the electrical connector and latch it into place.
Check the previous coding and code the new control module.
Refer to
esand
wage Module Functions
s
k
not Components,
2.2 Engine
Control
l
Vo
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Adapting,edpage 139 .
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5.2
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Pump Injector Unit
rrectness of i
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spec
at
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ss
Dial gauge holder -VW 387 Socket insert -3410 Special wrench, long reach -T10054 Puller -T10055 Torque wrench (5-50 Nm) -VAG 1331 Dial gauge
Grease -G 000 100Removing
do
c
um
en
Remove the upper toothed belt cover, refer to

5.3 Toothed Belt, page 54 , and the cylinder head cover,
refer to 5.1 Cylinder Head Cover, page 49 .
Rotate the crankshaft until the cam lobe pair for the respective
pump injector unit to be removed face upward simultaneously.
145
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Loosen the lock nut of the adjustment screw -1- and remove
the adjustment screw.
Loosen the bolts -2- for the rocker lever shaft from the outside
toward the inside, using the -3410- and remove the rocker
lever shaft.
Loosen the bolt -3- for the tension block using the -T10054and remove the tension block.
Pry out the electrical connector for pump injector unit using a
screwdriver. In order to avoid tilting, support the opposite side
of connector with light finger pressure.
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Observe the cylinder allocation of the pump injector units.

Install the -T10055- in place of the tension block into the side
slit of the pump injector unit.
Using careful knocking motions, pull the pump injector unit
upward out of its cylinder head seat.
Installing
Note
Install a new pump injector unit, also replace the correspond
ing adjustment bolt in the rocker arm.
For every procedure that requires adjustment of the pump in
jector unit, the adjustment screw in the rocker lever and the
ball pin of the pump injector unit must be replaced.
New pump injector units are shipped with O-rings and heat
protection seal.
Install the pump injector unit again, replace the O-rings and
the heat protection seal. Refer to
5.3 Pump Injector Unit O-rings, page 148 .
un
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Note
O-rings must not be twisted on themselves.
Lubricate the O-rings and install the pump injector unit with
great care into the cylinder head seat.
Using uniform pressure, push the pump injector unit into the
cylinder head seat until seated.
Insert the tension block into the lateral slot of the pump injector
unit.
Note
AG.
Align the pump injector unit at a right angle to the thrust bearing
of the camshaft.
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Install the new bolt into the tension block so far that the pump
injector unit can still be lightly turned.
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Align the pump injector unit as follows.
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If the pump injector unit does not stand at a right angle to the
tension block, the bolt can loosen and thereby cause damage to
the pump injector unit/cylinder head.
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Before installing the pump injector unit, check that the
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O-rings, heat protection seal and securing ring are
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147
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Using a caliper gauge (measuring range minimum 400 mm),
check dimension a from the outer edge of the cylinder head
to the round surface of the pump injector unit.
Cylinder
Dimension a
1
2
3
4
333.0 0.8 mm
245.0 0.8 mm
153.6 0.8 mm
65.6 0.8 mm
Realign the pump injector unit if necessary and tighten the bolt
as follows:
Tighten the tension block bolt to 12 Nm and turn an additional
270 (3/4 rotation, additional rotation may occur in several
stages).
Install the rocker lever shaft and tighten the new bolts as fol
lows:
Hand tighten the inner bolts -2-, then the outer bolts -1- equal
ly; then tighten in the same sequence to 20 Nm and 90 (1/4
turn).
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Place a dial gauge as shown onto the adjustmentoriscrew
of the
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pump injector unit.
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Remove the dial gauge.
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Rotate the crankshaft in direction of engine rotation until the

rocker arm roller stands at the camshaft point. Roller side
-arrow A- is positioned at the highest point, dial gauge
-arrow B- is positioned at the lowest point
Now turn the adjustment bolt into the rocker arm until signifi
cant resistance is noticeable (pump injector element stands at
stop).
Turn back the adjustment bolt from stop approximately 180
degrees.
Hold the adjustment bolt in this position and tighten the lock
nut to 30 Nm.
Assembly sleeve -T10056-
148
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Pump Injector Unit O-rings
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5.3
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Connect the pump injector unit electrical connector and install

the cylinder head cover, refer to
5.1 Cylinder Head Cover, page 49 , and the upper toothed
belt cover, refer to 5.3 Toothed Belt, page 54 .

Removing
Remove the pump injector unit. Refer to
5.2 Pump Injector Unit, page 145 .
Pry off old O-rings from the pump injector unit extremely care
fully.
Above all, make sure that no burrs develop at the O-ring seat.
Installing
Note
Always use assembly sleeves for installing the O-rings. Not
using them may cause the O-rings to be damaged during in

stallation.
O-rings without distinguishing color marks are gradually intro
duced. Ensure the correct allocation of O-rings to grooves: ring

strength decreases in direction toward injector.
Avoid rolling movements when sliding on O-rings. O-rings
must not be twisted on itself in the seat of pump injector unit.
Remove the heat protection seal together with the securing

ring.
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Clean the seating surfaces for the
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Install the -T10056/1- up
au to the stop on the pump injector unit.
rrectness of i
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wit
Install the -T10056/2- up to the stop on the pump injector unit.

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

sleeve and into the seat of the pump injector unit.
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149
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Install the -T10056/3- up to the stop on the pump injector unit.
Slide the lower O-ring carefully on the -T10056/3- and into the
seat of the pump injector unit.
Slide on a new heat protection seal together with securing ring.
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Install the pump injector unit. Refer to

5.2 Pump Injector Unit, page 145 .

Disassembly and Assembly
6.1 Variable Intake Manifold, page 151
6.1
Variable Intake Manifold

Note
To prevent the variable intake manifold from warping, tighten it

only in the sequence described.
Remove the variable intake manifold together with the lower
intake manifold.
Loosen the bolts.
Separate the upper and the lower intake manifold; if neces
sary, tap is lightly with a rubber mallet to loosen the two parts
from each other.
Clean the sealing surface.
Replace the gaskets.
Install the variable intake manifold together with the upper in

take manifold.
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Assemble the upper and blower
intake manifold and hand tight
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Tighten all the bolts
to
10
Nm
in
the
sequence
shown.
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6. Disassembly and Assembly
151
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Special Tools

5051B- , -VAS 5052- or -VAS 5053 Diagnosis cable -VAS 5051/1- or -VAS 5051/3 Test box 105 pin -VAG 1598/42- with adapter lead, 94 pin VAG 1598/39-2 Connector test set -VAG 1594 Hand multi meter -VAG 1526- or multi meter -VAG 1715-
AG.
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152
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Assembly sleeve -T10056-
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Golf 1999
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h
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Engine Mechanical,
Fuel Injection and Glow Plug - Edition
ra
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equipment required
Dial gauge holder -VW 387 Socket insert -3410 Special wrench, long reach
-T10054 Puller -T10055-
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7. Special Tools
153
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olkswagen AG
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Golf 1999 ,VoJetta
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b
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Engine Mechanical,
Fuel
Injection
and
Glow
Plug
ran
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s
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a
ss
1.1
Note
Exhaust manifold, removing and installing. Refer to
5.2 Turbocharger, page 129 .
After exhaust system repairs, make sure the exhaust system
is not under stress and that it has sufficient clearance to the

body. If necessary, loosen the double clamps and clamp and
align the exhaust pipe so that sufficient clearance is main
tained to the body and support rings carry uniform loads.
Replace self locking nuts.

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Note
Activation of the Exhaust Gas Recirculation (EGR) system oc

AG.
curs from the diesel direct fuel injection Engine Control Module
(ECM) to the mechanical EGR vacuum regular solenoid valve
or to the electrical EGR system.
Every relevant valve position is possible via cyclic activation.

Replace self locking nuts.
Connection diagram for vacuum hoses. Refer to
154
Rep. Gr.26 - Exhaust System, Emission Controls
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General Information
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Exhaust System, Emission Controls

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26
tee
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swage-n Edition
Engine Mechanical, Fuel Injection and
07.2007
G. VolkPlug
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Overview , page 155
2.2 Mufflers and Mounts Assembly Overview, page 156
Front Exhaust Pipe with Catalytic Converter Assembly Overview
6 - Oxygen Sensor Connector

-T6c7 - Suspended Mount
8 - Oxygen Sensor -G39-
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5 - to Rear Muffler
Prote
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by
4 - Front Exhaust Pipe with

Catalytic Converter
AG.
3 - Nut, 25 Nm
Always replace.
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2 - Gasket
Always replace.
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1 - from Turbocharger
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2.3 EGR System Assembly Overview, page 158
155

2.2
Mufflers and Mounts Assembly Overview
1 - Nut, 40 Nm
2 - from Front Exhaust Pipe
with Catalytic Converter
3 - Double Clamp
tion, refer to
Fig. Double Clamp
Installed Position ,
page 157 .
4 - Bolt, 25 Nm
9 - Rear Muffler
Rear muffler, aligning
free of stress, refer to
page 157 , and
Fig. Installing Muf
fler Free of Tension ,
page 157 .
rrectne
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spec
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8 - Suspended Mount
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7 - Bracket
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6 - Suspended Mount
With retaining ring.
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5 - Suspended Mount
tion, refer to
Fig. Suspended
Mount Installed Loca
tion , page 157 .
Prote
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by
156
AG.
12 - Tunnel Bridge
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11 - Nut, 20 Nm
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10 - Separating Point
For repairs.
Marked by three de
pressions around the
circumference of the ex
haust pipe.
At the factory, the exhaust pipe and rear mufflers are installed as a single component. Replacement
exhaust pipes and rear mufflers are supplied separately, with a replacement double clamp for connecting
the joint.
Cut through the exhaust pipe using a body repair saw -VAG 1523- for example, at right angles at the
separating point. Refer to Fig. Separation Point on Exhaust Pipe , page 157 .

Double Clamp Installed Position
Procedure
Position the double clamp approximately 5 mm from mark A
-arrow 1-.
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Mark -A- tapplies
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tomatic
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Note
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Procedure
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Suspended Mount Installed Location
Angled side of foot for suspended mount -arrow- faces the

front of the vehicle.
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Separation Point on Exhaust Pipe
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Body repair saw -VAG 1523Procedure
Cut through the exhaust pipe at a right angle at the separating
point -2-.
Position the repair double clamp -4- at the edge markings
-arrows 1 and 3- when installing. Tightening specification: 40
Nm.
Installing Muffler Free of Tension
Procedure
Bolt at exhaust pipe must be parallel to the tunnel bridge (di
mension -x- same on the left and right).
157

2.3
EGR System Assembly Overview
1 - Bracket
For the bypass flap.
2 - Bolt, 22 Nm
3 - Bolt, 5 Nm
4 - Intake Manifold
With the intake flap mo
tor.
5 - O-ring
Always replace.
(EGR) Vacuum Regulator Sol
enoid Valve -N18- (Electric)
Removing and instal
ling, refer to
4.2 EGR Vacuum
Regulator Solenoid
Valve, page 161 .
7 - Bolt, 10 Nm
8 - Gasket
Always replace.
13 - Nut, 22 Nm
Always replace.
15 - Gasket
Always replace.
ole,
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12 - Gasket
Always replace.
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spec
atio
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11 - Exhaust Manifold/Turbo
charger
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10 - Cooler
For the Exhaust Gas
Recirculation (EGR)
system.
Removing, refer to
4.1 Bypass Flap and
EGR Cooler, Connect
ing, page 160 .
un
le
9 - Connecting Pipe
AG.
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158
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16 - Bypass Flap
Guides the exhaust gas via activation through the EGR cooler switch over valve into the EGR cooler.
Vacuum diaphragm connection diagram. Refer to
Connecting, refer to 4.1 Bypass Flap and EGR Cooler, Connecting, page 160 .

Specifications
3.1

Component
Bypass Flap Bracket to Bypass Flap Rear Bolt

Bypass Flap Bracket to Intake Manifold Bolt
swagen A
Bypass Flap to Exhaust Gas Recirculation
Bolt
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Connecting Pipe to Bypass
Flap
Bolt
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Connecting Pipe to Intake
Manifold
Bolt
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t
au
5
10
10
22
22
22
40
10
10
10
25
25
25
25
20
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Always replace
do
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Suspended Mount to Subframe Bolt 1

Suspended Mount to Tunnel Bridge Bolt
Suspended Mount to Underbody Bolt
Tunnel Bridge to Underbody Nut
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Nm
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s Turbocharger/Exhaust Manifold Nut 1

Connecting Pipe sto
Double Clamp Nut
Exhaust Gas Recirculation Cooler to Bypass Flap Bolt
Exhaust Gas Recirculation Cooler to Intake Manifold Bolt
Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve to In
take Manifold Bolt
Front Exhaust Pipe with Catalytic Converter to Turbocharger/Ex
haust Manifold Nut 1
Fastener Size
3. Specifications
159
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4.2 EGR Vacuum Regulator Solenoid Valve, page 161
Bypass Flap and EGR Cooler, Connect

ing

Torque wrench (5-50 Nm) -VAG 1331Note
To prevent damage caused by tension, follow the procedure as

described.
Install the bypass flap -1- with a new seal -2- and two bolts
-5- to the Exhaust Gas Recirculation (EGR) cooler -3- and
hand-tighten.
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Hand tighten the EGR cooler -7- with the three bolts -8- to the
intake manifold -6- (the EGR cooler must make contact and
be moveable in the threaded connections).
Install the bolts -9- and tighten to 10 Nm.
Tighten the bolts -8- to 10 Nm.
160
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Install the four bolts -4- and tighten them to 10 Nm.
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Tighten bolt -11- to 22 Nm.

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the turbocharger/exhaust manifold -17- with the seals, bolts
-20- and new nuts -19-.
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Tighten the bolts -20- and nuts -19- to 22 Nm.

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EGR Vacuum Regulator Solenoid Valve

Note
To prevent damage to the exhaust gas recirculation (EGR) valve

when cleaning, do not use any solvent containing cleaners or
fuels or sharp edged tools or any metal tools.
Torque wrench (5-50 Nm) -VAG 1331 Brush with plastic bristles
Wet and dry vacuum -VAS 5128 Disconnect the electrical connector from the EGR vacuum
regulator solenoid valve and remove the bolts.
Carefully removing the EGR vacuum regulator solenoid valve
from its seat.
Use a brush with plastic bristles to clean the rusty surfaces;
then remove loose rust with a cloth.
161

Line the inner intake manifold with a lint free cloth to protect
against soot particles.
Clean the exhaust gas return valve seat in the intake manifold
using a brush with plastic bristles and a cloth. Make sure no
rust particles get into the intake manifold.
Take the cloth out of the intake manifold and clean the intake
manifold with a vacuum cleaner if necessary.
Replace the sealing ring.
Carefully place the EGR vacuum regulator solenoid valve in
the seat in the intake manifold, and tighten the bolts to 10 Nm.
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162
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5. Special Tools
163
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28
Ignition/Glow Plug System
General Information
1.1 Visual Characteristics of Ceramic and Metal Glow Plugs,

page 164
1.1
Visual Characteristics of Ceramic and

Metal Glow Plugs
A - Ceramic glow plug

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164
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B - Metal glow plug

Specifications

Component
Nm
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2. Specifications
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3.1 Glow Plug System, Checking, page 166

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Glow Plug System, Checking

Portable multi meter -VAG 1526A Test adapter kit -VAG 1594ATest Conditions
Fuse strip for the glow plugs in the fuse panel/battery OK
All electrical components such as, for example, lights and rear
window defroster must be switched off.
Diesel direct fuel injection engine Control Module (ECM) OK
Test Sequence
Disconnect the electrical connector for the Engine Coolant
Temperature (ECT) sensor.
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Note
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By disconnecting the connector from the sensor, a cold engine

state is simulated and a corresponding glow plug procedure is
performed when ignition is switched on.
Disconnect the glow plug connectors from the glow plugs.
Connect multi meter for voltage measurement between a glow
plug connector and the vehicle ground.
Switch the ignition on. The battery voltage must be displayed
for approximately 20 seconds.
If there is no voltage, refer to Vehicle diagnosis, testing and
information system VAS 5051 Wiring diagrams, Trouble
shooting & Component locations.
166
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4.1 Glow Plug, Metal, page 167

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

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Requirements
Ignition switched off.
Test Sequence
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Disconnect the electrical connectors from the glow plugs.

Connect the voltage test lamp wire to B+ using adapter clips
from the connector test kit.
Attach the test lead of the voltage test lamp to each glow plug
in succession. Light Emitting Diode (LED) lights up: Glow plug
OK. LED does not light up: Replace the glow plug
Removing
Remove and install the glow plugs using the -3220- .

Installing
Install the glow plugs using the -3220- and tighten to 15 Nm.
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Torque wrench (5-50 Nm) -VAG 1331 Hand multi meter -VAG 1526C- or multi meter -VAG 1526A Connector test set -VAG 1594C-
167

WARNING
The ceramic glow plugs

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

ement glow plugs.
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Remove the ceramic sheathed element glow plugs using the

-3220- .
Installing

the following:
Cylinder head bore and thread must be completely cleaned of
deposits before installing.
Note
Never oil or grease the threads of bore in the cylinder head and
ceramic sheathed element glow plugs.
If the malfunctioning ceramic sheathed element glow plug

is broken, remove all broken pieces from engine, other
wise they can cause damage to engine.
168
AG.
After installing and before the first engine start with a cold
engine, always perform a resistance test at all ceramic
sheathed element glow plugs.
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WARNING
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Then tighten ceramic sheathed element glow plugs. Tighten

ing specification: 15 Nm
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Install the ceramic sheathed element glow plugs into cylinder

head by hand using the -3220- .

Specified value: Max. 1
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If specified value is exceeded, replace malfunctioning ceramic

sheathed element glow plug.
169
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Special Tools
Special tools and workshop equipment
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Connector test set VAG 1594C-
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equipment required
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Cautions & Warnings

Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
=
If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
to
Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
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Any time the battery has been disconnected on an dautomatic
transmission vehicle, it owill
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s
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reestablish Transmission Control Module (TCM)orbasic settings using the VAG 1551 Scan Tool
eo
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ss
For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
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Page 1 of 3
2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
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ir sework area adequately but safely. Use a aportable
Illuminate the
safety light for working inside or under the vehicle.
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Make sure
the
bulb
is
enclosed
by
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wire
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The
hot
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of an accidentally broken bulb can ignite spilled
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fuel or oil.
Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
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Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
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Page 2 of 3
Version 1.0
Cautions & Warnings

=
gen A
Do not quick-charge the battery (for boost starting) for longer than one
and
do
exceed 16.5 volts at the
G. Volkswa
Aminute,
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not a second time.
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battery with the boosting cables attached. Wait at least one minute
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of the
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or by trained
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1551
Scan Tool (ST) or an approved equivalent. The airbag
unit
ss
Never use a test light to conduct electrical tests

Volkswagen Service technicians using the VAG
must never be electrically tested while it is not installed in the vehicle.
Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
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= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.
do
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Service

Engine Mechanical, Fuel Injection and Glow Plug

Service Department. Technical Information

All rights reserved.

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

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

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

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

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

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

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

AG. Volkswagen . d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

General, Technical Data

1.1 Engine Number, page 1

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

2.1 Engine Data, page 2

Rep. Gr.00 - General, Technical Data

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

1.1 Engine, Securing to Assembly Stand, page 3

aufixture -VW 313 Holding

Holding fixture -VW 540 Engine sling -2024Aes, in part or in w

Belt pulley side: 2. Bore of the hole rail in position 1

Flywheel side: 4. Bore of the hole rail in position 8

Engine and transmission jack -VAG 1383A-

Use the securing pins at the hooks and pins.

the belt pulley.

Loosen the coolant line on the flywheel side.

Engine and Transmission Mount, Align

Special tools and workshop equipment required

Before loosening the bolts, secure the assembly using the

Rep. Gr.10 - Engine Assembly

Edges -a and b- must be parallel to each other.

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

2.1 Fastener Tightening Specifications, page 5

Fastener Tightening Specifications

Bolts and Nuts

Mount bracket to body

Right Engine Mount

Left Transmission Mount (with a Manual Transmission)

Left Transmission Mount (with a Automatic Transmission)

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

Pendulum support to subframe

Rep. Gr.10 - Engine Assembly

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

Removal and Installation

3.1 Engine, Removing, page 7

Special tools and workshop equipment required

When doing any repair work, especially in the engine compart

Route lines of all types (for example: fuel, hydraulic, Evap

First, check whether a coded radio is installed. If necessary,

Disconnect the battery ground cable with the ignition switched

Remove the engine cover. Refer to

Remove the battery and battery holder.

Remove the air filter.

Disconnect the connecting pipe between the charge air cooler

3. Removal and Installation

Golf 1999 , Jetta 1999 , Jetta Wagon 1999

Drain the cooling system. Refer to auth