Engine AMF PDF

Service
Workshop Manual
FABIA 2000
1.4/55 TDI Engine, Mechanics

Edition 07.03
Engine code
AMF
Service Department. Technical Information
Printed in Czech Republic

S00.5325.00.20
The Workshop Manual is intended only for use within the Organisation koda.
It is not permitted to pass it on to other persons.
KODA AUTO a. s.
Service
Printed in Czech Republic

S00.5325.00.20
FABIA 2000 1.4/55 TDI Engine, Mechanics
List of Supplements to Workshop Manual
FABIA 2000
1.4/55 TDI Engine, Mechanics
Edition 07.03
Supplement
Edition
07.03
Edition 07.03
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Subject
Article Number
Basic Edition
S00.5325.00.20
List of Supplements
List of Supplements
Edition 07.03
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Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1
page
- Engine number ......................................................................................... 00-1
page
- Engine characteristics ................................................................................ 00-1
page
Removing and Installing Engine .................................................................... 10-1
page
- Removing engine ...................................................................................... 10-1
page
- Securing the engine to the assembly stand ....................................................... 10-1
page
- Installing the engine ................................................................................... 10-1
page
- Tightening torques .................................................................................... 10-1
page
- Assembly bracket ...................................................................................... 10-1
page
Removing and installing V-ribbed belt ............................................................ 13-1
page
- Removing and installing V-ribbed belt .............................................................. 13-1
page
- Routing of the V-ribbed belt .......................................................................... 13-1
page
Removing and installing, tightening the timing belt ........................................... 13-2
page
- Timing belt - Summary of components ............................................................. 13-2
page
- Removing and installing, tightening the timing belt .............................................. 13-2
page
Disassembling and assembling engine ........................................................... 13-3
page
- Cylinder block - Summary of components ......................................................... 13-3
page
Removing and installing sealing flange and flywheel ......................................... 13-4
page
- Replacing gasket ring for crankshaft - on the belt pulley side .................................. 13-4
page
- Removing and installing the front sealing flange ................................................. 13-4
page
Crankshaft, Piston and Conrod ..................................................................... 13-5
page
- Removing and installing crankshaft ................................................................ 13-5
page
- Disassembling and assembling piston and conrod .............................................. 13-5
page
- Checking piston projection in TDC .................................................................. 13-5
page
Removing and installing balancing shaft and retaining frame .............................. 13-6
page
- removing and installing balancing shaft ............................................................ 13-6
page
Removing and installing cylinder head ........................................................... 15-1
page
- Removing and installing cylinder head ............................................................. 15-1
page
- Testing the compression ............................................................................. 15-1
page
Repairing Valve Gear .................................................................................. 15-2
page
- Summary of components ............................................................................. 15-2
page
Camshaft ................................................................................................. 15-3
page
- Removing and installing camshaft .................................................................. 15-3
page
- Removing and installing gasket ring for camshaft ................................................ 15-3
page
.................................................... Valve seats, valves guides, valve stem seals 15-4
page
- Grinding in valve seats ............................................................................... 15-4
page
- Inspect valve guides .................................................................................. 15-4
page
- Replacing valve stem seals .......................................................................... 15-4
page
10 Removing and Installing Engine
13 Crankgear
15 Cylinder Head, Valve Gear
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Table of Contents
17 Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1
page
- Lubrication system - Summary of components ................................................... 17-1
page
- Disassembling and assembling oil filter holder ................................................... 17-1
page
Removing and installing oil pan .................................................................... 17-2
page
- Removing and installing oil pan ..................................................................... 17-2
page
Testing oil pressure and oil pressure switch .................................................... 17-3
page
Parts of cooling system - Summary of components ........................................... 19-1
page
- Parts of the cooling system fitted to body ......................................................... 19-1
page
- Parts of cooling system engine side ................................................................ 19-1
page
- Connection diagram for coolant hoses ............................................................. 19-1
page
- Draining and filling up coolant ....................................................................... 19-1
page
- Checking the coolant system for tightness ........................................................ 19-1
page
Removing and installing radiator, coolant pump and coolant thermostat ............... 19-2
page
- Removing and installing radiator .................................................................... 19-2
page
- Removing and installing coolant pump ............................................................ 19-2
page
- Removing and installing coolant regulator ........................................................ 19-2
page
Removing and installing parts of the fuel supply - Part 1 .................................... 20-1
page
- Fuel tank with component parts - Summary of components .................................... 20-1
page
- Repairing the fuel filter ................................................................................ 20-1
page
- Safety precautions when working on the fuel supply system ................................... 20-1
page
- Rules of cleanliness ................................................................................... 20-1
page
- Removing and installing the fuel delivery unit .................................................... 20-1
page
- removing and installing fuel gauge
................................................................ 20-1
page
- Check the fuel delivery unit .......................................................................... 20-1
page
Removing and installing parts of the fuel supply - Part 2 .................................... 20-2
page
- Removing and installing the fuel tank .............................................................. 20-2
page
- Removing and installing fuel cooler ................................................................ 20-2
page
- Inspecting a tandem pump ........................................................................... 20-2
page
- Removing and installing the tandem pump ........................................................ 20-2
page
Servicing accelerator pedal .......................................................................... 20-3
page
- Summary of components ............................................................................ 20-3
page
Charge air system with turbocharger ............................................................. 21-1
page
- Safety measures ...................................................................................... 21-1
page
- Rules of cleanliness ................................................................................... 21-1
page
- Removing and installing exhaust turbocharger with component parts ........................ 21-1
page
- Removing and installing parts of the charge air cooling ......................................... 21-1
page
- Removing and installing charge-air cooler ........................................................ 21-1
page
Charge-air system with exhaust turbocharger - Part 2 ........................................ 21-2
page
- Removing and installing turbocharger ............................................................. 21-2
page
- Checking charge pressure control .................................................................. 21-2
page
19 Cooling
20 Fuel Supply
21 Turbocharging
26 Exhaust System
II
Table of Contents
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Removing and installing parts of the exhaust system ........................................ 26-1
- Align exhaust system free of stress ................................................................ 26-1
page
page
1
2
- Replacing front or rear silencer ...................................................................... 26-1
page
Exhaust gas recirculation system .................................................................. 26-2
page
- Removing and installing parts of the exhaust gas recirculation system ...................... 26-2
page
- Testing mechanical exhaust gas recirculation valve ............................................. 26-2
page
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Table of Contents
III
IV
Table of Contents
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00
00 Technical Data
00-1
Technical Data
Engine number
The engine number (engine code and serial number)
is located at the front at the joint separating engine/gearbox.
In addition, a sticker with the engine identification characters and serial number is affixed to the timing belt
guard.
The engine identification characters are also indicated on
the vehicle data sticker.
Engine characteristics
Engine identification characters
AMF
Manufactured
06.03
Exhaust limits conforming to
EU-3
Displacement
Power output
kW at rpm
55/4000
Torque
Nm at rpm
195/2200
Bore
Stroke
1,4
mm
79,5
mm
95,5
Compression
19,5 : 1
CN
minimum
Firing order
49
1-2-3
Catalytic converter
yes
Exhaust gas recirculation
yes
Turbocharging
yes
Charge air cooler
yes
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Technical Data
00-1 page 1
00
00-1 page 2
Technical Data
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10
10 Removing and Installing Engine

10-1
Removing and Installing

Engine
Special tools, test and measuring equipment and

auxiliary items required
Workshop crane (e.g. -V.A.G 1202 A -)
Catch pan (e.g. - V.A.G 1306-)
Torque wrench
Engine/gearbox jack (e.g. -V.A.G 1383 A-)
Engine mount -T10012 Bushing -T30010 Socket insert -MP 9-200/7 Engine mount -MP 1-202 Assembly stand -MP 9-101 Lifting device -MP 9-201 Pliers for spring strap clips
Snap hook
Grease -G 000 100 Hot bolt paste -G 052 112 A3 Wire
Adhesive tape
Removing engine
Note
The engine is removed towards the front together with
the gearbox.
Jacking up points for raising the vehicle Inspection
and Maintenance.
Pay attention to the correct assignment of the connec-
tors, if necessary mark.

If the battery is disconnected and reconnected, carry
out certain additional operations Electrical System;

Rep. Gr. 27.
Procedure
Disconnect the battery-earth strap with the ignition off.

Remove the sound dampening system -arrows Body work; Rep. Gr. 50.
Remove drive shaft to the right Running gear;

Rep. Gr. 40.
Unscrew the drive shaft to the left of the gearbox

flange.
Raise drive shaft on the left and secure.

Remove front exhaust pipe with catalyst Chapter
S10-0114
26-1.
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Removing and Installing Engine
10-1 page 1
10
Remove front bumper Body work; Rep. Gr. 63.

Release screw -3-.
Remove charge-air pipe at bottom -1- with connecting
hose -2- -arrows-.
Remove charge-air routing from charge-air cooler

Chapter 21-1.
Unbolt the pendulum support -arrows-.

Drain coolant Chapter 19-1.
Remove engine cover.
Remove air filter with intake hose 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23.
Remove battery and battery tray Electrical System;

Rep. Gr. 27.
Unscrew the generator cables from the battery cover

and remove the wiring loom from the holder.
Remove the coolant hoses from the radiator.

For vehicles with air conditioning
Caution!
Refrigerant circuit of the air conditioning sys-
tem must not be opened. Therefore, when removing the lock carrier the hoses must be fitted
onto the air conditioning. They must neither be
folded nor exposed to stress.
To avoid damaging the condenser, wiring and
air conditioning hoses make sure the lines and

hoses are not excessively expanded, buckled or
bent.
Release the retaining clips of the AC system lines.

Remove AC compressor Heating, Air conditioning;
Rep. Gr. 87, the lines remain connected.
Tie up AC compressor to lock carrier.

For all vehicles
Removing lock carrier Body Work; Rep. Gr. 50 and

lay aside.
S10-0128
10-1 page 2
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Disconnect the coolant hose -1- from the pipe.

Disconnect the fuel-intake hose -3- and the fuel-return
hose -2- from the pipes.
3
2
S10-0148
Remove charge-air pipe at the top -1- with connecting

hose -2- -arrows-.
Pull off the coolant hose from the expansion bottle at

the bottom.
Pull out vacuum hoses from the valve block

Chapter 21-1 .
Remove the coolant feed hose -3- from the supports

-4-.
Remove the coolant return hose -2- from the heat ex-
changer connection fittings -1-.
2
1
S10-0150
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10
Unplug connector -1- from the engine control unit.

Disconnect the plug connections -2- and -3- and remove from bracket.
Unclip cable clip -4- -arrows-.

Remove shift cables of shift mechanism from bracket
1
2
at gearbox and place down to the side Manual

Gearbox 02R; Rep. Gr. 34.
Disconnect lines for brake fluid from clutch slave cyl-
inder Manual Gearbox 02R; Rep. Gr. 30.
Unplug connector from reversing light switch -F4-.

Unscrew the earth line from the body.
Disconnect connector and cables from the starter.
S10-0117
Disconnect the plug connections -2- and -3- under the

starter and remove from bracket.
2
S10-0151
Suspend lifting device -MP 9-201- as follows and

carefully raise engine with gearbox with workshop
crane -V.A.G 1202 A-.
Warning!
Use securing pins on the hooks and rig pins to
prevent release.
10-1 page 4
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Unscrew bolts for engine mounting -arrows-.

Note
If the engine/gearbox unit drops when the screws are released raise it up again.
ax
m
in
m
S10-0149
Unscrew bolts for gearbox mount -arrows-.

The note on unscrewing the engine mounting also applies for the gearbox mount.
Carefully raise the engine with gearbox and pull out

towards the front.
Note
Carefully guide the engine and gearbox during withdrawal. Ensure adequate clearance to other neighbouring
components.
Securing the engine to the assembly

stand
S10-0120
To perform the assembly work the engine must be secured to the assembly stand -MP 9-101-.
Note
When measuring the cylinder bore ( Chapter 13-4) the
engine must not be fixed to the assembly stand.
Modify engine mount -T10012-
Make additional hole -a- according to the given dimensions at the height of the already existing holes, if
these do not yet exist.
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10
Procedure
Screw centering pin -1- and centering pin -2- according to the illustration onto the engine mount -arrows-.
Fix engine mount -T10012- with fixing nut -3- and fixing bolt at cylinder block.
Unscrew the bottom fixing screws for the engine/gearbox.
Raise the engine and gearbox with the engine/gearbox jack.
Dismantle the lifting device -MP 9-201-.
Position engine/gearbox with engine/gearbox jack

onto a work bench.
Lower the engine/gearbox unit in such a way that the

gearbox is positioned on the support.
T 10012
V.A.G 1383/A
N10-0148
Remove cover plate -A- for flywheel behind the right

flange shaft -arrows-.
Unplug the connector from the speedometer sender

-G22-.
Remove engine/gearbox connecting screws.

Press gearbox from engine.
V34 - 3005
10-1 page 6
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Suspend lifting device -MP 9-201- and lift engine out

of engine/gearbox jack using the workshop crane.
On the belt pulley side: 4. Hole of the perforated bar in position 1
On the flywheel side: 2. Hole of the perforated bar in position 8
Warning!
Use -arrows- securing pins on the hooks and rig
pins to prevent release.
Note
The rig positions on the supporting bracket marked
14 point towards the belt pulley.

The holes in the perforated bars are counted from the
hook.
Unscrew Engine mount - T10012-.

Attach engine to the assembly stand -MP 9-101 - with
the engine / gearbox mount -MP 1-202 - and sleeves
-T30010-. (The figure shows the 1.9l/47kW SDI engine; the fixing system is identical).
MP 1-202
Note
Engine can be fixed at the engine mount -MP 1-202 without sleeves -T30010-.
T30010
Installing the engine

Note
Always replace the seals and gaskets during assem-
bly work.
S10-0123
Always replace self-locking nuts.

Coat stud bolts of exhaust manifold with hot bolt paste
-G 052 112 A3- before installing.

Tightening torques 10-1 page 9.
Assembly bracket 10-1 page 9.
Procedure
Installation is performed in the reverse order. Pay attention to the following points:
Check whether the dowel sleeves for centering the

engine/gearbox are present in the cylinder block; insert if necessary.
Check whether the intermediate plate has been inserted on the sealing flange and rests on the dowel
sleeves -arrows-.
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A10-0129
10-1 page 7
10
If necessary check the centering of the clutch driver

disc.
Inspect clutch release bearing for wear, replace if necessary.
Grease the drive shaft serration with grease

-G 000 100-.
Assemble together the engine with gearbox

Manual gearbox 02R; Rep. Gr. 34.
When installing the unit, ensure adequate clearance

to other components.
Align unit free of stress and attach firmly.

When tightening the bolts for engine and gearbox
mounts, engine and gearbox support brackets must
be resting fully against mount.
Tightening torques 10-1 page 9.
Connect lines for brake fluid to clutch slave cylinder

Manual Gearbox 02R; Rep. Gr. 30.
Install and adjust the shift cables of the shift mechanism Gearbox 02R; Rep. Gr. 34.
Install the right drive shaft and screw the left drive
shaft onto the gearbox Chassis; Rep. Gr. 40.
Install the front exhaust pipe with catalytic converter

and the exhaust system so that they are not under
tension. Chapter 26-1.
Install the lock carrier with component parts Body

Work; Rep. Gr. 50.
Electrical connections and proper routing Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Install coolant hoses Chapter 19-1.

Note
Only then re-use drained coolant if none of the following
components has been replaced: Engine block, cylinder
head, radiator, heat exchanger.
Top up coolant Chapter 19-1.

Check oil level before starting the engine.
Perform test drive, interrogate fault memory 1.4/55
TDI Engine, Fuel Injection; Rep. Gr. 23.
10-1 page 8
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Tightening torques
Component
Screws/nuts
Nm
M6
M8
23
M10
40
M12
60
In variation of this:
Front exhaust pipe to turbocharger
25 Nm
Assembly bracket
Engine assembly bracket
1 - 30 Nm + 90 (1/4 turn) - replace
2 - 40 Nm + 90 (1/4 turn)
3 - 45 Nm
1
1
Gearbox assembly bracket

1 - 50 Nm + 90 (1/4 turn) - replace
2 - 40 Nm + 90 (1/4 turn) - replace
S10-0125
Hinged bracket
Note
Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier.
1 - 30 Nm + 90 (1/4 turn) - replace
2 - 40 Nm + 90 (1/4 turn) - replace
1
2
S10-0126
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10
10-1 page 10
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13
13 Crankgear
13-1
Removing and installing

V-ribbed belt
Removing and installing V-ribbed belt

Locking pin -T10060-
Note
Mark the rotation direction before removing the V-
ribbed belt. Reversing the rotation direction of an already used belt may destroy it.
Pay attention to the correct position of the V-ribbed
belt in the belt pulley when installing it.
Removing the V-ribbed belt

hose -2-.
Mark the rotation direction of the V-ribbed belt.

Loosen the V-ribbed belt by turning the tensioning pulley in the -direction of the arrow-.
A13-0083
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13
Lock tensioning pulley with rig pin -T10060-.

Remove the V-ribbed belt.
Installing the V-ribbed belt
Installation is carried out in the reverse order.

Note
Inspect V-ribbed belt Inspection and Maintenance.
Before fitting the ribbed V-belt make sure that all as-
semblies (generator, AC compressor) are securely

mounted.
Pay attention to the correct position and rotation direc-
tion of the V-ribbed belt in the belt pulley when installing it.
Finally position the V-ribbed belt on the generator.
After finishing the work always:
Start engine and check belt run.
Routing of the V-ribbed belt

Belt run without AC compressor
Belt run with AC compressor
13-1 page 2
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13-2
13
Removing and installing, tightening the timing belt
Timing belt - Summary of components

1 - Timing belt guard - top part
2 - Timing belt
T before removing mark running direction
T check for wear
T do not kink
T removing and installing, tensioning 13-2 page 2
3 - 20 Nm + torque a further 1/8
turn (45 )
4 - Tensioning pulley
5 - 100 Nm
turn (45 )
7 - Camshaft sprocket
8 - Hub
T with rotor
T to release and tighten use
the counterholder -T10051 T to remove use the extractor
-T10052T removing and installing
Chapter 15-3
9 - 10 Nm
10 - Timing belt guard rear
11 - Sealing sleeve
T replace if damaged
12 - Guide pulley
13 - Coolant pump
T removing and installing
Chapter 19-2
14 - Timing belt gear - crankshaft
T contact surface between crankshaft timing belt sprocket and crankshaft must be clean and free of grease
T Fitting position: flats on timing belt sprocket and on crankshaft must be aligned
15 - 120 Nm + torque a further 1/4 turn (90)
T replace
T to release and tighten use counterholder -MP 1-310- or -T30004T neither oil nor grease new screw
16 - 15 Nm
17 - 20 Nm
18 - Timing belt guard - bottom part
19 - Belt pulley with vibration damper
T Assembly only possible in one position - holes offset
20 - 10 Nm + torque a further 1/4 turn (90)
21 - Timing belt guard - middle part
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13
Removing and installing, tightening the

timing belt
Rig pin -MP 1-301- or -3359 Two-hole nut turner -T10020 Locking device -T10050 Torque wrench
Supporting device -MP 9-200- with feet -MP 9-200/3-
Removing
Note
Adjusting work on the timing belt must only be performed
on a cold engine, as the position of the pointer at the tensioning element is temperature dependent.

hose -2-.
Remove the connecting pipe between the charge air

cooler and the intake Chapt. 21-1.
Install supporting device -MP 9-200- according to the

illustration and support engine in fitting position.
Remove engine mount -1- and engine console -2-.

Remove the V-ribbed belt Chapter 13-1.
Remove locating bolts -T10060- from tensioning element.
Remove timing belt guard - top part.
13-2 page 2
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Remove the noise insulation.
S10-0114
Release screw -3-.

Remove charge-air pipe at bottom -1- with connecting
hose -2- -arrows-.
Remove belt pulley item 19 in 13-2 page 1.

Remove middle part of timing belt guard item 21 in
13-2 page 1.
Remove bottom part of toothed belt guard item 18

in 13-2 page 1.
Position crankshaft on TDC cylinder 1.
Note
Turn crankshaft until the marking on the timing belt
sprocket and the marking on the timing belt guard stand
are opposite each other -arrows A- at the rear.
Lock hub with locking pin -MP 1-301- or -3359-. Insert

locking pin through the free left slot into the hole at the
cylinder head.
Secure crankshaft timing belt sprocket with locking

device-T10050-. Insert locking device from the front of
the timing belt sprocket into the teeth.
To facilitate this step, it is recommended to colour the
TDC marking at the crankshaft timing belt sprocket and
on the locking device-T10050- with white paint -arrows
B-.
Note
The marking on the crankshaft timing belt sprocket
and the marking on the locking device must be positioned opposite -arrows B-. Pin of locking device must
engage in the hole of the sealing flange -arrow C-.
Locking device - T10050- must not be used as a coun-
terholder when releasing or tightening the bolts for the

toothed belt gear - crankshaft.
Mark the rotation direction of the timing belt.

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13
Loosen the fixing nut on the tensioning roller.

Slacken bolts of camshaft sprocket -1- sufficiently so
that the camshaft sprocket can be turned in the area
of the slots.
Remove guide pulley item 12 in 13-2 page 1.
Turn two-hole nut turner -T10020- up to the stop and

first of all remove the timing belt from the coolant
pump and then from the other timing gears.
Install timing belt and tension

Note
Adjusting work on the timing belt must only be performed
on a cold engine, as the position of the pointer at the tensioning element is temperature dependent.
Turn camshaft sprocket in the slots anti-clockwise in

-direction of arrow- as far as the stop.
Fit timing belt onto crankshaft timing belt sprocket,

tensioning pulley, camshaft sprocket and onto the
coolant pump.
13-2 page 4
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13
Note
Pay attention to correct fitting of the tensioning pulley in
the rear timing belt guard -arrow-.
A13-0053
Install guide pulley item 12 in 13-2 page 1.

Carefully turn tensioning pulley with two-hole nut turner -T10020- in anti-clockwise direction until the pointer
is positioned in the middle of the recess in the base
plate.
Hold tensioning pulley in this position and tighten fixing nut of the tensioning pulley as follows:
20 Nm + torque a further 45 (1/8 turn)
Tighten bolts of camshaft sprocket to 20 Nm + torque

a further 1/8 turn (45).
Remove locking pin -MP 1-301- and locking device

-T10050-.
Turn crankshaft two turns further in the direction of rotation of the engine and again position on TDC for cylinder 1.
Note
Pin for locking device must engage in the sealing
flange. (Locking device should be inserted just ahead

of TDC on toothed belt sprocket.)
If the crankshaft is positioned after TDC of piston for
cylinder 1 and the pin of the locking device does not

engage in the sealing flange, rotate the crankshaft
back no more than 1/4 revolution and again set the
crankshaft to the TDC of the piston for cylinder 1 by
turning in direction of rotation of engine.
It is not permittedto carry out the correction by turning
in the opposite direction of rotation of the engine in order to insert the locking device.
Check after inserting the locking device -T10050-, if

the hub can be interlocked with the rig pin -MP 1-301or -3359-.
If the hub cannot be arrested:
Remove pin for locking device from the hole at the

sealing flange and rotate the crankshaft until the hub
can be arrested with the rig pin.
Slacken bolts of camshaft sprocket -1-.
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13
Rotate crankshaft in opposite direction of rotation of

engine long enough until the pin for the locking device
in the sealing flange is positioned close to the hole -arrow-.
Now turn crankshaft in direction of rotation of engine

until the pin for the locking device clicks during this
motion into the sealing flange.
Tighten bolts of camshaft sprocket to 20 Nm + torque

a further 1/8 turn (45).
Remove locking pin -MP 1-301- and locking device

-T10050-.
Turn crankshaft two turns further in direction of rotation of engine until the crankshaft is again in TDC for
cylinder 1.
Note
Pin for locking device must engage in the sealing
flange. (Locking device should be inserted just ahead

of TDC on toothed belt sprocket.)
If the crankshaft is positioned after TDC of piston for
cylinder 1 and the pin of the locking device does not

engage in the sealing flange, rotate the crankshaft
back no more than 1/4 revolution and again set the
crankshaft to the TDC of the piston for cylinder 1 by
turning in direction of rotation of engine.
It is not permitted to carry out the correction by turning
in the opposite direction of rotation of the engine in order to insert the locking device.
Further installation occurs in a similar way in reverse

order to removal.
Tightening torques for engine mounts and pendulum support Chapter 10-1.
Tightening torque of the engine mount on the vehicle
body: 45 Nm.
13-2 page 6
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13-3
13
Disassembling and assembling engine
Cylinder block - Summary of components

1 - 45 Nm
2 - Engine mount
3 - Cylinder block
T removing and installing the
sealing flange and flywheel
Chapter 13-4
T disassembling and assembling pistons and conrod
Chapter 13-5
4 - Connection fitting, 40 Nm
T for oil return line from turbocharger
T replace
5 - Distance sleeve
6 - Rubber bearing
7 - Bracket
T for plug connections from
hall sender -G40- for camshaft position and for engine
speed sender -G288 - 10 Nm
9 - Gasket
T replace
10 - Oil filter holder
T disassembling and assembling Chapter 17-1
turn (90)
T replace
T first of all set up the bolt at
the top left and the bottom
right and then tighten all four
bolts cross-wise
12 - O-ring
T replace
13 - 20 Nm
14 - Engine speed sender -G2815 - Connection fittings
T for coolant regulator
16 - 15 Nm
17 - Coolant regulator
T removing and installing Chapter 19-2
18 - 45 Nm
T Tightening sequence: from inside to outside
19 - Compact holder
T for generator, AC compressor and tensioning pulley for ribbed V-belt
T note the fitting bush between the compact holder and the cylinder block
T for the V-ribbed belt
21 - 25 Nm
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13-3 page 1
13
22 - Oil pan
T clean sealing surface before installing
T fit with silicone sealant -D 176 404 A2- Chapter 17-2
T The gearbox must be removed in order to remove the oil pan Manual Gearbox 02R; Rep. Gr. 34
23 - 15 Nm
T The gearbox must be removed in order to remove the rear bolts to the gearbox Manual Gearbox 02R;
Rep. Gr. 34
24 - Cover
T with sealing tape
T clean strainer if dirty
25 - Retaining frame
T before assembly, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in
the retaining frame
26 - 40 Nm
27 - Protective cap
T for drive shaft
13-3 page 2
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13
13-4

sealing flange and flywheel
Note
Repairs to clutch Manual Gearbox 02R; Rep. Gr.
30.
Secure the engine with engine mount - MP 1-202- and
distance sleeves - T30010- on the assembly stand before performing assembly work.
1 - Gasket ring
T do not additionally lubricate
or grease sealing lips of the
gasket ring
T before installing remove oil
residues on crankshaft journal with a clean cloth
T replace the gasket ring for
the crankshaft - on the belt
pulley side 13-4 page 2
2 - Front sealing flange
T must be positioned on dowel
sleeves
13-4 page 3
T install with silicone sealant
-D 176 404 A- 13-4
page 4
3 - Cylinder block
crankshaft Chapter 13-5
T disassembling and assembling pistons and conrod
Chapter 13-5
4 - Flywheel
T for removing and installing
secure Fig. 1 in 13-4
page 2 the flywheel using
-MP 1-5045 - 60 Nm + torque a further 1/4
turn (90)
T replace
6 - Intermediate plate
T must be positioned on dowel sleeves
T do not damage/bend during assembly work
T hang on the sealing flange Fig. 2 in 13-4 page 2
7 - 15 Nm
8 - Sealing flange with sealing ring
T must be replaced completely
T do not additionally lubricate or grease sealing lips of the gasket ring
T before installing remove oil residues on crankshaft journal with a clean cloth
T use supporting sleeve supplied for installing
T supporting sleeve must not be removed until after pushing sealing flange onto the crankshaft journal
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Removing and installing sealing flange and flywheel
13-4 page 1
13
Fig. 1:

Lock the flywheel
Position the flywheel lock -MP 1-504- on the ring gear
MP 1-202
and turn until it rests against the distance sleeve

-T30010-.
T30010
T30010
MP 1-504
S13-0191
Fig. 2:
Installing intermediate plate
Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-.
Replacing gasket ring for crankshaft - on

the belt pulley side
Gasket ring extractor -MP1-226 Counterholder -T 30004 Assembly device -T10053 A10-0129
Torque wrench
Removing
Remove the timing belt Chapter 13-2.

Remove crankshaft timing belt sprocket. To this end
lock the timing belt gear with counterholder -T 30004-.
To guide the gasket ring extractor, screw central bolt

by hand fully into the crankshaft.
Unscrew inner part of the gasket ring extractor

-MP1-226- two turns (approx. 3 mm) out of the outer
part and lock with knurled screw.
13-4 page 2
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13
Oil the thread head of the gasket ring extractor, position and forcely screw into the gasket ring as far as
possible.
Release knurled screw and turn the inner side against

the crankshaft until the gasket ring is pulled out.
Installing
Note
Sealing lip of the gasket ring must not be oiled or greased
additionally.
Remove oil residue on the crankshaft stub with a

clean cloth.
Install guide bushing -T10053/1- on the crankshaft

stub.
Slide gasket ring over the guide bushing onto the

crankshaft stub.
Press in gasket ring -T10053- with the pressure plate

up to the stop of the central screw.
Note
Replace central screw for toothed belt gear - crankshaft.
Tighten new central screw for toothed belt gear crankshaft to 120 Nm and turn a further 90 (1/4 turn).
Installing the timing belt, tightening Chapter 13-2.
Removing and installing the front sealing flange

Counterholder -MP1-226 Assembly device -T10053 Torque wrench
Hand-held power drill with plastic brush insert
Silicone sealant - D 176 404 A2 Flat scraper
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13-4 page 3
13
Removing

Remove crankshaft timing belt sprocket. To this end
lock the timing belt gear with counterholder -T30004-.
Removing oil pan Chapter 17-2.

Unscrew front sealing flange.
Remove sealing flange, if necessary release by applying slight blows with a rubber-headed hammer.
Use a flat scraper to remove sealant residues on the

cylinder block.
Cover the gasket ring with a clean cloth.
Use a rotating plastic brush to remove sealant residues on the sealing flange (wear protective goggles).
Clean the sealing surfaces. They must be free of oil

and grease.
Installing
Note
Pay attention to the 'use by date' on sealant.
The sealing flange must be installed within 5 minutes
after applying the silicone sealant.
Cut off nozzle tube of the silicone sealant at the front

marking ( of nozzle approx. 3 mm).
Apply silicone sealant to the clean sealing surface of

the sealing flange, as shown in the illustration.
Thickness of sealant bead -arrows-: 2...3 mm
Note
The sealant bead must not be thicker, otherwise ex-
cess sealant may get into the oil pan, clogg the strainer in the retaining frame cover and can get onto the
sealing surface of the sealing ring for the crankshaft.
Before applying the sealant bead cover over the gas-
ket ring with a clean cloth.
Fit sealing flange immediately and lightly tighten all

bolts.
13-4 page 4
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13
Note
When installing the sealing flange with the gasket ring fitted use guide sleeve -T10053/1-.
Tighten the fixing screws of the sealing flange crosswise. Tightening torque: 15 Nm
Remove excess sealant.

Installing oil pan Chapter 17-2.
Note
After installing, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in.
Installing the toothed belt and setting the timing

Chapter 13-2.
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T10053/1
S13-0194
13-4 page 5
13
13-4 page 6
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13
13-5
Crankshaft, Piston and

Conrod
Removing and installing crankshaft

Note
Before removing the crankshaft, ensure a suitable
place is available for placing it down so that the sensor

rotor ( item 5) does not rest against anything or get
damaged.
Before assembly moisten all bearing and work surfac-
es with oil.
1 - Bearing shells 1, 2 and 4
T for bearing cap without lubricating groove
T for cylinder block with lubricating groove
T do not mix up used bearing
shells (mark)
turn (90 )
T replace
3 - Bearing caps
T Bearing cap 1: on the belt
pulley side
T retaining lugs of the bearing
shells of the cylinder block/
bearing cap must be on top
of one another
4 - Bearing shell 3
T for bearing cap without lubricating groove
T for cylinder block with lubricating groove
5 - Rotor
T for engine speed sender
-G28 T replace if damaged
Fig. 2 in 13-5 page 2
3
1

turn (90 )
T replace
7 - Fit pin
T Checking projection from crankshaft Fig. 1 in 13-5 page 2
8 - Crankshaft
Crankshaft bearing journal: 54.00 mm
Conrod bearing journal 47.80 mm
T Axial play when new: 0.07...0.17 mm
Wear limit: 0.37 mm
9 - Thrust washer
T for cylinder block, bearing 3
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Crankshaft, Piston and Conrod
13-5 page 1
13
Fig. 1:
Checking projection of fit pin from crankshaft

Depth gauge
Test sequence
Use depth gauge to inspect projection -a- of dowel pin

when rotor -1- is removed.
1 - Rotor
2 - Fixing screw
3 - Projection of the fit pin -3- from crankshaft a =
2.5...3.0 mm
Fig. 2:
Removing and installing sensor rotor
Always replace the sensor rotor -2- each time the
bolts -1- are slackened.

Tightening torque: 10 Nm + 90 (1/4 turn)
Note
After being attached a second time, the attachment point
of the recess head screws in the sensor rotor is sufficiently misshapen that the bolt heads rest against crankshaft
-3- -arrows- and the sensor rotor is positioned loosely below the screws.
A13-0150
13-5 page 2
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13
Disassembling and assembling piston and conrod

1 - Piston rings
T Offset joint 120
T use piston ring pliers for removing and installing
T Marking TOP faces up
T inspect gap clearance
T inspect end clearance
2 - Piston
T with combustion chamber
T mark installation position and
matching cylinder
T Installation position and assignment of piston/cylinder
T arrow on piston crown faces
towards the belt pulley side
T use piston ring tensioning
strap for installing
T if cracks present on piston
stem - replace piston
T inspect piston projection at
TDC 13-5 page 5
Pistons: 79.47 mm
3 - Piston pin
T if stiff, heat piston to 60C
T removing and installing with
Drift -222A4 - Circlip
5 - Conrod
T replace as a set only
T mark matching cylinder -arrows AT Fitting position: Markings -arrows B- point towards the belt pulley side
6 - Bearing shell
T Check fitting position
T Pay attention to version:
top bearing shell (towards the piston) must be in long wearing material
Distinguishing feature:
Black streak on working surface close to separation cut
T do not mix up used bearing shells
T insert bearing shells in the middle
T check for firm seating
T Axial clearance:
Wear limit: 0.37 mm
7 - Cylinder block
T inspect cylinder bore Fig. 5 in 13-5 page 5
Cylinder: 79.51 mm
8 - Conrod cap
9 - Oil injection nozzle
T for cooling pistons
10 - Pressure relief valve, 25 Nm
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13-5 page 3
13

T opens at an overpressure of 0.25 to 0.32 MPa (2.5 to 3.2 bar)
T replace without sealant
11 - Conrod bolt, 30 Nm + torque a further 1/4 turn (90)

T replace
T oil thread and head contact surface
Fig. 3:
Inspecting piston ring gap clearance

Feeler gauge
Insert ring at right angles from above down into lower

cylinder opening, about 15 mm away from edge of cylinder.
Piston ring
dimensions in mm
new
Wear limit
1. Compression ring
0,25...0,40
1,0
2. Compression ring
0,20...0,40
1,0
Oil scraper ring
0,25...0,50
1,0
Fig. 4:
Inspect piston ring end clearance

Feeler gauge
Clean ring groove before inspecting.

Piston ring
dimensions in mm
new
Wear limit
1. Compression ring
0,06...0,09
0,25
2. Compression ring
0,05...0,08
0,25
Oil scraper ring
0,03...0,06
0,15
13-5 page 4
V13 - 0687
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Fig. 5:
13
Inspecting cylinder bore

Internal precision measuring instrument 50...100 mm
Piston dimenston item 2 in 13-5 page 3.

Cylinder dimenston item 7 in 13-5 page 3.
Test sequence
Measure at 3 points crosswise in a transverse direction -A- and lengthwise -B-.

Variations compared to nominal dimension max. 0.10
mm
Note
Do not measure the cylinder bore if the cylinder block is
fixed to the assembly stand with the engine mount
-MP 1-202-, as this may result in incorrect measurements.
Fig. 6:
Piston fitting position and assignment of

the piston/cylinder

e.g. electric stylus
Procedure
Mark installation position and assignment on inside of

piston (not on piston crown), with e.g. an electric stylus.
Piston in cylinder -1- and -2-:
Large piston relief for inlet valve to flywheel side -arrowsPiston in cylinder -3-:
Large piston relief for inlet valve to belt pulley side -arrowNote
For new pistons the cylinder assignment is colour-
coded on the piston crown.

Pistons in cylinders 1 and 2: Identification 1/2
Piston in cylinder 3: Identification 3
Checking piston projection in TDC

Measuring tool for piston projection -MP 1-107-
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13-5 page 5
13
Procedure
When installing new pistons or a short engine, inspect the
piston projection at TDC. Depending on the piston projection fit the relevant cylinder head seal in accordance with
the table below:
Note
Turn the engine in a clockwise direction in order to measure the piston projection in TDC.
Piston projection over
cylinder block - top side
Marking of bore
0.91 mm 1.00 mm
1.01 mm 1.10 mm
1.11 mm 1.20 mm
Identify cylinder head gasket

Spare parts No. = -arrow 1 Control code = -arrow 2- (ignore)
Bores = -arrow 3-
Note
If different values are measured during the piston projection measurement, the greatest dimension applies for the
seal assignment.
13-5 page 6
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13-6
13

balancing shaft and retaining frame
Note
Before assembly moisten all bearing and work surfaces
with oil.
1 - Chain
T pay attention to correct installation position 13-6
page 2
T before removing mark running direction
turn (90 )
T replace
T tightening may occur in successive stages
3 - Balancing weight
T can be installed only in one
position
4 - Sprocket
T for balancing shaft
position
5 - Fitting sleeve
turn (90 )
T replace
7 - Sprocket
T for oil pump
position
8 - Cover
T Clean strainer if dirty
9 - 5 Nm
10 - O-ring
T replace
T check tightness
T lightly oil for assembly
11 - 20 Nm
12 - Oil pump
T with pressure relief valve 1.15 MPa (11.5 bar)
T Before installing, check whether both dowel sleeves are present
13 - Balancing shaft
T removing and installing 13-6 page 2
14 - Retaining frame
T before assembly, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in
the retaining frame
15 - O-ring
T replace
T check for correct fitting in the retaining frame
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Removing and installing balancing shaft and retaining frame
13-6 page 1
13
16 17 18 19 -

Cylinder block
Chain sprocket for guide pulley
20 Nm
Chain tensioner with tensioning rail
T to remove lock with -T10060T removing and installing 13-6 page 2
20 - 8 Nm + torque a further 1/4 turn (90 )

T replace
removing and installing balancing shaft

Locating bolts -T10060 Torque wrench
Removing

Removing oil pan Chapter 17-2.
Remove the sealing flange on the belt pulley side
Chapter 13-3.
Unscrew fixing screws for cover.

Remove cover from retaining frame.
Lock chain tensioner with locating bolts -T10060- -arrow-.
Unscrew chain sprocket for guide pulley -1- from retaining frame.
Unscrew fixing screws -2- from the chain tensioner

and remove chain tensioner.
Remove chain from chain sprockets and place on a

clean surface.
Lock balancing shaft with open-end wrench -1-.

Note
The open-end wrench must be positioned in the centre
for the safety weight of the balancing shaft and at right
angles to the balancing shaft.
Loosen fixing bolt -2- for balancing weight.

Note
Only loosen fixing bolt -2- for balancing weight, do not unscrew.
Unscrew retaining frame -3- from cylinder block and

remove retaining frame with balancing shaft.
Lay aside retaining frame on a clean surface.

Unscrew fixing bolt from the balancing weight.
13-6 page 2
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13
Remove balancing weight and chain sprocket from

the balancing shaft.
Turn balancing shaft in such a way that it can be taken

out of its bearing.
Installing
Oil work surfaces of the bearing.

Insert balancing shaft in the bearing.
Slide chain sprocket and balancing weight onto the
balancing shaft.
Note
Assembly of chain sprocket and balancing weight is only
possible in one position.
Tighten fixing bolt for balancing weight and chain

sprocket by hand.
Screw retaining frame onto cylinder block clearance

free and by hand.
Note
When installing the retaining frame ensure, that the
dowel sleeve is seated in the cylinder block and the Oring in the retaining frame.
Align retaining frame in such a way, that it is aligned
on the belt pulley side with the cylinder block outer

side.
Screw retaining frame with balancing shaft onto cylinder block.

Tightening torque: 20 Nm.
Check if the retaining frame is aligned on the belt pulley side with the cylinder block outer side.
Lock balancing shaft with open-end wrench -1- according to the illustration.
Note
The open-end wrench must be positioned in the centre
for the safety weight of the balancing shaft and at right
angles to the balancing shaft.
Tighten fixing bolt -2- for balancing weight.

Tightening torque: 100 Nm + torque a further 1/4 turn (90)
Note
Fixing bolt is an antifatigue bolt and must always be replaced.
Install chain tensioner.

Tightening torque: 8 Nm + torque a further 1/4 turn (90)
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13-6 page 3
13
Note
Fixing bolts for chain tensioner are antifatigue bolts and
must always be replaced.
Clean chain with a non-fluffy cloth.

Check, if the marking -arrow- at the chain sprocket of
the crankshaft is located at the top.
Fit chain onto chain sprocket of crankshaft, onto chain

sprocket of oil pump and onto chain sprocket of balancing shaft. While doing so the markings of the colour marked chain links -arrows- at chain sprocket of
crankshaft and at chain sprocket of balancing shaft
must be opposite each other, as shown.
Note
Colour marked chain links are additionally marked with a
notch.
Insert chain sprocket for guide pulley into the chain

and screw chain sprocket for guide pulley onto retaining frame.
Remove locating bolts -T10060- from chain tensioner.

Check if the markings of the colour marked chain links
-arrows- at chain sprocket of crankshaft and at chain
sprocket of balancing shaft are opposite each other.
Note
Colour marked chain links are additionally marked with a
notch.
Install the sealing flange on the belt pulley side

Chapter 13-3.
Install cover for balancing shaft.

Note
Oil O-ring for oil pump and inner shank of cover before
installing the cover.

Pay attention to correct fitting of the sealing tape in the
cover.
When installing the cover ensure that it locks into the
retaining frame.
Installing oil pan Chapter 17-2.
13-6 page 4
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13
Install the timing belt Chapter 13-2.
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13-6 page 5
13
13-6 page 6
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15
15 Cylinder Head, Valve Gear

15-1

cylinder head
Removing and installing toothed belt Chapter 13-2

Testing compression pressure 15-1 page 6.
Note
When installing an exchange cylinder head with the
camshaft installed, it is necessary to oil the contact

surfaces between bucket tappets and the cam track.
Do not remove the plastic covers supplied as a protec-
tion for the open valves until just before fitting on the
cylinder head.
If the cylinder head is replaced, also the entire coolant
must be replaced.
It is not permissible to rework the cylinder head of die-
sel engines.
1 - Timing belt guard - top part
2 - Timing belt
T removing and installing, tensioning Chapter 13-2
3 - 10 Nm
turn (45 )
5 - 100 Nm
6 - Camshaft sprocket
7 - Hub
T with rotor
T to release and tighten use
the counterholder -T10051 T to remove the extractor
-T10052- use
Chapter 15-3
8 - Timing belt guard rear
9 - Sealing sleeve
10 - Camshaft position sensor
-G40T for removing the sealing
grommet item 9 from the
timing belt cover remove
from behind
11 - Cylinder head bolt
T replace
T pay attention to sequence for
loosening and tightening
15-1 page 3
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Removing and installing cylinder head
15-1 page 1
15
12 13 14 15 -
16 17 18 19 20 21 22 23 24 25 26 27 -
28 -
29 -
30 31 32 33 -
34 -
35 -

T if bearing caps of the camshaft are removed, insert special bases into the cylinder block before installing the
cylinder head bolts Chap. 15-2
Bolts, 10 Nm
T for the engine cover
Cylinder head cover
T before fitting on, thoroughly clean sealing surface with a clean cloth
to charge air pipe at the rear
10 Nm
T tighten all bolts first of all by hand
T Tighten crosswise from the inside outwards
Pressure control valve
Oil filler inlet
Cap
Sealing sleeve
Bracket
T with fuel line
Gasket for cylinder head cover
20 Nm
Lifting eye
The unit injector
T removing and installing 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23
Central plug connection
T for pump-nozzle unit
To the brake servo unit
Tandem pump
T for fuel and vacuum supply
T inspect Chapter 20-2
Intake hose
T from the fuel filter Chapter 20-1
T white marking
T secure with spring strap clamps
Return-flow hose
T to fuel filter Chap. 20-1
T blue marking
T secure with spring strap clamps
Gasket
T replace
Bracket
Hexagon taper nut
Cylinder head
T after replacing fill entire system with fresh coolant
T Inspecting the cylinder head for distortion Fig. 1 in 15-1 page 3
Cylinder head gasket
T replace
T Pay attention to the marking Fig. 2 in 15-1 page 3
Glow plug
T 15 Nm
15-1 page 2
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15
Fig. 1:
Inspecting the cylinder head for distortion

Feeler gauge
Knife-edge straightedge
Max. permissible distortion: 0.1 mm

Note
It is not permissible to rework the cylinder heads of diesel
engines.
V15 - 0673
Fig. 2:
Identify cylinder head gasket
Spare parts No. = -arrow 1 Control code = -arrow 2- (ignore)

Bores = -arrow 3-
Note
Cylinder head seals of different thicknesses are fitted depending on the piston projection from the cylinder block.
If only the gasket is replaced, then it must be replaced
with a gasket with the same marking.

Supporting device - MP 9-200 Bracket -T10014 Catch pan (e.g. -V.A.G 1306-)
Torque wrench
Hand vacuum pump, e.g. -V.A.G 1390 Ventilation reservoir e.g. -V.A.G 1390/1-
Removing
Remove intake hose between air filter and intake

manifold 1.4/55 TDI Engine, Fuel Injection;
Rep. Gr. 23.
Remove battery and battery tray Electrical System;

Rep. Gr. 27.
Removing charge air pipe at the rear with connecting

hose Chap. 21-1.
Unplug connector with glow plugs.
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15-1 page 3
15
Remove front exhaust pipe with catalytic converter

from exhaust manifold.
Remove charge air connection hose between turbo-
charger and charge air pipe at bottom Chapter 211.
Pull out vacuum hoses from the turbocharger
Chapter 21-1 .
Remove oil feed and oil return line for the exhaust tur-
bocharger Chapter 21-1.

Unscrew inlet connection from intake manifold and
place to the side with the hoses connected 1.4/55

Slacken bolts of cylinder head cover.

Use hand vacuum pump and bleeding bottle to extract
the fuel at the return-flow hose of the tandem pump

Chap. 20-2.
S15-0165
Remove fuel hoses -1- and -4-.

Remove coolant hose -5-.
Remove central plug connection -2- for pump-nozzle
unit.
Disconnect plug -3- from the fuel temperature sender
-G81-.
Unbolt oil feed line at the brackets for oil filter, turbocharger and from the mounts.
Disconnect coolant hose -1- from T-piece and the

coolant hoses -2- and -3- from the connection fittings.
Disconnect plug -4- from the coolant temperature
sender -G62-.
4
S15-0166
Remove the coolant hose -3- from the supports -4-.

Pull off vacuum hose -6- from tandem pump -5-.
2
1
S10-0150
15-1 page 4
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15
Screw bracket -T10014- into the threaded holes in the

area of the coolant pump in the cylinder block. Tightening torque: 20 Nm.
Follow the specified order for loosening cylinder head

bolts.
Installing
Note
Always replace the cylinder head bolts.
When conducting repairs sealant residues should
carefully be removed from the cylinder block and cylinder head using a chemical cleaner.
Remove the new cylinder head seal from its wrapping
immediately before fitting.

Treat the new seal with the utmost care. Damage to
the silicone layer and in the area of the bead results in

leakages.
Before fitting the cylinder head position the crankshaft

on the TDC marking.
Turn crankshaft against the running direction of the

engine until all pistons are almost evenly at TDC.
Fit on cylinder head gasket.

Fit on cylinder head and screw on all 8 cylinder head
bolts by hand.
Tighten cylinder head in four stages in the following

order:
1. Pre-tighten with torque wrench:
Stage I = 40 Nm
stage II = 60 Nm
2. Tighten further with a rigid wrench:
Stage III = 1/4 turn (90)
Stage IV = 1/4 turn (90)
Note
Tightening up the cylinder head bolts after doing repair
work is not necessary.
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15-1 page 5
15
After securing the cylinder head turn the camshaft in

such a way that the cams for cylinder 1 point upwards
evenly. Before fitting on the timing belt set the crankshaft in the direction of rotation of the engine to the
TDC Chapter 13-2.
After installing the cylinder head, fill tandem pump and

cylinder head with fuel using a hand vacuum pump
and ventilation reservoir Chapter. 20-2.
Further installation occurs in reverse order to removal.

Perform test drive, interrogate fault memory 1.4/55
Testing the compression

Test condition
Engine oil temperature at least 30 C

Flexible-head wrench for glow plugs
Torque wrench
Adapter (e.g. -V.A.G 1381/12-)
Compression tester e. g. (-V.A.G 1763-)
Test sequence
Separate central plug connection for unit injector.

Remove all glow plugs using a flexible-head wrench.
Screw in adapter -V.A.G 1381/12- instead of the glow
plugs.
Check compression pressure with compression tester

-V.A.G 1763 -.
Note
Use of tester Operating Instructions.
Zyl
Operate starter until the tester no longer indicates a
bar
Zylinder
pressure rise.
PRINT
Compression readings:
V.A.G 1783
New engine
Wear limit
Pressure difference between

individual cylinders
2.5...3.1MPa
(25...31 bar)
1.9 MPa
(19 bar)
max. 0.5 MPa

(5 bar)
Screw in glow plugs with flexible-head wrench.

Tightening torque: 15 Nm
Interrogate fault memory 1.4/55 TDI Engine, Fuel

Injection System; Rep. Gr. 23.
15-1 page 6
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15
Note
Faults are stored as a result of separating the central plug
connection for the unit injector. For this reason interrogate fault memory or erase 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 01.
Edition 07.03
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15-1 page 7
15
15-1 page 8
Edition 07.03
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15
15-2
Repairing Valve Gear
Summary of components
Note
Cylinder heads with cracks between the valve seats may
continue to be used without any reduction in the life time
provided the cracks are slight and max. 0.5 mm wide.
turn (90 )
T replace
T Pay attention to tightening
and release sequence
Chapter 15-3
2 - Valve-lever shaft
T do not interchange
3 - Cylinder head bolt
T replace
T Pay attention to tightening
and release sequence
Chapter 15-1
T before installing, insert
washers item 4 into the
cylinder head
4 - Washer
T for cylinder head screws
T before installing the bearing
cap, insert into the cylinder
head
5 - Bucket tappets
T do not interchange
T with hydraulic valve clearance compensation
T lay aside with contact surface facing down
T before installing check axial
play of the camshaft Fig. 1
in 15-2 page 2
T oil contact surfaces
T before removing, take off
camshaft bearing shell
6 - Collets
7 - Valve spring retainer
8 - Valve spring outside
T removing and installing:
Cylinder head removed: with - MP 1-206-, -MP 1-211-, -MP 1-213 Cylinder head installed Chap. 15-4
9 - Valve spring inside
T removing and installing:
Cylinder head removed: with - MP 1-206-, -MP 1-211-, -MP 1-213 Cylinder head installed Chap. 15-4
10 - Valve stem seal
T replacing Chapter 15-4
11 - Valve guide
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15-2 page 1
15
12 13 -
14 -
15 16 -
17 -
18 -

The unit injector
T removing and installing 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23
Cylinder head
T pay attention to note 15-2 page 1
T reworking valve seats Chapter 15-4
Gasket ring
T Neither oil nor grease sealing lip of sealing ring
T before installing, remove oil residues on the camshaft studs with a clean cloth
T before fitting cover slot on the camshaft cone with adhesive tape (e.g. Scotch tape).
Valves
T Valve dimensions Fig. 3 in 15-2 page 3
Bearing shell
T do not mix up used bearing shells (mark)
T ensure the retaining lugs are correctly located in the bearing caps and in the cylinder head
Camshaft
T inspecting axial play Fig. 1 in 15-2 page 2
T Slack: max. 0.01 mm
T Identification, timing Fig. 4 in 15-2 page 3
Bearing caps
T Fitting sequence Chap. 15-3
T Bearing cap 4 is identified like bearing cap 5.
T for installing seal the separator surfaces of bearing caps 1 and 4 with sealant -AMV 174 004 01- Fig. 2 in
15-2 page 3

T replace
Fig. 1:
Inspecting axial play of camshaft

MP 3-447
Universal dial gauge holder -MP 3-447 Dial gauge
Perform measurement with removed bucket tappets and

installed bearing caps.
Wear limit: max. 0.15 mm
S15-0168
15-2 page 2
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15

Fig. 2:
Seal contact surface of bearing caps 1 and 4

with sealant -AMV 174 004 01-
Apply a thin layer of sealant -AMV 17400401- evenly to

the sealing surfaces -1-.
Note
Make sure no sealant penetrates into the slots -ar-
rows-.
Bearing cap 4 is identified like bearing cap 5.
N15-0270
Fig. 3:
Valve dimensions
Note
Valves must not be reworked. Only grinding in is permissible.
Dimension
Inlet valve
Exhaust valve
mm
35,95
31,45
mm
6,980
6,956
mm
89,95
89,95
45
45
Fig. 4:
Camshaft identification, timing
Base circle of cam: a = 52.8 mm

Camshaft identified with digits and characters
stamped in on the end face of the cam for outlet valve

on 3rd cylinder.
3. Cylinder -arrow-
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858 C
15-2 page 3
15
15-2 page 4
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15
15-3
Camshaft
Removing and installing camshaft

Counterholder - T10051 Extractor -T10052 Torque wrench
Sealant -AMV 174 004 01-
Removing

Unscrew fixing screws -1- for camshaft sprocket.
Take camshaft sprocket off the hub.
Loosen fixing screw -1- of the hub.
Use counterholder -T10051- for this purpose.
Turn bolt attaching the hub out about 2 turns.

Position extractor -T10052- align them with the hub
bores.
Screw fixing screws -1- into the hub.

Put the hub under tension by uniformly tightening the
central bolt -2- until the hub is released from the camshaft cone.
Note
Hold the extractor firmly using an open-end wrench.
Remove hub from cone of camshaft.

Remove cylinder head cover.
Remove valve-lever shaft.
Note
First release crosswise the two outer and then both inner
fixing screws.
Remove tandem pump Chap. 20-2.

First remove bearing caps 2 and 3. Release bearing
caps 1 and 4 alternately and crosswise.
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Camshaft
15-3 page 1
15
Note
Installing
Note
When fitting the camshaft the cams of cylinder 1 must
point upwards.
Do not mix up used bearing shells (mark).
When installing the camshaft, ensure it is correctly lo-
cated in the retaining lugs of the bearing shells in the

bearing caps and in the cylinder head.
Before installing the bearing caps make sure the
washers for the cylinder head screws have been inserted in the cylinder head.
Oil the contact surfaces of the bearing shells.

Tighten bearing caps 2 and 3 alternately crosswise
and tighten to 8 Nm + torque a further 1/4 turn (90 )
(replace screws).
Install bearing caps 1 and 4 and also tighten to 8 Nm

+ torque a further 1/4 turn (90 ) (replace screws).
Note
Seal the separator surface of bearing caps 1 and 4
with sealant -AMV 174 004 01- Chap. 15-2
Bearing cap 4 must be aligned with the outer edge of
the cylinder head, as this may otherwise cause leaks

on the tandem pump
Install camshaft seal 15-3 page 3.

Install valve-lever shafts and tighten evenly and crosswise, clearance free to bearing, first the two inside and
then the outside fixing screws, once again tighten.
Tightening torque: 20 Nm + torque a further 1/4 turn
(90 ) (replace)
Position hub onto camshaft.

Tighten fixing screw -1- of the hub.
Use counterholder -T10051- for this purpose.
15-3 page 2
Camshaft
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15
Push camshaft sprocket onto hub.

Note
The gear segment -arrow- of the camshaft timing gear
must be at the top.
Align camshaft so that the longitudinal holes are in the

centre position.
Fit the bolts -1- attaching the camshaft sprocket on by

hand so that no play exists.
Lock hub with rig pin -3359-.

Install tandem pump Chap. 20-2.
Note
After installing new bucket tappets, the engine must not
be started for about 30 minutes. The hydraulic clearance
compensation elements must settle (otherwise valves
would strike the pistons).
Removing and installing gasket ring for

camshaft
Insertion tool -MP 1-214 Gasket ring extractor -T30003 Torque wrench
Screw -M12x65-
Removing

Remove camshaft sprocket and hub 15-3 page 1.
Unscrew inner part of the gasket ring extractor
-T 30003- two turns (approx. 3 mm) out of the outer
part and lock with knurled screw.
Oil the thread head of the gasket ring extractor, position and forcely screw into the gasket ring as far as
possible.
Slacken knurled screw and turn inner part of gasket

ring extractor against the camshaft until the gasket
ring is pulled out.
Installing
Note
Sealing lip of the gasket ring must not be oiled or greased
additionally.
Remove oil residue on the camshaft stud with a clean

cloth.
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Camshaft
15-3 page 3
15
Cover slot on the camshaft cone with commercially

available adhesive tape (e.g. with sellotape).
Carefully fit seal onto the camshaft.

Push on the sealing ring with the pressure plate of the
insertion tool -MP 1-214- and with screw -M12x65- up
to the stop.
15-3 page 4
Camshaft
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15
15-4
Valve seats, valves

guides, valve stem seals
Grinding in valve seats

Depth gauge
Note
Do not re-mill valve seats. Only grinding in of valves is
permissible.
inspecting valve guides 15-4 page 2. If the wear
limit is exceeded, repeat measurement with new

valves. If the wear limit is again exceeded, replace cylinder head.
Calculating max. permissible reworking dimension
15-4 page 1. If the wear limit is exceeded, repeat

measurement with new valves. If the wear limit is
again exceeded, replace cylinder head.
Calculating max. permissible reworking dimension
Insert valve and press firmly into the valve seat.

Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
Measure distance -a- between the end of the valve

stem and the upper face of the cylinder head.
Calculate max. permissible reworking dimension from

the distance -a- measured and from the minimum dimension.
Minimum dimension:
Inlet valve 43.4 mm

Outlet valve 43.2 mm
Measured distance less minimum dimension = max. permissible reworking dimension.

N15-0253
Example:
=
Measured distance
minimum dimension
Max. permissible reworking dimension
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44,1 mm
43,4 mm
0,7 mm
Valve seats, valves guides, valve stem seals
15-4 page 1
15
Note
If the max. permissible reworking dimension is 0 mm, repeat measurement with a new valve. If the max. permissible reworking dimension is again 0 mm, replace
cylinder head.
Inspect valve guides

Universal dial gauge holder -MP 3-447 Dial gauge
Test sequence
Insert a new valve into the guide. The end of valve

stem must be flush with guide.
Because of the different stem diameters only use inlet
valve in inlet guide or outlet valve in outlet guide.
Valve rock: max. 1.3 mm
Note
If the wear limit is exceeded, repeat measurement
with new valves. If the wear limit is again exceeded,

replace cylinder head.
If the valve is replaced when carrying out repair work,
use a new valve for the measurement.
Replacing valve stem seals

Assembly device -MP 1-213 Extractor -MP 1-206 Insertion tool -MP 1-212 Valve lever -MP 1-211-
Removing
MP 1-213
(Cylinder head fitted)
Removing camshaft Chap. 15-3.

Remove bucket tappets and lay aside with the contact
surface facing down. Make sure that you do not mix up
the tappets.
Position piston of the relevant cylinder in dead centre.

Insert the assembly device -MP 1-213- and adjust
bearing to the stay bolt height.
Remove valve springs with valve lever -MP 1-211-.
MP 1-211
15-4 page 2
S15-0171
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15
Note
The valves rest on the piston crown.
Release collets that are tight by striking with light
blows of a hammer on the valve lever.
Pull off valve stem seals with -MP 1-206-.
Installing
Insert the supplied plastic bushings -A- on the relevant

valve stem. This will prevent any damage to the new
valve stem seals -B-.
Insert the new valve stem seal in the insertion tool

-MP 1-212-.
Oil the sealing lip of the valve stem seal and carefully
slide into the valve guide.
Note
After carrying out work on the valve gear, carefully
crank engine at least 2 revolutions to ensure that no

valve touches the piston when the engine is started.
After installing the camshaft, the engine must not be
started for about 30 minutes. The hydraulic clearance

compensation elements must settle (otherwise valves
would strike the pistons).
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15-4 page 3
15
15-4 page 4
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17
17 Lubrication
17-1

parts of the lubrication
system
Note
If considerable quantities of metal swarf or abrasion is
found in the engine oil when carrying out engine repairs, carefully clean the oil galleries in order to avoid
consequential damage and additionally replace the oil
cooler.
Testing oil pressure and oil pressure switch
Chapter 17-3.
The oil level must never exceed the max marking -
risk of damage to catalytic converter!

Check oil specifications, capacity and oil level
Inspection and Maintenance; Chap. 02-3
Lubrication system - Summary of components

1 - 15 Nm
2 - Sealing flange
T with gasket
T must be positioned on dowel
sleeves
Chapter 13-4
T fit with silicone sealant
-D 176 404 A2- Chapter
13-4
T Neither oil nor grease sealing
lip of sealing ring
T before installing remove oil
residues on crankshaft journal with a clean cloth
T replace sealing ring for
crankshaft at belt pulley side
Chapter 13-4
3 - Cylinder block
4 - Gasket
T replace
T disassembling and assembling 17-1 page 3
turn (90 )
T replace
bolts cross-wise
7 - Dipstick
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Removing and installing parts of the lubrication system
17-1 page 1
17
8910 11 12 -
13 -
14 15 -
16 17 18 -
19 -
20 21 -
22 23 -
24 25 26 -

T oil level must not exceed max. marking
Filler funnel
T Remove for extracting oil
5 Nm
Guide tube
10 Nm
O-ring
T replace
T check tightness
T lightly oil for assembly
Cover
T with sealing tape
20 Nm
Oil pump
T with pressure relief valve 11.5 MPa (1.15 bar)
T Before installing, check whether both dowel sleeves are present
Fitting sleeve
25 Nm
T replace without sealant
Retaining frame
T before installing, check whether the dowel sleeve is present in the cylinder block and the O-ring is seated in
the retaining frame
Oil injection nozzle
T for cooling pistons
T check fitting position: Turn oil injection nozzle anti-clockwise up to the stop in the cylinder block and tighten
in this position
O-ring
T replace
Oil pan
T clean the sealing surfaces before installing
T fit with silicone sealant -D 176 404 A2- Chapter 17-2
T The gearbox must be removed in order to remove the oil pan Manual Gearbox 02R; Rep. Gr. 34
Bracket
T for connection pipe of charge air cooler
15 Nm
T The gearbox must be removed in order to remove the rear bolts to the gearbox Manual Gearbox 02R;
Rep. Gr. 34
Gasket ring
T replace
Oil drain plug, 30 Nm
T replace
Sprocket
T for oil pump
T can be installed only in one position

T replace
28 - Chain
T Observe the correct fitting position Chapter 13-6
29 - Sprocket
T for balancing shaft
17-1 page 2
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17

T replace
T tightening may occur in successive stages
T to release and tighten use the socket wrench -T1006131 - Wheel weight
32 - 20 Nm
33 - Chain sprocket for guide pulley
T replace
35 - Chain tensioner with tensioning rail
T to remove lock with -T10060 T removing and installing Chapter 13-6
36 - O-ring
T replace
37 - Oil level/temperature sender -G266T check Binder Current Flow Diagrams, Fault Finding with -VAS 5051C-
Disassembling and assembling oil filter holder

1 - Gasket
T replace
turn (90 )
T replace
bolts cross-wise
4 - Gasket ring
T replace
T for oil feed line to turbocharger
6 - Oil feed line
T to turbocharger
7 - Oil pressure switch 0.07 MPa
-F1-, 20 Nm
T Cut open gasket ring if leaking and replace
8 - Cap, 25 Nm
9 - O-ring
T replace
10 - Oil filter element
T if replaced, fit new O-rings
item 9
11 - Screw plug, 10 Nm
12 - Gasket
T replace
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17-1 page 3
17
T fit into the grooves on the oil cooler

13 - Oil cooler
14 - Gasket
T replace
15 - Screw plug, 25 Nm
17-1 page 4
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17
17-2

oil pan
Removing and installing oil pan

Hand-held power drill with plastic brush insert
Silicone sealant - D 176 404 A2 Flat scraper
Removing
Remove noise insulation -arrows-.

Drain engine oil.
Removing the gearbox Body Work; Rep. Gr. 50
Removing the oil pan.
S10-0114
Release oil pan if necessary by applying slight blows

with a rubber-headed hammer.
Use a flat scraper to remove sealant residues on the

cylinder block.
Remove sealant residues on the oil pan with a rotating

brush, e.g. with a hand drill with plastic brush attachment (wear protective goggles).
Clean the sealing surfaces. They must be free of oil

and grease.
Installing
Note
Pay attention to the 'use by date' on sealant.
Oil pan must be installed within 5 minutes after apply-
N17-0012
ing the silicone sealant.
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).

the oil pan, as shown in the illustration.
Thickness of sealant bead: 2...3 mm
The sealant bead must be run past on the inside in the
area of the bolt holes -arrows-.

Note
The sealant bead must not be thicker otherwise excess
sealant may get into the oil pan and clog the strainer in
the oil pump.
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N17-0019
17-2 page 1
17

the oil pan, as shown in the illustration. (The diagram
shows the sealant bead on the cylinderblock.)
Fit oil pan immediately and lightly tighten all oil pan
screws.
Tighten oil pan screws to 15 Nm.

Installing the gearbox Gearbox 02R; Rep. Gr. 34.
Tighten the oil pan/gearbox screws to a torque of 45
Nm.
Note
After installing the oil pan, allow the sealant to dry for
about 30 minutes. Only then may engine oil be filled

in.
Oil pan must be aligned with cylinder block.
Further installation occurs in reverse order to removal.
17-2 page 2
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17-3
17
Testing oil pressure and

oil pressure switch

Oil pressure tester (e.g. -V.A.G 1342-)
Diode test lamp (e.g. -V.A.G 1527 B-)
Measuring tool set -V.A.G 1594 C Current flow diagram
Function of dynamic oil pressure warning system if

oil pressure low
The oil pressure switch is opened when pressureless and
closed when the switching pressure is reached.
The oil pressure warning is activated for about 10 seconds after the ignition is switched on (terminal 15 on).
Activation delay of oil pressure warning system: max. 3
seconds. De-activation delay of the oil pressure warning
system: max. 5 seconds.
Test warning light
After the ignition is switched on and with the engine not
running, the oil pressure warning light in the dash panel
insert must come on for about 3 seconds and then go out.
The check is ended when the engine is started.
Warning criteria
The visual oil pressure warning is switched on (oil pressure warning light flashes) and the buzzer sounds 3 times
as an audible warning if at least one of the following conditions exists:
Ignition on, engine not running, oil pressure switch

closed
Engine speed above 1500 rpm, oil pressure switch

open
At an engine speed above 5000 rpm, the oil pressure

warning is also not cancelled if the oil pressure switch
is closed. The oil pressure warning is cancelled once
engine speed is below 5000 rpm.
If the oil pressure switch is opened for only 0.5 to 3 s

at an engine speed of above 500 rpm, this is stored in
the combination processor of the dash panel insert. If
this situation occurs 3 times when the engine is running, the oil pressure warning is immediately activated
and is also not cancelled once engine speed is below
1500 rpm. The oil pressure warning is cancelled once
the oil pressure switch is closed for more than 5 s at
an engine speed of above 1500 rpm, or if ignition off.
Test conditions
Engine oil level o.k., testing Chap. 17-1

Oil pressure warning light (-K3-) must come on for
about 3 seconds when ignition is switched on.
Engine oil temperature at least 80 C (radiator fan

must have run once).
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17-3 page 1
17
Test sequence
Unplug connector from oil pressure switch.

Unscrew oil pressure switch and screw in oil pressure
V.A.G 1342
tester ( e.g. - V.A.G 1342-)
Screw oil pressure switch -2- into tester -V.A.G 1342-.

Connect brown cable -1- of tester to earth (-).
Connect diode test lamp (e. g. -V.A.G 1527 B-) to oil
pressure switch -2- and to battery positive (+).
The LED must not light up.
If the LED lights up, replace the oil pressure switch.

Start engine and slowly increase engine speed.
The LED must come on at an overpressure of
0.0550.085 MPa The oil pressure switch has be replaced if it does not come on.
2
A17-0025
Increase engine speed further. At 2000 rpm and an oil

temperature of 80 C the oil pressure should be at
least 0.2 MPa.
At higher engine speeds the oil pressure must not be lower than 0.7 MPa, if necessary replace oil filter holder together with pressure relief valve.
17-3 page 2
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19
19 Cooling
19-1
Parts of cooling system Summary of components
Note
When the engine is warm the cooling system is under
pressure. If necessary reduce pressure before repairs.

The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips.

Use pliers for spring strap clips to remove and fit the
spring strap clips.

Always replace seals and gasket rings.
When installing fit the coolant hoses free of stress,
without them touching any other components (pay attention to the marking on the coolant connection and
hose).
Coolant mixing ratios 19-1 page 4.
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Parts of cooling system - Summary of components
19-1 page 1
19
Parts of the cooling system fitted to body
19-1 page 2
3
4
7
8
G12
1 - Radiator
1
2
Chapter 19-2
T after replacing fill entire system with fresh coolant
2 - O-ring
T replace
3 - Top coolant hose
19
T attached to radiator by retaining clips
T connection diagram for coolant hoses 19-1 page 4
4 - Cap
18 17
T Pressure test 19-1
page 6
5 - Connector
6 - Double screw, 2 Nm
16
5
7 - Air duct scoop
8 - 5 Nm
9 - Expansion reservoir
T check the coolant system for
tightness 19-1 page 6
10 - Auxiliary fan
T on vehicles with air condi2
15
tioning
11 - Fan holder
12 - Retaining clip
T for ventilator cable
T check correct fitting
13 - Fan for radiator
14 - Bracket
T for fan connector
15 - Bottom coolant hose
T attached to radiator by retaining clips
16 - Thermoswitch for radiator fan -F18-, 35 Nm
T for radiator fan
T switching temperatures:
1. Stage
on: 9197 C
off: 8491 C
2. Stage
on: 99105 C
off: 9198 C
17 - Bottom radiator bearing
18 - 5 Nm
19 - Top radiator bearing
9
10
13
8
11
14
5
11
12
12
S19-0088
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19
Parts of cooling system engine side

1 - Coolant hose
T to heat exchanger
2 - Connection fittings
3 - 10 Nm
4 - Coolant hose
T from heat exchanger
5 - 25 Nm
6 - Coolant hose
T to the expansion reservoir
7 - Holding claw
8 - Coolant pipe
9 - O-ring
T replace
10 - Coolant hose
T to the expansion reservoir
11 - Coolant hose
T towards top radiator
12 - Coolant hose
T from bottom of radiator
13 - Connection fittings
T for coolant regulator
14 - 15 Nm
15 - Coolant regulator
T Observe the fitting position Chapter 19-2
T test: heat up regulator in a water bath
T Start of opening approx. 85C
T finish with approx.105C
T opening stroke at least 7 mm
16 - Coolant pump
T check smooth operation
17 - O-ring
T check tightness
T replace
18 - Retaining clip
T check tightness
19 - Sender for coolant temperature -G62T with coolant temperature gauge sensor -G2-
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19-1 page 3
19
Connection diagram for coolant hoses

123456789-
Intake manifold
Expansion reservoir
Heat exchanger for heating
Coolant pipe
Oil cooler
Top coolant hose
Radiator
Bottom coolant hose
Coolant pump/coolant regulator
10 - Cylinder block/cylinder head
Draining and filling up coolant

Catch pan (e.g. -V.A.G 1306-)
Pliers for spring strap clips
antifreeze tester
Draining
Caution!
Hot steam may escape when the compensation
bottle is opened. Cover the cap with a cloth and
open carefully.
Open the cap of the compensation bottle.
19-1 page 4
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19

Place a catch pan under the engine.
S10-0114
Turn the drain plug -arrow- on the radiator to the left

and to the rear; fit auxiliary hose onto connection if
necessary.
A10-0118
Also pull off the coolant hoses on the oil cooler -arrows- in order to drain coolant out of the engine.
Note
Observe the disposal instructions for coolant.
Filling up
Select the appropriate coolant additive from the original
spare parts catalogue KODA or from the list of allowed
coolant additives Inspection and Maintenance;
Rep. Gr. 02.
Recommended mixture ratios:
Antifreeze protection down to
Antifreeze
concentration1)
Water 2)
-25 C
40% (2.0 ltr.)
60% (3.0 litres)
-35 C
1)
50% (2.5 litres) 50% (2.5 litres)
The proportion of coolant additive must not go below 30% due to

corrosion protection considerations but must also not exceed 60%
otherwise the frost protection effect will be reduced and the cooling
effect worsened.
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19-1 page 5
19
2)
The coolant amount may differ according to the version of the vehicle.
Insert and tighten the coolant drain plug.

Fit coolant hose onto oil cooler.
Fill up coolant up to max marking on the expansion
reservoir.
Seal expansion reservoir.

Run engine until fan starts.
Caution!
open carefully.
Check the level of coolant and top up if necessary.
max
min
When engine is at operating temperature the coolant

level must be at the max marking, when engine is
cold between the min and max markings.
V19-0579
Checking the coolant system for tightness

Coolant system tester (e. g. -V.A.G 1274-)
Adapter (e.g. -V.A.G 1274/9 -)
Adapter (e.g. -V.A.G 1274/9 -)
Test condition
Engine must be warm

Test sequence
Caution!
open carefully.
V.A.G 1274
Open the cap of the coolant expansion reservoir.

Position coolant system tester (e.g. -V.A.G 1274-)
with adapter (e.g. -V.A.G 1274/8-) on the compensation bottle.
Using the hand pump of the testing device generate

an overpressure of approx. 0.1 MPa (1 bar).
If the pressure drops determine position of the leak
V.A.G 1274/8
G12
and repair.
S19-0082
19-1 page 6
Edition 07.03
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19
Testing the pressure relief valve in the cap
Screw cap onto tester with adapter (e.g. -V.A.G 1274/

9 -).
Using the hand pump of the testing device generate

an overpressure of approx. 0.15 MPa (1.5 bar).
The pressure relief valve should open at a pressure of

0.120.15 MPa (1.2...1.5 bar).
Edition 07.03
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19-1 page 7
19
19-1 page 8
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19
19-2

radiator, coolant pump
and coolant thermostat
1
Removing and installing radiator

Catch pan (e.g. - V.A.G 1306 -)

Torque wrench
Removing

Remove connector -1- from thermo-switch for the
S19-0078
coolant fan -F18- and disconnect plug connection -2at the fan shroud.
To do so press the latch clips.
There are 2 plug connections on vehicles fitted with air
conditioning.
Separate the coolant hose from the radiator at the top

and bottom of the connection fittings.
To do so pull the retaining clip -3- up to the stop and
remove the quick coupling towards the rear.
Vehicles without air conditioning
Unbolt cable clip -1- from the starter -arrow-.

Lay cable with cable clip towards the rear.
1
S19-0079

Unscrew bolts for radiator bearing -arrows-.
Pull radiator with fan backwards and remove downwards.
Vehicles with air conditioning

Caution!
Do not open the refrigerant circuit of the air conditioning system.
S19-0080
Edition 07.03
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Removing and installing radiator, coolant pump and coolant

thermostat
19-2 page 1
19
Unscrew bolts for radiator bearing -arrows-.

Remove the lock carrier with component parts

Body work; Rep. Gr. 50.
Attach the condenser with the radiator to the engine or

support.
Note
Do not suspend the condenser to the wires.
Do not fold the condenser wires.
S19-0083
Unscrew fixing bolts for condenser -arrows- and take

out radiator with fan.
Installing
Installation is carried out in the reverse order. Pay attention to the following:

Re-adjust headlights on vehicles fitted with air conditioning.
Removing and installing coolant pump
S19-0081

Catch pan (e.g. - V.A.G 1306 -)
Torque wrench
Removing
Note
Cover the toothed belt with a cloth before removing
the coolant pump in oder to protect it from the coolant.

S10-0114
19-2 page 2

thermostat
Edition 07.03
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19
Unscrew the fixing screws -1- of the coolant pump -2and carefully remove the coolant pump.
Installing
N19-0234
Clean sealing surface for O-ring.

Moisten new O-ring -3- with coolant and fit onto coolant pump.
Position the coolant pump -2- in the cylinder block and

tighten the fixing screws -1-.
Note
Plugs of coolant pump point downwards.
Install toothed belt and tension Chapter 13-2.

Removing and installing coolant regulator
N19-0234

Catch pan (e.g. -V.A.G 1306-)
Torque wrench
Removing
Note

Remove alternator Electrical System; Rep. Gr. 27.
Detach coolant hoses from connection fitting.
Unscrew the fixing bolts -1- of the connection fittings
-2- and remove connection fitting -2- with coolant regulator -4-.
Turn coolant thermostat -4- 1/4 turn (90 ) to the left

and remove from connection fittings -2-.
Edition 07.03
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thermostat
19-2 page 3
19
Installing
Moisten new O-ring -3- with coolant.

Fit coolant regulator -4- in the connection fitting -2and turn 1/4 turn. (90 ) to the right.
Note
Coolant thermostat arms must be practically vertical.
Insert connection fitting -2- together with coolant thermostat -4- into the engine block.
19-2 page 4

thermostat
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20
20 Fuel Supply
20-1

parts of the fuel supply Part 1
Fuel tank with component parts - Summary of components

Note
Fuel lines are secured with quick-release fittings.
Fuel hoses at engine and fuel filter must only be se-
cured with spring strap clamps. The use of clamp-type

or screw-type clips is not allowed.
Observe safety measures 20-1 page 4.
Observe rules for cleanliness 20-1 page 4.
Repairing the accelerator control Chap. 20-3

1 - Fuel filler cap
2 - 1.5 Nm
3 - Fuel tank lid unit
T Removing and installing
Body Work; Rep. Gr. 50
4 - Gravity valve
T to remove, unclip valve at top
and lift out of filler neck.
T inspect valve for blockage:
valve vertical: Valve open
valve tilted 45: Valve closed
5 - Earth connection
6 - 10 Nm
7 - Vent line
T clipped in place at top of fuel
tank
8 - 25 Nm
9 - Fuel tank
T support with engine/gearbox
jack -V.A.G 1383 A- when
removing
Chapter 20-2
10 - Tensioning strap
11 - Fuel delivery unit
T Pay attention to the correct
fitting position of the flange at
fuel tank Fig. 1 in 20-1
page 2
20-1 page 5
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2
3
16
15
14
6
13
17
12
11
8
9
10
Removing and installing parts of the fuel supply - Part 1
8
S20-0091
20-1 page 1
20
12 -
13 14 -
15 -
16 -
17 -

T Check the fuel delivery unit 20-1 page 6.
T removing and installing fuel gauge 20-1 page 6
Gasket ring
T moisten with fuel before installing
Union nut
T use wrench -MP 1-227- for removing and installing
Feed line
T to fuel filter item 7 in 20-1 page 3
T clipped in place on fuel tank
T black
T to remove from flange press release button on the connecting part
Return-flow line
T from fuel cooler Chapter 26-2
T blue or blue marking
T clipped in place on fuel tank
T to remove from flange press release button on the connecting part
Vent valve
T Check Fig. 2 in 20-1 page 3
T when removing, unclip valve at side and take out of filler neck.
T before installing, unscrew fuel filler cap
O-ring
Fig. 1:
Installation position of flange of fuel delivery unit
Marking on the flange must be aligned with marking on

the fuel tank -arrows-.
Blue or blue marked return-flow line -1- to connection

marked -R-.
Black feed line -2- to connection marked -V-.
V
Note
After installing the flange of the fuel delivery unit, check

whether the feed, return-flow and vent lines are still
clipped in place on the fuel tank.
20-1 page 2
1
A20-0096
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20

Fig. 2:
Inspect vent valve
Lever in off position: closed

Lever pushed in -direction of arrow-: open
Note
Before installing the vent valve, unscrew fuel filler cap.
V20-1040
Repairing the fuel filter

The fuel flow direction is indicated with arrows on the hoses, on the glow valve and on the fuel filter.
1 - Return-flow hose
T from the tandem pump
T blue marking
2 - Intake hose
T to the tandem pump
T white marking
3 - Retaining clip
4 - Preheating valve
T Fitting position: Arrow points
to fuel tank
T if the filter is replaced remove
retaining clip and preheating
valve with the fuel lines connected
T Temperature less than +
15C: access to filter open
T Temperature above + 31C:
access to filter closed
5 - Return-flow hose
T to fuel filter Chap. 20-2
T blue marking
6 - Intake hose
T from fuel tank
T white marking
7 - Fuel filter
T fill with diesel fuel before fitting
T do not interchange connections
8 - Gasket
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1
6
11
7
8
10
9
10
10
S20-0096
20-1 page 3
20
9 - Drain plug
T to ventilate remove the retaining clip of the preheating valve and remove preheating valve with the fuel lines
connected
T release and drain approx. 0.1 litre fluid (catch)
10 - 25 Nm
11 - Bracket
12 - Plastic insert
T with holder item 11 a spare part
Fig. 3:
Removing and installing fuel filter
Remove the preheating valve with the fuel hoses fitted

(pull out retaining clip).
Remove fuel feed line.

Push the retaining lugs -arrows- of the plastic insert
outwards.
Remove fuel filter from the top.

Note
Fuel filter can be removed in one position only.
Safety precautions when working on the

fuel supply system
S20-0097
Pay attention to the following points when removing and

installing the fuel delivery unit/the fuel gauge sender on a
fuel tank that is filled or partially filled:
The extraction hose of an exhaust extraction system
which is switched on, must be positioned close to the

assembly opening of the fuel tank in order to extract
the released fuel gases, even before the work is commenced. If no exhaust extraction system is available,
a radial fan (motor not in air flow of fan) with a delivery
volume above 15 m3/h must be used.
Avoid skin contact with fuel! Wear fuel-resistant
gloves!
Rules of cleanliness
Carefully observe the following 6 rules for cleanliness
when working on the fuel supply or injection system.
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use

any parts which have been stored unwrapped (e.g. in
tool boxes).
20-1 page 4
Edition 07.03
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20

When the system is open: Avoid using compressed
air. Avoid moving the vehicle.

Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately.

Immediately replace contaminated hoses.
Removing and installing the fuel delivery

unit
Wrench for union nut -MP 1-227 Torque wrench
Removing
Observe safety measures 20-1 page 4.
Observe rules for cleanliness 20-1 page 4.
Fold rear seat forwards.

Removing fuel delivery unit guard.
Pull out 4-pole plug connector and feed and return
flow line from flange.
Note
Press buttons on the hose connections.
Unscrew union nut with wrench -MP 1-227-.

Pull the fuel delivery unit and the gasket ring out of the
opening of the fuel tank.
Note
You must empty the old delivery unit before disposing of
it if you wish to replace it.
Installing
Installation of the fuel delivery unilt occurs in reverse

order.
Note
Do not bend the fuel gauge sender when installing it.
Insert dry gasket ring of the flange or the fuel delivery
unit into the opening of the fuel tank.
Moisten gasket ring with fuel only when installing the
flange or the fuel delivery unit.

Make sure the fuel hoses fit tightly.
After installing the fuel delivery unit, check whether
the feed, return-flow and vent lines are still clipped in

place on the fuel tank.
Pay attention to installed position of flange of fuel de-
livery unit: Marking on the flange must be aligned with

marking on the fuel tank -arrows-.
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1
A20-0096
20-1 page 5
20
removing and installing fuel gauge

Removing
Removing fuel delivery unit 20-1 page 5.

Unlatch and disconnect the line contact studs -3- and
-4-.
Raise catches -1- and -2- with a screwdriver and remove the fuel gauge towards the bottom -arrow-.
Installing
Insert the fuel gauge sender in the fuel delivery unit

guides and press upwards until they latch into position.
Check the fuel delivery unit

Multimeter, e.g. -V.A.G 1715 Remote control, e.g. -V.A.G 1348/3A Measuring tool set, e.g. -V.A.G 1594 C Wrench for union nut -MP 1-227 Pressure gauge appliance, e.g. -V.A.G 1318 Adapter, e.g. -V.A.G 1318/1 Adapter, e.g. -V.A.G 1318/11 Adapter, e.g. -V.A.G 1318/17 Adapter, e.g. -V.A.G 1318/23 Measuring vessel
Test conditions
Battery voltage at least 11.5 volts

Fuses o.k.
Inspecting proper operation and power supply
Removing fuel delivery unit guard.

Switch on ignition. The fuel delivery unit must be
heard to start running.
Switch off ignition.

If the fuel delivery unit does not run:
Remove cover from the fuse holder.

Remove fuse No. 61 from the fuse holder.
Connect remote control -V.A.G 1348/3A- with the
adapter cable combination from the adapter cable set
in fuse holder 61 and to positive terminal of battery (+).
Activate remote control.

If the fuel delivery unit runs:
20-1 page 6
1
2
3
4
5
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
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20
Test fuel pump relay Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the fuel delivery unit does not run:
Disconnect 4-pin plug from flange at the fuel delivery

unit.
Connect multimeter for voltage measurement to contacts 1 and 4.
Activate remote control.

V
Specified value: approx. battery voltage.

If the specified voltage value is not reached:
Determine and remove open circuit in the wiring according to the current flow diagram Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
A20-0099
If the specified voltage value is reached:
Unscrew union nut with wrench -MP 1-227-.

Remove fuel delivery unit and check whether the electric wiring between the flange and fuel delivery unit is
connected.
If no open circuit was detected:
Replace the fuel delivery unit.

Inspecting fuel flow rate
Test conditions
Supply voltage is o.k.

Battery voltage at least 11.5 V.
Fuel temperature 15...30 C.
Fuel tank at least 1/4 full.
Test sequence
Unscrew the fuel tank cap from the filler neck.

Remove cover of fuel delivery unit/fuel gauge sender
unit under rear seat.
Unplug the 4-pin plug from the fuel delivery unit.

Connect remote control -V.A.G 1348/3A- with con-
1
4
nection lines from measuring tool set to contact -1- of

the fuel delivery unit and to battery +.
Use connection lines from the measuring tool set to

connect the contacts -4- to the plug and to the fuel delivery unit.
V.A.G 1348/3A
M20-0076
Edition 07.03
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20-1 page 7
20
Pull off the fuel feed line -arrow- and gather residual
fuel in a cloth.
Caution!
The fuel feed line is pressurized! Place a clean
cleaning cloth around the connection point before
detaching hose connections. Reduce pressure by
carefully releasing the connection point.
S20-0136
Connect pressure gauge -V.A.G 1318- with adapter
V.A.G 1318
V.A.G 1318/11
V.A.G 1318/23
-V.A.G 1318/23 - and -V.A.G 1318/17- to the fuel feed

line.
Connect hose -V.A.G 1318/1- to adapter

-V.A.G 1318/11- of the pressure gauge and hold in the
measuring vessel.
Open shut-off cock of the pressure measuring device.

The lever points in the direction of flow -A-.
Activate remote control -V.A.G 1348/3A-. Slowly

close the shut-off cock until the manometer displays 3
bar overpressure (0.3 MPa). Now do not change the
position of the shut-off cock.
Emty measuring vessel.

Activate remote control for 30 seconds.
A
B
V.A.G 1318/17
V.A.G 1318/1
N20-0132
Compare the amount of the fuel pumped to the specified value (the amount of the fuel pumped is dependent on the voltage of the fuel delivery unit).
If the minimum flow rate is not reached:
Check the fuel lines for possible diameter restrictions

(kinks) or blocking.
Remove the fuel delivery unit and check whether the

pump strainer is not clogged up.
If no fault was detected until now:
Replace the fuel delivery unit.
20-1 page 8
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20
20-2

parts of the fuel supply Part 2
Removing and installing the fuel tank

Observe the safety precautions Chapter 20-1.
Observe the rules for cleanliness Chapter 20-1.
Torque wrench
Engine/gearbox jack (e.g. -V.A.G 1383 A-)
Fuel extraction device
Removing
Note
If the battery is disconnected and reconnected, carry out
certain additional operations Electrical System;
Rep. Gr. 27.
Disconnect the earth strap from the battery with the ignition off.
Fold rear seat forwards.

Remove the fuel delivery unit guard and disconnect
the plug connection at the fuel delivery unit flange.
Drain fuel tank using the fuel extraction device. Fuel

tank cap remains removed.
Removing rear axle Running Gear; Rep. Gr. 42.

Removing front and rear silencer Chap. 26-1.
Remove left heat shield next to the fuel tank.
Remove rear right wheelhouse liner.
S20-0093
Unscrew bolts at tank filler neck -arrows-.
Detach feed line (black) -1- and return-flow line (blue)

-2- from the fuel tank (press release buttons).
Position the engine/gearbox jack under the fuel tank

for support.
S20-0094
Edition 07.03
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20-2 page 1
20
Release the securing bolts of the fuel tank -arrows-.

Draw the filler neck from the rubber bowl of the tank lid
unit and lower fuel tank.
Installing
Installation occurs in reverse order. Pay attention to the
following:
Do not mix-up the fuel feed and fuel return line.

Interrogate fault memory and erase 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 01.
Removing and installing fuel cooler
S20-0095

Torque wrench
Removing
Observe the rules for cleanliness Chapter 20-1.
Note
Fuel cooler is located at the return-flow line to the fuel
tank. It is attached to the underfloor of the vehicle body.
Removing cover -A-.

Separate fuel line at fuel cooler.
Unscrew fixing nuts -arrows-.
Installing
Installation is carried out in the reverse order. Pay attention to the following:
Tighten nuts of the fuel cooler to 15 Nm.
Inspecting a tandem pump

N20-0294
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C Torque wrench
Pressure gauge appliance (e.g. -VAS 5187 - )
Test conditions
Coolant temperature must be at least 85 C.

Unit injector must be O.K.
Fuel filter and fuel line must not be blocked.
20-2 page 2
Edition 07.03
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20
The non-return valve in the fuel-intake hose must be

O.K.
Fuel gauge sender must be O.K.

Procedure
Unscrew screw plug -arrow-.
N20-0288
Connect pressure gauge appliance (e.g. -VAS 5187-),

as shown in the figure.
VAS 5187
Connect vehicle system tester -V.A.G 1552- and select address word 01 Engine electronics. The engine
must be running in idle 1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 01.
Select function
0 8 Read measured value block

and display group 002.
N20-0292
Read off idle speed value in display block 1.

Engine speed must increase to more than 1500 rpm.
Observe pressure displayed on pressure gauge.
Reading measured value block

1
2
3
->
4
Specified value: at least 3.5 bar (0.35 MPa)

If the specified value is not reached:
Replace tandem pump 20-2 page 4.

Note
After removing the pressure gauge appliance tighten the
plug to 25 Nm. Always replace the gasket ring.
Edition 07.03
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20-2 page 3
20
Removing and installing the tandem

pump
Torque wrench
V.A.G 1390
Hand vacuum pump (e.g. -V.A.G 1390 -)

Water drain reservoir, (e.g. -V.A.G 1390/1-)
Removing
Separate feed hose -1- (marked in white) and returnflow hose -2- (marked in blue) from the fuel filter.
Connect hand vacuum pump -V.A.G 1390- with water

drain reservoir -V.A.G 1390/1- at return-flow hose.
V.A.G 1390/1
1
2
Operate hand vacuum pump until no more fuel comes

out of the return-flow hose.
S20-0109
Ensure that no fuel is drawn into the hand vacuum

pump.
Disconnect vacuum hose -1- for brake servo unit from

tandem pump -4-.
Remove feed hose -2- (marked in white) at the tan-
dem pump -4-.
Unscrew securing bolts -arrows-.

Remove tandem pump -4- from cylinder head.
Pull tandem pump -4- upwards, separate return-flow
hose -3- (marked in blue) and remove tandem pump
-4-.
Installing
N15-0254
Note
Ensure the tandem pump coupling is correctly insert-
ed into the camshaft.

Always replace the tandem pump seals.
Connect return-flow hose -3- (marked in blue) to the

return-flow coupling of the tandem pump.
Install tandem pump and tighten the top fixing screws
to 20 Nm.
Tighten the bottom fixing screws to 10 Nm.

Connect the feed hose -2- (marked in white) to the
feed connection and the vacuum hose -1- of the brake
servo unit to the tandem pump -4-.
4
N15-0254
20-2 page 4
Edition 07.03
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20
Connect feed hose -1- (marked in white) to fuel filter.

Connect hand vacuum pump (e.g. -V.A.G 1390-) to-
V.A.G 1390
gether with water drain reservoir (e.g. -V.A.G 1390/1-)

at return-flow hose -2- (marked in blue) of fuel filter.
Operate hand vacuum pump until fuel flows out of the

return-flow hose.
Ensure that no fuel is drawn into the hand vacuum
pump.
Connect return-flow hose -2- (marked in blue) to fuel

filter.
V.A.G 1390/1
1
2
S20-0109
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20-2 page 5
20
20-2 page 6
Edition 07.03
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20
20-3
Servicing accelerator pedal
Summary of components
1 - Bracket
Chassis; Rep. Gr. 46
2 - Connector
T 6-pin, black
3 - Accelerator pedal position
sender -G79T not adjustable
T The sender transmits the
driver's instructions (by depressing the brake pedal as
shown) to the engine control
unit.
T remove the footwell cover
before removing the sender
(driver side)
T inspecting 1.4/55 TDI Engine, Fuel Injection;
Rep. Gr. 28
4 - 10 Nm
S20-0110
Edition 07.03
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20-3 page 1
20
20-3 page 2
Edition 07.03
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21
21 Turbocharging
21-1
Charge air system with

turbocharger
Safety measures
Caution!
When undertaking all assembly work, particularly
in the engine compartment due to its cramped construction, please observe the following:
Lay lines of all kinds (e.g. for fuel, hydraulic flu-
id, the active charcoal container-unit, cooling

fluid and refrigerent, brake fluid, vacuum) and
electrical lines in such a way that the original
line guide is re-established.
Ensure that there is adequate free access to all
moving or hot components.

If test and measuring devices are required during test
drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them

there.
If the test and measuring devices are operated from the
passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.
Rules of cleanliness
Carefully observe the following rules for cleanliness when
working on the exhaust turbocharger:
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts: Remove spare parts from
their wrapping immediately before fitting. Do not use

any parts which have been (stored unwrapped, e.g.
on a shelf or in a tool box).
Transportation and protection packaging as well as fit-
tings should only be removed immediately before fitting.

During repairs clean supports and hose ends from oil.
When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
Edition 07.03
S00.5325.00.20
Charge air system with turbocharger
21-1 page 1
21
Removing and installing exhaust turbocharger with component parts

Note
The charge-air system must be tight.
Before connecting the oil feed line, fill the exhaust turbocharger on the connection fitting with engine oil.
After installing the exhaust turbocharger, run engine at idling speed for about 1 minute and do not increase the
speed immediately. This secures the lubrication of the turbocharger.

1 - Exhaust manifold
2 - 30 Nm
T replace
T Coat thread and head contact surfaces with paste
-G 052 112 A33 - Intake manifold
4 - from charge-air cooler
5 - Gasket
T replace
6 - 25 Nm
7 - Gasket
8 - Bracket
T for the shield plate item 10
9 - Washer
10 - Shield
T secure in the bracket
item 8
11 - 10 Nm
12 - Circlip
13 - Vacuum unit
T for the charge pressure control valve
T Component part of the exhaust turbocharger cannot
be replaced separately
14 - of valve block
T Connection diagram for vacuum hoses 21-1 page 3
15 - Release rod
16 - 10 Nm
T coat with -D 000 600 A217 - Bracket
18 - Connecting hose
T from rear charge air pipe 21-1 page 4
19 - Hollow screw, 15 Nm
20 - Gasket ring
T replace
21 - of valve block
T Connection diagram for vacuum hoses 21-1 page 3
T replace
T Coat thread and head contact surfaces with paste -G 052 112 A3-
21-1 page 2
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21
23 - Oil return line, 30 Nm

T To cylinder block
24 - 15 Nm
25 - Gasket
T replace
26 - Front exhaust pipe
27 - 25 Nm
T replace
28 - Exhaust turbocharger
T replace
T Coat thread and head contact surfaces with paste -G 052 112 A3T before connecting the oil feed line fill connection fitting with engine oil.
30 - Oil feed line, 22 Nm
T from oil filter holder Chapter 17-1
T Check oil feed line for continuity before installing.
Connection diagram for vacuum hoses

Connect vacuum hoses at valve block
1234567-
Connection air filter/exhaust turbocharger

to vacuum reservoir at exhaust turbocharger
To turbocharger
To intake manifold flap
To air filter
from non-return valve for brake servo unit
to mechanical exhaust gas recirculation valve
Edition 07.03
S00.5325.00.20
21-1 page 3
21
Removing and installing parts of the charge air cooling

Note
The hose connections are secured with clamps.
The charge-air system must be tight.
Remove oil and grease from the charge pressure hoses and charge pressure pipes and from their connections
before installing.
1 - Air deflector
2 - Charge air cooler
21-1 page 4
3 - 8 Nm
4 - O-ring
5 - Intake manifold pressure
sender -G71- with intake manifold temperature sender
-G726 - Bracket
7 - 5 Nm
8 - Connecting hose
9 - Top charge-air pipe
10 - To induction pipe
11 - From air filter
12 - From cylinder head cover
T Crankcase ventilation
13 - Rear charge-air pipe
14 - Exhaust turbocharger
15 - Bottom charge air pipe
16 - Bracket
T screwed onto the V-ribbed
belt holder Chapter 13-1
Removing and installing charge-air cooler

Torque wrench
21-1 page 4
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21
Removing
Removing right headlights Electrical System;

Rep. Gr. 94.
Remove plug -1- from the intake manifold pressure

sender -G71- with intake manifold temperature sender
- G72- (-2-).
Remove the connecting hose -3- from the supports.

Remove the front right wheelhouse liner Body
work; Rep. Gr. 66.
Unclip front charge-air routing.
Remove the connecting hose -1- from the charge-air

cooler -3-.
Release screws -2- and remove charge-air cooler -3-.

Installing
Installation is carried out in the reverse order.
S21-0027
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21-1 page 5
21
21-1 page 6
Edition 07.03
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21
21-2
Charge-air system with

exhaust turbocharger Part 2
Removing and installing turbocharger

Torque wrench
Removing

hose -2- -arrows-.
Removing connecting hose intake manifold/air filter

1.4/55 TDI Engine, Fuel Injection; Rep. Gr. 23.
Removing connecting tube inlet connection/exhaust

manifold Chap. 26-2.
Remove connecting tube for rear charge-air pipe with

connecting hose to turbocharger Chap. 21-1.
Unscrew the oil feed line for the exhaust turbocharger

Chapter 21-1.
Unscrew fixing screws of exhaust manifold at turbocharger Chapter 21-1.

Remove drive shaft to the right Running gear;
Rep. Gr. 40.
Unscrew the propeller-shaft guard from the cylinder

block.
Removing bottom charge air pipe with connecting

hose to turbocharger Chap. 21-1.
Pull out vacuum hoses from the turbocharger

Chapter 21-1 .
Unscrew the oil return-flow line from the cylinder block

Chap. 21-1.
Remove front exhaust pipe with catalyst Chapter

26-1.
S10-0114
Remove fixing nut of turbocharger at exhaust manifold

Chapter 21-1.
Remove turbocharger downwards.

Installing
Installation occurs in reverse order. Pay attention to the
following:
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Charge-air system with exhaust turbocharger - Part 2
21-2 page 1
21
Note
Tightening torques Chapter 21-1
After installing the exhaust turbocharger, run engine
at idling speed for about 1 minute to ensure that oil is

supplied to the exhaust turbocharger.
Checking charge pressure control

Hand vacuum pump (e.g. -V.A.G 1390-)
Hand multimeter (e.g. -V.A.G 1715-)
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C Adapter cable set (e.g. -V.A.G 1594 C-)
Test box -V.A.G 1598/31-
Test conditions
No fault stored in fault memory 1.4/55 TDI Engine,

Fuel Injection; Rep. Gr. 01
No leaks on the intake and exhaust side

No fault on the engine/fuel injection system
Engine oil temperature at least 80 C
Test sequence
If test and measuring devices are required during test
drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them

there.
If the test and measuring equipment is operated from
the front passenger seat, this can result in injuries to

the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.
The charge pressure is measured with vehicle system

tester -V.A.G 1552- when the engine is idling and during a road test.
Connect vehicle system tester -V.A.G 1552- and select address word 01 Engine electronics. (the engine
must be idling at the time) 1.9/74 TDI Engine, Fuel
Injection; Rep. Gr. 01.
Select function
0 4 for Basic setting and display
group 0 1 1 .
Readout on display:
21-2 page 2
Basic setting 11
1400 rpm
OFF
200 mbar
->
99 %
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21
Note
After selecting display group 011, the idling speed is increased by the engine control unit in display block 1 to
13801420 rpm.
The display in display field 2 must switch between off
and on every 10 seconds.
The following readouts must fluctuate in display fields 3
and 4:
Display field 2: off.
Specification in display field 3: Atmospheric pressure
in mbar
Specification in display field 4: 98100 %
Display field 2: on.

Specification in display field 3: Atmospheric pressure
in mbar +80250 mbar

Specification in display field 4: 02 %
Continue the test as follows:

Press .
Select function
0 8 for Read measured value
block and display group 0 1 1 .
Accelerate vehicle in 3rd gear at full throttle from

about 1500 rpm.
At about 3000 rpm read off the value indicated in display block.
Reading measured value block 11

3090 rpm
1866 mbar
1917 mbar
->
62 %
Specification in display field 3: 18502250 mbar

If the specified value is not reached:
Activate charge pressure control solenoid valve with
final control diagnosis 1.4/55 TDI Engine, Mechanics; Rep. Gr. 01.
Charge pressure control solenoid valve must operate for

this test. While doing so the linkage of the charge pressure control vacuum unit at the bottom of the turbocharger must move back and forward. This linkage must move
at least 34 times as long as a vacuum is present in the
vacuum system.
If the linkage moves and the nominal charge pressure is
not reached:
Check charge air pressure system for leaks.

Replace exhaust turbocharger 21-2 page 1.
If the linkage does not move because the charge pressure control solenoid valve is not operating:
Inspect charge pressure control solenoid valve -N75 1.4/55 TDI Engine, Mechanics; Rep. Gr. 23.
Inspect vacuum hoses Chapter 21-1 .

If the linkage does not move although the charge pressure control solenoid valve is operating:
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21-2 page 3
21
Connect hand vacuum pump to charge pressure control valve and inspect linkage for unobstructed movement.
If the linkage only moves with difficulty or does not move
at all:
Replace exhaust turbocharger 21-2 page 1.
21-2 page 4
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26
26 Exhaust System
26-1

parts of the exhaust system
Note
After performing installation work on the exhaust sys-
tem, make sure the exhaust system is not mounted

under tension and has adequate clearance from the
vehicle body. If necessary slacken double clamp and
collar clamp and align silencer and exhaust pipe so
that ithere is adequate clearance between these components and the body and that the weight is evenly
distributed over the hangers.
Gaskets and self-locking nuts must be replaced.
1 - Gasket
T replace
2 - 25 Nm
T replace
3 - Spring loop
4 - Front exhaust pipe with catalytic converter
5 - Identification
6 - Dimension -a- = approx. 12
mm.
7 - Double clamp
8 - 40 Nm
9 - Hanger
T with spring loop
10 - 25 Nm
11 - Rear silencer
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Removing and installing parts of the exhaust system
26-1 page 1
26
Align exhaust system free of stress

Torque wrench
Procedure
The exhaust system is aligned when cold.

Slacken bolted connections of double clamp between
catalytic converter and front silencer and replace nuts.
Position double clamp at the distance -a- = 5 mm from

the marking on the pipe of the catalytic converter
(bolts at bottom and horizontal) and tighten front bolted connection slightly.
S26-0064
Push front silencer -1- sufficiently far forward into the

double clamp until the dimension -b- of 37 mm is
achieved between hanger of body and hanger of front
silencer.
-Arrow- points in direction of travel.
Tighten bolted connections on the double clamp in

this position.
Note
After tightening the double clamp, inspect dimension -band adjust if necessary.
b
S26-0065
Replacing front or rear silencer

Torque wrench
Body saw (e.g. -V.A.G 1523-)
A separation point is provided for repair purposes for replacing the front silencer or rear silencer.
Separate exhaust pipe with body saw at right angles
at the separation point -arrow 1-.
When installing double clamp -4- position on the side

markings -arrows 2 and 3-.
Align exhaust system free of stress 26-1 page 2.

Align rear silencer horizontally.
Tighten bolted connections of the double clamp evenly to 40 Nm.
3
2
Installation position of double clamp: Bolts positioned

vertically at front of exhaust pipe.
1
S26-0063
26-1 page 2
Removing and installing parts of the exhaust system
Edition 07.03
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26-2
26
Exhaust gas recirculation

system
Note
The exhaust gas recirculation system is operated by
the diesel direct injection system control unit -J248via the EGR valve -N18- to the mechanical exhaust
gas recirculation valve.
The mechanical exhaust gas recirculation valve with
cone-shaped valve plunger makes it possible to

achieve different opening cross-sections at different
valve strokes.
Any desired valve position is possible as a result of the
pulsed operation
Removing and installing parts of the exhaust gas recirculation system

1 - Intake manifold
2 - O-ring
T replace
3 - Inlet connection
T with mechanical exhaust gas
recirculation valve and intake
manifold flap
4 - Mechanical exhaust gas recirculation valve
T part of inlet connection
T Must be replaced together
with the inlet connection
5 - 10 Nm
6 - from charge-air cooler
7 - Gasket
T replace
8 - 25 Nm
9 - Exhaust manifold
10 - Connecting tube
Edition 07.03
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Exhaust gas recirculation system
26-2 page 1
26
Testing mechanical exhaust gas recirculation valve

Hand vacuum pump (e.g. -V.A.G 1390 -)
Test sequence

Disconnect vacuum hose on mechanical exhaust-gas
recirculation valve.
V.A.G 1390
Connect hand vacuum pump to valve.

Operate pump and observe.
The diaphragm must move in the -direction of the arrow-.
Detach hose of hand vacuum pump from mechanical

exhaust gas recirculation valve.
The diaphragm must move back to its original position
against the -direction of the arrow-.
S13-0161
26-2 page 2
Exhaust gas recirculation system
Edition 07.03
S00.5325.00.20

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Service

1.4/55 TDI Engine, Mechanics

Service Department. Technical Information

Printed in Czech Republic

Printed in Czech Republic

FABIA 2000 1.4/55 TDI Engine, Mechanics

List of Supplements to Workshop Manual

FABIA 2000 1.4/55 TDI Engine, Mechanics

FABIA 2000 1.4/55 TDI Engine, Mechanics

- Engine number ......................................................................................... 00-1

- Engine characteristics ................................................................................ 00-1

Removing and Installing Engine .................................................................... 10-1

- Removing engine ...................................................................................... 10-1

- Securing the engine to the assembly stand ....................................................... 10-1

- Installing the engine ................................................................................... 10-1

- Tightening torques .................................................................................... 10-1

- Assembly bracket ...................................................................................... 10-1

Removing and installing V-ribbed belt ............................................................ 13-1

- Removing and installing V-ribbed belt .............................................................. 13-1

- Routing of the V-ribbed belt .......................................................................... 13-1

Removing and installing, tightening the timing belt ........................................... 13-2

- Timing belt - Summary of components ............................................................. 13-2

- Removing and installing, tightening the timing belt .............................................. 13-2

Disassembling and assembling engine ........................................................... 13-3

- Cylinder block - Summary of components ......................................................... 13-3

Removing and installing sealing flange and flywheel ......................................... 13-4

- Removing and installing the front sealing flange ................................................. 13-4

Crankshaft, Piston and Conrod ..................................................................... 13-5

- Removing and installing crankshaft ................................................................ 13-5

- Disassembling and assembling piston and conrod .............................................. 13-5

- Checking piston projection in TDC .................................................................. 13-5

- removing and installing balancing shaft ............................................................ 13-6

Removing and installing cylinder head ........................................................... 15-1

- Removing and installing cylinder head ............................................................. 15-1

- Testing the compression ............................................................................. 15-1

Repairing Valve Gear .................................................................................. 15-2

- Summary of components ............................................................................. 15-2

Camshaft ................................................................................................. 15-3

- Removing and installing camshaft .................................................................. 15-3

- Removing and installing gasket ring for camshaft ................................................ 15-3

.................................................... Valve seats, valves guides, valve stem seals 15-4

- Grinding in valve seats ............................................................................... 15-4

- Inspect valve guides .................................................................................. 15-4

- Replacing valve stem seals .......................................................................... 15-4

10 Removing and Installing Engine

15 Cylinder Head, Valve Gear

FABIA 2000 1.4/55 TDI Engine, Mechanics

- Lubrication system - Summary of components ................................................... 17-1

- Disassembling and assembling oil filter holder ................................................... 17-1

Removing and installing oil pan .................................................................... 17-2

- Removing and installing oil pan ..................................................................... 17-2

Testing oil pressure and oil pressure switch .................................................... 17-3

Parts of cooling system - Summary of components ........................................... 19-1

- Parts of the cooling system fitted to body ......................................................... 19-1

- Parts of cooling system engine side ................................................................ 19-1

- Connection diagram for coolant hoses ............................................................. 19-1

- Draining and filling up coolant ....................................................................... 19-1

- Checking the coolant system for tightness ........................................................ 19-1

- Removing and installing radiator .................................................................... 19-2

- Removing and installing coolant pump ............................................................ 19-2

- Removing and installing coolant regulator ........................................................ 19-2

- Fuel tank with component parts - Summary of components .................................... 20-1