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Workshop Manual

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Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system AG. Volkswagen AG d
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg K0051008120


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . k.s. . . . . . . . . . . . . . . . . . . . . . . . 4
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1.2 Securing engine to assembly stand . . . . . . . l.ks.w.a.ge.n. . . . . . . . . . .A.G. d.o.es. n. . . . . . . . . . . . . . 7
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1.3 Notes on installing . . . . . . . . . . . . . . . .e.d b. y.V. . . . . . . . . . . . . . . . . . . . . . . . .g.ua. ra. . . . . . . . . . 7
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1.4 Specified torques . . . . . . . . . . . . . .th.or.i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e .o . . . . . . 8
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1.5 Aligning engine and gearbox mountings ss
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1.6 Specified torques for assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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1.7 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . 10
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 18
2.1 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25


3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


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4.1 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30


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4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 en


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1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1.1 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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1.2 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Contents i
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.1 Parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77


1.2 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.8 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.9 Checking oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98


1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.2 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.3 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.5 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.6 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.7 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.8 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.9 Removing and installing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.10 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.11 Removing, installing and checking suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.12 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.13 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.14 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1 Charge air system with turbocharger . . . . . . . . . . . .n .AG . .. V.o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . 125
1.1 Assembly overview - turbocharger with attachments lks wage . . . . . . . . . . . . .d.oe. s.n. . . . . . . . . . . . . . 125
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1.2 Removing and installing parts of chargeisair ed cooling . . . . . . . . . . . . . . . . . . . . .ra.n . . . . . . . .
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1.3 Checking charge air system for leaks aut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a. . . . .
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1.4 Vacuum hose schematic diagram ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . 135
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1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137


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1.6 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138


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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


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1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


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1.3 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140


1.4 Assembly overview - Intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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1.5 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146


1.6 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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1.7 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149


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2 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155


2.1 Checking speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156


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3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156


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3.2 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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3.3 Adapting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157


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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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1.1 Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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1.2 Vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

ii Contents
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. . . 167

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Removing and installing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . 167

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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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1.2 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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Contents iii
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

AG. Volkswagen AG d
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iv Contents
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

00 – Technical data
1 Technical data

1.1 Engine number


The engine number (“code letters” and “serial number”) -arrow-
can be found on the joint between engine and gearbox.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine code is also included on the vehicle data plate.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.

1.2 Engine data


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Output kW at rpm 85/4000 110/4000 96/4000 74/4000


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Torque Nm at rpm 285/1900 320/1900 310/1900 240/ 1800 …


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Bore ∅ mm 79.5 79.5 79.5 79.5


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Stroke mm 95.5 95.5 95.5 95.5


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Compression ratio 18.0 19.5 19.0 19.0


t to the co

Fuel according to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
rrectness of i

Catalytic converter yes yes yes yes


l purpos

Exhaust gas recirculation yes yes yes yes


Turbocharging/supercharging yes yes yes yes
nf
ercia

Charge air cooler yes yes yes yes


rm
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Engine code AUY AXR


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Manufactured 05.00 ▸ 05.01 ▸


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Emissions fulfil EU3 standard EU3 + D4 standards
Co
Cop py
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Capacity gh
l 1.9 1.9
ht
pyri by
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Output by c
kW at rpm 85/4000 74/4000
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Torque Nm at rpm 310/1900 240/ 1800 …2400
Bore ∅ mm 79.5 79.5
Stroke mm 95.5 95.5
Compression ratio 18.0 19.0
Fuel according to DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2
Catalytic converter yes yes

1. Technical data 1
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Engine code AUY AXR


Exhaust gas recirculation yes yes
Turbocharging/supercharging yes yes
Charge air cooler yes yes

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2 Rep. Gr.00 - Technical data


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

10 – Removing and installing engine


1 Removing and installing engine

Special tools and workshop


equipment required
♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Workshop crane -V.A.G
1202-
♦ Drip tray -V.A.G 1306-

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t to the co
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tion in
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Cop py
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1. Removing and installing engine 3


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Torque wrench (5…50 Nm)


-V.A.G 1331-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024-
♦ Ladder -V.A.S 5085-
♦ Grease (vehicles with man‐ agen
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♦ Bolt M10×25 / 8.8 horis
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1.1 Removing engine
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Note

♦ The engine is removed downwards together with the gearbox.


♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
♦ First check whether a coded radio is fitted. If so, obtain anti-
theft coding.

4 Rep. Gr.10 - Removing and installing engine


AG. Volkswagen AG d
agen oes
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Vol not
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d ara
orise 4-cylinder diesel nteengine with unit injector - Edition 08.2009
h eo
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WARNING
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When doing any repair work, especially in the engine compart‐
erm

ab
ility
ment, pay attention to the following due to the cramped condi‐
ot p

wit
tions:
is n

h re
ole,

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

spec
urposes, in part or in wh

vated charcoal filter system, coolant and refrigerant, brake

t to the co
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or

rrectne
hot components.

ss o
cial p

f
Procedure

inform
mer

– With ignition switched off, disconnect earth strap from battery.

atio
om

– Remove engine cover.

n
c

i
or

n thi
e

– Remove battery and battery retainer.


t

sd
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pr

c
– Remove air filter.

um
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fo

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t.
yi
– Disconnect connecting pipe between charge air cooler and in‐
Co
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take connecting flange at intake connecting flange.
t. C rig
gh ht
pyri by
Vo
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– Disconnect fuel supply and return lines at fuel filter. by c lksw
cted agen
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WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

Vehicles with manual gearbox


– Remove hydraulic clutch slave cylinder ⇒ Rep. Gr. 30
– Disconnect selector mechanism from gearbox ⇒ Rep. Gr. 34
Vehicles with automatic gearbox
– Remove selector lever cable from gearbox: ⇒ Rep. Gr. 37 .
Continuation for all vehicles
– Remove centre, left and right insulation tray ⇒ Rep. Gr. 50

Note

On vehicles with engine code “ARL”, connecting hoses on charge


oil cooler must be removed ⇒ page 130 Removing and installing
parts of charge air cooling system.

– Drain coolant ⇒ page 85 .


– Pull connectors off thermal switch and radiator fan.
– Pull coolant hoses off radiator.

1. Removing and installing engine 5


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Disconnect all electric wires from gearbox, alternator and


starter and lay to side.
– Unbolt pendulum support in sequence specified -arrows-.
– On vehicles with four-wheel drive, unscrew front propshaft at
gearbox ⇒ Rep. Gr. 39 .
– Removing front exhaust pipe ⇒ page 159 , removing and in‐
stalling parts of exhaust system.
– Remove poly V-belt ⇒ page 16 .
– Unbolt power steering vane pump on bracket and place to one
side, hoses remain connected ⇒ Rep. Gr. 48
– Separate all connecting, coolant, vacuum and intake hoses
from engine.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay clear.
– Remove right drive shaft and disconnect left drive shaft at
gearbox: ⇒ Rep. Gr. 40 .
– Remove securing clamps for power steering pressure line.
– On vehicles with air conditioner, observe additional notes and
assembly work ⇒ page 10 .
– Insert engine support -T10012- in engine and gearbox jack -
V.A.G 1383 A- .

– Fit engine bracket -T10012- onto cylinder block with securing


nut and M10 X 25/ 8.8 bolt and tighten to approx. 40 Nm.
– Lift engine and gearbox slightly using engine and gearbox jack
-V.A.G 1383 A- .

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– Unbolt engine side of assembly mounting from engine bracket


ility
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from above -arrows-.


wit
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hole

spec

Note
es, in part or in w

t to the co

To remove securing bolts, use stepladder V.A.S -V.A.S 5085- .


rrectness of i
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6 Rep. Gr.10 - Removing and installing engine


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Unbolt gearbox side of assembly mounting from gearbox


bracket -arrows- from above.
– Carefully lower engine with gearbox.

Note

Engine with gearbox must be guided carefully when lowering to


prevent damage to bodywork.
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1.2 Securing engine to assembly stand
s

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When working on the engine, secure it to support clamp -VW 313-


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rm

of the assembly stand using engine and gearbox support -VW

ab
pe

ility
540- .
ot

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Procedure

h re
hole

spec
– Remove gearbox.
es, in part or in w

t to the co
– On vehicles with automatic gearbox, prevent torque converter
from “falling out” after engine is separated from gearbox.

rrectness of i
– Attach lifting tackle -2024 A- as follows and lift off engine and
gearbox jack -V.A.G 1383 A- using workshop crane.
l purpos

Pulley end: 2nd hole of hook rail in position 1

nform
ercia

Flywheel end: 4th hole of hook rail in position 8


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WARNING
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The hooks and locating pins must be secured with locking pins.
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♦ The holes marked with 1 … 4 of the support bar point to the
AG.

belt pulley.
♦ The holes in the hook rails are counted up from the hook.

– Secure engine with engine and gearbox support -VW 540- on


support clamp -VW 313- .

Note

First loosen coolant pipe at flywheel end.

1.3 Notes on installing


Installation is carried out in the reverse order. When installing,
note the following:
– Check clutch release bearing for wear and renew if necessary.
– Lightly lubricate clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease -G 000 100- .
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.

1. Removing and installing engine 7


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– When installing engine and gearbox, ensure that there is suf‐


ficient clearance to drive shafts.
– Aligning engine and gearbox mountings ⇒ page 8 . Speci‐
fied torques for assembly mountings ⇒ page 9 .
– Install drive shafts ⇒ Rep. Gr. 40 .
– Installing front exhaust pipe ⇒ page 159 , removing and in‐
stalling parts of exhaust system
– On vehicles with four-wheel drive, install propshaft ⇒ Rep. Gr.
39 .
Vehicles with manual gearbox
– Install hydraulic clutch slave cylinder
en AG. V
o⇒
lkswRep.
agen AGr.
G
30
ag does
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– Adjust selector mechanism
yV and, if necessary, selector
ot gcables
ua
db
⇒ Rep. Gr. 34 ris e ran
te
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ut
Vehicles with automatic
ss
a gearbox ra
c

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– Install gate lever cable on gearbox, adjust if necessary ⇒ Rep.


un

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Gr. 37 .
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Continuation for all vehicles

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– Install power-assisted steering vane pump ⇒ Rep. Gr. 48 .

h re
ole,

– Reconnect connecting pipe between charge air cooler and in‐

spec
urposes, in part or in wh

take manifold at intake manifold.


– Electrical connections and routing ⇒ Rep. Gr. 97 . t to the co
– On vehicles with air conditioner: install air conditioner com‐
rrectne

pressor ⇒ Rep. Gr. 87 .


– Install poly V-belt ⇒ page 16 .
ss o
cial p

– Remove centre, left and right sound insulation tray ⇒ Rep. Gr.
inform

50 .
mer

atio
m

– Fill with coolant ⇒ page 85 .


o

n
c

i
or

– Carry out a road test and read fault memory ⇒ page 156
thi
te

sd
a

Reading and clearing fault memory of engine control unit.


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1.4 Specified torques


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Threaded connection Specified torque
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Bolts, nuts by c
M6 10 Nm
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M8 20 Nm
M10 45 Nm
M 12 60 Nm
Deviations
Front exhaust pipe to turbocharger 25 Nm

1.5 Aligning engine and gearbox mountings

WARNING

The assemblies must be supported with support bracket


10-222A before the bolts are loosened.

8 Rep. Gr.10 - Removing and installing engine


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Engine assembly mountings


a = 14.0 mm
b = At least 10.0 mm
Both bolt heads -1- must be flush with edge -c-.

Gearbox assembly mounting


The edges -a- and -b- must be parallel with one another.
c = 18…20 mm

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Specified torques for assembly mount‐ ac
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Right assembly mounting


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1- Mounting to body 1) 40 Nm + 90°


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2- Mounting/bracket to body 25 Nm
hole

spec

3- Mounting to engine bracket 100 Nm


es, in part or in w

t to the co

1) Renew bolts.
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1. Removing and installing engine 9


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Left assembly mounting on vehicles with manual gearbox: n AG. Volkswagen AG do


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1- Mounting to body 2) 40 Nm + 90° d byV ua
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2- Mounting to body 25 Nm tho tee
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3- Mounting to gearbox console 100 Nm ss

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2) Renew bolts.

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Assembly mounting, left on vehicles with automatic gearbox:
1- Mounting to body 3) 40 Nm + 90°

rrectness of i
2- Mounting to body 25 Nm
l purpos

3- Mounting to gearbox console 100 Nm

nform
ercia

3) Renew bolts.
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tion in
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Pendulum support C py
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Installation sequence:
p by
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Prote
1- Pendulum support to subframe 25 Nm
AG.

2- Pendulum support to gearbox 50 Nm


3- Pendulum support to gearbox 50 Nm

1.7 Additional information and removal in‐


structions for vehicles with air condition‐
er

WARNING

The air conditioner refrigerant circuit must not be opened.

Note

To prevent damage to condenser or to refrigerant pipes and ho‐


ses, ensure that pipes and hoses are not stretched, kinked or
bent.

To facilitate removing and installing engine without opening re‐


frigerant circuit:
– Remove retaining clamp(s) for refrigerant lines.
– Remove poly V-belt ⇒ page 16 .

10 Rep. Gr.10 - Removing and installing engine


AG. Volkswagen AG d
agen oes
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by Vol
gu
ara
Bora 1999 ➤ , Golf 1998 ➤
d
orise 4-cylinder diesel nteengine
eo
with unit injector - Edition 08.2009
th
au ra
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– Remove air conditioner compressor ⇒ Rep. Gr. 87 . s

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nl

pt
– Secure air conditioner compressor to towing eye so that the du

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itte

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refrigerant lines/hoses are not under tension.
erm

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ility
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Note

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spec
To prevent damage to bumper protect with adhesive tape.
es, in part or in w

t to the co
rrectness of i
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ercia

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1. Removing and installing engine 11


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

13 – Crankshaft group
1 Dismantling and assembling engine

Note

If large quantities of swarf or metal particles (caused, for example,


by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the oil cooler in order to prevent subse‐
quent damage.

1.1 Overview

l - ⇒ page 13
II - ⇒ page 14
III - ⇒ page 15

AG. Volkswagen AG d
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urposes, in part or in wh

t to the co
rrectness o
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mer

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12 Rep. Gr.13 - Crankshaft group


n AG. Volkswagen AG do
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b ua
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ran diesel
tee engine with unit injector - Edition 08.2009
tho
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1.1.1 ss Part I

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1 - Toothed belt guard - upper
erm

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ility
part
ot p

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2 - Toothed belt

h re
hole

spec
❑ Mark direction of rota‐
es, in part or in w

tion before removing.

t to the co
❑ Check for wear.
❑ Do not kink.

rrectness of i
❑ Removing, installing
and tensioning
l purpos

⇒ page 37 .
3 - 20 Nm + turn 45° further

nform
ercia

4 - Tensioning roller
m

at
om

ion
5 - 100 Nm
c

in t
or

his
te

6 - 25 Nm
a

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cum
or

7 - Camshaft toothed belt pul‐


f

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ley
t.
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. rig
8 - Hub
t
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❑ With sender wheel.
c by lksw
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❑ Use counterhold -
T10051- to loosen and
tighten
❑ To remove, use puller -
T10052-
❑ Removing and installing
⇒ page 60 Removing
and installing camshaft
9 - 10 Nm
❑ Renew
10 - Rear toothed belt guard
11 - Sealing grommet
❑ Renew if damaged.
12 - Toothed belt tensioner
❑ Only vehicles with hydraulic belt tensioning system
13 - Idler roller
❑ Only vehicles with hydraulic belt tensioning system
14 - Coolant pump
❑ Removing and installing ⇒ page 90
15 - Crankshaft toothed belt pulley
16 - 120 Nm + turn 90° further
❑ Renew
❑ Use counterhold tool -3099- to loosen and tighten.
❑ Do not add oil or grease to thread and shoulder
❑ Turning further can be done in several stages

1. Dismantling and assembling engine 13


AG. Volkswagen AG d
agen oes
olksw not
Bora 1999 ➤ , Golf 1998 ➤ d by
V gu
ara
e nte
4-cylinder diesel engine with unit injector - Edition
horis
08.2009 eo
aut ra
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17 - 15 Nm

ce
le
un

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18 - 20 Nm

itte

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ab
19 - Toothed belt guard - lower part

pe

ility
ot

wit
, is n
20 - Pulley and vibration damper

h re
hole
❑ Can only be installed in one position, holes are offset.

spec
es, in part or in w
21 - 10 Nm + turn 90° further

t to the co
22 - Cover

rrectness of i
23 - Toothed belt guard - centre part
l purpos

1.1.2 Part II

nform
mercia

a
com

ti
1 - Poly V-belt

on in
r
te o

❑ Mark direction of rota‐

thi
s
iva

tion before removing.

do
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rp

cum
❑ Check for wear.
fo

en
ng

t.
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❑ Do not kink.
Co
Cop py
t.
❑ Removing and installing
rig
gh ht
yri by
⇒ page 16 op Vo
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2 - 10 Nm + turn 90° further
AG.

3 - Pulley and vibration damper


❑ Can only be installed in
one position, holes are
offset.
4 - 25 Nm
5 - Poly V-belt tensioner
❑ Swing with open-end
spanner to slacken poly
V-belt ⇒ page 16
6 - Alternator
7 - Bracket for ancillaries
❑ For alternator, power
steering vane pump and
A/C compressor
8 - 45 Nm
❑ Observe tightening se‐
quence ⇒ page 16 .
9 - Banjo bolt, 30 Nm
10 - Seal
❑ Renew
11 - Pressure line
12 - Vane pump
❑ For power steering
❑ Removing and installing ⇒ Rep. Gr. 48
13 - Pulley
❑ For vane pump

14 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.1.3 Part III

1 - 45 Nm
2 - Screen
3 - Cylinder block
❑ Removing and installing
sealing flange and fly‐
wheel ⇒ page 18
❑ Removing and installing
crankshaft
⇒ page 25 .
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❑ Dismantling and assem‐ lkswage es n
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bling pistons and con‐ d byV ua
ran
rods ⇒ page 27 ir se tee
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4 - 10 Nm ss

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5 - Bracket

pt
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❑ For vacuum reservoir
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ility
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6 - Vacuum reservoir

wit
, is n

❑ Attached to charge air

h re
hole

pipe on vehicles with en‐

spec
gine code ARL
es, in part or in w

t to the co
⇒ page 130 Removing
and installing parts of
charge air cooling sys‐
tem

rrectness of i
7 - 15 Nm
l purpos

8 - Gasket

nf
ercia

❑ Renew

orm
m

atio
9 - Oil filter bracket
om

n in
c

❑ Dismantling and assem‐


or

thi
e

bling ⇒ page 69 .
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rp

cu
10 - 15 Nm + turn 90° further
o

m
f

en
ng

❑ Renew
t.
yi Co
op py
❑ First fit upper left and
t. C rig
gh ht
yri
lower right bolts and then tighten all four bolts in diagonal sequence p by
co Vo
by lksw
cted agen
11 - Engine speed sender -G28- Prote AG.

12 - Connection
❑ For thermostat
13 - 15 Nm
14 - O-ring
❑ Renew
15 - Thermostat
❑ Removing and installing ⇒ page 92
❑ Observe installation position, ⇒ page 92 Removing and installing thermostat
❑ Checking: Heat thermostat in water.
❑ Opening begins at approx. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift min. 7 mm.
16 - 45 Nm
❑ Observe tightening sequence ⇒ page 16 .

1. Dismantling and assembling engine 15


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

17 - Bracket for ancillaries


❑ For alternator, power steering vane pump and A/C compressor
18 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D 176 404 A2- ⇒ page 72 .
19 - 15 Nm

Sequence for tightening ancillary bracket to cylinder block


Procedure
– Place ancillary bracket on cylinder block (observe dowel
sleeve between ancillary bracket and cylinder block).
– Tighten ancillary bracket as shown in following tightening se‐
quence:
1 - Tighten bolt -A- to 45 Nm
n AG. Volkswagen AG do
2 - Tighten bolt -B- to 45 Nm olkswage es n
ot g
byV ua
3 - Tighten bolt -C- to 45 Nm ir se
d ran
tee
tho
or
4 - Tighten bolt -D- toss45
au Nm ac

ce
e

5 - Tighten bolt -E- to 45 Nm


nl

pt
du

an
itte

y li
6 - Tighten bolt -F- to 45 Nm
erm

ab
ility
ot p

1.2 Removing and installing poly V-belt


wit
, is n

h re
hole

spec

Special tools and workshop equipment required


es, in part or in w

t to the co

♦ Locking pin -T10060 A-


rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi
Removing
Co
Cop py
t. rig
gh ht
– Remove right noise insulation ⇒ Rep. Gr. 50 . yri
p by
co Vo
by lksw
cted
– Mark direction of rotation of poly V-belt.
agen
Prote AG.

– Swing tensioning device in direction of arrow to relieve tension


on poly V-belt.

16 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Lock tensioning element in position with locking pin -T10060


A- .
– Remove poly V-belt.
Installing
– Installation is carried out in the reverse order of removal.

Note

♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐


nator, air conditioner compressor, vane pump) are secured
tightly.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
♦ For vehicles without air conditioning, fit poly V-belt on alterna‐
tor last.
♦ For vehicles with air conditioning, fit poly V-belt on air condi‐
tioner compressor last.

After completing repairs always:


– Start engine and check belt running.

Belt drive without air conditioner compressor

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Belt drive with air conditioner compressor ut
ho eo
ra
s a c
s ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

17
op Vo
by c lksw
Prote
cted 1. Dismantling and assembling engine
AG.
agen
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

2 Removing and installing sealing


flanges and flywheel or drive plate

Note
G. Volkswage
♦ Repair measures to clutch (vehicles with front-wheel
lksw
agen
A
drive) ⇒ n AG does n
Rep. Gr. 30 yV
o ot g
ua
db ran
ir se
♦ Repair measures to clutch (vehicles
ut
ho with four-wheel drive) ⇒ tee
or
Rep. Gr. 30 ss
a ac

ce
e
nl

pt
du

an
itte

y li
1 - Seal
erm

ab
ility
ot p

❑ Do not additionally oil or

wit
grease the oil seal seal‐
, is n

h re
ing lip.
hole

spec
❑ Before installing, re‐
es, in part or in w

move oil residue from

t to the co
crankshaft journal using
a clean cloth.

rrectness of i
❑ Renewing crankshaft oil
seal - belt pulley end
l purpos

⇒ page 19 .
2 - Sealing flange

nform
ercia

❑ Must seat on dowel


m

at
sleeves.
om

ion
c

❑ Removing and installing

in t
or

⇒ page 22
his
ate

do
riv

❑ Install with silicone seal‐


p

cum
or

ant -D 176 404 A2-


f

en
ng

t.
⇒ page 22 .
yi Co
Cop py
t. rig
3 - Cylinder block
gh ht
pyri by
Vo
co
❑ Removing and installing
by lksw
cted agen
crankshaft
Prote AG.

⇒ page 25 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 27
4 - Flywheel/drive plate
❑ To remove and install
flywheel, counterhold
with 3067
❑ Removing and installing
drive plate
⇒ page 20 .
5 - 60 Nm + turn 90° further
❑ Renew
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
7 - 15 Nm
8 - Sealing flange with oil seal.
❑ Only renew complete.
❑ Do not additionally oil or grease the oil seal sealing lip.

18 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
AG. Volks4-cylinder
wagen AG diesel engine with unit injector - Edition 08.2009
agen does
olksw not
V g
❑ Before installing, ed remove oil residue from crankshaftujournal
by ara
nte
using a clean cloth.
ris
❑ Use support thsleeve supplied when installing.
o eo
au ra
c
❑ Only remove
ss supporting sleeve after sealing flange has been slid onto crankshaft journal.

ce
le
un

pt
an
d
itte

y li
erm

ab
2.1 Renewing crankshaft oil seal - pulley end

ility
ot p

wit
is n

h re
ole,

Special tools and workshop

spec
urposes, in part or in wh

equipment required

t to the co
♦ Toothed belt pulley coun‐
terhold tool -3099-

rrectne
♦ Oil seal extractor -3203-
♦ Fitting tool -T10053-

ss o
cial p

f
♦ Torque wrench -V.A.G

inform
1331-
mer

atio
♦ Torque wrench -V.A.G
om

n
1332-
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove toothed belt ⇒ page 37 .

2. Removing and installing sealing flanges and flywheel or drive plate 19


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Remove crankshaft toothed belt pulley. To do this, lock belt


pulley using counterhold tool -3099- .

Note
AG. Volkswagen AG d
When bolting on counterhold, place 2 washers
olks
wabetween
gen belt pul‐ oes
not
ley and counterhold. d by V gu
ara
e nte
ris
tho eo
– To guide seal extractor, screw
ss
centre bolt into au crankshaft to ra
c
stop by hand.

ce
e
nl

pt
du

an
– Screw inner part of oil seal extractor -3203- two turns (approx.
itte

y li
3 mm) out of outer part and lock using knurled screw.
erm

ab
ility
ot p

wit
– Lubricate threaded head of oil seal extractor, place it in posi‐
, is n

h re
tion and, exerting firm pressure, screw it into oil seal as far as
hole

spec
possible.
es, in part or in w

t to the co
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
Installing

rrectness of i
l purpos

Note

nf
ercia

o
The sealing lip of the oil seal must not be additionally oiled or

rm
m

greased.

atio
om

n in
or c

thi
– Remove oil residue from crankshaft journal using clean cloth.
te

sd
iva

o
r
rp

cu
o

– Fit guide sleeve -T10053/1- onto crankshaft journal.


m
f

en
ng

t.
yi Co
– Slide oil seal over guide sleeve onto crankshaft journal. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Press in assembly device -T10053- onto stop with centre bolt.


– Install and tension toothed belt ⇒ page 37 .

2.2 Removing and installing drive plate


Special tools and workshop equipment required
♦ Clutch counterhold tool -VW 558-
♦ Hexagon bolt M8×45

20 Rep. Gr.13 - Crankshaft group


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Bora 1999 ➤ , Golf 1998 ➤
ise nte
r
ut
ho 4-cylinder diesel engine with eo
ra unit injector - Edition 08.2009
s a c
s
♦ - zwei Sechskantmuttern M10-

ce
e
nl

pt
du

an
itte
♦ Depth gauge

y li
erm

ab
ility
Loosening and tightening drive plate
ot p

wit
, is n

– Secure clutch counterhold tool -VW 558- to drive plate with

h re
hole

hexagon bolt M8x45. Insert two M10 hexagon nuts between

spec
counterhold tool and drive plate.
es, in part or in w

t to the co
Position of counterhold tool:
A - To loosen

rrectness of i
B - To tighten
l purpos

– Loosen drive plate bolts.

nf
ercia

Install drive plate

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Fit drive plate using packing plate with recesses -1-.
– Fit new bolts -3- and tighten to 30 Nm.
Check dimension -a- at three points and calculate average.

Specification: 19.5…21.1 mm

Note

Measure through hole in drive plate to milled surface of cylinder


block.

If the specification is not attained:

2. Removing and installing sealing flanges and flywheel or drive plate 21


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit. Vinjector
gen AG
olkswage-n Edition
AG d 08.2009
wa oes
olks not
yV gu
– Remove drive plate again
ise
d and fit
b shim -2-. Tighten bolts -3- aran
again to 30 Nm. uthor tee
or
a ac
ss
– Tighten bolts -3- to 60 Nm and turn 90° (1/4 turn) further (turn‐

ce
le
ing further can be done in several stages).
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
2.3 Removing and installing sealing flange - pulley end

ss o
cial p

Special tools and workshop

f in
equipment required

form
mer

atio
♦ Toothed belt pulley coun‐
om

terhold tool -3099-

n
c

i
or

n thi
e

♦ Fitting tool -T10053-


t

sd
iva

o
pr

cum
♦ Torque wrench -V.A.G
r
fo

en
ng

1331-
t.
yi Co
Cop py
♦ Torque wrench -V.A.G
t. rig
gh ht
yri
1332-
p by
co Vo
by lksw
cted agen
♦ Hand drill with plastic brush
Prote AG.

attachment
♦ Silicone sealant -D 176 404
A2-
♦ Flat scraper

Removing
– Remove toothed belt ⇒ page 37 .

22 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Remove crankshaft toothed belt pulley. To do this, lock belt


pulley using counterhold tool -3099- .

Note

When bolting on counterhold, place 2 washers between belt pul‐


ley and counterhold.

– Drain engine oil.


AG. Volkswagen AG d
– Remove sump ⇒ page 72 . lksw
agen oes
not
o
byV gu
– Unbolt front sealing flange. rised ara
nte
tho eo
– Remove sealing flange; if necessary, loosen susing light blows
au ra
c
with a rubber headed hammer. s

ce
e
nl

pt
– Remove sealant residue on cylinder block with a flat scraper. du

an
itte

y li
erm

ab
ility
– Remove residual sealant on sealing flange using a rotating
ot p

wit
plastic brush (wear protective glasses).
, is n

h re
hole

– Clean sealing surfaces. They must be free of oil and grease.

spec
es, in part or in w

Installing

t to the co
Note

rrectness of i
l purpos

♦ Observe the use-by date of the sealing compound.


♦ Sealing flange must be installed within 5 minutes of silicone

nf
ercia

sealant application.

orm
m

atio
om

n in
c

– Cut off tube nozzle at forward marking (approx. 3 mm nozzle


or

thi
e

∅).
t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
Note
yi Co
Cop py
ht. rig
rig ht
♦ Sealant bead must not be wider than 2…3 mm as otherwise py by
co Vo
excess sealant can enter sump and block strainer in oil pump
by lksw
cted agen
Prote
suction line and also drip onto crankshaft oil seal.
AG.

♦ Before applying sealant bead, cover sealing surface of oil seal


with a clean cloth.

2. Removing and installing sealing flanges and flywheel or drive plate 23


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Apply silicone sealant bead as shown to clean sealing surface


of sealing flange.
– Fit sealing flange immediately and lightly tighten all bolts.

Note

When fitting sealing flange with oil seal installed, use guide sleeve
-T10053/1- . AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– Tighten sealing flange securing bolts diagonally andrisalternate‐
ed ara
nte
ly. Specified torque: 15 Nm ut
ho eo
ra
s a c
– Install oil sump ⇒ page 72 . s

ce
e
nl

pt
du

an
itte

y li
erm

Note

ab
ility
ot p

wit
, is n

Sealing compound must dry for approx. 30 minutes after instal‐

h re
lation. Only then fill with engine oil.
hole

spec
es, in part or in w

t to the co
Installing toothed belt and adjusting valve timing ⇒ page 37 .

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

24 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

3 Removing and installinglkscrankshaft


wage
n AG. Volkswagen AG do
es n
o o t gu
yV
edb ara
ris nte
1 - Bearing shells 1, 2, 4 and 5 aut
ho eo
ra
ss c
❑ For bearing cap without

ce
e
oil groove.

nl

pt
du

an
itte
❑ For cylinder block with

y li
erm

ab
oil groove.

ility
ot p
❑ Do not interchange

wit
, is n

used bearing shells

h re
hole

(mark).

spec
es, in part or in w

2 - 65 Nm + turn 90° further

t to the co
❑ Renew
❑ To measure radial clear‐

rrectness of i
ance, tighten to 65 Nm
but not further
l purpos

3 - Bearing cap

nform
ercia

❑ Bearing cap 1: Pulley


end.
m

at
om

i
❑ Bearing cap 3 with re‐

on
c

cesses for thrust wash‐

in t
or

his
e

ers.
at

do
riv

❑ Bearing shell retaining


p

cum
or

lugs in cylinder block


f

en
ng

t.
yi
and bearing caps must
Co
op py
be on the same side.
t. C rig
gh ht
pyri by
Vo
4 - Bearing shell 3
co lksw
by
cted agen
Prote
❑ For bearing cap without
AG.

oil groove.
❑ For cylinder block with
oil groove.
5 - Thrust washer
❑ For bearing cap 3
❑ Note fixing arrangement
6 - Sender wheel
❑ For engine speed send‐
er -G28-
❑ Renew if damaged.
❑ Always renew sender wheel if securing bolts have been unscrewed
❑ Removing and installing ⇒ page 26
7 - 10 Nm + turn 90° further
❑ Renew
8 - Fitted pin
❑ Check projection from crankshaft ⇒ page 26
9 - Crankshaft
❑ Axial clearance new: 0.07…0.17 mm , wear limit: 0.37 mm
❑ Check radial clearance using Plastigage new: 0.03…0.08 mm, wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 26 .
10 - Thrust washer
❑ For cylinder block, bearing 3

3. Removing and installing crankshaft 25


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Checking projection of fitted pin from crankshaft

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

Special tools and workshop equipment required

h re
hole

spec
♦ Depth gauge
es, in part or in w

t to the co
Test procedure
– Use depth gauge to check projection -a- of fitted pin with send‐
er wheel -1- removed.

rrectness of i
1 - Sender wheel
l purpos

2 - Securing bolt

nform
ercia

3 - Projection of fitted pin -3- from crankshaft -a- = 2.5…3.0 mm


m

a
Removing and installing sender wheel
com

tion in
r

– Always renew sender wheel -2- each time bolts -1- are loos‐
te o

thi
ened.

s
iva

do
r
rp

cum
Tightening torque: 10 Nm + 90° (1/4 turn)
fo

en
ng

t.
yi Co
Cop py
ht. rig
Note
rig ht
py by
co Vo
by lksw
cted agen
Prote
The second time the bolts are tightened, the contact point of the
AG.

countersunk bolts in the sender wheel is deformed so much that


the bolt heads will come into contact with the crankshaft -3-
-arrows- and the sender wheel will be loose beneath the bolts.

3.1 Crankshaft dimensions


Honing dimen‐ Main journal ∅ Conrod journal ∅
sion
-0.022 -0.022
Basic dimension -54.00 -47.80
-0.042 -0.042
-0.022 -0.022
1st oversize -53.75 -47.55
-0.042 -0.042
-0.022 -0.022
2nd oversize -53.50 -47.30
-0.042 -0.042
-0.022 -0.022
3rd oversize -53.25 -47.05
-0.042 -0.042

26 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

4 Dismantling and assembling pistons and conrods

1 - Piston rings
❑ Offset gaps by 120°.
❑ Remove and install us‐
ing piston ring pliers.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 28 .
❑ Checking ring-to-groove
clearance ⇒ page 28 .
2 - Piston
❑ With combustion cham‐
ber.
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 30
❑ Arrow on piston crown
points to pulley end.
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston
❑ Checking piston projec‐
tion at TDC agen
AG. Volkswagen AG d
oes
⇒ page 30 . olksw not
y V gu
d b ara
3 - Piston pin rise nte
tho eo
u ra
❑ If difficult to remove, ss a c
heat piston to 60 °C.
ce
le
un

pt

❑ Remove and install with


an
d
itte

y li

drift -VW 222 a- .


erm

ab
ility
ot p

4 - Circlip
wit
is n

h re

5 - Conrod
ole,

spec

❑ Mark cylinder allocation -A- with coloured pen


urposes, in part or in wh

t to the co

❑ Installation position: marking -B- faces towards pulley end


❑ With industrially cracked bearing caps on engine codes AJM, ATD, AUY, ASZ, AXR
❑ With conventional bearing caps on engine codes ASZ, ARL
rrectne

6 - Bearing shell
ss

❑ Note installation position.


o
cial p

f in

❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
form
mer

cation: Black line on bearing surface in area of joint.


atio
m

❑ Do not interchange used bearing shells.


o

n
c

i
or

❑ Insert bearing shells centrally.


thi
te

sd
a

❑ Check for secure seating.


iv

o
pr

cum
r

❑ Axial clearance wear limit: 0.37 mm.


fo

en
ng

t.
yi
❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking
Co
Cop py
radial clearance
t. rig
gh ht
pyri by
Vo
o
7 - Cylinder block
c by lksw
cted agen
Prote AG.
❑ Checking cylinder bores ⇒ page 29 .

4. Dismantling and assembling pistons and conrods 27


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
❑ Piston and cylinder dimensions ⇒ page 32 .
8 - Conrod bearing cap
❑ Note installation position.
❑ Vehicles with engine codes AJM, ATD, AUY, ASZ and AXR: bearing caps only fit in one position and
only on associated conrod due to nature of separating procedure (industrially cracked).
9 - Oil spray jet
❑ For piston cooling.
10 - 25 Nm
❑ Insert without sealant.
11 - Conrod bolt, 30 Nm + 90° further
❑ Renew
❑ Oil threads and contact surface.
❑ Use old bolts to measure radial clearance.

Checking piston ring gap

AG. Volkswagen AG d
agen oes
olksw not
Special tools and eworkshop
db
y V
equipment required gu
ara
ris nte
o
♦ Feeler gauges
auth eo
ra
ss c
Test procedure
ce
le
un

pt
an
d

– Push ring squarely from above down to approx. 15 mm from


itte

y li

bottom end of cylinder.


rm

ab
pe

ility
ot

Piston ring New Wear limit


wit
, is n

h re

dimensions in mm
hole

spec

1st compression ring 0.20 …0.40 1.0


es, in part or in w

t to the co

2nd compression ring 0.20 …0.40 1.0


Oil scraper ring 0.25 …0.50 1.0
rrectness of i

Checking ring-to-groove clearance


l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required Prote
cted AG.
agen

♦ Feeler gauges

28 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Test procedure agen


AG. Volkswagen AG d
oes
olksw not
– Clean ring groove before checking.
d by V gu
ara
rise nte
o eo
Piston ring dimensions in aut New
h
Wear limit ra
mm ss c

ce
e
nl

pt
1. compression ring 0.06 …0.09 0.25

du

an
itte

y li
2. compression ring 0.05 …0.08 0.25
erm

ab
ility
ot p

Oil scraper ring 0.03 …0.06 0.15

wit
, is n

h re
Checking cylinder bores
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools and workshop equipment required


♦ Internal dial test indicator 50…100 mm
Test procedure
– Measure at 3 positions both across -A- and in-line with engine
-B-.
Difference between actual and nominal diameter: not more than
0.10 mm.

4. Dismantling and assembling pistons and conrods 29


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Note

Cylinder bores must not be measured when cylinder block is


mounted on a repair stand with engine and gearbox support -VW
540- , as measurements may then be incorrect.

Piston installation position and piston allocation to cylinder


Piston in cylinders 1 and 2:
Larger inlet valve recess -arrows- towards flywheel.
Piston in cylinders 3 and 4:
Larger inlet valve recess -arrows- towards belt pulley end.

Note

♦ New piston allocation to cylinders is shown by a coloured mark


stamped on the piston crown.
♦ Piston for cylinders 1 and 2: marked 1/2
♦ Piston for cylinders 3 and 4: marked 3/4
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
4.1 Separating new conrod ise nte
or eo
h
aut ra
s c
– Mark cylinder allocation of conrod ⇒ Item 5 (page 27) s

ce
e
nl

pt
du

– Lightly clamp the conrod in a vice using aluminium vice

an
itte

y li
clamps, as shown in the illustration.
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
♦ To prevent damage to the conrod, only clamp conrod in lightly.
es, in part or in w

t to the co
♦ Clamp conrod in below the marked line.

rrectness of i
– Unscrew the two bolts -arrows- approx. 5 turns.
l purpos

nf
ercia

– Using a plastic hammer, carefully knock against conrod bear‐


orm
ing cap -arrow- until it is loose.
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4.2 Checking piston projection at TDC


Special tools and workshop equipment required

30 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Measuring bridge -VW 382/7-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
♦ End dimension plate -VW 385/17- rised
nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Test procedure
l purpos

If new pistons or replacement engine are installed, piston projec‐


tion must be measured at TDC of all pistons. Use following table

nf
ercia

to select correct cylinder head gasket in relation to piston projec‐

orm
tion:
m

atio
om

n in
or c

thi
e

Note
t

sd
iva

o
r
rp

cu
o

Turn engine clockwise to measure piston projection at TDC. m


f

en
ng

t.
yi Co
Cop py
ht. rig
Piston projection Identification rig ht
py by
Notches/holes co Vo
by lksw
cted agen
Prote
0.91 mm … 1.00 mm 1
AG.

1.01 mm … 1.10 mm 2
1.11 mm … 1.20 mm 3

4.2.1 Cylinder head gasket identification


♦ Part No. = -arrow 1-
♦ Production control code = -arrow 2- (can be disregarded)
♦ Holes = -arrow 3-

Note

If different values are determined during the projection measure‐


ment, use the largest dimension for selecting the gasket.

4. Dismantling and assembling pistons and conrods 31


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

4.3 Piston and cylinder dimensions


Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimen‐ mm 79.47 79.51
sion
1st oversize mm 79.72 79.76
2nd oversize mm 79.97 80.01

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

32 Rep. Gr.13 - Crankshaft group


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

15 – Cylinder head,
agen
valve gear
AG. Volkswagen AG d
oes
ksw not
Vol gu
by
1 Assembly overview - cylinder headd ara
e nte
ris
utho eo
ra
a c
ss

ce
le

Note
un

pt
an
d
itte

y li
erm

♦ When installing an exchange cylinder head with fitted cam‐

ab
ility
shaft, the contact surfaces between the bucket tappets and
ot p

wit
the cam must be oiled before installing the cylinder head cov‐
is n

h re
er.
ole,

spec
urposes, in part or in wh

♦ The plastic packing pieces for protecting the open valves must

t to the co
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is renewed, the entire coolant must also
be renewed.

rrectne
Checking cylinder head for distortion ⇒ page 35

ss o
cial p

f
Checking compression ⇒ page 53

inform
mer

Cylinder head gasket identification ⇒ page 35

atio
om

n
c

i
or

n
1 - Toothed belt guard - upper

thi
te

sd
a

part
iv

o
pr

cum
r
fo

2 - Toothed belt en
ng

t.
yi Co
❑ Mark direction of rota‐ t. Cop py
tion before removing.
rig
gh ht
pyri by
Vo
❑ Check for wear.
co lksw
by
cted agen
Prote
❑ Do not kink.
AG.

❑ Removing, installing
and tensioning
⇒ page 37 .
3 - 10 Nm
❑ Renew
4 - 25 Nm
5 - 100 Nm
6 - Camshaft toothed belt pul‐
ley
7 - Hub
❑ With sender wheel.
❑ Use counterhold tool -
T10051- to loosen and
tighten.
❑ To remove, use puller -
T10052-
❑ Removing and installing
⇒ page 60 Removing
and installing camshaft
8 - Rear toothed belt guard
9 - Sealing grommet
❑ Renew if damaged.
10 - Hall sender -G40-
❑ For camshaft position

1. Assembly overview - cylinder head 33


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
❑ To remove, pull sealing grommet ⇒ Item 9 (page 33) out of rear toothed belt guard
11 - Cylinder head bolt
❑ Note sequence when loosening and tightening ⇒ page 49 , Removing and installing cylinder head.
❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 56)
12 - Cylinder head cover
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
13 - Pressure regulating valve
❑ For crankcase ventilation. AG. Volkswagen AG d
agen oes
lksw not
14 - To turbocharger d byV
o gu
ara
ise nte
r
15 - Cap ut
ho eo
ra
a
❑ Renew seal if damaged. ss c

ce
e
nl

pt
16 - Seal
du

an
itte

y li
❑ Renew if damaged.
erm

ab
ility
ot p

17 - 10 Nm

wit
, is n

h re
❑ Note tightening sequence ⇒ page 36 , removing and installing cylinder head cover
hole

spec
18 - Gasket for cylinder head cover
es, in part or in w

t to the co
❑ Renew if damaged.
❑ Before putting in place, seal transitions with AMV 174 004 01 ⇒ page 36 , Removing and installing
cylinder head cover

rrectness of i
❑ Renew together with cylinder head cover only.
l purpos

19 - 20 Nm

nf
ercia

20 - Lifting eye

orm
m

21 - Unit injector

atio
om

n in
❑ Removing and installing ⇒ page 149
or c

thi
te

22 - 10 Nm

sd
iva

o
r
rp

23 - Central connector cu
o

m
f

en
ng

t.
yi
❑ For unit injector
Co
Cop py
ht. rig
24 - From brake servo rig ht
py by
co Vo
by lksw
25 - Tandem pump
cted agen
Prote AG.
❑ For fuel and vacuum supply.
❑ Checking ⇒ page 119 .
❑ Removing and installing ⇒ page 122
❑ Must not be taken apart
26 - Supply hose
❑ From fuel filter ⇒ page 105 .
❑ White or with white marking.
❑ Check for secure seating.
❑ Secure with spring-type clips.
27 - Return hose
❑ To fuel filter ⇒ page 105 .
❑ Blue or with blue marking.
❑ Check for secure seating.
❑ Secure with spring-type clips.
28 - Gasket
❑ Renew

34 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

29 - Bolt
30 - Cylinder head
❑ Removing and installing ⇒ page 49
❑ After renewing, renew entire
wage
n Acoolant.
G. Volkswagen AG d
oe
ks s no
Vol t gu
31 - Cylinder head gasket db
y ara
rise nte
❑ Renew tho eo
au ra
❑ Note marking
ss ⇒ page 35 c

ce
le
un

❑ After renewing, renew entire coolant.

pt
an
d
itte

y li
32 - Glow plug
rm

ab
pe

ility
❑ 15 Nm
ot

wit
, is n

❑ Checking ⇒ page 173 .

h re
hole

spec
33 - Tensioning roller
es, in part or in w

t to the co
34 - 20 Nm + turn 45° further

rrectness of i
Checking cylinder head for distortion
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.

♦ Straightedge 500 mm -VAS 6075-


♦ -Fühlerblattlehre-
Max. permissible distortion: 0.1 mm.

Note

Reworking diesel cylinder heads is not permissible.

Cylinder head gasket identification


♦ Part No. = -arrow 1-
♦ Production control code = -arrow 2- (can be disregarded)
♦ Holes = -arrow 3-

Note

Different thicknesses of cylinder head gasket are fitted depending


on the piston projection. When renewing gaskets, install gasket
of the same type.

1. Assembly overview - cylinder head 35


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.1 Removing and installing cylinder head


cover
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
♦ Sealant -AMV 174 004 01-

Removing
– Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and pull forwards out of rear fas‐
tening -arrow B-. agen
AG. Volkswagen AG d
o w es n
olks ot g
– Remove toothed belt guard - upper part.
db
yV ua
ran
e
ris tee
– Disconnect crankcase breather ahose
ut
ho at union on rear of or
ac
charge air pipe. ss

ce
e
nl

– Remove cylinder head cover.


pt
du

an
itte

y li
Installing
erm

ab
ility
ot p

Installation is carried out in the reverse order of removal. When wit


, is n

doing this, note the following: h re


hole

spec
es, in part or in w

t to the co

Note

Renew cylinder head cover gasket and seal for bolts if damaged.
rrectness of i
l purpos

– Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm)


-arrows- on edges of both sealing surfaces of bearing cap and
cylinder head at front of engine.
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

36 Rep. Gr.15 - Cylinder head, valve gear


n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua Bora 1999 ➤ , Golf 1998 ➤
d ran
ir se
tho 4-cylinder diesel engine with tee
ounit injector - Edition 08.2009
au ra
c
ss
– Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm)

ce
e
nl

pt
-arrows- on edges of both sealing surfaces of bearing cap and

du

an
itte
cylinder head at rear of engine.

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Screw on cylinder head cover hand-tight in the sequence -1…

nf
ercia

13-.

orm
m

– Tighten bolts to 10 Nm in the sequence -1…13-.

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.2 Removing, installing and tensioning toothed belt

1. Assembly overview - cylinder head 37


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Bora 1999 ➤ , Golf 1998 ➤ aut
h
ra
s c
4-cylinder diesel engine with unit injector - Edition 08.2009 s

ce
e
nl

pt
du

an
Special tools and workshop

itte

y li
erm
equipment required

ab
ility
ot p
♦ Locking pin for diesel injec‐

wit
, is n
tion pump -3359-

h re
hole

spec
♦ Pin wrench -3387-

es, in part or in w

t to the co
♦ Crankshaft stop -T10050-
♦ Torque wrench -V.A.G

rrectness of i
1331-

l purpos
♦ Torque wrench -V.A.G
1332-

nf
ercia
♦ Marking plate -T10008-

or
(only on vehicles with hy‐

m
m

atio
draulic tensioning system)
om

n in
or c

♦ Drill bit ∅ 4 mm (only on ve‐

thi
te

hicles with hydraulic ten‐

sd
iva

o
r

sioning system)
rp

cu
o

m
f

en
ng

♦ Support bracket -10-222A-


t.
yi Co
op
with rack -10-222A/1- C py
ht. rig
rig ht
by
♦ Locking pin -T10115- (only copy Vo
by lksw
on vehicles with friction cted agen
Prote AG.
damper tensioning system)

38 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.2.1 Vehicles with hydraulic tensioning sys‐


tem
Identification: with belt tensioning damper -arrow-

Note

Always perform adjustment work on toothed belts only on cold


engines.

Removing
– Remove poly V-belt ⇒ page 16 .
– Remove poly V-belt tensioner.
Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR:
– Remove right headlight ⇒ Rep. Gr. 94 .
– Remove charge air pipe between charge air cooler and turbo‐
charger ⇒ page 130 .
Continuation for all vehicles
– Remove coolant expansion tank (coolant hoses remain con‐
nected).
– Unscrew power steering reservoir and fuel filter and place to
one side (hoses remain connected).
– Detach fuel line from cylinder head cover.

WARNING AG. Volkswagen AG d


agen oes
olksw not
y V gu
♦ The fuel and the fuel lines in the fuel system can become ise
d b ara
nte
very hot (danger of scalding)! uthor eo
ra
s a c
♦ The fuel system is also under pressure! Before sopening

ce
le

the system, place cloths around the connections. Then


un

pt
an
d

carefully loosen connection to release the pressure!


itte

y li
erm

ab
♦ Wear eye and hand protection when performing any type

ility
ot p

of repair work on the fuel system!

wit
is n

h re
ole,

spec
urposes, in part or in wh

– Fit support bracket -10-222A- and take up weight of engine in


t to the co
installation position.
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Assembly overview - cylinder head 39


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Unscrew securing bolts from assembly mounting/engine


bracket, assembly mounting/body and assembly mounting/
body bracket -arrows- and remove assembly mounting com‐
plete.

Note

♦ The assembly mounting may only be removed if the engine is


supported with support bracket -10-222A- !
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.

– Unbolt engine bracket from cylinder block -arrows- and re‐


move.

Note

♦ When loosening both upper engine mounting bolts the engine


Volkswa
must be raised slightly with theksw
support
agen
AG.bracket.
gen AG
does
ol not
yV gu
♦ When loosening the lower
ise
d b engine mounting bolt the engine ara
nte
must be lowered slightly
tho
r with the support bracket. eo
au ra
c
ss
– Remove vibration damper/belt pulley.
ce
le
un

pt
an
d
itte

– Remove centre and lower toothed belt guards.


y li
rm

ab
pe

ility
– Turn crankshaft to TDC No. 1 cylinder.
ot

wit
, is n

h re
hole

spec

Note
es, in part or in w

t to the co

Turn crankshaft until mark on crankshaft toothed belt pulley is at


the top and arrow on rear toothed belt guard aligns with the lug
rrectness of i

on hub sender wheel -arrows-.


l purpos

– Lock the hub using diesel injection pump locking pin -3359- .
To do this, slide locking pin through the free elongated hole on
nform
ercia

left into hole in cylinder head.


m

– Lock crankshaft toothed belt pulley with crankshaft stop -


com

tio

T10050- . To do this, slide crankshaft stop into teeth of toothed


n in
r
te o

belt pulley from its face side.


thi
s
iva

do
r
rp

cum
fo

Note
en
ng

t.
yi Co
Cop py
. rig
The marks on the crankshaft toothed belt pulley and the crank‐
t
gh ht
yri by
shaft stop must align. When doing this, the pin of the crankshaft cop Vo
by lksw
stop must engage in the drilling of sealing flange.
cted agen
Prote AG.

– Mark direction of rotation of toothed belt.

40 Rep. Gr.15 - Cylinder head, valve gear


AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Bora 1999 ➤ , Golf 1998 ➤
e nte
horis 4-cylinder diesel eengine with unit injector - Edition 08.2009
aut or
ac
ss
– Insert a hexagon key into the hexagon hole onto stop and use

ce
le
un
it to press the tensioning roller anti-clockwise in -direction of

pt
an
d
itte

arrow- until the toothed belt tensioning device can be locked

y li
erm

ab
with the marking plate -T10008- .

ility
ot p

wit
is n

h re
Note
ole,

spec
urposes, in part or in wh

If the Allen key is not inserted deeply enough there is a risk of it

t to the co
slipping out.

rrectne
– Loosen tensioning roller securing nut.

ss o
– Unscrew securing bolts -1- of toothed belt tensioning device
cial p

f i
and remove tensioning device.

nform
mer

– Remove toothed belt.

atio
om

n
c

Installing

i
or

n thi
te

sd
iva

o
pr

cum
r

Note
fo

en
ng

t.
yi Co
op
Always perform adjustment work on toothed belts only on cold
C py
t. rig
gh
engines.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Loosen securing bolts -1- of camshaft pulley until the camshaft


pulley can be moved within the elongated holes.
– Turn camshaft pulley clockwise -direction of arrow- in elonga‐
ted holes onto stop.

– Now carefully turn eccentric clockwise with pin wrench 3387


until eccentric lug is located directly before limit stop -B-.
– Fit toothed belt on camshaft belt pulley, tensioning roller,
crankshaft belt pulley and finally on coolant pump belt pulley.
– Install toothed belt tensioning device.

1. Assembly overview - cylinder head 41


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Turn eccentric using pin wrench -3387- anti-clockwise (lug of


eccentric moves in direction of limit stop -A-) until marking
plate -T10008- can be pulled out without resistance and di‐
mension -a- is less than 4 mm.
– Tension toothed belt by releasing force of tensioning device
clockwise (lug of eccentric thereby moves in direction of limit
stop -B-) until measurement -a- is reached. Specification -a-:
4 ± 1 mm.

Note

♦ Dimension -a- is reduced when the tensioning roller securing


nut is tightened. Therefore, adjust generously using ∅ 4 mm
drill bit.
♦ Measurement -a- may be reduced to 1 mm if engine is at op‐
erating temperature.

– Hold tensioning roller in thisagposition


en AG. V andagtighten
olksw en AG tensioning
does
roller securing nut as yfollows:
Vo lksw 20 Nm and 45° (1/8 turn) not further.
g b ua
ed ran
oris tee
– Tighten boltsau-1-
th of camshaft toothed belt pulley to 25 Nm. or
ac
ss
– Remove locking pin for diesel injection pump -3359- and
ce
e
nl

pt
crankshaft stop -T10050- .
du

an
itte

y li

– Turn crankshaft two rotations in engine direction of rotation


erm

ab
ility

and set again to TDC no. 1 cylinder.


ot p

wit
, is n

h re
hole

Note
spec
es, in part or in w

t to the co

♦ When doing this, the crankshaft stop pin must engage in the
sealing flange whilst turning.
rrectness of i

♦ If the crankshaft is turned past TDC no. 1 cylinder and the


crankshaft stop could not engage in the sealing flange, turn
l purpos

the crankshaft back 1/4 turn so that the crankshaft can again
be turned in engine direction of rotation to allow it to be set to
TDC no. 1 cylinder. Making corrections against engine direc‐
nf
ercia

tion of rotation in order to insert the crankshaft stop is not


rm
m

permissible.
atio
om

n in
or c

thi

– Once crankshaft stop -T10050- has been inserted, check


te

sd
a

whether:
iv

o
r
rp

cu
o

1.) Dimension -a- can be reached.


f

en
ng

t.
yi Co
op
2.) The hub can be locked using locking pin for diesel injection
C py
ht. rig
pump -3359- .
rig ht
py by
co Vo
by lksw
If dimension -a- is not achieved:
cted agen
Prote AG.

– Tension the tensioning roller again. To do this, counterhold


tensioning roller using pin wrench -3387- , loosen securing nut
and adjust counterforce of tensioning device until measure‐
ment -a- is achieved. Specification -a-: 4 ± 1 mm.
– Tighten securing nut to 20 Nm and 45° (1/8 turn) further.
If the hub cannot be locked:
– Pull crankshaft stop pin out of drilling in sealing flange and turn
crankshaft until hub can be locked with locking pin.

42 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Loosen securing bolts -1- of camshaft pulley.

AG. Volkswagen AG d
agen oes
olksw not
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ce
le

– Turn crankshaft slightly against engine direction of rotation


un

pt
until the pin of the crankshaft stop is positioned just before the

an
d
itte

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hole in the sealing flange -arrow-.
erm

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ility
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– Now turn crankshaft in engine direction of rotation until crank‐

wit
is n

shaft stop pin engages in sealing flange whilst turning.

h re
ole,

spec
– Tighten securing bolts of camshaft belt pulley to 25 Nm.
urposes, in part or in wh

t to the co
– Remove locking pin for diesel injection pump -3359- and
crankshaft stop -T10050- .
– Turn crankshaft 2 rotations in engine direction of rotation until
rrectne
crankshaft is set to TDC No. 1 cylinder again.
ss o
cial p

Note
inform
mer

♦ When doing this, the pin of the crankshaft stop must engage
atio
m

in the sealing flange from the rotational movement.


o

n
c

i
or

n thi
e

♦ If the crankshaft is turned past TDC no. 1 cylinder and the


t

sd
va

crankshaft stop could not engage in the sealing flange, turn


i

o
pr

cum

the crankshaft back 1/4 turn so that the crankshaft can again
r
fo

en
ng

be turned in engine direction of rotation to allow it to be set to


t.
yi Co
op
TDC no. 1 cylinder. Making corrections against engine direc‐
C py
t. rig
tion of rotation in order to insert the crankshaft stop is not
gh ht
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permissible.
cop Vo
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cted agen
Prote AG.

– Repeat check.
– Install lower toothed belt guard and vibration damper/pulley.
– Install centre toothed belt guard.

1. Assembly overview - cylinder head 43


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Fit engine bracket to cylinder block and tighten -arrows-.


Specified torque: 45 Nm.
– Install upper toothed belt guard.

Note

Before installing assembly mounting, tighten all engine bracket


bolts to specified torque.

– Install engine to body assembly mounting(renew securing


bolts). Tightening torque: 40 Nm + 90° (1/4 turn)
– Align assembly mounting on engine side ⇒ page 8 Aligning
assembly mounting for engine and gearbox.
– Fit engine assembly mounting to engine bracket by bringing
contact surfaces together using support bracket -10-222 A- .
Specified torque: 100 Nm.
– Install assembly mounting bracket on body. Specified torque:
25 Nm.
– Install coolant expansion tank.
– Install power steering reservoir and fuel filter.
Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR
– Install charge air pipe between charge air cooler and intake
connecting pipe ⇒ page 130 .
– Install right headlight ⇒ Rep. Gr. 94 . n AG. Volkswagen AG do
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Continuation for all vehicles byV
olk ot g
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– Install poly V-belt tensioning element.
tho Specified torque: tee
or
25 Nm. ss
au ac
ce
le

– Install poly V-belt ⇒ page 16 .


un

pt
an
d
itte

y li

– Install noise insulation.


erm

ab
ility
ot p

1.2.2 Vehicles with friction damper tensioning


wit
is n

h re
ole,

system
spec
urposes, in part or in wh

t to the co

Note
rrectne

Adjustment work on toothed belt must be performed on cold en‐


gines only.
ss o
cial p

Removing
inform
mer

– Remove poly V-belt ⇒ page 16 .


atio
om

– Remove poly V-belt tensioner.


n
c

i
or

n thi
e

Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR:


t

sd
iva

o
pr

cum

– Remove right headlight ⇒ Rep. Gr. 94 .


r
fo

en
ng

t.
yi
– Remove charge air pipe between charge air cooler and ex‐
Co
Cop py
haust turbocharger ⇒ page 130 .
t. rig
gh ht
pyri by
Vo
o
Continuation for all vehicles
c by lksw
cted agen
Prote AG.
– Remove coolant expansion tank (coolant hoses remain con‐
nected).
– Unscrew power steering reservoir and fuel filter and place to
one side (hoses remain connected).

44 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Detach fuel line from cylinder head cover.

WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

– Fit support bracket -10-222A- and take up weight of engine in


installation position.

AG. Volkswagen AG d
agen oes
olksw not
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rm

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pe

ility
ot

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, is n

– Unscrew securing bolts from assembly mounting/engine


h re
hole

bracket, assembly mounting/body and assembly mounting/


spec

body bracket -arrows- and remove assembly mounting com‐


es, in part or in w

plete.
t to the co

Note
rrectness of i
l purpos

♦ The assembly mounting may only be removed if the engine is


supported with support bracket -10-222A- !
nform
ercia

♦ The engine bracket must be loosened only when the assembly


mounting has been removed.
m

a
com

tion in
r
te o

thi

– Unbolt engine bracket from cylinder block -arrows- and re‐


s
iva

do

move.
r
rp

cum
fo

en
ng

t.
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op
Note
C py
t. rig
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pyri by
Vo
co
♦ When loosening both upper engine bracket bolts the engine
by lksw
cted agen
Prote
must be raised slightly with the support bracket.
AG.

♦ When loosening the lower engine bracket bolt the engine must
be lowered slightly with the support bracket.

– Remove vibration damper/belt pulley.


– Remove centre and lower toothed belt guards.
– Turn crankshaft to TDC No. 1 cylinder.

1. Assembly overview - cylinder head 45


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Note

Turn crankshaft until mark on crankshaft toothed belt pulley is at


the top and arrow on rear toothed belt guard aligns with the lug
on hub sender wheel -arrows-.

– Lock the hub using diesel injection pump locking pin -3359- .
To do this, slide locking pin through the free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley with crankshaft stop -
T10050- . To do this, slide crankshaft stop into teeth of toothed
belt pulley from its face side.

Note

The marks on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. When doing this, the pin of the crankshaft
stop must engage in the drilling of sealing flange.

– Mark direction of rotation of toothed belt. agen


AG. Volkswagen AG d
oes
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– Loosen tensioning roller securing nut. d by
V gu
ara
ise nte
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h
ut
– Loosen securing bolts -1- of camshaft pulley
ss auntil the camshaft ra
c
pulley can be moved within the elongated holes.

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Now turn pin wrench -3387- anti-clockwise (against direction


of arrow) until toothed belt tensioning roller can be locked with
locking pin -T10115- .
nform
ercia

– Now turn pin wrench in direction of arrow onto stop and tighten
m

a
com

ti

securing nut by hand.


on in
r
te o

thi

– Remove toothed belt first from coolant pump and then from
s
iva

remaining pulleys.
do
r
rp

cum
fo

Installing
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
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by c lksw
cted agen
Prote AG.
♦ Adjustment work on toothed belts must be performed only on
cold engines, as the indicator position on the tensioning ele‐
ment varies depending on the engine temperature.
♦ Tensioning roller must be locked with locking pin -T10115- and
fixed against right limit stop.

46 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Turn camshaft pulley in elongated holes anti-clockwise -direc‐


tion of arrow- onto stop.
– Fit toothed belt to crankshaft toothed belt pulley, tensioning
roller and camshaft pulley.
– Finally, fit toothed belt on coolant pump belt pulley.

Note
AG. Volkswagen AG d
agen oes
Ensure that tensioning roller seats correctly in reary Vtoothed
olks
w
belt not
gu
guard -arrow-. ised b ara
nte
r
ho eo
aut ra
– Loosen tensioning roller securing nut.ss c

ce
le
un

– Then release tension on tensioning roller by turning against

pt
an
d
itte

direction of arrow with pin wrench and remove locking pin from

y li
rm

ab
tensioning roller.
pe

ility
ot

wit
, is n

h re
hole

spec
– Now carefully turn tensioning roller in direction of arrow using
es, in part or in w

pin wrench -3387- until indicator is in middle of gap in the base

t to the co
plate, -arrow-.
– Hold tensioning roller in this position and tighten tensioning

rrectness of i
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
l purpos

– Tighten bolts of camshaft toothed belt pulley to 25 Nm.


– Remove locking pin for diesel injection pump -3359- and

nform
ercia

crankshaft stop -T10050- .


m

– Turn crankshaft two rotations in engine direction of rotation

a
com

tio
and set again to TDC no. 1 cylinder.
n in
r
te o

thi
s
iva

do
r

Note
rp

cum
fo

en
ng

t.
yi Co
♦ When doing this, the pin of the crankshaft stop must engage Cop py
t.
in the sealing flange from the rotational movement.
rig
gh ht
pyri by
Vo
co
♦ If the crankshaft is turned past TDC no. 1 cylinder and the
by lksw
cted agen
Prote
crankshaft stop could not engage in the sealing flange, turn
AG.

the crankshaft back 1/4 turn so that the crankshaft can again
be turned in engine direction of rotation to allow it to be set to
TDC no. 1 cylinder. Making corrections against engine direc‐
tion of rotation in order to insert the crankshaft stop is not
permissible.

– Once the crankshaft stop -T10050- has engaged, check


whether the hub can be fixed in place using locking pin for
diesel injection pump -3359- .
If the hub cannot be locked:
– Pull crankshaft stop pin out of drilling in sealing flange and turn
crankshaft until hub can be locked with locking pin.

1. Assembly overview - cylinder head 47


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Loosen securing bolts -1- of camshaft pulley.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
– Turn crankshaft slightly against engine direction of rotation
hole

spec
until the pin of the crankshaft stop is positioned just before the
es, in part or in w

hole in the sealing flange -arrow-.

t to the co
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin engages in sealing flange whilst turning.

rrectness of i
– Tighten securing bolts of camshaft belt pulley to 25 Nm.
l purpos

– Remove locking pin for diesel injection pump -3359- and


crankshaft stop -T10050- .

nform
ercia

– Turn crankshaft 2 rotations in engine direction of rotation until


m

a
crankshaft is set to TDC No. 1 cylinder again.
com

tion in
r
te o

thi
s
iva

Note

do
r
rp

cum
fo

en
g

♦ When doing this, the pin of the crankshaft stop must engage
n

t.
yi Co
in the sealing flange from the rotational movement. Cop py
t. rig
gh ht
yri
♦ If the crankshaft is turned past TDC no. 1 cylinder and the
p by
co Vo
lksw
crankshaft stop could not engage in the sealing flange, turn
by
cted agen
Prote
the crankshaft back 1/4 turn so that the crankshaft can again
AG.

be turned in engine direction of rotation to allow it to be set to


TDC no. 1 cylinder. Making corrections against engine direc‐
tion of rotation in order to insert the crankshaft stop is not
permissible.

– Repeat check.
– Install lower toothed belt guard and pulley vibration damper.
– Install centre toothed belt guard.

48 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Fit engine mounting to cylinder block and tighten -arrows-.


Specified torque: 45 Nm.
– Install lower part of toothed belt guard.

Note

Before installing assembly mounting, tighten all engine bracket


bolts to specified torque.

– Install engine to body assembly mounting(renew securing


bolts). Specified torque: 40 Nm + 90° (1/4 turn)
– Align assembly mounting on engine side ⇒ page 8 Aligning
assembly mounting for engine and gearbox.
– Fit engine assembly mounting to engine bracket by bringing
contact surfaces together using support bracket -10-222 A- .
Specified torque: 100 Nm.
– Install assembly mounting bracket on body. Specified torque:
25 Nm.
– Install coolant expansion tank.
– Install power steering reservoir and fuel filter.
Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR
– Install charge air pipe between charge air cooler and intake
connecting pipe ⇒ page 130 .
– Install right headlight ⇒ Rep. Gr. 94 .
Continuation for all vehicles AG. Volkswagen AG d
agen oes
lksw not
– Install poly V-belt tensioningd belement.
yV
o
Specified torque: gu
ara
25 Nm. orise nte
h eo
ut ra
– Install poly V-belt ⇒ spage
s a 16 . c
ce
e
nl

– Install noise insulation.


pt
du

an
itte

y li
erm

ab

1.3 Removing and installing cylinder head


ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Assembly overview - cylinder head 49


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
♦ Bracket -T10014-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

50 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
AG. Volkswagen AG d
Removing ksw
agen oes
not
V ol
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– Remove engine cover. ise
d b To do this, pull front edge of engine ara
nte
cover abruptly upwards
uthor
-arrow A- and pull forwards out of rear eo
securing clipsss a-arrow B-. ra
c

ce
e
– Remove air filter with air intake hoses.
nl

pt
du

an
itte

y li
– Remove battery ⇒ Electrical system; Rep. Gr. 27 .
erm

ab
ility
ot p

– Drain coolant ⇒ page 85 .

wit
, is n

h re
– Remove unions ⇒ Item 14 (page 79) .
hole

spec
– Pull off or disconnect all other electrical connections as nec‐
es, in part or in w

t to the co
essary from cylinder head and lay to side.
– Separate all connection, coolant, vacuum and intake hoses
from cylinder head.

rrectness of i
– Remove front exhaust pipe ⇒ page 159 .
l purpos

– Disconnect fuel supply and return lines as well as coolant line


on cylinder head.

nform
ercia

– Before removing cylinder head extract fuel using hand vacuum


m

at
om

pump with accessories -V.A.G 1390- and fluid receptacle -

ion
c

V.A.G 1390/1- on the tandem pump ⇒ page 122 .

in t
or

⇒ page 122 .

his
ate

do
priv

c
– Remove toothed belt ⇒ page 37 .

um
for

en
ng

t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
co lksw
by
Before removing toothed belt from camshaft belt pulley, lock
cted agen
Prote AG.
toothed belt tensioning device.

– Remove toothed belt tensioning roller ⇒ page 37 .


– Remove hub for camshaft pulley ⇒ page 60 .
– Unscrew rear toothed belt guard.
– Remove charge air pipe for charge air cooler/intake pipe
⇒ page 130 .
– Remove oil return line from turbocharger
⇒ Item 19 (page 129) .
– Remove oil supply line ⇒ Item 1 (page 129) .
– Remove connecting pipe from exhaust gas recirculation cooler
⇒ page 167 .

Note

♦ Before taking toothed belt off camshaft pulley, lock toothed


belt tensioning device ⇒ page 37 Removing, installing and
tensioning toothed belt.
♦ Both lifting eyes for the support bracket are located on the cyl‐
inder head.
♦ This is the reason why an additional bracket must be attached
to the cylinder head to support the engine.

1. Assembly overview - cylinder head 51


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Bolt bracket -T10014- -as shown- to cylinder block at threaded


hole near coolant pump. Specified torque: 20 Nm.
– Lift engine slightly using spindle -A- until spindle -B- is relieved.
– Remove spindle -B-.
– Before removing cylinder head extract fuel from tandem pump
using hand vacuum pump with accessories -V.A.G 1390- and
water drainage container -V.A.G 1390/1- ⇒ page 122 wage , Re‐
n AG. Volkswagen AG do
es n
s
moving and installing tandem pump. yV
olk ot g
u b ara
ed nte
– Remove hub for camshaft belt pulley ⇒thopage
ris 60 Removing e or
and installing camshaft. s au ac
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Maintain sequence when loosening and tightening cylinder
head bolts.

rrectness of i
Installing
l purpos

Note

nf
ercia

orm
m

♦ Always renew cylinder head bolts.

atio
om

n in
c

♦ In cases of repair carefully remove gasket remains from cyl‐


or

thi
e

inder head and cylinder block. Ensure that no long scores or


t

sd
iva

scratches are made on the surfaces. When using abrasive

o
r
rp

cu
paper do not use a grade less than 100.
o

m
f

en
ng

t.
yi Co
♦ Carefully remove remains of emery and abrasives. t. Cop py
rig
gh ht
♦ Remove new cylinder head gasket from packaging, just before pyri by
Vo
co
installation.
by lksw
cted agen
Prote AG.
♦ Handle gasket extremely carefully. Damaging the silicone lay‐
er or the indented area will lead to leaks.

– Turn crankshaft to TDC marking before fitting cylinder head.


– Turn crankshaft against engine direction of rotation until all
pistons are nearly uniformly below TDC.
– Place cylinder head gasket on.
– Fit cylinder head and tighten all 8 cylinder head bolts by hand.

52 Rep. Gr.15 - Cylinder head, valve gear


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Bora
eo 1999 ➤ , Golf 1998 ➤
ut
ss a 4-cylinder diesel engine with unit injector
ra
c - Edition 08.2009

ce
e
nl

pt
– Tighten cylinder head in 4 stages in sequence shown as fol‐

du

an
itte
lows:

y li
erm

ab
ility
– 1. Tighten initially with torque wrench:

ot p

wit
, is n
Stage I = 40 Nm, stage II = 60 Nm

h re
hole

spec
– 2. Turn further with rigid spanner:
es, in part or in w

t to the co
Stage III = 1/4 turn (90°), Stage IV = 1/4 turn (90°)

rrectness of i
Note
l purpos

Later retightening of cylinder head bolts is not necessary after


repairs.

nform
mercia

at
om

io
– After tightening cylinder head, turn camshaft so that cams for

n
c

in t
r

No. 1 cylinder point equally upwards. Before fitting toothed


o

his
te

belt, turn crankshaft in engine direction of rotation to TDC


a

do
riv

⇒ page 37 Removing, installing and tensioning toothed belt.


p

cum
for

en
ng

– Install hub for camshaft belt pulley ⇒ page 60 Removing and


t.
yi Co
op
installing camshaft. C py
t. rig
gh ht
yri by
– Carry out a road test and read fault memory ⇒ page 156
op Vo
by c lksw
Reading and clearing fault memory of engine control unit. cted agen
Prote AG.

1.4 Checking compression

1. Assembly overview - cylinder head 53


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Jointed wrench 10 mm
-3220-
♦ Torque wrench -V.A.G
1331-
♦ Adapter -V.A.G 1381/12-
♦ Compression tester -V.A.G
1763-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
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hole

spec
es, in part or in w

t to the co

Test prerequisite
rrectness of i

• Engine oil temperature at least 30 °C


l purpos

Test procedure
nf
ercia

– Pull off central connector for unit injectors.


orm
m

atio
m

– Remove all glow plugs using 10 mm jointed wrench -3220- .


o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

54 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Screw in adapter -V.A.G 1381/12- in place of glow plugs.


– Check compression using compression tester -V.A.G 1763- .

Note

Using the compression tester ⇒Operating instructions

– Operate starter until tester shows no further pressure in‐


crease.
Compression pressures:
New: 25…31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar
– Install glow plugs using 10 mm jointed spanner -3220- , speci‐
fied torque: 15 Nm. en AG. V
olkswagen AG
ag does
lksw not
– Reading fault memory ⇒ page 156 ; reading and y Vclearing fault
o gu
db ara
memory of engine control unit. ris
e nte
tho eo
s au ra
c
s

ce
Note
e
nl

pt
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an
itte

y li
Disconnecting the central connector for unit injectors causes
erm

ab
faults to be stored. Therefore read and clear fault memory.

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
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Prote AG.

1. Assembly overview - cylinder head 55


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

2 Assembly overview - valve gear

Note

♦ Cylinder heads with cracks between the valve seats may con‐
tinue to be used without reducing the expected service life.
♦ If it is a question of light, max. 0.5 mm wide cracks.

1 - 20 Nm + turn 90° further


❑ Renew
❑ Note sequence when
loosening and tighten‐
ing ⇒ page 60 , Re‐
moving and installing
camshaft.
2 - Rocker arm shaft
❑ Do not interchange.
3 - Cylinder head bolt
❑ Note sequence when
loosening and tighten‐
ing ⇒ page 49 , Remov‐ G. Volkswagen AG d
ing and installing cylin‐lkswagen A oes
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❑ Before installing,
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washers ins acylinder ra
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head s
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⇒ Item 4 (page 56) .


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4 - Washer
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❑ For cylinder head bolts.


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❑ Set in cylinder head be‐


h re

fore installing bearing


hole

spec

caps.
es, in part or in w

t to the co

5 - Bucket tappet
❑ Do not interchange.
rrectness of i

❑ With hydraulic valve


clearance compensa‐
l purpos

tion.
❑ Store with cam contact
nform
ercia

surface downwards.
❑ Before installing check
m

a
com

ti

camshaft axial clear‐


on in

ance ⇒ page 57 .
r
te o

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❑ Oil contact surface.


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❑ Before removing, remove camshaft bearing caps.


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7 - Valve spring plate
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8 - Outer valve spring
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❑ To remove and install with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed ⇒ page 59 Renewing valve stem seals
9 - Inner valve spring
❑ To remove and install with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed ⇒ page 59 Renewing valve stem seals

56 Rep. Gr.15 - Cylinder head, valve gear


olkswagen AG
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lk not
4-cylinder diesel d byengine
Vo with unit injector - Edition g08.2009
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10 - Valve stem seal aut or
ac
ss
❑ Renew ⇒ page 59 .

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11 - Valve guide

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❑ Checking ⇒ page 58 .

ility
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wit
12 - Unit injector

, is n

h re
❑ Removing and installing ⇒ page 149

hole

spec
es, in part or in w
13 - Cylinder head

t to the co
❑ See note ⇒ page 56 .
14 - Seal

rrectness of i
❑ Do not additionally oil or grease the oil seal sealing lip.
l purpos
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape).

nf
ercia

o
❑ Removing and installing ⇒ page 64

rm
m

atio
m

15 - Valves
o

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or c

❑ Valve dimensions ⇒ page 58

thi
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16 - Bearing shell

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❑ Do not interchange used bearing shells (mark).
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❑ Ensure proper seating of retaining lugs in bearing caps and cylinder head. t. Cop py
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17 - Camshaft p by
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❑ Checking axial clearance ⇒ page 57 .
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❑ Removing and installing ⇒ page 60
❑ Check radial clearance with plastigage, wear limit: 0.11 mm.
❑ Runout: max. 0.01 mm.
❑ Identification and valve timing ⇒ page 58 .
18 - Bearing cap
❑ Installation sequence ⇒ page 60 , removing and installing camshaft.
❑ To install, seal parting surfaces of bearing caps 1 and 5 with -AMV 174 004 01- sealant ⇒ page 58
19 - 8 Nm + turn 90° further
❑ Renew

Checking camshaft axial clearance

Special tools and workshop equipment required


♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Test procedure
Check with bucket tappets removed and with first, third and last
bearing caps fitted.

2. Assembly overview - valve gear 57


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Wear limit: max. 0.15 mm.


Seal parting surfaces of bearing caps 1 and 5 with -AMV 174 004
01-
– Apply sealant -AMV 174 004 01- thinly and evenly to surfaces
-1-.

Note

Ensure that no sealant gets into the grooves -arrows-.

Valve dimensions

Note

Valves must not be reworked. Only lapping-in is permitted.

Dimension Inlet valve Exhaust valve


∅a mm 35.95 31.45
∅b mm 6.980 6.956
c mm 89.95 89.95
α ∠° 45 45
Identification
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Camshaft identification, valve timing agen oes
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♦ Cam base diameter: a = ∅ 52.8 mm. rised
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♦ Identification by stamped numbers and letters on facess of No.
a ra
c
4 cylinder exhaust cam.

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Cylinder 4 -arrow- 038 R or 858 R


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Valve timing at 1 mm valve lift
ot p

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Inlet opens ATDC 15.8°
ole,

spec
Inlet closes ABDC 25.3°
urposes, in part or in wh

t to the co
Exhaust opens BBDC 28.2°
Exhaust closes BTDC 18.7° rrectne

2.1 Checking valve guides


ss o
cial p

f inform
mer

atio
om

n
c

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or

n thi
te

sd
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pr

cum
r
fo

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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Special tools and workshop equipment required
Prote AG.

♦ Universal dial gauge bracket -VW 387-


♦ Dial gauge

58 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to differences in stem diameters,
use only an inlet valve in inlet guide and an exhaust valve in
exhaust guide.
– Determine rock. Wear limit: max. 1.3 mm.
– Cylinder head must be renewed if rock exceeds wear limit.

AG. Volkswagen AG d
agen oes
olksw not
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2.2 Renewing valve stem seals ris nte
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aut ra
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Special tools and workshop
du

an
itte

equipment required

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erm

ab
ility
♦ Valve assembly device
ot p

-2036-

wit
, is n

h re
hole

♦ Puller -3047 A-

spec
es, in part or in w

♦ Fitting tool -3129-

t to the co
♦ Valve lever -VW 541/1 A-
♦ Thrust piece for VW 541 / 1

rrectness of i
A and 2037 -VW 541/5-
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.

Removing
(With cylinder head installed)
– Remove camshaft ⇒ page 60 .

2. Assembly overview - valve gear 59


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that tappets are not
interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Fit valve assembly tool -2036- and adjust mountings to height
of studs.
– Remove valve springs using valve lever -VW 541/1 A- and
thrust piece for VW 541 / 1 A and 2037 -VW 541/5- .

Note
. Volkswagen AG
The valves are supported by the piston crown.
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– Pull off valve stem seals using puller -3047 A- .
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Installing
erm

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spec
es, in part or in w

t to the co
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– Place the plastic sleeve -A- supplied on the respective valve nform
ercia

stem. This will prevent the new valve stem seal -B- from be‐
m

at

coming damaged.
om

ion
c

in t

– Place new valve stem seal in fitting tool -3129- .


or

his
ate

– Oil valve stem seal sealing lip and press carefully onto the
do
priv

valve guide.
um
for

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t.
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Vo
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Prote AG.

2.3 Removing and installing camshaft

60 Rep. Gr.15 - Cylinder head, valve gear


AG. Volkswagen AG d
agen oes
olksw not
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ris nte
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Bora 1999 ➤ , Golf 1998 ➤
a
ss 4-cylinder diesel enginec with unit injector - Edition 08.2009

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nl

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Special tools and workshop du

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equipment required
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ility
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♦ Counterhold tool -T10051-

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, is n

h re
♦ Puller -T10052-
hole

spec
♦ Torque wrench -V.A.G
es, in part or in w

t to the co
1331-
♦ Torque wrench -V.A.G
1332-

rrectness of i
♦ Sealant -AMV 174 004 01-
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove toothed belt ⇒ page 37 .
– Remove securing bolts for camshaft toothed belt pulley -1-.
– Pull camshaft belt pulley off hub.

2. Assembly overview - valve gear 61


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Loosen hub securing bolt -1-.


– To do this, use counterhold -T10051- .
– Loosen hub securing bolt by approx. 2 turns.

– Fit puller -T10052- and align it with holes in hub.


– Apply tension to hub by evenly tightening puller until hub sep‐
arates from taper of camshaft. n AG. Volkswagen AG do
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When doing this, hold puller with AF 30 mm spanner.

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– Remove hub from taper of camshaft.
erm

ab
ility
ot p

– Remove cylinder head cover.

wit
, is n

h re
– Remove rocker arm shafts.
hole

spec
es, in part or in w

t to the co
Note

First loosen both outer and then inner securing bolts respectively.

rrectness of i
l purpos

– Mark rocker arm shafts using a permanent felt tip marker to


prevent interchanging. This will prevent having to perform ba‐

nf
ercia

sic settings of unit injectors -arrows-.

orm
m

atio
– Remove tandem pump ⇒ page 122 .
om

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thi
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– First remove bearing caps 5, 1 and 3. Loosen bearing caps 2


and 4 alternately and diagonally.
– Remove camshaft.
Installing

62 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Note

♦ When camshaft is installed, No. 1 cylinder cams must point


upwards.
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retain‐
ing lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.

– Oil running surfaces of shell bearings.


– Tighten bearing caps 2 and 4 alternately and diagonally to 8
Nm + turn 90° further (renew).
– Install bearing caps 5, 1 and 3 and also tighten to 8 Nm + turn
90° further (renew).

Note

♦ Seal separating surfaces of bearing caps 1 and 5 with AMV


174 004 01 ⇒ page 58 .
♦ Bearing cap 5 must be flush with outer edge of cylinder head,
otherwise leaks can occur at the tandem pump.

– Install camshaft oil seal ⇒ page 64 .

– Install injector rocker arm shafts with new securing bolts and
tighten, first the inner -2- and then the outer -1-, evenly and in
diagonal sequence. Specified torque: 20 Nm + turn 90° further.
Volkswa AG. gen AG
agen does
– Place hub on
yV
ocamshaft.
lksw not
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ility
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spec

– Tighten hub securing bolt -1- to prescribed torque: 100 Nm.


urposes, in part or in wh

t to the co

– To do this, use counterhold -T10051- .


rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Assembly overview - valve gear 63


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Push camshaft belt pulley onto hub.

Note

The toothed segment -arrow- of the camshaft belt pulley must be


on top.

– Align camshaft belt pulley to centre position in elongated


holes.
– Tighten securing bolts -1- to camshaft belt pulley by hand so
there is no play.
– Lock the hub using diesel injection pump locking pin -3359- .
– Install and tension toothed belt ⇒ page 37 .
– Install tandem pump ⇒ page 122 .

AG. Volkswagen AG d
Note agen oes
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d by ara
e
When new bucket tappets have been installed the engine must
ris nte
tho eo
not be started for sabout
au 30 minutes. Hydraulic compensation el‐ r ac
ements must settle (otherwise valves will strike pistons).
s
ce
le
un

pt
an
d
itte

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ab
2.4 Removing and installing camshaft oil seal
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

64 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Fitting tool -10 - 203- AG. Volkswagen AG d
agen oes
olksw not
♦ Oil seal extractor -3240- d by V gu
ara
rise nte
♦ Torque wrench -V.A.G ut ho eo
ra
1331- s s a c

ce
le
♦ Torque wrench -V.A.G un

pt
an
d
1332-
itte

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erm

ab
♦ Bolt M12×1.5 × 65

ility
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wit
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Remove toothed belt ⇒ page 37 .
– Remove camshaft belt pulley and hub ⇒ page 60 Removing
and installing camshaft.
– Screw inner part of oil seal extractor -3240- two turns (approx.
3 mm) out of outer part and lock using knurled screw.

2. Assembly overview - valve gear 65


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Lubricate threaded head of oil seal extractor, place it in posi‐


tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing

Note

The oil seal sealing lip must not be additionally oiled or greased.

– Remove oil residue from camshaft journal using a clean cloth.


– Tape over groove in taper of camshaft (e.g. with Sellotape).
– Fit oil seal carefully on camshaft.

– Press in oil seal onto stop using fitting tool -10 - 203- and
M12×1.5×65 bolt.
– Install and tension toothed belt ⇒ page 37 .

AG. Volkswagen AG d
agen oes
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un

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pe

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ot

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, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

66 Rep. Gr.15 - Cylinder head, valve gear


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

17 – Lubrication
1 Removing and installing parts of lu‐
brication system

Note

♦ If large quantities of metal chips and abraded material are


found in the engine oil, e.g. caused by fretting damage to
crankshaft and/or conrod bearings.
♦ Clean the oil passages thoroughly and renew the oil cooler in
order to prevent further damage from occurring later.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter!

Engine oil specification ⇒ Maintenance ; Booklet 38


Checking engine oil level ⇒ page 67
Oil capacities ⇒ page 67 agen
AG. Volkswagen AG d
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Checking oil pressure and oil pressure switched by ⇒ page 74 .
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1.1 Engine oil h eo
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1.1.1 Oil capacities

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With oil filter 4.3 l.

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Without oil filter 3.8 l.
hole

spec
1.2 Checking engine oil level
es, in part or in w

t to the co
1 - Max. mark
2 - Min. mark rrectness of i

a - Area above hatched field up to max. mark: do not top-up with


l purpos

engine oil!
b - Oil level within hatched field: Can be topped up with engine
nf
ercia

oil.
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m

atio
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c - Area from min. mark up to hatched zone: must be topped up,


o

n in
c

max. 0.5 l of engine oil!


or

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te

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1.3 Removing and installing parts of lubri‐


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cation system
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Part I: Assembly overview - oil pump ⇒ page 67 op Vo
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Part II: Assembly overview - oil filter bracket ⇒ page 69
AG.

Part III: oil supply line ⇒ page 70

1.3.1 Part I

1. Removing and installing parts of lubrication system 67


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
AG. Volkswagen AG d
agen oes
1 - 15 Nm olksw not
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2 - 25 Nm horis nte
eo
aut ra
3 - Bracket ss c

ce
le
❑ For oil level/tempera‐
un

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an
d

ture sender wiring har‐


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ness.
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ab
pe

ility
4 - Oil dipstick
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h re
❑ The oil level must not be
hole

above the max. mark!

spec
es, in part or in w

❑ Markings ⇒ page 67

t to the co
5 - Piston fitting tool
❑ Pull out to extract oil.

rrectness of i
6 - Guide tube
l purpos

7 - Dowel sleeves

nform
ercia

8 - O-ring
m

❑ Renew

a
com

tion in
9 - 15 Nm
r
te o

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iva

10 - Suction line

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❑ Clean strainer if soiled.
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11 - Baffle plate Cop py
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12 - 15 Nm py by
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13 - 15 Nm Prote AG.

14 - Sump
❑ Clean sealing surface
before fitting.
❑ Install with silicone seal‐
ant -D 176 404 A2-
⇒ page 72 .
15 - Seal
❑ Renew
16 - Oil drain plug, 30 Nm
17 - 10 Nm
18 - Oil level and oil temperature gauge -G266-
❑ Black 3-pin connector
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations and ⇒ Vehicle diagnosis,
testing and information system VAS 5051
19 - Seal
❑ Renew
20 - Oil pump
❑ With 12 bar pressure relief valve.
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
21 - Oil pump sprocket
22 - Engine codes AJM, ATD, AUY, AXR: 25 Nm, engine codes ARL, ASZ: 20 Nm + turn 90° further
23 - 15 Nm
24 - Sealing flange
❑ With oil seal.

68 Rep. Gr.17 - Lubrication


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
❑ Must seat on dowel sleeves.
❑ Removing and installing ⇒ page 22
❑ Install with silicone sealant -D 176 404 A2- ⇒ page 22 .
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Renewing crankshaft oil seal - pulley end ⇒ page 19
25 - Chain
26 - Chain tensioner with tensioning rail, 15 Nm
❑ When installing, pre-tension spring and fit.
27 - Oil spray jet
❑ For piston cooling.
28 - 25 Nm
❑ Insert without sealant.

1.3.2 Part II

1 - Oil pressure switch -F1- , 20


Nm
❑ 0.7 bar switch: Brown or
0.9 bar switch: grey
❑ If seal is leaking, nip
open and renew.
❑ Checking ⇒ page 74 .
2 - Gasket
❑ Renew
3 - 15 Nm + turn 90° further
❑ Renew AG. Volkswagen AG d
agen oes
❑ First fit upper left and olksw not
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lower right bolts and ed b ara
nte
is
then tighten all 4 bolts in tho r eo
diagonal sequence. ss au ra
c
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4 - Oil filter bracket


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d
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5 - Seal
erm

ab

❑ Renew
ility
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6 - Oil supply line


h re
ole,

❑ To turbocharger
spec
urposes, in part or in wh

t to the co

7 - Banjo bolt, 25 Nm
8 - Sealing cap, 25 Nm
rrectne

❑ Loosen and tighten with


oil filter spanner -3417-
s

9 - O-ring
s o
cial p

❑ Renew
inform
mer

10 - Oil filter element


atio
m

❑ Note installation posi‐


o

n
c

i
or

tion: top = uppermost


thi
te

sd
va

11 - Plug, 25 Nm
i

o
pr

cum
r
fo

en
ng

12 - Gasket yi
t.
Co
op
❑ Renew
C py
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69
agen
Prote AG.
1. Removing and installing parts of lubrication system
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

13 - Oil cooler
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 67 .
❑ Checking oil cooler for leaks ⇒ page 95
14 - Gasket
❑ Renew
❑ Fit into lugs on oil cooler.
15 - Plug, 10 Nm
❑ If seal is leaking, nip open and renew.
16 - Plug
❑ For pressure relief valve
❑ Do not loosen

1.3.3 Part III

1 - Oil supply line


❑ To turbocharger
2 - Union nut, 22 Nm
❑ When loosening and
tightening, counterhold
union
3 - Seal
❑ Renew
4 - Banjo bolt, 25 Nm
5 - Clip
6 - 10 Nm
7 - Bracket agen
AG. Volkswagen AG d
oes
olksw not
8 - 25 Nm ed by
V gu
ara
is nte
❑ Renew ut
hor eo
a ra
s c
9 - 10 Nm s
ce
e
nl

pt
du

10 - 10 Nm
an
itte

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erm

ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
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or c

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Assembly sequence
iv

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t.
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Cop py
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70
op Vo
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Rep. Gr.17 - Lubrication Prote
cted AG.
agen
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

Removing
– Remove noise insulation.
– Place drip tray -V.A.G 1306- underneath.
– Remove air filter housing.
– Remove union nut -2- or banjo bolt -4- from turbocharger.
– Remove bolt -9- from bracket -7-.
– Remove nut -8- and take off bracket -7-.
– Remove oil supply line.

1. Removing and installing parts of lubrication system 71


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Installing ss
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e
nl

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an
itte

WARNING
y li
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ility
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It is essential that installation of the oil supply line is carried out


wit
, is n

as follows.
h re
hole

spec
es, in part or in w

t to the co

– Screw bracket -7- with nut -8- loosely to exhaust manifold.


– Screw union nut -2- or banjo bolt -4- to turbocharger by hand.
rrectness of i

– Tighten union nut -2- or banjo bolt -4- on oil filter bracket to
prescribed torque.
l purpos

– Tighten union nut -2- on turbocharger to prescribed torque.


nf
ercia

– Position clamps -5- on oil supply line.


orm
m

atio

– Tighten bolts -6- and -9- to prescribed torque.


om

n in
or c

– Tighten nut -8- to prescribed torque.


thi
te

sd
iva

1.4 Removing and installing sump


o
r
rp

cu
o

m
f

en
ng

t.
Special tools and workshop equipment required Cop
yi Co
py
t. rig
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pyri by
Vo
co lksw
by
cted agen

72
Prote AG.
Rep. Gr.17 - Lubrication
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Torque wrench -V.A.G 1331-

♦ Hand drill with plastic brush attachment


♦ Silicone sealant -D 176 404 A2-
♦ Protective glasses
♦ Flat scraper
Removing
– Remove centre, left and right insulation tray ⇒ Rep. Gr. 50
– Drain engine oil.
AG. Volkswagen AG d
agen oes
olksw not
V
Note ed by gu
ara
ris nte
ho eo
ut
Observe
ss aenvironmental regulations for disposal. ra
c
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nl

pt
du

– Pull 3-pin connector off oil level and temperature sender -


an
itte

y li

G266- and unclip line from sump.


erm

ab
ility
ot p

– Remove sump.
wit
, is n

h re

– Loosen oil sump with light blows of a rubber headed hammer


hole

if necessary.
spec
es, in part or in w

t to the co

– Remove sealant residue on cylinder block with a flat scraper.


– Remove sealant residue on sump using rotating brush, e.g. a
hand drill with plastic brush attachment (wear protective
rrectness of i

glasses).
l purpos

– Clean sealing surfaces. They must be free of oil and grease.


Installing
nf
ercia

orm
m

atio
m

Note
o

n in
or c

thi
te

sd
a

♦ Observe the use-by date of the sealing compound.


iv

o
r
rp

cu
o

♦ The oil sump must be installed within 5 minutes of applying


m
f

en
ng

t.
silicone sealing compound.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Removing and installing parts of lubrication system 73


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Cut off tube nozzle at forward marking (approx. 3 mm nozzle


∅).
– Apply silicone sealing compound, as shown, to clean sealing
AG. Volkswagen AG d
surface on oil sump. Sealant bead must be: lkswagen oes
n o ot g
yV ua
♦ 2…3 mm thick. risedb ran
tee
ho
♦ Run bead along inner side of bolt ut -arrows-.
holes
a
or
ac
ss

ce
e
nl

pt
du

an
Note
itte

y li
erm

ab
ility
ot p

The sealing compound bead must not be thicker. Otherwise ex‐

wit
, is n

cess sealing compound will enter the sump and can block the oil

h re
suction line strainer.
hole

spec
es, in part or in w

t to the co
– Apply silicone sealant as shown to clean sealing surface of oil
sump. (The figure shows the position of the sealant bead on
the cylinder block.)

rrectness of i
– Install sump immediately and tighten all sump bolts lightly.
l purpos

nf
ercia

Note

orm
m

atio
m

The sump must be flush with cylinder block.


o

n in
or c

thi
te

– Tighten oil sump bolts in diagonal sequence to 15 Nm.

sd
iva

o
r
rp

cu
– Tighten sump/gearbox bolts to 45 Nm.
o

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f

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ng

t.
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Cop py
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gh
Note
ht
pyri by
Vo
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cted agen
Prote
Let sealing compound dry for approx. 30 minutes after installing
AG.

sump. Only then fill with engine oil.

Further assembly is basically the reverse of the dismantling pro‐


cedure.

1.5 Checking oil pressure and oil pressure switch

74 Rep. Gr.17 - Lubrication


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Voltage tester -V.A.G 1527
B-
♦ Auxiliary measuring set -
V.A.G 1594 A-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
ss

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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tio

Note
n in
r
te o

thi
s

Functional check and repair of the visual and acoustic oil pressure
iva

do
r

warning ⇒ Current flow diagrams, Electrical fault finding and Fit‐


rp

cum
fo

ting locations and ⇒ Vehicle diagnosis, testing and information


en
ng

t.
yi
system VAS 5051
Co
Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

1. Removing and installing parts of lubrication system 75


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Test procedure
– Remove oil pressure switch -F1- and screw it into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527B- using auxiliary cables -
V.A.G 1594 A- to battery positive (+) and oil pressure switch.
LED must not light up.
– Start engine and increase speed slowly. AG. Volkswagen AG d
agen oes
olksw not
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Oil pressure switch, brown: d b ara
rise nte
ho eo
– At 0.55…0.85 bar the LED must light up, aotherwise renew oil
ut ra
c
pressure switch. ss

ce
le
un

pt
– Increase engine speed further. At 2000 rpm and an oil tem‐

an
d
itte

y li
perature of 80 °C the oil pressure should be at least 2.0 bar.
rm

ab
pe

ility
At higher engine speed, oil pressure must not exceed 7.0 bar.
ot

wit
Renew oil filter bracket, if necessary
, is n

h re
hole

Oil pressure switch, grey:

spec
es, in part or in w

– At 0.75…1.05 bar the LED must light up, otherwise renew oil

t to the co
pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐

rrectness of i
perature of 80 °C the oil pressure should be at least 2.0 bar.
l purpos

At higher engine speed, oil pressure must not exceed 7.0 bar.
Renew oil filter bracket, if necessary

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

76 Rep. Gr.17 - Lubrication


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

19 – Cooling
1 Removing and installing parts of cool‐
ing system

WARNING n AG. Volkswagen AG do


lkswage es n
o ot g
byV ua
ed engine compart‐
When doing any repair work, especially oinristhe
ran
tee
ment, pay attention to the following due
au to the cramped condi‐
th or
ac
tions: ss

ce
le
un

pt
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

an
d
itte

vated charcoal filter system, coolant and refrigerant, brake

y li
rm

ab
fluid and vacuum) and electrical wiring in their original po‐
pe

ility
sitions.
ot

wit
, is n

h re
♦ Ensure that there is sufficient clearance to all moving or
hole

hot components.

spec
es, in part or in w

t to the co
Note

rrectness of i
l purpos

♦ When the engine is warm, the cooling system is under pres‐


sure. If necessary, release pressure before beginning repair
work.

nform
ercia

♦ Hoses are secured with spring-type clips. In case of repair,


m

a
com

t
only use spring-type clips.

ion in
r
te o

♦ Spring-type clip pliers -VAS 5024A- or hose clip pliers -V.A.G

thi
s
iva

1921- are recommended for installation of spring-type clips.

do
r
rp

cum
fo

♦ When installing coolant hoses, route stress-free so that they


en
ng

t.
yi
do not come into contact with other components (observe
Co
op py
markings on coolant connection and hose). t. C rig
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pyri by
Vo
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by
Test for leaks in cooling system using cooling system tester - cted agen
Prote AG.
V.A.G 1274- and adapter for cooling system tester -V.A.G 1274/8-
and adapter for cooling system tester -V.A.G 1274/9- .
Parts of cooling system - body side ⇒ page 77 .
Parts of cooling system - engine side ⇒ page 79 .
Coolant hose schematic diagram ⇒ page 80 .
Draining and filling with coolant ⇒ page 85 .
Coolant mixture ratios ⇒ page 85 , Draining and filling with cool‐
ant.
Removing and installing radiator ⇒ page 88 .
Removing and installing coolant pump ⇒ page 90 .
Removing and installing thermostat ⇒ page 92
Checking cooling system for leaks ⇒ page 94 .
Checking oil cooler for leaks ⇒ page 95

1.1 Parts of cooling system - body side

1. Removing and installing parts of cooling system 77


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Radiator
❑ Removing and installing
⇒ page 88
❑ After renewing, renew
entire coolant.
2 - O-ring
❑ Renew
3 - Upper coolant hose
❑ Secured to radiator with
retaining clip.
❑ Coolant hose schematic agen
AG. Volkswagen AG d
oes
diagram ⇒ page 80 . olksw not
byV gu
ara
ed
4 - Cowling horis nte
eo
aut ra
5 - 5 Nm ss c

ce
le
un

6 - Additional fan

pt
an
d
itte

y li
❑ Only vehicles with op‐
erm

ab
tional equipment.

ility
ot p

wit
is n

7 - Fan ring

h re
ole,

8 - Securing clip

spec
urposes, in part or in wh

❑ Check for secure seat‐

t to the co
ing.
9 - Connector

rrectne
10 - Radiator fan

s
11 - To coolant pipe

s o
cial p

f
❑ Coolant hose schematic

inform
diagram ⇒ page 80 .
mer

atio
m

12 - Expansion tank
o

n
c

i
or

n
❑ Test cooling system for

thi
te

leaks using cooling sys‐

sd
iva

o
r

tem tester -V.A.G 1274-


p

cum
r
fo

and adapter for cooling system tester -V.A.G 1274/8- .


en
ng

t.
yi Co
❑ Test pressure 1.4…1.6 bar ht. Cop py
rig
❑ Observe markings ⇒ page 85 Draining and filling coolant rig ht
py by
co Vo
by lksw
13 - Cap
cted agen
Prote AG.
❑ Check using cooling system tester -V.A.G 1274- and adapter for cooling system tester -V.A.G 1274/9- .
❑ Pressure relief valve must open at between 1.4 and 1.6 bar.
14 - Bracket
❑ For fan connector.
15 - Lower coolant hose
❑ Secured to radiator with retaining clip.
❑ Coolant hose schematic diagram ⇒ page 80 .
16 - O-ring
❑ Renew
17 - Radiator fan thermal switch -F18- , 35 Nm
❑ For radiator fan.
❑ Switching temperatures: stage 1 on: 92…97 °C off: 84…91 °C; stage 2 on: 99…105 °C off: 91…98 °C
18 - Bracket
❑ For radiator.
❑ Note installation position.

78 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
❑ Note various versions.
19 - 5 Nm

1.2 Parts of cooling system - eengine side


n AG. Volkswagen AG
wag does
olks not
byV gu
ara
ed
1 - 15 Nm ris nte
tho eo
au ra
2 - Coolant pump ss c

ce
le
❑ Check for ease of move‐
un

pt
an
ment.
d
itte

y li
rm

ab
❑ Note installation posi‐
pe

ility
tion.
ot

wit
, is n

❑ Removing and installing

h re
hole

⇒ page 90

spec
es, in part or in w

3 - O-ring

t to the co
❑ Renew
4 - To top of radiator

rrectness of i
❑ Coolant hose schematic
l purpos

diagram ⇒ page 80 .
5 - To cylinder head

nform
ercia

❑ Coolant hose schematic


m

diagram ⇒ page 80 .

a
com

tion in
6 - To top of expansion tank
r
te o

thi
❑ Coolant hose schematic

s
iva

do
r

diagram ⇒ page 80 .
rp

cum
fo

en
g

7 - Upper coolant pipe


n

t.
yi Co
op py
❑ Clipped into bulkhead of
. C rig
ht ht
rig
plenum chamber. py by
co Vo
by lksw
❑ Coolant hose schematic
cted agen
Prote AG.
diagram ⇒ page 80 .
8 - O-ring
❑ Renew
9 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture gauge sender -G2- .
10 - Securing clip
❑ Check for secure seating.
11 - To heat exchanger
❑ Coolant hose schematic diagram ⇒ page 80 .
12 - From heat exchanger
❑ Coolant hose schematic diagram ⇒ page 80 .
13 - 10 Nm
14 - Connection
15 - Coolant pipe
❑ Coolant hose schematic diagram ⇒ page 80 .
16 - To top of radiator
❑ Coolant hose schematic diagram ⇒ page 80 .

1. Removing and installing parts of cooling system 79


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

17 - To bottom of expansion tank


❑ Coolant hose schematic diagram ⇒ page 80 .
18 - To bottom of radiator
❑ Coolant hose schematic diagram ⇒ page 80 .
19 - Connection
❑ For thermostat
20 - Thermostat
❑ Removing and installing ⇒ page 92
❑ Observe installation position, ⇒ page 92 Removing and installing thermostat
❑ Checking: Heat thermostat in water.
❑ Opening begins at approx. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift min. 7 mm.
21 - Oil cooler

1.3 Coolant hose schematic diagram

1.3.1 Vehicles with manual gearbox: engine


codes AJM, ASZ, ATD, AUY
Vehicles with manual gearbox: engine codes ARL, AXR
⇒ page 82 .
Vehicles with automatic gearbox: engine codes AJM, ATD, AUY AG. Volkswagen AG d
⇒ page 83 . agen oes
olksw not
byV gu
ara
Vehicles with automatic gearbox: engine codes ASZ, AXR rised
nte
⇒ page 84 . aut
ho eo
ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

80 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Expansion tank
2 - Intake manifold
3 - Cylinder head/cylinder
block
4 - Heater unit heat exchanger
5 - Coolant pipe
6 - Upper coolant hose
7 - Radiator
8 - Lower coolant hose
9 - Oil cooler
10 - Coolant pump and ther‐
AG. Volkswagen AG d
mostat ksw
agen oes
not
Vol
by gu
d ara
ise nte
or eo
h
aut ra
ss c

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le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Removing and installing parts of cooling system 81


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.3.2 Vehicles with manual gearbox: engine codes ARL, AXR

1 - Expansion tank
2 - Intake manifold
3 - Radiator
❑ For exhaust gas recircu‐
lation
4 - Heater unit heat exchanger
5 - Coolant pipe
6 - Lower coolant hose
7 - Upper coolant hose
8 - Radiator
9 - Oil cooler
10 - Coolant pump and ther‐ agen
AG. Volkswagen AG d
oes
mostat olksw not
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ara
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11 - Cylinder head/cylinder horis nte
eo
block s aut ra
c
s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

82 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.3.3 Vehicles with automatic gearbox: engine codes AJM, ATD, AUY

1 - Expansion tank
2 - Intake manifold
3 - Cylinder head/cylinder
block
4 - Heater unit heat exchanger
5 - Coolant pipe . Volkswagen AG
gen AG does
swa
6- Gearbox oil cooler y Volk not
gu
edb ara
nte
7- Upper coolant hose horis
eo
aut ra
8- Radiator ss c

ce
e
nl

pt
9 - Lower coolant hose
du

an
itte

y li
erm

10 - Oil cooler

ab
ility
ot p

11 - Coolant pump and ther‐

wit
, is n

mostat

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Removing and installing parts of cooling system 83


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.3.4 Vehicles with automatic gearbox: engine codes ASZ, AXR

1 - Expansion tank
2 - Intake manifold AG. Volkswagen AG d
agen oes
olksw not
y V gu
3 - Radiator d b ara
rise nte
❑ For exhaust gas recircu‐ autho eo
ra
lation ss c

ce
le
un
4 - Heater unit heat exchanger

pt
an
d
itte

y li
5 - Coolant pipe
erm

ab
ility
ot p

6 - Gearbox oil cooler

wit
is n

h re
7 - Upper coolant hose
ole,

spec
urposes, in part or in wh

8 - Radiator

t to the co
9 - Lower coolant hose
10 - Oil cooler

rrectne
11 - Coolant pump and ther‐
mostat

ss o
cial p

f
12 - Cylinder head/cylinder

inform
block
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

84 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.4 Draining and filling coolant


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Special tools andbyworkshop
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♦ Refractometer
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♦ Drip tray -V.A.G 1306-


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♦ Spring-type clip pliers -VAS
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Not illustrated:
♦ Cooling system charge unit -VAS 6096-

1.4.1 Draining
– Open filler cap on coolant expansion tank.

WARNING

Hot steam may escape when expansion tank is opened. Place


cloth over cap and open with caution.

– Remove noise insulation ⇒ Rep. Gr. 50 .

1. Removing and installing parts of cooling system 85


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Vehicles with drain plug for radiator


– To drain coolant from radiator, open drain plug -arrow-.
Vehicles without drain plug for radiator

– Pull off bottom coolant hose retaining clip -arrow- and remove
coolant hose from quick release coupling on radiator.
Continuation for all vehicles

– To drain coolant from engine, also remove coolant hose from


oil cooler -arrow-.

Note

Observe environmental regulations


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en Adisposal.
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86 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.4.2 Filling

Note

♦ Only use coolant additive G 12 in accordance with


TL VW 774 F. Identification: purple colour.
♦ G 12 purple (in accordance with TL VW 774 F) can be mixed
with the previous coolant additive G 12 red!
♦ G 12 and coolant additives marked "In accordance with
TL VW 774 F" prevent frost and corrosion damage, scaling
and also raise boiling point of coolant. Therefore, the cooling
system must be filled all year round with coolant additive and
corrosion protection additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection is required down to about -25 °C (in countries
with arctic climates: down to about -35 °C). . Volkswagen AG
gen AG does
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♦ The coolant concentration must not be reduced by adding y V wa‐
olk not
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ter even in warmer seasons and in warmer countries.rised The
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coolant additive must be at least 40% of mixture.
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♦ If for climatic reasons greater frost protection is required, the
s

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amount of G 12 can be increased, but only up to 60% (frost


un

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protection to about -40°C). Otherwise frost protection and


itte

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cooling effectiveness are reduced again.
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♦ If radiator, heat exchanger, cylinder head or cylinder head

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, is n

gasket is renewed, do not reuse old coolant.

h re
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spec
es, in part or in w

Recommended mixture proportions:

t to the co
Frost protection Anti-freeze G 124) Water4)
to quantity

rrectness of i
-25 °C 40 % 2.4 l 3.6 l
l purpos

-35 °C 50 % 3.0 l 3.0 l

nform
4) The quantity of coolant can vary depending upon vehicle equipment.
ercia

Vehicles with drain plug for radiator


m

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tion in
– Close radiator drain plug.
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Vehicles without drain plug for radiator


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– Install lower coolant hose and secure with retaining clip


fo

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-arrow-.
n

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.
Continuation for all vehicles
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1. Removing and installing parts of cooling system 87


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Push coolant hose onto oil cooler connection and secure with
a spring-type clip.
With cooling system charge unit -VAS 6096- :
– Fill coolant circuit using cooling system charge unit -VAS
6096- ⇒ Operating instructions for cooling system charge unit
VAS 6096.
Without cooling system charge unit -VAS 6096- :
Vehicles with max. marking on expansion tank.

– Fill with coolant up to max. mark on expansion tank.


– Fit expansion tank cap.
– Run engine until radiator fan cuts in.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
at the max. mark; when the engine is cold, the coolant level
must be between the min. and max. marks.
Vehicles without max. marking on expansion tank

– Slowly fill coolant to upper marking of shaded field on expan‐ agen


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– Fit expansion tank cap. oris tee
th or
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– Run engine until radiator fan cuts in. ss
ac

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nl

– Check coolant level and replenish as necessary:

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When engine is at operating temperature, coolant level must be
erm

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at upper mark of hatched area.

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On cold engine, coolant level should be roughly in middle of

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hatched area.
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spec
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1.5 Removing and installing radiator
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Prote AG.

88 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Refractometer -T10007-
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -V.A.G
1331-
♦ Spring-type clip pliers -VAS
5024A-

n AG. Volkswagen AG do
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d ran
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erm

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es, in part or in w

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rrectness of i
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orm
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Removing
or

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Note
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On vehicles with engine code “ARL”, connecting hoses on charge
C py
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oil cooler must be removed ⇒ page 130 Removing and installing
ht
pyri by
parts of charge air cooling system.
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– Drain coolant ⇒ page 85 .


– Pull coolant hoses off radiator.
– Pull connectors off thermal switch and radiator fan.
– Remove front bumper ⇒ Rep. Gr. 63
– Bring lock carrier into service position ⇒ Rep. Gr. 50 .
– Unscrew securing bolts of radiator and take out radiator with
fan downwards (on engine code “ARL” including charge air
cooler upwards).
Vehicles with air conditioning:
– Observe additional information and installation work
⇒ page 90 .

1. Removing and installing parts of cooling system 89


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Fill with coolant ⇒ page 85 .

1.5.1 Additional information and removal in‐


structions for vehicles with air condition‐
er

WARNING

The air conditioner refrigerant circuit must not be opened.

Note

To prevent damage to condenser or to refrigerant pipes and ho‐


ses, ensure that pipes and hoses are not stretched, kinked or
bent.

– Remove retaining clamp(s) for refrigerant lines.


– Unbolt condenser from radiator and secure to lock carrier.

1.6 Removing and installing coolant pump

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agen oes
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90 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
Volkswagen AG
n AG.unit
4-cylinder diesel engine
kswagewith injector - dEdition
oes
n
08.2009
ol ot g
yV ua
db ran
Special tools and workshop ris
e
tee
equipment required tho or
au ac
ss
♦ Refractometer -T10007-

ce
e
nl

pt
du

an
♦ Drip tray -V.A.G 1306-

itte

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erm

ab
♦ Torque wrench -V.A.G

ility
ot p
1331-

wit
, is n

h re
♦ Spring-type clip pliers -VAS

hole

spec
5024A-

es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
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c

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or

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for

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Removing

Note

♦ Renew gaskets and seals.


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

– Remove toothed belt ⇒ page 37 .


– Drain coolant ⇒ page 85 .

1. Removing and installing parts of cooling system 91


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Unscrew securing bolts -1- of coolant pump -2- and carefully


remove coolant pump.
Installing

Note

♦ If the new coolant pump contacts the rear toothed belt guard,
the toothed belt guard must be adapted using workshop equip‐ n AG. Volkswagen AG
ment. olks
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♦ Remove marked surface -arrow-. db ara
ir se nte
ho eo
ut
♦ For the sake of clarity, the rear toothed belt guard
ss
a and the ra
c
coolant pump are shown removed.

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Installation is carried out in the reverse order. When installing,
rm

ab
note the following:
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ility
ot

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– Moisten new O ring -3- with coolant.
hole

spec
– Insert coolant pump -2- into cylinder block and tighten securing
es, in part or in w

t to the co
bolts -1-. Specified torque: 15 Nm.

rrectness of i
Note
l purpos

The sealing plug of the coolant pump faces downwards.

nform
ercia

– Install and tension toothed belt ⇒ page 37 .


m

a
– Fill with coolant ⇒ page 85 .
com

tion in
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1.7 Removing and installing thermostat


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92 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Refractometer -T10007-
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -V.A.G
1331-
♦ Spring-type clip pliers -VAS
5024A-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
ss c
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du

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itte

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erm

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ility
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wit
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hole

spec
es, in part or in w

Removing
t to the co

Note
rrectness of i
l purpos

Renew gaskets and seals.


nform
ercia

– Drain coolant ⇒ page 85 .


m

– Pull coolant hose off connection.


at
om

ion
c

– Remove connecting flange -2- securing bolts -1- and remove


in t
or

his
e

connecting flange -2- with thermostat -4-.


at

do
priv

– Turn thermostat -4- 1/4 turn (90°) to left and remove from con‐
um
for

en
g

nection -2-.
n

t.
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Installing
rig
gh ht
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Installation is carried out in the reverse order. When installing,
lksw
cted agen
Prote
note the following:
AG.

1. Removing and installing parts of cooling system 93


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Moisten new O ring -3- with coolant.


– Insert thermostat -4- into union -2- and turn 1/4 turn (90 °) to
right.

Note

The brace on the thermostat must be almost vertical.

– Fit connection -2- with thermostat -4- into cylinder block.


– Tighten securing bolts -1-. Specified torque: 15 Nm.
– Fill with coolant ⇒ page 85 .

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1.8 Checking cooling system for leaksolkswagen A oes
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Special tools and workshop tho eo
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equipment required ss

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du

♦ Cooling system tester -

an
itte

V.A.G 1274-

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erm

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ility
♦ Adapter for cooling system
ot p

wit
tester -V.A.G 1274/8-
, is n

h re
hole

♦ Adapter for cooling system

spec
tester -V.A.G 1274/9-
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

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or

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ate

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for

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Prote AG.

Test prerequisite
• Engine at operating temperature.

94 Rep. Gr.19 - Cooling


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Test sequence:

WARNING

Hot steam may escape when expansion tank is opened. Place


cloth over cap and open with caution.

n AG. Volkswagen AG do
– Open cap on coolant expansion wage
olks tank.
es n
ot g
V
by ua
– Attach cooling system tester
ris
ed
-V.A.G 1274- with cooling system ran
tee
tester adapter -V.A.Gautho
1274/8- to expansion tank. or
ac
ss
– Use hand pump on tester to create a pressure of about 1.0 bar.

ce
le
un

pt
an
d

If pressure drops:
itte

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rm

ab
– Find leaks and rectify.
pe

ility
ot

wit
, is n

Checking pressure relief valve in filler cap

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Attach cooling system tester -V.A.G 1274- with cooling system
tester adapter -V.A.G 1274/9- to cap.
l purpos

– Use hand pump on cooling system tester to create a pressure


of max. 1.6 bar.

nform
ercia

The pressure relief valve must not open.


m

a
com

tion in
If the pressure relief valve opens prematurely:
r
te o

thi
s
iva

– Renew sealing cap.


do
r
rp

cum
fo

– Increase pressure to above 1.6 bar.


en
ng

t.
yi Co
op
The pressure relief valve must open. C py
t. rig
gh ht
yri
If the pressure relief valve does not open:
p by
o Vo
by c lksw
cted agen
– Renew sealing cap.
Prote AG.

1.9 Checking oil cooler for leaks

1. Removing and installing parts of cooling system 95


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Refractometer -T10007-
♦ Hose clamps up to Ø 25
mm -3094-
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
tester -V.A.G 1274/8-
♦ Spring-type clip pliers -VAS AG. Volkswagen AG d
5024 A- agen oes
olksw not
V gu
by ara
♦ Drip tray -V.A.G 1306- or rised
nte
drip tray -VAS 6208- ut
ho eo
ra
s a c
s

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
om

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c

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or

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ate

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for

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Special tools and workshop equipment required t. C rig
gh ht
pyri by
♦ Torque wrench -V.A.G 1331-
o Vo
by c lksw
cted agen
Prote AG.

Not illustrated
♦ Expansion tank -1K0 121 407 A bzw. 6Q0 121 407 A bzw. 1J0
121 407 B-
♦ Plug -191 211 343-
♦ Cap -1J0 121 324-
♦ Coolant hose -251 265 056-

96 Rep. Gr.19 - Cooling


n AG. VolkswBora
agen A1999
G do ➤ , Golf 1998 ➤
wage e
4-cylinder diesel y Vo engine with unit injectors-nEdition
lks ot g 08.2009
d b ua
ran
ir se tee
Prerequisites: ut
ho or
a ac
ss
• Engine cold

ce
e
nl

pt
du

an
Test procedure

itte

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erm

ab
– Remove noise insulation.

ility
ot p

wit
– Clamp supply line and return line off oil cooler using hose

, is n

h re
clamps to Ø 25 mm -VAS 3094- .

hole

spec
– Loosen hose clamps -arrows- using spring type clip pliers -

es, in part or in w

t to the co
VAS 5024- .

rrectness of i
Note
l purpos

Collect escaping coolant with drip tray -V.A.G 1306- or drip tray -
VAS 6208- .

nform
ercia

– Pull coolant hoses off oil cooler.


m

at
om

ion
c

in t
or

– Slide cover -5- onto rear connection of oil cooler -4-.

his
ate

do
riv

– Secure sealing plug -2- to breather connection of expansion


p

cum
or

tank -1-.
f

en
ng

t.
yi Co
op
– Secure coolant hose -3- to oil cooler and expansion tank. C py
t. rig
gh ht
yri
– Fill expansion tank up to “Max” marking.
p by
co Vo
by lksw
cted agen
– Attach cooling system tester -V.A.G 1274- with cooling system
Prote AG.

tester adapter -V.A.G 1274/8- to expansion tank.


– Use hand pump on tester to create a pressure of about 1.6 bar.
– Watch pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If pressure drops:
– Renew oil cooler ⇒ page 69 .
Installation is carried out in the reverse order. When installing,
note the following:
– Check coolant level, if necessary replenish coolant
⇒ page 85 .

1. Removing and installing parts of cooling system 97


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

20 – Fuel supply system


1 Removing and installing parts of fuel
supply system

Note

♦ Hose connections are secured with either spring-type or


clamp-type clips.
♦ Renew clamp-type clips with spring-type clips.
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of clamp or screw-type clips is not n AG. Volkswagen AG do
permissible. olkswage es n
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byV ua
♦ Spring-type clip pliers -VAS 5024A- or hose clip pliers -V.A.G
ir se
d ran
tee
1921- are recommended for installation of spring-typeuclips.
tho
or
a ac
ss

ce
le

Assembly overview - fuel tank with attachments ⇒ page 98


un

pt
an
d
itte

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Assembly overview - fuel filter ⇒ page 105 .
rm

ab
pe

ility
Observe safety precautions ⇒ page 107 .
ot

wit
, is n

h re
Observe rules for cleanliness ⇒ page 107 .
hole

spec
Removing and installing fuel cooler ⇒ page 107
es, in part or in w

t to the co
Removing and installing fuel tank ⇒ page 108
Removing and installing fuel delivery unit ⇒ page 110 .

rrectness of i
Removing and installing fuel gauge sender ⇒ page 112
l purpos

Removing and installing fuel pump ⇒ page 113


Checking fuel pump ⇒ page 114 .

nform
mercia

Removing, installing and checking suction jet pump

a
com

ti
⇒ page 116

on in
r
te o

thi
Repairing throttle mechanism ⇒ page 118 .
s
iva

do
r
rp

c
Checking tandem pump ⇒ page 119
um
fo

en
ng

t.
Removing and installing tandem pump ⇒ page 122 .
yi Co
Cop py
t. rig
1.1 Assembly overview - fuel tank with at‐
gh ht
pyri by
Vo
co
tachments
by lksw
cted agen
Prote AG.

1.1.1 Vehicles with front-wheel drive ▸ 08.00


Vehicles with front-wheel drive 09.00 ▸ ⇒ page 100 .
Vehicles with four-wheel drive ⇒ page 103 .

98 Rep. Gr.20 - Fuel supply system


n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua Bora 1999 ➤ , Golf 1998 ➤
d ran
ir se
tho 4-cylinder diesel engine twith ee unit injector - Edition 08.2009
o
au ra
c
ss
1 - Cap

ce
e
nl

pt
du

an
❑ With retainer clip.

itte

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erm

ab
2 - Seal

ility
ot p
❑ Renew if damaged.

wit
, is n

h re
hole

3 - Securing bolt

spec
es, in part or in w

4 - Tank flap unit

t to the co
❑ With rubber cup.
5 - Earth connection

rrectness of i
❑ Check for secure seat‐
l purpos

ing.
6 - O-ring

nf
ercia

o
❑ Renew if damaged.

rm
m

atio
m

7 - Breather valve
o

n in
or c

❑ To remove valve unclip

thi
te

sideways out of support.

sd
iva

o
r
rp

cu
❑ Unscrew cap before in‐
o

m
f

en
ng

stalling yi
t.
Co
op
❑ Checking ⇒ page 100 .
C py
t. rig
gh ht
yri by
8 - 10 Nm cop Vo
by lksw
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Prote
9 - Breather line
AG.

❑ Clipped onto top of fuel


tank.
❑ Check for secure seat‐
ing.
❑ Secure with spring-type
clips.
10 - Clamping washer
11 - Heat shield
❑ For fuel tank.
12 - Fuel tank cover
13 - 20 Nm + turn 90° further
❑ Renew
14 - Securing strap
❑ Note differing lengths.
15 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
❑ Removing and installing ⇒ page 108
16 - Seal
❑ Renew if damaged.
❑ When installing, insert seal dry into fuel tank opening.
❑ Moisten with fuel only when installing flange.
17 - Fuel gauge sender -G-
❑ Note installation position on fuel tank ⇒ page 100 .
18 - Union nut
❑ Remove and install using union nut tool -3217- .
19 - Supply line
❑ To fuel filter ⇒ page 105 .
❑ Black

1. Removing and installing parts of fuel supply system 99


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
❑ Clipped onto fuel tank
❑ Check for secure seating.
❑ To pull off flange, press release button on connecting piece
20 - Return line
❑ From fuel cooler gen AG
. Volkswagen AG
swa does
❑ On connection -R- yV
olk not
gu
d b ara
❑ Blue or with blue marking. orise nte
eo
h
ut
❑ Clipped onto fuel tank. ss a ra
c
❑ Check for secure seating.

ce
le
un

pt
an
d

❑ To pull off flange, press release button on connecting piece.


itte

y li
erm

ab
21 - Gravity/overflow valve

ility
ot p

wit
❑ To remove valve unclip upwards out of support.
is n

h re
ole,

❑ Check valve for through-flow; valve vertical: open, valve tilted 45°: closed

spec
urposes, in part or in wh

22 - Angled piece

t to the co
Installation position of fuel gauge sender

rrectne
Marking on sender must align with the marking on fuel tank

s
-arrows-.

s o
cial p

f inform
mer

Note

atio
om

n
c

i
After installing fuel gauge sender, check whether fuel supply line
or

n thi
e

-2- and fuel return line -1- (identification R) are still clipped onto
t

sd
va

fuel tank.
i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
Checking vent valve co Vo
by lksw
cted agen
Prote AG.
Lever in rest position: closed
Lever pushed in direction of arrow: open

Note

Before installing vent valve remove fuel tank cap.

1.1.2 Vehicles with front-wheel drive 09.00 ▸

Note

Ensure, on completion of all work on the fuel delivery unit and fuel
gauge that the fuel supply and fuel return hoses do not touch the
fuel tank (transfer of pumping noises).

100 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Cap
❑ With retainer clip.
2 - Seal
❑ Renew if damaged.
3 - Securing bolt
AG. Volkswagen AG d
4 - Tank flap unit agen oes
olksw not
y V gu
❑ With rubber cup. ise
d b ara
nte
or eo
h
5 - Earth connection s aut ra
c
s
❑ Check for secure seat‐

ce
e
nl

pt
ing.
du

an
itte

y li
6 - O-ring
erm

ab
ility
ot p

❑ Renew if damaged.

wit
, is n

h re
7 - Breather valve
hole

spec
❑ To remove valve unclip
es, in part or in w

sideways out of support.

t to the co
❑ Unscrew cap before in‐
stalling

rrectness of i
❑ Checking ⇒ page 102 .
l purpos

8 - 10 Nm
9 - Breather line

nf
ercia

o
❑ Clipped onto top of fuel

rm
m

atio
tank.
om

n in
c

❑ Check for secure seat‐


or

thi
ing.
te

sd
iva

o
❑ Secure with spring-type
r
rp

cu
o

m
clips.
f

en
ng

t.
yi Co
op
10 - Clamping washer C py
t. rig
gh ht
yri
11 - Heat shield
p by
co Vo
by lksw
cted
❑ For fuel tank.
agen
Prote AG.

12 - Fuel tank cover


13 - 25 Nm
14 - Securing strap
❑ Note differing lengths.
15 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
❑ Removing and installing ⇒ page 108
16 - Seal
❑ Renew if damaged.
❑ When installing, insert seal dry into fuel tank opening.
❑ Moisten with fuel only when installing flange.
17 - Fuel delivery unit
❑ Note installation position of flange on fuel tank ⇒ page 102 .
❑ Removing and installing ⇒ page 110
❑ Checking fuel pump ⇒ page 114
❑ With fuel gauge sender -G-
❑ Removing and installing fuel gauge sender ⇒ page 112
❑ Clean strainer if soiled.

1. Removing and installing parts of fuel supply system 101


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

18 - Union nut
❑ Remove and install using union nut tool -3217- .
19 - Supply line
❑ To fuel filter ⇒ page 105 .
❑ Black.
❑ Clipped onto fuel tank. AG. Volkswagen AG d
agen oes
❑ Check for secure seating. Volksw not
gu
by ara
❑ To pull off flange, press release button on connectingrispiece.
ed
nte
ho eo
ut
20 - Return line ss
a ra
c
❑ From fuel cooler

ce
e
nl

pt
du

an
❑ On connection -R-

itte

y li
erm

ab
❑ Blue or with blue marking.

ility
ot p

❑ Clipped onto fuel tank.

wit
, is n

h re
❑ Check for secure seating.
hole

spec
❑ To pull off flange, press release button on connecting piece.
es, in part or in w

t to the co
21 - Gravity/overflow valve
❑ To remove valve unclip upwards out of support.

rrectness of i
❑ Check valve for through-flow; valve vertical: open, valve tilted 45°: closed
l purpos

22 - Angled piece

nform
ercia

Installation position of fuel delivery unit


m

at
om

io
Marking on flange must align with the marking on fuel tank

n
c

in t
or

-arrows-.

his
ate

do
riv

Blue or blue marked return line -1- to connection marked -R-.


p

cum
for

en
g

Black supply line -2- to connection marked -V-.


n

t.
yi Co
Cop py
t. rig
gh ht
yri by
Note
op Vo
by c lksw
cted agen
Prote AG.

After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.

Checking vent valve


Lever in rest position: closed
Lever pushed in direction of arrow: open

Note

Before installing vent valve remove fuel tank cap.

102 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.1.3 Vehicles with four-wheel drive

Note

Ensure, on completion of all work on the fuel delivery unit and fuel
gauge that the fuel supply and fuel return hoses do not touch the
fuel tank (transfer of pumping noises).

1 - Connector
❑ Black, 4-pin.
2 - Connector
❑ Black, 2-pin.
3 - Return hose bracket
4 - Return hose
5 - Gravity/overflow valve agen
AG. Volkswagen AG d
oes
lksw not
❑ To remove valve unclip d byV
o gu
ara
upwards out of support. oris e nte
th eo
❑ Check valve for s au ra
c
through-flow; valve ver‐s

ce
le

tical: open, valve tilted


un

pt
an
d

45°: closed
itte

y li
erm

ab
6 - Angled piece

ility
ot p

wit
is n

7 - O-ring

h re
ole,

❑ Renew if damaged.

spec
urposes, in part or in wh

8 - Cap

t to the co
❑ With retainer clip.
9 - Seal rrectne
❑ Renew if damaged.
ss

10 - Securing bolt
o
cial p

f in

11 - Tank flap unit


form
mer

❑ With rubber cup.


atio
om

n
c

12 - Breather valve
i
or

n thi
e

❑ To remove valve unclip


t

sd
iva

sideways out of support.


pr

cum
r
fo

❑ Unscrew cap before in‐


en
ng

t.
yi Co
stalling . Cop py
rig
ht
❑ Checking ⇒ page 105 . rig ht
py by
co Vo
by lksw
13 - Earth connection cted agen
Prote AG.
❑ Check for secure seating.
14 - 10 Nm
15 - Union nut
❑ Remove and install using union nut tool -3217- .
16 - Fuel gauge sender 2 -G169-
❑ Note installation position on fuel tank ⇒ page 100 .
❑ To remove, pull supply hose off fuel pump, unclip return hose retainer from fuel pump and separate 2
pin connector ⇒ page 113 Removing and installing fuel pump
❑ Only renew complete with supply and return hoses.
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations and ⇒ Vehicle diagnosis,
testing and information system VAS 5051

1. Removing and installing parts of fuel supply system 103


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
❑ Removing, installing and checking suction jet pump ⇒ page 116
17 - Seal
❑ Renew if damaged.
❑ When installing, insert seal dry into fuel tank opening.
❑ Moisten with fuel only when installing flange.
18 - Breather line
❑ Clipped onto top of fuel tank.
❑ Check for secure seating.
19 - Fuel tank
❑ When removing, support
wage
nAusing
G. Volkengine
swagen Aand
G do gearbox jack -V.A.G 1383 A- .
e ks s no
Vol t gu
20 - 25 Nm ed by ara
ris nte
21 - tho
Securingaustrap eo
ra
ss c
❑ Note differing lengths.

ce
e
nl

pt
du

22 - Clamping washer

an
itte

y li
erm

ab
23 - Heat shield

ility
ot p

❑ For fuel tank.

wit
, is n

h re
24 - Retaining strut
hole

spec
es, in part or in w

25 - Supply hose
❑ To remove from fuel pump press release button on connecting piece t to the co
26 - Fuel system pressurisation pump -G6-
rrectness of i

❑ With fuel gauge sender -G-


l purpos

❑ Note installation position on fuel tank ⇒ page 105 .


❑ Removing and installing ⇒ page 113
nf
ercia

❑ Checking fuel pump ⇒ page 114


rm
m

atio

❑ Clean strainer if soiled.


om

n in
or c

27 - Return line
thi
te

sd
a

❑ From fuel cooler


iv

o
r
rp

cu

❑ Blue or with blue marking.


o

m
f

en
ng

t.
yi
❑ Clipped onto fuel tank
Co
Cop py
t. rig
❑ Check for secure seating.
gh ht
pyri by
Vo
o
❑ To pull off flange, press release button on connecting piece
c by lksw
cted agen
Prote AG.
28 - Supply line
❑ To fuel filter ⇒ page 105 .
❑ Black
❑ Clipped onto fuel tank
❑ Check for secure seating.
❑ To pull off flange, press release button on connecting piece

104 Rep. Gr.20 - Fuel supply system


AG. Volkswagen AG d Bora 1999 ➤ , Golf 1998 ➤
agen oes
olksw 4-cylinder diesel engine
not with unit injector - Edition 08.2009
yV gu
db ara
rise nte
Installation position of fueluthpump
o flange or fuel gauge sender eo
ra
s a c
Marking on sender or fuel pump must align with the marking on s

ce
e
nl
fuel tank -arrows-.

pt
du

an
itte

y li
erm

ab
ility
Note
ot p

wit
, is n

h re
After installing fuel pump, ensure that fuel supply pipe -2- and fuel
hole

spec
return line -1- are securely clipped onto fuel tank.
es, in part or in w

t to the co
rrectness of i
Checking vent valve
l purpos

Lever in rest position: closed

nf
ercia

Lever pushed in direction of arrow: open

orm
m

atio
om

n in
c

Note
or

thi
te

sd
iva

o
Before installing vent valve remove fuel tank cap.
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
1.2 Assembly overview - fuel filter
AG.

1. Removing and installing parts of fuel supply system 105


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Supply line
❑ From fuel tank.
❑ White or with white
marking.
❑ Check for secure seat‐
ing.
2 - Return line
❑ To fuel cooler
❑ Blue or with blue mark‐
ing.
❑ Check for secure seat‐
ing.
3 - O-ring
❑ Renew
AG. Volkswagen AG d
agen oes
4 - Control valve olksw not
byV gu
ara
d
❑ Installation position: ar‐ orise nte
row points towards fuel aut
h eo
ra
tank ss c

ce
le

❑ When changing filter,


un

pt
an
d

remove securing clip


itte

y li
and take control valve
erm

ab
ility
off complete with fuel
ot p

wit
lines.
is n

h re
ole,

❑ Below +15 °C: passage

spec
to filter open.
urposes, in part or in wh

t to the co
❑ Over +31 °C: passage
to filter closed.
5 - Securing clip

rrectne
❑ Check for secure seat‐
ing.

ss o
cial p

f
6 - Return line

inform
❑ Check for secure seat‐
mer

ing.

atio
om

❑ From tandem pump ⇒ Item 25 (page 34) n


c

i
or

n thi
te

sd

7 - Supply line
iva

o
pr

❑ Check for secure seating.


um
r
fo

en
ng

t.
❑ To tandem pump ⇒ Item 25 (page 34)
yi Co
Cop py
ht. rig
8 - Fuel filter rig ht
py by
o Vo
❑ Fill with diesel before installing
by c lksw
cted agen
Prote AG.
❑ Direction of flow is marked by arrows
❑ Do not interchange connections
❑ Renew if damaged.
9 - Gasket
❑ Renew if damaged.
10 - Water drainage plug
❑ To bleed, remove control valve securing clip and take off control valve complete with fuel lines
❑ Loosen and allow approx. 100 cm3 fluid to drain

106 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.3 Safety precautions when working on


fuel supply system

WARNING

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


ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel
agen
system!
AG. Volkswagen AG d
o
w es n
olks ot g
byV ua
d ran
ir se tee
When removing uth and installing fuel gauge sender or fuel pump
o
or
(fuel delivery
ss
aunit) from a full or partly full fuel tank, observe theac
following:
ce
e
nl

pt
du

an

♦ Even before work commences, the extraction hose of an ac‐


itte

y li

tivated fume extraction system has to be placed in the vicinity


erm

ab
ility

of the assembly opening of the fuel tank to extract any escap‐


ot p

ing fumes. If no exhaust gas extraction system is available, a


wit
, is n

h re

radial fan with a displacement greater than 15 m3/h can be


hole

spec

used providing that motor is not in air flow.


es, in part or in w

t to the co

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

1.4 Rules for cleanliness


rrectness of i

When working on the fuel supply and injection systems, pay care‐
l purpos

ful attention to the following “6 rules” for cleanliness:


♦ Thoroughly clean all unions and adjacent areas before dis‐
nform
ercia

connecting.
m

at

♦ Place removed parts on a clean surface and cover. Do not use


om

io

fluffy cloths!
n
c

in t
or

his
e

♦ Carefully cover opened components or seal if repairs cannot


at

do
riv

be carried out immediately.


p

cum
for

en
g

♦ Install clean components only. Do not remove replacement


n

t.
yi Co
parts from packing until immediately before installing. Do not Cop py
t. rig
use parts that have not been stored in their packing (e.g. in gh ht
yri by
tool boxes etc.). cop Vo
by lksw
cted agen
Prote AG.
♦ When system is open: Do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that diesel fuel does not get on the coolant hoses.
If necessary hoses must be cleaned immediately. Contami‐
nated hoses must be replaced.

1.5 Removing and installing fuel cooler


Special tools and workshop equipment required

1. Removing and installing parts of fuel supply system 107


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Torque wrench -V.A.G 1331-

Removing
Observe safety precautions ⇒ page 107 .
n AG. Volkswagen AG do
Observe rules for cleanliness ⇒ page 107 . lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Note ss
au ac

ce
e
nl

pt
The fuel cooler is located in the return line to the fuel tank. It is
du

an
itte

located on the vehicle underbody.

y li
erm

ab
ility
ot p

– Remove cover -A-.

wit
, is n

h re
– Detach fuel lines from fuel cooler.
hole

spec
es, in part or in w

– Remove securing nuts -arrows-.

t to the co
Installing
Installation is carried out in the reverse order of removal. When

rrectness of i
doing this, note the following:
l purpos

♦ Tighten fuel cooler securing nuts to 20 Nm.

nform
mercia

at
om

ion
c

1.6 Removing and installing fuel tank in t


or

his
ate

do
riv

Special tools and workshop equipment required


p

cum
for

en
g

♦ Torque wrench -V.A.G 1331-


n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

108 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Engine and gearbox jack -V.A.G 1383 A-

Removing
Observe safety precautions ⇒ page 107 .
Observe rules for cleanliness ⇒ page 107 .
– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– Open fuel tank filler flap.
– With ignition switched off, disconnect earth strap from battery.
– Remove rear axle ⇒ Rep. Gr. 42 .
– Remove rear right wheel housingAG
liner
. Volk⇒ Rep.
swagen A Gr. 68 .
gen G do
swa es n
Front-wheel drive vehicles
by
Vol
k ot g
ua
d ran
se
– Remove fuel tank
tho cover.
ri tee
or
au ac
Continuation forsall
s
vehicles
ce
le
un

pt

– Drain fuel tank and clean fuel filler neck and surrounding area.
an
d
itte

y li
erm

ab

– Unscrew securing bolt and remove tank flap unit with rubber
ility
ot p

cup.
wit
is n

h re

– Remove filler neck securing bolts.


ole,

spec
urposes, in part or in wh

– Fold rear seat bench forwards.


t to the co

– Remove cover plate and pull connector off flange.


rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Removing and installing parts of fuel supply system 109


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009AG. Volkswagen A
n G do
wage es n
Volks ot g
– Separate fuel supply and return lines on front right ofedfuel
by tank. ua
ran
oris tee
th or
au ac
WARNING ss

ce
e
nl

pt
du

an
♦ The fuel and the fuel lines in the fuel system can become

itte

y li
very hot (danger of scalding)!

erm

ab
ility
ot p
♦ The fuel system is also under pressure! Before opening

wit
, is n
the system, place cloths around the connections. Then

h re
carefully loosen connection to release the pressure!
hole

spec
♦ Wear eye and hand protection when performing any type es, in part or in w

t to the co
of repair work on the fuel system!

rrectness of i
l purpos

Note

nf
To do this, press down buttons on hose couplings -arrows-.
ercia

orm
m

atio
m

Vehicles with four-wheel drive


o

n in
or c

thi
te

– Remove securing nuts/bolts -arrows-.

sd
iva

o
r
rp

cu
Continuation for all vehicles
o

m
f

en
ng

t.
yi Co
– Remove securing straps. When doing this, support fuel tank . Cop py
with engine and gearbox jack -V.A.G 1383 A- .
ht rig
rig ht
py by
co Vo
– Lower fuel tank.
by lksw
cted agen
Prote AG.
Installing
Installation is carried out in the reverse order of removal. When
doing this, note the following:
♦ Route breather and fuel hoses free of kinks.
♦ Ensure that fuel hoses are tight.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Clip supply and return lines onto fuel tank.

Note

After installing fuel tank, check that the supply, return and breath‐
er pipes are still clipped onto the fuel tank.

1.7 Removing and installing fuel delivery


unit

1.7.1 Vehicles with front-wheel drive 09.00 ▸


Special tools and workshop equipment required

110 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Union nut tool -3217-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

♦ Torque wrench -V.A.G 1332-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

Removing

his
ate

do
riv

Observe safety precautions ⇒ page 107 .


p

cum
for

en
g

Observe rules for cleanliness ⇒ page 107 .


n

t.
yi Co
Cop py
– First check whether a coded radio is fitted. If so, obtain anti-
t. rig
gh ht
yri
theft coding. p by
o Vo
by c lksw
cted agen
– With the ignition switched off, disconnect battery earth strap. Prote AG.

– Fold rear seat bench forwards.


– Remove cover from fuel delivery unit.
– Pull 4-pin connector as well as supply and return pipes off
flange.

WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

Note

Press buttons on hose couplings to do this.

1. Removing and installing parts of fuel supply system 111


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Unscrew union nut with union nut tool -3217- .


– Pull fuel delivery unit and seal out of the opening in fuel tank.

Note

If delivery unit is to be renewed, drain old delivery unit before dis‐


posal.

Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.

Note

♦ Do not bend fuel sender when installing.


♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Ensure that fuel hoses are tight.
♦ After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
♦ Note installation position of fuel delivery unit flange: mark on
flange must align with mark on fuel tank (arrows).
AG. Volkswagen AG d
agen oes
olksw not
1.8 Removing and installing fuel gauge
V gu
d by ara
ise nte
r
sender aut
ho eo
ra
ss c
ce
e
nl

pt
du

an

Note
itte

y li
erm

ab
ility

Vehicles with four-wheel drive have two fuel gauge senders. To


ot p

wit

remove fuel gauge sender 2 -G169- ⇒ page 116 Removing and


, is n

h re

installing suction jet pump.


hole

spec
es, in part or in w

1.8.1 Vehicles with front-wheel drive 09.00 ▸


t to the co

Removing
rrectness of i

– Remove fuel delivery unit ⇒ page 110 .


l purpos

– Release connector lugs on lines -3- and -4- and pull off.
– Lift retaining tabs -1- and -2- using a screwdriver and pull fuel
nform
ercia

gauge sender off downwards -arrows-.


m

at
om

Installing
ion
c

in t
or

– Insert fuel sender into guides on fuel delivery unit and press
his
ate

upwards until it engages.


do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

112 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
AG. Volkswagen AG d
1.9 Removing and installing fuel pump olksw
agen oes
not
byV gu
ara
ed
ris nte
ho eo
ut
1.9.1 Vehicles with four-wheel drive ss a ra
c

ce
le
un
Special tools and workshop equipment required

pt
an
d
itte

y li
♦ Union nut tool -3217-

erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
Removing
om

n
c

i
or

n
Observe safety precautions ⇒ page 107 .

thi
te

sd
va

Observe rules for cleanliness ⇒ page 107 .


i

o
pr

cum
r
fo

– First check whether a coded radio is fitted. If so, obtain anti-

en
ng

t.
yi Co
theft coding. . Cop py
rig
ht ht
rig
– With the ignition switched off, disconnect battery earth strap. py by
co Vo
by lksw
cted agen
– Fold rear seat bench forwards. Prote AG.

– Remove cover under bench seat.


– Pull 4-pin connector as well as supply and return pipes off
flange.

WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

Note

Press buttons on hose couplings to do this.

1. Removing and installing parts of fuel supply system 113


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Unscrew union nut with union nut tool -3217- .


– Pull supply hose off fuel pump ⇒ Item 25 (page 104) .

Note

Press button on hose coupling to do this.

– Separate 2-pin connector ⇒ Item 2 (page 103) .


– Unclip return hose bracket out of fuel pump
⇒ Item 3 (page 103) .
– Pull fuel pump and seal out of the opening in fuel tank.

Note

If the fuel pump is to be renewed then drain old fuel pump before
disposal.

Installing
– Installation of the fuel pump is carried out in the reverse order
of removal.

Note

♦ Do not bend fuel sender when installing. agen


AG. Volkswagen AG d
oes
olksw not
♦ Insert seal for fuel pump or sender 2 dryeinto
d by Vfuel tank opening. gu
ara
ris nte
o
♦ Moisten seal with fuel only when installing
aut
h fuel pump or sender eo
ra
2. ss c
ce
le
un

pt

♦ Ensure that fuel hoses are tight.


an
d
itte

y li

♦ Note Installation position of fuel pump flange: mark on flange


erm

ab
ility

must align with mark on fuel tank -arrows-.


ot p

wit
is n

♦ After installing fuel pump flange, check that supply line -2- and
h re
ole,

return line -1- are still clipped onto fuel tank.


spec
urposes, in part or in wh

t to the co

1.10 Checking fuel pump


rrectne

1.10.1 Vehicles with front-wheel drive 09.00 ▸


and vehicles with four-wheel drive
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
Special tools and workshop equipment required by c lksw
cted agen
Prote AG.
♦ Hand multimeter -V.A.G 1526B- or multimeter -V.A.G 1715-
♦ Adapter set -V.A.G 1594C-
♦ Voltage tester -V.A.G 1527B-

114 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Test prerequisites
• Fuses must be OK.
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.

1.10.2 Checking function and voltage supply


– Fold rear seat bench forwards.
– Remove cover under bench seat.
– Briefly operate starter. Fuel pump must be heard to run.
– Switch off ignition.
If the fuel pump does not run:
– Pull 4-pin connector off fuel delivery unit flange.
– Connect voltage tester -V.A.G 1527- to outer contacts of con‐
nector using adapter cables from -V.A.G 1594- .
AG. Volkswagen
– Switch on ignition; LED must light up for lapprox.
ksw
agen 2 seconds. AG does
n o ot g
yV ua
If LED does not light up risedb ran
tee
ho
– Check activation of fuel for open circuit ut
pumps arelay and wiring
or
ac
and short circuit ⇒ Current flow diagrams, Electrical fault find‐ s
ce
le

ing and Fitting locations.


un

pt
an
d
itte

y li

LED lights up (voltage supply OK):


erm

ab
ility
ot p

– Remove fuel delivery unit ⇒ page 110 .


wit
is n

h re

– Check that electrical wiring between flange and fuel pump is


ole,

spec

connected and has continuity.


urposes, in part or in wh

t to the co

If no open circuit can be found:


– Renew fuel delivery unit ⇒ page 110 .
rrectne

1.10.3 Checking current draw of fuel pump


ss o

– Pull 4-pin connector off fuel delivery unit flange.


cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Removing and installing parts of fuel supply system 115


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Set multimeter to measuring range 20 A and connect in series


between contacts -1- of connector and fuel pump using meas‐
uring cables -V.A.G 1594/1- .

Note

The current pick-up clamp of multimeter -V.A.G 1715- can also


be attached to an auxiliary cable between contact -1- of connector
and fuel pump.

– Connect contacts -4- of connector and Afuel pump


G. Volkswagusing
en AG one of
agen does
measuring cables -V.A.G 1594/1-
Volksw . not
y gu
db ara
– Start engine and run atoridling
ise speed. nte
h eo
ut ra
– Measure current draw
ss
a of fuel pump. Specification: 3.5…4.5 c
Amperes.

ce
le
un

pt
an
d

– If the measured value is not within specifications:


itte

y li
erm

ab
– Renew fuel delivery unit ⇒ page 110 .

ility
ot p

wit
is n

h re
1.11 Removing, installing and checking suc‐
ole,

spec
urposes, in part or in wh

tion jet pump

t to the co
Special tools and workshop equipment required
♦ Union nut tool -3217-

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
♦ Torque wrench -V.A.G 1332-
c by lksw
cted agen
Prote AG.

1.11.1 Vehicles with four-wheel drive


Function
On vehicles with four-wheel drive, fuel has to be pumped with a
suction-jet pump from the area of fuel gauge sender 2 -G169- ,
⇒ Item 16 (page 103) , to the fuel pump due to the shape of the
fuel tank. The suction jet pump works according to one of the rules
of physics. It is driven by an additional connection on the fuel
pump by the supply of fuel.

116 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Note

An inspection is only necessary if the engine stops as a result of


insufficient fuel, despite the fuel gauge showing there is still fuel
in the tank (more than reserve).

Test prerequisites
• Both fuel gauge senders have been checked, referring to fault
finding program, and are OK ⇒ Vehicle diagnosis, testing and
information system VAS 5051
• Fuel tank has been emptied
Procedure
Observe safety precautions ⇒ page 107 .
Observe rules for cleanliness ⇒ page 107 .

Note

Before carrying out further work, disconnect battery earth strap.


Check whether a coded radio is fitted. Obtain anti-theft coding first
if necessary.

– With the ignition switched off, disconnect battery earth strap.


– Fold rear seat bench forwards.
– Remove cover under bench seat.
– Pull 4-pin connector and fuel hoses off fuel pump (right side of
vehicle) and remove fuel pump ⇒ page 113 , Removing and
installing fuel pump.

WARNING AG. Volkswagen AG d


agen oes
olksw not
V gu
♦ The fuel and the fuel lines in the fuel system can become ed by ara
nte
is
very hot (danger of scalding)! hor eo
aut ra
♦ The fuel system is also under pressure! Before s opening
s c ce
le

the system, place cloths around the connections. Then


un

pt
carefully loosen connection to release the pressure!
an
d
itte

y li
rm

ab

♦ Wear eye and hand protection when performing any type


pe

ility

of repair work on the fuel system!


ot

wit
, is n

h re
hole

spec
es, in part or in w

– Now remove fuel gauge sender 2 -G169- union nut on left side
t to the co

of vehicle.
– Lift fuel gauge sender 2 -G169- upwards as far as possible.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
117
agen
Prote AG.
1. Removing and installing parts of fuel supply system
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Separate cable tie on fuel line -arrow- and carefully open out
mounting for suction jet pump on sender 2.
– Now unclip the suction-jet pump with fuel supply and return
lines from fuel gauge sender 2 -G169- and remove.
– Check that the fuel lines on suction jet pump are fitted securely
and are not damaged.
– Additionally check suction jet pump for possible soiling.
If no fault is found:
– Install suction jet pump and fuel gauge sender 2 -G169- again
in reverse order of removal.

Note

♦ Remember to insert the seal dry in the opening of the fuel tank
before installing the fuel pump or sender 2.
♦ Renew seals if the fuel has caused them to swell.
♦ Ensure that fuel hoses are tight. agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
r
1.12 Assembly overview - accelerator mechanism ho eo
aut ra
ss c

ce
le
un

pt
an
1 - Mounting bracket
d
itte

y li
rm

ab
2 - Connector
pe

ility
ot

❑ Black, 6-pin.

wit
, is n

h re
hole

3 - Accelerator pedal position

spec
sender -G79-
es, in part or in w

t to the co
❑ Not adjustable.
❑ The accelerator pedal
position sender trans‐

rrectness of i
mits the driver's input to
the engine control unit
l purpos

❑ Remove footwell cover


to remove sender.

nform
ercia

4 - 10 Nm
m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

118 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.13 Checking tandem pump


Checking delivery pressure ⇒ page 119
Checking for internal leaks ⇒ page 120

1.13.1 Checking delivery pressure


Special tools and workshop equipment required
♦ Tandem pump tester -VAS 5187-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
♦ Torque wrench (5…50 Nm) -V.A.G oris1331-
e nte
eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Vehicle diagnostic, testing and information system -VAS 5051- rrectness of i
l purpos

♦ Diagnostic cable -VAS 5051/6A-


nform
ercia

Test prerequisites
m

at

Coolant temperature must be at least 85 °C.


om

ion
c

in t
r

Unit injectors OK.


o

his
ate

do
riv

Fuel filter and fuel lines must not be blocked.


p

cum
for

Procedure
en
ng

t.
yi Co
op py
– Remove engine cover.
. C rig
ht ht
rig by
py
– Remove securing bolt -arrow-.
co Vo
by lksw
cted agen
Prote AG.

1. Removing and installing parts of fuel supply system 119


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Connect tandem pump tester -VAS 5187- as shown.


– Start engine and run at idling speed.
– Connect vehicle diagnostic, testing and information system -
VAS 5052- and select operating mode “Vehicle self-diagno‐
sis”.
– Press button “01 - Engine electronics” on display.
– Press diagnosis function “08 - Read measured value block”.
– Enter display group “1” using number block (key pad) and
confirm entry with Q button.
– Read engine idling speed in display zone “1”.
– Increase engine speed to 4000 rpm.
– Observe pressure indicated on pressure gauge.
Specification: min. 7.5 bar
If the specification is not attained:
– Using a hose clip, clamp-off return line between fuel filter and
tandem pump.
– Increase engine speed to 4000 rpm.
– Observe pressure indicated on pressure gauge.
Specification: min. 7.5 bar
If specification is now obtained:
Pressure loss at unit injectors.
– Renew unit injector O-rings. agen
AG. Volkswagen AG d
oes
olksw not
If the specification is not attained: ed byV gu
ara
ris nte
o
– Renew tandem pump ⇒ page 122 . auth eo
ra
ss c
ce
e
nl

pt
du

Note
an
itte

y li
erm

ab

After removing pressure tester, tighten plug to 25 Nm. The seal


ility
ot p

must be renewed.
wit
, is n

h re
hole

spec
es, in part or in w

1.13.2 Checking for internal leaks


t to the co

Note
rrectness of i
l purpos

The tandem pump must be checked for internal leaks between


fuel side and oil side after reinstalling a used tandem pump, e.g.
after renewing or repairing a cylinder head and/or when installing
nform
ercia

a "short" engine. When leaking it is possible for the fuel to mix


m

with the oil which may cause the engine to fail.


at
om

ion
c

in t
or

Special tools and workshop equipment required


his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

120 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Tester -V.A.G 1687-

Procedure
– Pull fuel supply hose (white marking) ⇒ Item 26 (page 34) and
fuel return hose (blue marking) ⇒ Item 27 (page 34) off tandem
pump.
– Seal fuel return union on tandem pump with a plug. Secure
sealing plug with a spring-type clamp.
. Volkswagen AG
gen AG does
Prepare test unit -V.A.G 1687- as
Vol
kfollows:
swa not
by gu
d ara
– Unscrew pressure regulating
oris
e valve -2- and close valves -3- nte
eo
and -4-. auth
ra
ss c
– Connect test connection -5- to fuel supply union of tandem

ce
e
nl

pt
pump using a commercially available compressed air connec‐
du

an
itte

tion and a section of fuel hose. Use a spring-type clamp to

y li
erm

ab
secure.
ility
ot p

wit
, is n

Note h re
hole

spec
es, in part or in w

t to the co
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Removing and installing parts of fuel supply system 121


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Bora 1999 ➤ , Golf 1998 ➤ aut ra
c
s
4-cylinder diesel engine with unit injector - Edition 08.2009 s

ce
e
nl

pt
du

an
itte
– Connect compressed air hose -1- (compressed air source) to

y li
erm

ab
charge air system tester -V.A.G 1687- .

ility
ot p

wit
, is n

h re
Note

hole

spec
es, in part or in w
If there is water in the sight glass, drain at water drain screw -6-.

t to the co
– Open valve -3-.

rrectness of i
– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
l purpos

Caution

nf
ercia

orm
The maximum test pressure is 1.3 bar and this must not be
m

atio
m

exceeded.
o

n in
or c

thi
te

sd
iva

o
– Open valve -4- and wait until the test circuit is filled. If neces‐
r
rp

cu
o

m
sary readjust pressure to 1.0 bar.
f

en
ng

t.
yi Co
op
– Close valve -3- to retain pressure and observe the pressure C py
t. rig
drop over a period of 1 minute. gh ht
pyri by
Vo
o
by c lksw
If the pressure does not drop the tandem pump can be reused, if Prote
cted AG.
agen
the pressure drops the tandem pump must be renewed.

1.14 Removing and installing tandem pump

DANGER!

The tandem pump may, under no circumstances, be disman‐


tled as the vacuum part could otherwise malfunction. This
would result in the failure of the brake servo.

122 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Special tools and workshop


equipment required
♦ Torque wrench -V.A.G
1331-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
♦ Hose clip pliers -V.A.G
1921-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

Removing f inform
mer

– Pull supply hose -1- (white marking) and return hose -2- (blue
atio
m

marking) off fuel filter.


o

n
c

i
or

n thi
te

sd
a

WARNING
iv

o
pr

cum
r
fo

en
ng

♦ The fuel and the fuel lines in the fuel system can become
t.
yi Co
very hot (danger of scalding)! Cop py
t. rig
gh ht
yri
♦ The fuel system is also under pressure! Before opening
p by
co Vo
by lksw
the system, place cloths around the connections. Then Prote
cted AG.
agen
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

– Connect hand vacuum pump with accessories -V.A.G 1390-


with water drainage container -V.A.G 1390/1- to return hose.
– Operate hand vacuum pump until no more fuel escapes from
return hose. Be careful that no fuel is sucked into hand vacuum
pump.

1. Removing and installing parts of fuel supply system 123


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Pull vacuum line -1- from brake servo off tandem pump -4-.
– Pull supply hose -2- (white marking) off tandem pump -4-.
– Remove securing bolts -arrows-.
– Remove tandem pump -4- from cylinder head.
– Pull tandem pump -4- upwards slightly, pull off return hose
-3- (blue marking) and remove tandem pump -4-.
Installing
Installation is carried out in the reverse order. When installing,
wage
n AG. Volkswagen AG do
es n
note the following: yV
olks ot g
u b ara
ed nte
oris e
th or
Note au ac
ss

ce
e
nl

pt
du

♦ Ensure that tandem pump coupling seats properly in cam‐

an
itte

y li
shaft.
erm

ab
ility
ot p

♦ Always renew tandem pump seals.

wit
, is n

h re
hole

spec
– Attach return hose -3- (blue marking) to return connection of
es, in part or in w

tandem pump.

t to the co
– Install tandem pump and tighten upper securing bolts to
20 Nm.

rrectness of i
– Tighten lower securing bolts to 10 Nm.
l purpos

– Attach supply hose -2- (white marking) to supply connection


and vacuum line -1- from brake servo to tandem pump -4-.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

c
– Attach supply hose -1- (white marking) to fuel filter.
um
for

en
ng

t.
– Connect hand vacuum pump with accessories -V.A.G 1390-
yi Co
op py
and water drainage container -V.A.G 1390/1- to return hose t. C rig
gh ht
-2- (blue marking) of fuel filter. yri
p by
co Vo
by lksw
cted
– Operate hand vacuum pump until fuel escapes from return
agen
Prote AG.
hose. Be careful that no fuel is sucked into hand vacuum
pump.
– Connect return hose -2- (blue marking) to fuel filter.

124 Rep. Gr.20 - Fuel supply system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

21 – Turbocharging/supercharging
1 Charge air system with turbocharger

1.1 Assembly overview - turbocharger with


attachments

Note

♦ All hose connections are secured.


♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before screwing on oil supply line, fill turbocharger at connec‐
wage
n AG. Volkswagen AG do
e
tion with engine oil. Vol
ks s no
t gu
d by ara
e nte
ris
Observe rules for cleanliness ⇒ page 137 . utho eo
ra
a c
ss
Observe safety precautions ⇒ page 138 .

ce
e
nl

pt
du

an
Engine codes AJM, ATD, AUY ⇒ page 125 .
itte

y li
erm

ab
Engine codes ARL, ASZ ⇒ page 127 .

ility
ot p

wit
, is n

Engine code AXR ⇒ page 129

h re
hole

spec
Removing and installing parts of charge air cooling
es, in part or in w

⇒ page 130 .

t to the co
Checking charge air system for leaks ⇒ page 133
Vacuum hose schematic diagram ⇒ page 135

rrectness of i
1.1.1 Engine codes AJM, ATD, AUY
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Charge air system with turbocharger 125


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Exhaust manifold
❑ With turbocharger
❑ Only renew complete
2 - Intake manifold
3 - From charge air cooler
4 - Gasket
❑ Renew
❑ Coating (beading) to‐
wards intake manifold
5 - 25 Nm
❑ Renew
6 - Gasket
❑ Renew
❑ Note installation posi‐
tion.
7 - Bracket
❑ For heat shield
⇒ Item 9 (page 126)
8 - Washer
9 - Heat shield
❑ Engage in bracket
⇒ Item 7 (page 126)
10 - From air filter
11 - Turbocharger
❑ Renew only complete
with exhaust manifold agen
AG. Volkswagen AG d
oes
olksw not
❑ To remove turbocharg‐ d byV gu
ara
er, remove right-hand orise nte
eo
drive shaft from gear‐ aut
h
ra
box: ⇒ Running gear, ss c
ce
le

axles, steering - Front and four-wheel drive; Rep.-Gr. 40; Repairing drive shafts; Removing and installing
un

pt

drive shafts
an
d
itte

y li
erm

ab

12 - Pressure unit
ility
ot p

❑ For charge pressure control


wit
is n

h re

❑ Integral part of turbocharger and cannot be replaced.


ole,

spec
urposes, in part or in wh

13 - Seal
t to the co

❑ Renew
14 - 40 Nm
rrectne

15 - 17 Nm
s

16 - Oil return line with union nut


s o
cial p

❑ Tighten to cylinder block to 25 Nm


inform
mer

❑ To cylinder block
atio
m

17 - Oil return line gasket


o

n
c

i
or

❑ Renew
thi
te

sd
iva

o
r

18 - Gasket
p

cum
r
fo

en
ng

❑ Renew yi
t.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

126 Rep. Gr.21 - Turbocharging/supercharging


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

19 - Front exhaust pipe


20 - Union, 30 Nm
❑ Renew
❑ Coat threads and bolt head contact surface with -G 052 112 A3- .
21 - 10 Nm
22 - Oil supply line
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.

1.1.2 Engine codes ARL, ASZ

1 - Oil supply line


❑ Before installing, fill tur‐
bocharger with engine
oil through oil supply line
connection.
2 - Union nut, 22 Nm
3 - 22 Nm
4 - Union, 30 Nm
❑ Renew
❑ Coat threads and bolt
head contact surface
with -G 052 112 A3- .
AG. Volkswagen AG d
agen oes
5 - 10 Nm olksw not
y V gu
d b ara
6 - Banjo bolt, 25 Nm rise nte
tho eo
au ra
7 - Seal ss c
ce
le

❑ Renew
un

pt
an
d
itte

y li

8 - Intake manifold
erm

ab
ility
ot p

9 - Gasket
wit
is n

❑ Renew
h re
ole,

spec

❑ Note installation posi‐


urposes, in part or in wh

tion.
t to the co

10 - Washer
11 - 25 Nm
rrectne

❑ Renew
ss

12 - Support
o
cial p

f i

❑ Between turbocharger
nform

and cylinder block.


mer

atio
m

13 - 40 Nm
o

n
c

i
or

❑ First tighten all bolts by


thi
te

sd
a

hand
iv

o
pr

cum
r
fo

14 - Connecting pipe
en
ng

t.
yi Co
❑ Air filter/turbocharger t. Cop py
rig
gh ht
15 - Transition piece yri
p by
co Vo
by lksw
cted
16 - Turbocharger
agen
Prote AG.

❑ Renew only complete with exhaust manifold


❑ To remove turbocharger, unbolt right-hand drive shaft from gearbox ⇒ Rep. Gr. 40

1. Charge air system with turbocharger 127


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

17 - Gasket
❑ Renew
18 - Union, 40 Nm
19 - Oil return line
❑ To cylinder block
20 - 17 Nm
21 - Vacuum hose
❑ To charge pressure control solenoid valve -N75-
❑ Vacuum hose schematic diagram ⇒ page 135
22 - 20 Nm
❑ First tighten all bolts by hand
23 - 20 Nm
❑ Renew
24 - Heat shield
25 - Front exhaust pipe
26 - Bracket
❑ For oil supply line ⇒ Item 1 (page 127)
❑ Before installing, secure oil supply line
27 - 22 Nm
❑ Renew
28 - Connecting pipe
❑ On vehicles with engine codes ARL and ASZ with automatic gearbox to exhaust gas recirculation cooler
⇒ page 169

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

128 Rep. Gr.21 - Turbocharging/supercharging


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.1.3 Engine code AXR

1 - Oil supply line


❑ Before installing, fill tur‐
bocharger with engine
oil through oil supply line
connection.
2 - Union nut, 22 Nm
3 - 22 Nm
AG. Volkswagen AG d
agen oes
4 - Union, 30 Nm olksw not
byV gu
ara
d
❑ Renew orise nte
h eo
❑ Coat threads and bolt aut ra
s c
head contact surface s

ce
e
nl

with -G 052 112 A3- .

pt
du

an
itte

y li
5 - 10 Nm
erm

ab
ility
ot p

6 - Banjo bolt, 25 Nm

wit
, is n

h re
7 - Seal
hole

spec
❑ Renew
es, in part or in w

t to the co
8 - Intake manifold
9 - Gasket

rrectness of i
❑ Renew
l purpos

❑ Note installation posi‐


tion.

nform
ercia

10 - Washer
m

at
11 - 25 Nm
om

ion
c

❑ Renew

in t
or

his
ate

12 - Support

do
priv

cum
❑ Between turbocharger
for

en
g

and cylinder block.


n

t.
yi Co
Cop py
13 - 40 Nm ht. rig
rig ht
py by
❑ First tighten all bolts by
co Vo
by lksw
cted
hand
agen
Prote AG.

14 - Connecting pipe
❑ Air filter/turbocharger
15 - Transition piece
16 - Turbocharger
❑ Renew only complete with exhaust manifold
❑ To remove turbocharger, unbolt right-hand drive shaft from gearbox ⇒ Rep. Gr. 40
17 - Gasket
❑ Renew
18 - Union, 40 Nm
19 - Oil return line
❑ To cylinder block
20 - 17 Nm
21 - Vacuum hose
❑ To charge pressure control solenoid valve -N75-
❑ Vacuum hose schematic diagram ⇒ page 135

1. Charge air system with turbocharger 129


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

22 - 20 Nm
❑ First tighten all bolts by hand
23 - 20 Nm
❑ Renew
24 - Heat shield
25 - Front exhaust pipe
26 - Bracket
❑ For oil supply line ⇒ Item 1 (page 129)
❑ Before installing, secure oil supply line
27 - 22 Nm
❑ Renew
28 - Connecting pipe
❑ To exhaust gas recirculation cooler ⇒ page 171

1.2 Removing and installing parts of charge


air cooling

Note

♦ All hose connections of charge air system are secured by


spring-type clips or by connector couplings. Always check the
following points with connector couplings:
♦ Release connection by pulling the locking clip -arrow-.
♦ Pull hose/pipe off without the use of tools.
♦ When installing, ensure the locking lugs -A- engage correctly.
♦ Checking charge air system for leaks ⇒ page 133 wagen AG. Volkswagen AG doe
ks s no
Vol t gu
d by ara
e nte
ris
tho eo
Note au ra
c
ss
ce
le
un

pt

Charge air system must be free of leaks.


an
d
itte

y li
rm

ab
pe

ility

1.2.1 Engine codes AJM, ATD, AUY, AXR


ot

wit
, is n

h re
hole

Engine code ARL ⇒ page 132 .


spec
es, in part or in w

Engine code ASZ ⇒ page 133 .


t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen

130
Prote AG.
Rep. Gr.21 - Turbocharging/supercharging
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Connecting hose
2 - Connecting pipe
3 - Connecting hose
❑ Connecting pipe/intake
connection
4 - Connecting hose
❑ Charge air pipe/turbo‐
charger
5 - 10 Nm
6 - Charge air pipe
7 - Charge air cooler AG. Volkswagen AG d
agen oes
lksw not
8 - O-ring d by Vo gu
ara
❑ Renew if damaged. rise nte
tho eo
au ra
9 - Intake manifold pressure ss c

ce
le

sender -G71- with intake mani‐


un

pt
fold temperature sender -G72-

an
d
itte

y li
rm

ab
10 - 5 Nm
pe

ility
ot

wit
11 - Bracket
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Charge air system with turbocharger 131


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.2.2 Engine code ARL

1 - Charge air cooler


2 - Connecting hose
3 - Connecting pipe
4 - 8 Nm
5 - Connecting hose
n AG. Volkswagen AG do
❑ To turbocharger lkswage es n
o ot g
yV ua
6 - O-ring ir se
d b ran
tee
o
❑ Renew if damaged. auth or
ac
ss
7 - Connecting hose

ce
le
un

pt
an
8 - Connecting hose d
itte

y li
erm

ab
❑ Charge air pipe/intake

ility
ot p

manifold

wit
is n

h re
9 - To intake manifold
ole,

spec
urposes, in part or in wh

10 - Connecting pipe

t to the co
❑ Air filter/turbocharger
11 - Transition piece

rrectne
12 - To turbocharger

s
13 - To air filter

s o
cial p

f i
14 - Vacuum reservoir

nform
mer

15 - Charge air pipe

atio
om

n
c

16 - Intake manifold pressure

i
or

n thi
sender -G71- with intake mani‐
te

sd
va

fold temperature sender -G72-


i

o
pr

cum
r
fo

17 - Connecting hose

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

132 Rep. Gr.21 - Turbocharging/supercharging


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.2.3 Engine code ASZ

1 - 5 Nm
2 - O-ring
❑ Renew if damaged.
3 - Connecting pipe
4 - Connecting hose
❑ From intake connecting
pipe
AG. Volkswagen AG d
5 - Rubber grommet ksw
agen oes
not
Vol
y gu
6- 8 Nm ise
d b ara
nte
or eo
h
7- Connecting
s a hose
ut ra
c
s
❑ To turbocharger

ce
e
nl

pt
du

an
8 - Connecting hose
itte

y li
erm

ab
9 - 10 Nm

ility
ot p

wit
, is n

10 - Charge air pipe

h re
hole

spec
11 - Connecting pipe
es, in part or in w

t to the co
12 - Bracket
13 - Air duct
14 - Charge air cooler rrectness of i
l purpos

15 - Intake manifold pressure


sender -G71- with intake mani‐
fold temperature sender -G72-
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
1.3 Checking charge air system for leaks
Prote AG.

Special tools and workshop equipment required


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

♦ Adapter -V.A.G 1687/10-


– Remove intake hose -1- from air filter.

1. Charge air system with turbocharger 133


AG. Volkswagen AG d
agen oes
ksw not
Bora 1999 ➤ , Golf 1998 ➤ by Vol
gu
ara
d
4-cylinder diesel engine with unit injector - Edition 08.2009
orise nte
eo
th
au ra
s c
– Insert adapter -V.A.G 1687/10- in intake hose -1- ands secure

ce
e
with clip.

nl

pt
du

an
itte

y li
Prepare charge air system tester -V.A.G 1687- as follows:

erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
– Unscrew pressure regulating valve -2- and close valves -3-
o

m
f

en
ng

and -4-.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Note
co Vo
by lksw
cted agen
Prote AG.

To turn the pressure regulating valve -2- the knob must be pulled
upwards.

– Connect charge air system tester -V.A.G 1687- to adapter -


V.A.G 1687/10- as shown.

134 Rep. Gr.21 - Turbocharging/supercharging


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Connect compressed air hose -1- (compressed air source) to


charge air system tester -V.A.G 1687- .

Note

If there is water in the sight glass, drain at water drain screw -6-.

– Open valve -3-.


– Adjust pressure to 0.5 bar with pressure regulating valve -2-.

Caution

The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.

– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by hearing, touching,
with commercially available leak detector nspray
AG. Volor
kswusing
agen Aultra‐
G do
sonic tester -V.A.G 1842- . lkswage es n
Vo ot gu
by ara
ed nte
oris eo
th
Note ss
au ra
c

ce
le
un

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

an
d
itte

instructions

y li
erm

ab
ility
♦ If leaks occur, when doing any repair work observe notes for
ot p

wit
charge air system ⇒ page 130 .
is n

h re
ole,

♦ Before removing the adapter, depressurise the test circuit by


spec
urposes, in part or in wh

pulling coupling off adapter -V.A.G 1687/10- . t to the co

1.4 Vacuum hose schematic diagram


rrectne

Engine codes AJM, ATD, AUY ⇒ page 135 .


ss

Engine codes ARL, ASZ, AXR ⇒ page 137


o
cial p

f inform

1.4.1 Engine codes AJM, ATD, AUY


mer

atio
m

Engine codes ARL, ASZ, AXR ⇒ page 137 .


o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Charge air system with turbocharger 135


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Mechanical exhaust gas re‐


circulation valve
❑ Part of intake connect‐
ing pipe
❑ Can only be renewed to‐
gether with intake con‐
necting pipe
2 - Exhaust gas recirculation
valve -N18- (electro-pneumat‐
ic)
3 - Non-return valve
❑ White connection to
charge air control sole‐
noid valve -N75-
⇒ Item 4 (page 136)
and to vacuum reser‐
voir.
4 - Charge pressure control
solenoid valve -N75- agen
AG. Volkswagen AG d
oes
olksw not
5 - Vacuum reservoir ed by V gu
ara
ris nte
6 - Air filter aut
ho eo
ra
ss c
7 - Intake manifold flap
ce
e
nl

changeover valve -N239-


pt
du

an
itte

y li

8 - Pressure unit
erm

ab
ility
ot p

❑ For charge pressure


wit
, is n

control
h re
hole

❑ Integral part of turbo‐


spec

charger and cannot be


es, in part or in w

t to the co

replaced.
9 - Vacuum connection
rrectness of i

❑ Between tandem pump


and brake servo
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

136 Rep. Gr.21 - Turbocharging/supercharging


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.4.2 Engine codes ARL, ASZ, AXR

1 - Vacuum unit
❑ On engine codes ARL,
ASZ for variable intake
manifold changeover
❑ On engine code AXR for
exhaust gas recircula‐
tion changeover
2 - Exhaust gas recirculation
valve -N18- (electro-pneumat‐
ic)
3 - Change-over valve
❑ On engine codes ARL,
ASZ for variable intake
manifold flap -N239-
❑ On engine code AXR for
exhaust gas recircula‐
tion cooler -N345- n AG. Volkswagen AG do
lkswage es n
4 - Charge pressure control byV
o ot g
ua
solenoid valve -N75- ir se
d ran
tee
tho
u or
5 - Non-return valve ss
a ac

❑ White connection to var‐

ce
e
nl

pt
du

iable intake manifold

an
itte

y li
flap changeover valve
erm

ab
⇒ Item 3 (page 137) , to

ility
ot p

charge air control sole‐

wit
, is n

noid valve -N75-

h re
hole

⇒ Item 4 (page 137) and

spec
to vacuum reservoir.
es, in part or in w

t to the co
6 - Vacuum reservoir
7 - Air filter

rrectness of i
8 - Pressure unit
l purpos

❑ For charge pressure


control
nform
ercia

❑ Integral part of turbo‐


charger and cannot be replaced.
m

at
om

io

9 - Exhaust gas recirculation valve (mechanical)


n
c

in t
or

his
e

❑ Part of intake connecting pipe


at

do
riv

❑ Can only be renewed together with intake connecting pipe


p

cum
for

en
g

10 - Vacuum connection
n

t.
yi Co
op py
❑ Between tandem pump and brake servo
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.5 Rules for cleanliness


When working on the exhaust gas turbocharger, pay careful at‐
tention to the following “5 rules”:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Do not use
fluffy cloths!
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.

1. Charge air system with turbocharger 137


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Install clean components only. Do not remove replacement


parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: Do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.

1.6 Safety precautions

WARNING

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


ment, pay attention to the following due to the cramped condi‐
tions: . Volkswage AG n AG d
agen oes
♦ Route all the various lines (e.g.y Vfor
olksfuel, hydraulics, acti‐
w not
gu
vated charcoal filter system,isecoolant and refrigerant, brake
d b ara
nte
fluid and vacuum) and electrical
ho
r
wiring in their original po‐ eo
ut
sitions. ss a ra
c

ce
le

♦ Ensure that there is sufficient clearance to all moving or


un

pt
an
hot components.
d
itte

y li
rm

ab
pe

ility
ot

wit
Note the following if testers and measuring instruments have to
, is n

h re
be used during a road test:
hole

spec
♦ Test and measuring instruments must be secured to rear seat
es, in part or in w

t to the co
and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
rrectness of i
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

138 Rep. Gr.21 - Turbocharging/supercharging


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

23 – Mixture preparation - injection


1 Repairing diesel direct injection sys‐
tem
The diesel direct injection system control unit is equipped with a
fault memory. The fault memory must be read before and after
repairs or adjustments ⇒ page 156 ; Reading and clearing fault
memory of engine control unit.
Safety precautions ⇒ page 139 .
Rules for cleanliness ⇒ page 107 .

1.1 Safety precautions

WARNING n AG. Volkswagen AG do


lk swage es n
o ot g
yV
When doing any repair work, especially
ir se
d b in the engine compart‐ ua
ran
ment, pay attention to the following
tho due to the cramped condi‐ tee
or
tions: ss
au ac

ce
le

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
un

pt
an
vated charcoal filter system, coolant and refrigerant, brake
d
itte

y li
fluid and vacuum) and electrical wiring in their original po‐
erm

ab
sitions.

ility
ot p

wit
is n

♦ Ensure that there is sufficient clearance to all moving or

h re
ole,

hot components.

spec
urposes, in part or in wh

t to the co
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:

rrectne
♦ Connect and disconnect wiring of glow plug and injection sys‐
tem only with ignition switched off (includes test cables). ss o

♦ If the engine is to be turned at starter speed, without starting,


cial p

f in

e.g. when checking compressions, disconnect unit injector


form
mer

connector on cylinder head.


atio
m

♦ Before disconnecting battery, obtain radio code for radios with


o

n
c

i
or

anti-theft coding.
thi
te

sd
va

♦ Disconnecting and connecting the battery must only be done


i

o
pr

cum

with the ignition switched off, as otherwise the control unit for
r
fo

en
ng

diesel direction injection system could become damaged.


t.
yi Co
Cop py
Note the following if testers and measuring instruments have to
t. rig
gh ht
yri
be used during a road test:
p by
co Vo
by lksw
cted agen
♦ Test and measuring instruments must always be secured to
Prote AG.

rear seat and operated by a second person from this location.


If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.

1.2 Rules for cleanliness


When working on the fuel supply and injection systems, pay care‐
ful attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Do not use
fluffy cloths!

1. Repairing diesel direct injection system 139


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

♦ Carefully cover opened components or seal if repairs cannot


be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: Do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that diesel fuel does not get on the coolant hoses.
If necessary hoses must be cleaned immediately. Contami‐
nated hoses must be replaced.

1.3 Fitting locations overview

1.3.1 Engine codes AJM, ATD, AUY, AXR


Engine code ARL ⇒ page 141 .
Engine code ASZ ⇒ page 143 .
AG. Volkswagen AG d
Components A to D are not shown in the illustration. lksw
agen oes
not
Vo gu
by ara
d
rise nte
A - Brake pedal switch -F47- autho eo
ra
s c
❑ In footwell on brake ped‐ s

ce
le

al
un

pt
an
d
itte

y li
B - Brake light switch -F-
rm

ab
pe

ility
❑ In footwell on brake ped‐
ot

wit
al
, is n

h re
hole

C - Accelerator pedal position

spec
sender -G79-
es, in part or in w

t to the co
❑ In footwell on accelera‐
tor pedal

rrectness of i
D - Clutch pedal switch -F36-
❑ In footwell on clutch
l purpos

pedal
1 - Exhaust gas recirculation nform
ercia

valve (mechanical)
m

❑ With intake manifold


com

tion in

flap
r
te o

thi

2 - Change-over valve
s
iva

do
r
rp

❑ On engine codes AJM,


um
fo

en
g

ATD, AUY for variable


n

t.
yi Co
intake manifold flap t. Cop py
changeover valve -
rig
gh ht
yri by
N239- cop Vo
by lksw
cted agen
❑ On engine code AXR for Prote AG.
exhaust gas recircula‐
tion cooler changeover

140 Rep. Gr.23 - Mixture preparation - injection


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

valve -N345-
3 - Exhaust gas recirculation valve -N18- (electro-pneumatic)
4 - Diesel direct injection system control unit -J248-
❑ With altitude sender -F96-
❑ Renew ⇒ page 156 .
5 - Charge pressure control solenoid valve -N75-
6 - Coolant temperature sender -G62-
❑ For engine control unit.
❑ With coolant temperature gauge sender -G2- .
❑ If necessary, release pressure in cooling system before removing.
7 - Air mass meter -G70-
8 - Connector
❑ For ( unit injector cyl. no. 1 -N240- … unit injector cyl. no. 4 -N243- )
9 - Engine speed sender -G28-
10 - Fuel temperature sender -G81-
11 - Connector
❑ Engine speed sender -G28-
12 - Connector
❑ For Hall sender -G40- , for camshaft position
AG. Volkswagen AG d
agen
13 - Hall sender -G40- olksw
oes
not
byV gu
ara
❑ For camshaft position rised
nte
ho eo
ut
14 - Intake manifold pressure sender
ss a -G71- with intake manifold temperature sender r-G72-
ac

ce
e
nl

pt
du

an
itte

y li
1.3.2 Engine code ARL
erm

ab
ility
ot p

Components A to D are not shown in the illustration.


wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Repairing diesel direct injection system 141


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

A - Brake pedal switch -F47-


❑ In footwell on brake ped‐
al
B - Brake light switch -F-
❑ In footwell on brake ped‐
al
C - Accelerator pedal position
sender -G79-
❑ In footwell on accelera‐
tor pedal
D - Clutch pedal switch -F36-
❑ In footwell on clutch
pedal
1 - Exhaust gas recirculation AG. Volkswagen AG d
valve (mechanical) agen oes
olksw not
yV gu
❑ With intake manifold sed b ara
nte
flap thori
eo
au ra
c
2 - Diesel direct injection
ss sys‐

ce
le

tem control unit -J248-


un

pt
an
d
itte

❑ With elevation sender -

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

142 Rep. Gr.23 - Mixture preparation - injection


AG. Volkswagen AG d
agen Bora 1999oes ➤ , Golf 1998 ➤
olksw not
yV gu
4-cylinder eddiesel engine with unit injector - Edition
b ara 08.2009
nte
ris
ho eo
ut ra
F96- . ss a c

ce
e
❑ Renewing ⇒ page 156 .

nl

pt
du

an
itte
3 - With heater element for crankcase breather -N79-

y li
erm

ab
❑ For crankcase breather

ility
ot p

wit
, is n
4 - Exhaust gas recirculation valve -N18- (electro-pneumatic)

h re
hole

spec
5 - Variable intake manifold flap change-over valve -N239-

es, in part or in w

t to the co
6 - Connector
❑ For exhaust gas recirculation valve -N18- (electro-pneumatic)
❑ For variable intake manifold flap changeover valve -N239-

rrectness of i
❑ For charge pressure control solenoid valve -N75-
l purpos

❑ For heater element for crankcase breather -N79- .

nform
ercia

7 - Charge pressure control solenoid valve -N75-


m

8 - Coolant temperature sender -G62-

at
om

ion
❑ For engine control unit.
c

in t
or

his
e

❑ With coolant temperature gauge sender -G2- .


at

do
riv

❑ If necessary, release pressure in cooling system before removing.


p

cum
for

en
ng

9 - Air mass meter -G70-


t.
yi Co
Cop py
. rig
10 - Connector
ht ht
rig by
opy Vo
❑ For ( unit injector cyl. no. 1 -N240- … unit injector cyl. no. 4 -N243- ) by c lksw
cted agen
Prote AG.
11 - Engine speed sender -G28-
12 - Fuel temperature sender -G81-
13 - Intake manifold pressure sender -G71- with intake manifold temperature sender -G72-
14 - Connector
❑ For Hall sender -G40- , for camshaft position
15 - Connector
❑ For engine speed sender -G28-
16 - Hall sender -G40-
❑ For camshaft position

1.3.3 Engine code ASZ


Components A to D are not shown in the illustration.

1. Repairing diesel direct injection system 143


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

A - Brake pedal switch -F47- B


❑ In footwell on brake ped‐
al
B - Brake light switch -F-
❑ In footwell on brake ped‐
al
C - Accelerator pedal position
sender -G79-
❑ In footwell on accelera‐
tor pedal AG. Volkswagen AG d
agen oes
olksw not
V gu
D - Clutch pedal switch -F36- d by ara
ise nte
r
❑ In footwell on clutch aut
ho eo
ra
pedal ss c

ce
e
nl
1 - Exhaust gas recirculation

pt
du

an
itte

valve (mechanical)

y li
erm

ab
❑ With intake manifold

ility
ot p

flap

wit
, is n

h re
2 - Diesel direct injection sys‐
hole

spec
tem control unit -J248-
es, in part or in w

t to the co
❑ With elevation sender -

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

144 Rep. Gr.23 - Mixture preparation - injection


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

F96- .
❑ Renewing ⇒ page 156 .
3 - With heater element for crankcase breather -N79-
❑ For crankcase breather
4 - Exhaust gas recirculation valve -N18- (electro-pneumatic)
5 - Variable intake manifold flap change-overAG
valve
. Volks-N239-
wagen n AG do
ks wage es
6 - Connector Vol
not
gu
d by ara
❑ For exhaust gas recirculation
orise valve -N18- (electro-pneumatic) nte
eo
th
❑ For variable intakessmanifold
au
flap changeover valve -N239- ra
c
❑ For charge pressure regulation solenoid valve -N75- .

ce
e
nl

pt
du

an
❑ For heater element for crankcase breather -N79- .
itte

y li
erm

ab
7 - Charge pressure control solenoid valve -N75-

ility
ot p

wit
, is n

8 - Coolant temperature sender -G62-

h re
hole

❑ For engine control unit.

spec
es, in part or in w

❑ With coolant temperature gauge sender -G2- .

t to the co
❑ If necessary, release pressure in cooling system before removing.
9 - Air mass meter -G70-

rrectness of i
10 - Connector
l purpos

❑ For ( unit injector cyl. no. 1 -N240- … unit injector cyl. no. 4 -N243- )
11 - Engine speed sender -G28-

nf
ercia

orm
12 - Fuel temperature sender -G81-
m

atio
om

n in
13 - Connector
or c

thi
e

❑ For engine speed sender -G28- , for camshaft position


t

sd
iva

o
r
rp

cu

❑ Black
o

m
f

en
ng

t.
14 - Connector
yi Co
Cop py
❑ For engine speed sender -G28-
t. rig
gh ht
pyri by
❑ Grey
co Vo
by lksw
cted agen
Prote AG.
15 - Hall sender -G40-
❑ For camshaft position
16 - Intake manifold pressure sender -G71- with intake manifold temperature sender -G72-

1.4 Assembly overview - Intake manifold


flap
The intake manifold flap is closed for approx. 3 seconds when
stopping engine and then opens again. This reduces the stop jolt.

1. Repairing diesel direct injection system 145


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Intake manifold flap


changeover valve -N239-
❑ Vehicles with engine
code ARL or ASZ: at‐
tached to left bulkhead
of plenum chamber
⇒ page 140 Overview of
installation positions
❑ Not on engine code
AXR
2 - Bracket
3 - Intake manifold
n AG. Volkswagen AG do
4 - O-ring olkswage es n
ot g
yV
❑ Renew d b ua
ran
ir se tee
ho
5 - Intake connecting pipe aut or
ac
ss
❑ With exhaust gas recir‐

ce
e
nl

culation valve (mechan‐

pt
du

an
itte

ical) and intake manifold

y li
erm

ab
flap

ility
ot p

❑ On engine code AXR

wit
, is n

with intake manifold flap

h re
hole

motor -V157-

spec
es, in part or in w

6 - Exhaust gas recirculation

t to the co
valve (mechanical)
❑ Part of intake connect‐
ing pipe

rrectness of i
7 - 10 Nm
l purpos

8 - Gasket

nform
ercia

❑ Renew
m

at
9 - Connecting pipe
om

ion
c

❑ To exhaust manifold in t
or

his
e

(engine codes AJM,


at

do
riv

ATD, AUY and ASZ with


p

cum

manual gearbox) ⇒ page 167


for

en
ng

t.
yi
❑ To exhaust gas recirculation cooler (engine codes ARL, AXR and ASZ with automatic gearbox)
Co
op py
⇒ page 167 t. C rig
gh ht
pyri by
10 - 10 Nm
co Vo
by lksw
cted agen
Prote AG.
11 - Bracket
12 - Vacuum actuator
❑ Not on engine code AXR
13 - 22 Nm
14 - Vacuum hose
❑ From vacuum reservoir
❑ Not on engine code AXR

1.5 Assembly overview - unit injector


♦ Observe rules for cleanliness ⇒ page 107
♦ Always renew seals and O-rings

146 Rep. Gr.23 - Mixture preparation - injection


n AG. Volkswagen AG do Bora 1999 ➤ , Golf 1998 ➤
lkswage es n
d
4-cylinder
byV
o
diesel engine with unit injector
ot g
ua - Edition 08.2009
ran
ir se tee
tho
1 - 20 Nm + turn 90° further au
or
ac
ss
❑ Renew

ce
e
nl

pt
du
❑ Note sequence when

an
itte

y li
loosening and tighten‐

erm

ab
ing ⇒ page 149 Remov‐

ility
ot p
ing and installing unit

wit
, is n
injector

h re
hole

spec
2 - Rocker arm shaft
es, in part or in w

t to the co
❑ With rocker arm.
❑ Removing and installing
⇒ page 149 , Removing

rrectness of i
and installing unit injec‐
tor.
l purpos

3 - Lock nut, 30 Nm

nf
ercia

4 - Adjustment screw

orm
m

❑ Renew if installing new

atio
m

unit injector or if signs of


o

n in
or c

wear are evident

thi
te

sd
a

❑ Adjusting ⇒ page 149


iv

o
r
rp

cu
Removing and installing
o

m
f

unit injector

en
ng

t.
yi Co
op py
5 - Unit injector t. C rig
gh ht
yri by
❑ Check ball pin for signs cop Vo
by lksw
of wear, replace if nec‐ cted agen
Prote AG.
essary.
❑ Removing and installing
⇒ page 149
6 - O-ring
❑ Renew ⇒ page 148 .
7 - O-ring
❑ Renew ⇒ page 148 .
8 - O-ring
❑ Renew ⇒ page 148 .
9 - Heat insulation seal
❑ Renew
10 - Circlip
11 - Cylinder head
12 - Tensioning block
13 - 12 Nm + turn 270° further.
❑ Renew

1. Repairing diesel direct injection system 147


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
AG. Volkswagen AG d
agen oes
1.6 Removing and installing O-rings for unit d byV
olksw not
gu
ara
injector ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Special tools and workshop equipment required

rrectness of i
♦ Assembly sleeves -T10056-
l purpos

Removing
– Remove unit injector ⇒ page 149 .

nform
ercia

– Lever old O-rings very carefully off unit injector.


m

a
com

tion in
– Pay particular attention to ensure that no burrs are created on
r
te o

thi
seat of O-rings.

s
iva

do
r

Installing
rp

cum
fo

en
ng

t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
♦ Always use the assembly sleeves to fit the O-rings. There is a
cted agen
Prote AG.
danger of damaging the O-rings if the sleeves are not used.
♦ Gradual introduction of O-rings with no coloured markings.
Note the correct allocation of O-rings to grooves: the thickness
of the rings reduces towards injector nozzle.
♦ Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in unit injector.

– Pull heat shield seat off together with securing clip.


– Clean O-ring seating surfaces on unit injector very carefully.
– Fit assembly sleeve -T10056/1- onto stop on unit injector.
– Slide upper, thicker O-ring carefully onto assembly sleeve and
into seat on unit injector.
– Remove assembly sleeve.

148 Rep. Gr.23 - Mixture preparation - injection


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Fit assembly sleeves -T10056- onto stop on unit injector.


– Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.
– Remove assembly sleeve.

– Slide assembly sleeve -T10056/3- onto limit stop on unit in‐


jector.
– Slide lower O-ring carefully on to assembly sleeve and into
seat on unit injector.
– Remove assembly sleeve.
– Fit new heat shield seal together with securing clip.
– Install unit injector ⇒ page 149 .

1.7 Removing and installing unit


wage
n AG.injector
Volkswagen AG
doe
ks s no
Vol t gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Repairing diesel direct injection system 149


AG. Volkswagen AG d
agen oes
ksw not
Bora 1999 ➤ , Golf 1998 ➤ by Vol
gu
ara
d
4-cylinder diesel engine with unit injector - Edition
orise 08.2009 nte
eo
th
au ra
s c
Special tools and workshop s

ce
le
equipment required

un

pt
an
d
itte

y li
♦ Universal dial gauge brack‐

erm

ab
et -VW 387-

ility
ot p

wit
is n
♦ Allen key, long reach -

h re
T10054-

ole,

spec
urposes, in part or in wh
♦ Puller -T10055-

t to the co
♦ Torque wrench -V.A.G
1331-

rrectne
♦ Dial gauge
♦ G 000 100 grease

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

For introduction of extended service interval, adjusting screw -1-


and ball head pin -2- of unit injector have been modified. On older
engines with no extended service interval, a mixture of both types
of unit injector may be installed.

Removing
– Remove the upper toothed belt guard and the cylinder head
cover.
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.

150 Rep. Gr.23 - Mixture preparation - injection


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Loosen lock nut of adjuster screws -1- and screw adjuster


screws out until the relevant rocker arm lies against the plung‐
er spring of the unit injector.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket 3410 and take rocker arm shaft off.
– Remove tensioning block securing bolt -3- with special
wrench, long reach -T10054- and remove the block.
– Lever connector off unit injector with a screwdriver. To avoid
canting, support opposite side of connector with light finger
pressure.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Repairing diesel direct injection system 151


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Seat the puller into the slot on the side of the unit injector in‐
stead of the tensioning block.
– Pull unit injector out of cylinder head seat with gentle taps.
Installing

Note

♦ If a new unit injector is installed, the appropriate adjustment


screw in the rocker arm must also be renewed. . Volkswagen AG
gen AG does
swa
♦ Each time work is performed which requires the unit injector by V olk not
gu
to be adjusted, the adjustment screw in the rocker arm and rised ara
nte
also the unit injector ball pin must be cleaned and checked ut for
ho eo
ra
signs of wear. If wear is evident the ball pin and the adjustment
ss a c
screw must be replaced.

ce
le
un

pt
an
d
♦ On older version of unit injector, lubricate contact surface be‐ itte

y li
tween ball pin and adjusting screw with G 000 100 grease.
rm

ab
pe

ility
ot

♦ New unit injectors are supplied with O-rings and heat shield

wit
, is n

seal.

h re
hole

spec
es, in part or in w

– Heat insulating seal and O-rings must be renewed if old unit

t to the co
injector is reused ⇒ page 148 .
– Before installing the unit injector, check that the three O-rings,

rrectness of i
the heat shield seal and securing clip are seated correctly.
l purpos

Note

nform
ercia

The O-rings must not be twisted.


m

a
com

tion in
– Oil the O-rings and fit the unit injector into the cylinder head
r
te o

thi
extremely carefully.

s
iva

do
r
rp

c
– Push the unit injector evenly into the cylinder head onto its limit

um
fo

stop.

en
ng

t.
yi Co
op py
– Fit the tensioning block into the slot on the side of the unit t. C rig
gh ht
injector. pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note

If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.

– Therefore align the unit injector as follows.


– Screw new securing bolt into clamping block, but do not tighten
(it must still be possible to turn the unit injector slightly).
– Now align unit injector perpendicular to camshaft bearing ped‐
estals.
– Check dimension “a” from outer edge of cylinder head to roun‐
ded edge of unit injector with a vernier gauge (measuring
range at least 400 mm).

152 Rep. Gr.23 - Mixture preparation - injection


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Note

Gradual introduction of unit injector with new solenoid valve nut.


A mixture of both types is permissible providing dimension “a” is
reached.

Unit injector with old solenoid valve nut


Cylinder Dimension “a”
1 332.2 ± 0.8 mm
2 244.2 ± 0.8 mm
3 152.8 ± 0.8 mm
4 64.8 ± 0.8 mm

Unit injector with new solenoid valve nut


Cylinder Dimension “a”
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
Continuation for all unit injectors . Volkswagen AG
gen AG does
swa
– Align unit injector if necessary and tighten y V securing bolt as fol‐
olk not
gu
lows: e db ara
ris nte
tho eo
– Tighten securing bolt to 12 Nm s auand turn 270° (3/4 turn) further ra
c
(turning further can be done in several stages).
s
ce
e
nl

pt
du

an
itte

– Fit rocker arm shaft and tighten new securing bolts as follows:
y li
erm

ab
ility

– First tighten inner bolts -2- then outer bolts -1- by hand. Then
ot p

wit

using same sequence, tighten to 20 Nm and turn 90° (1/4 turn)


, is n

h re

further.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Repairing diesel direct injection system 153


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Fit the dial gauge onto the adjustment screw of the unit injector
as shown.
– Turn crankshaft in direction of engine rotation until roller of
rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point, dial gauge -arrow B-
positioned at lowest point.
– Remove dial gauge.
– Now turn the adjuster screw into rocker arm until significant
resistance can be felt (unit injector is at limit stop).

– Turn adjuster screw 180° back off stop.


– Hold adjustment screw in this position and tighten the lock nut
to 30 Nm.
– Push on unit injector connector and install cylinder head cover
and toothed belt guard.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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pt
du

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
154
AG.
Rep. Gr.23 - Mixture preparation - injection
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

2 Checking additional signals

2.1 Checking speed signal


Function
The engine speed signal is output via contact 27
n AGon
. Vengine
olkswagecontrol
n AG d
wage oes
unit. The signal is required, by amongst olksother things, the auto‐ not
yV gu
matic gearbox control unit to calculate
ed b gear changes and the rev ara
nte
is
counter in the dash panel. tho r eo
au ra
c
Special tools and workshop
ss equipment required

ce
le
un

pt
♦ Test box -V.A.G 1598/31-

an
d
itte

y li
erm

ab
♦ Auxiliary measuring set -V.A.G 1594-

ility
ot p

♦ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715-

wit
is n

h re
ole,

♦ Current flow diagram

spec
urposes, in part or in wh

Test procedure

t to the co
– Connect test box -V.A.G 1598/31- to control unit wiring har‐
ness.

rrectne
– Check wiring connection between test box socket 27 and dash
panel insert using current flow diagram for open circuit and

ss
short circuit. Wire resistance: max. 1.5 Ω ⇒ Current flow dia‐

o
cial p

f
grams, Electrical fault finding and Fitting locations

inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Checking additional signals 155


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

3 Engine control unit

3.1 Removing and installing engine control


unit
– Before removing engine control unit, first read control unit
identification and thereby the coding of the engine control unit
currently installed ⇒ page 156 ; Reading and clearing engine
control unit fault memory.
Removing
– Switch off ignition.
– Remove windscreen wiper arms and plenum chamber cover:
⇒ Rep. Gr. 92
– Release connectors on engine control unit and pull off con‐
nector.
– Push control unit to right and remove.
Installing
– Insert new control unit and push to left.
– Fit connectors and lock in position.
AG. Volkswagen AG d
agen oes
– Check previous coding and code new control
Vol
ksw unit not
gu
⇒ page 157 Adapting components.sed by ara
nte
ri
ho eo
aut ra
ss c ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

3.2 Reading and clearing engine control unit


wit
, is n

fault memory
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

io

Special tools and workshop equipment required


n
c

in t
or

his
e

♦ Vehicle diagnostic, testing and information system -VAS 5051-


at

do
priv

♦ Diagnostic cable -VAS 5051/1- or diagnostic cable -VAS


um
for

en
g

5051/3-
n

t.
yi Co
op py
Procedure
t. C rig
gh ht
pyri by
Vo
o
– Connect vehicle diagnostic, testing and information system -
c by lksw
cted agen
VAS 5051- as follows: Prote AG.

156 Rep. Gr.23 - Mixture preparation - injection


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Pull cover -1- off in direction of arrow.


– Connect diagnosis cable -VAS 5051/1- or diagnosis AGcable - agen AG d
. Volksw
agen
VAS 5051/3- to diagnosis connector. V olksw
oes
not
g y ua
db ran
– Start engine and run at idling speed.
or
ise tee
th or
au
Only if engine does not start: ss
ac

ce
e
nl
– Switch on ignition.

pt
du

an
itte

y li
Select operating mode:
erm

ab
ility
ot p
– Press button on display for “Vehicle self-diagnosis”.

wit
, is n

h re
Select vehicle system:
hole

spec
– Press button “01 - Engine electronics” on display.
es, in part or in w

t to the co
The control unit identification and coding are indicated on the dis‐
play.

rrectness of i
Select diagnostic function:
l purpos

– Press button “02 - Read fault memory” on display.


– If no fault is stored in engine control unit “0 fault detected” is

nform
ercia

displayed.
m

at
– If faults are stored in the engine control unit, these are shown
om

ion
one below the other on the display.
c

in t
or

his
te

– Press the ← button.


a

do
priv

cum
or

– Press button “05 - Clear fault memory” on display.


f

en
ng

t.
yi Co
op
– Press function “06-End output”. C py
ht. rig
rig ht
py by
co Vo
3.3 Adapting components
by lksw
cted agen
Prote AG.

Special tools and workshop equipment required


♦ Vehicle diagnostic, testing and information system -VAS 5051-
♦ Diagnostic cable -VAS 5051/1- or diagnostic cable -VAS
5051/3-
Select “Guided fault finding” on vehicle diagnosis tester -
VAS 5051- .
After all control units have been read:
– Press “GoTo” button.
– Select “Function/component selection”.
– “Select power train”.
– Select “Engine code”.
– Select “01 Systems capable of self-diagnosis”.
– Select “engine control”.

3. Engine control unit 157


. Volkswage
Bora 1999 ➤ , kGolf 1998
wage
n AG ➤ n AG d
oes
ol s not
4-cylinderddiesel
by
V engine with unit injector - Edition
gu
ar 08.2009
e an
ris tee
ho
– Select “Functions”.
au
t or
ac
ss
– Select “Function or component”.

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

158 Rep. Gr.23 - Mixture preparation - injection


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel
agen AGengine
. Volkswawith
gen Aunit
G do injector - Edition 08.2009
w es n
olks ot g
byV ua
ed ran

26 – Exhaust system
ris tee
tho or
au ac
ss

ce
le
un

pt
1 Removing and installing parts of ex‐

an
d
itte

y li
erm
haust system

ab
ility
ot p

wit
is n

h re
ole,
Note

spec
urposes, in part or in wh

t to the co
♦ Removing and installing exhaust manifold ⇒ page 125 Re‐
moving and installing turbocharger with attachments.
♦ After working on the exhaust system, ensure that the system

rrectne
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and

ss
align silencer and exhaust pipe so that sufficient clearance is

o
cial p

f
maintained to the bodywork and the support rings are evenly

inform
loaded.
mer

atio
♦ Renew self-locking nuts.
om

n
c

i
or

n thi
e

Vehicles with front-wheel drive ⇒ page 159 .


t

sd
iva

o
pr

cum
Vehicles with four-wheel drive ⇒ page 162 .
r
fo

en
ng

t.
yi
1.1 Front-wheel drive vehicles
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
1.1.1 Front exhaust pipe and catalytic converter with attachments
Prote AG.

1. Removing and installing parts of exhaust system 159


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - From turbocharger
2 - Gasket
❑ Renew
3 - 25 Nm wage
n AG. Volkswagen AG do
es n
lks
❑ Renew d byV
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ua
ran
ir se tee
4 - Front exhaust pipe with cat‐ utho
or
alytic converter ss
a ac

ce
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nl
5 - To rear silencer

pt
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itte

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6 - Mounting

erm

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ility
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rrectness of i
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om

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c

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or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

160 Rep. Gr.26 - Exhaust system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.1.2 Silencer with mountings

1 - 40 Nm
2 - From catalytic converter
n AG. Volkswagen AG do
wage es n
3 - Double clamp Vol
ks ot g
d by ua
❑ Note installation oposi‐
ris
e ran
tee
tion ⇒ page 161
au
th. or
ac
ss
4 - 25 Nm

ce
le
un

pt
an
d

5 - Mounting
itte

y li
erm

ab
❑ Note installation posi‐

ility
ot p

tion ⇒ page 162 .

wit
is n

h re
6 - Mounting
ole,

spec
❑ With support ring.
urposes, in part or in wh

t to the co
7 - Bracket
8 - Mounting

rrectne
9 - Rear silencer
❑ Aligning rear silencer

ss
free of stress

o
cial p

f i
⇒ page 162

nform
mer

10 - Separating point

atio
om

❑ For repair cases.

n
c

i
or

n thi
❑ Marked by three inden‐
te

sd
va

tations on circumfer‐
i

o
pr

ence of exhaust pipe


um
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fo

en
ng

t.
❑ Exhaust pipe and rear
yi Co
op
silencer are fitted as
C py
t. rig
gh
standard as one unit. In
ht
pyri by
Vo
o
the event of repair, ex‐ by c lksw
cted agen
haust pipe and rear si‐ Prote AG.
lencer are supplied indi‐
vidually with a double
clamp to facilitate con‐
nection.
❑ Using e.g. pneumatic
sabre saw -V.A.G 1523A- , cut through exhaust pipe at right angles on the separating point
⇒ page 162
11 - 20 Nm
12 - Tunnel bridge

Installation position of double clamp


Procedure
– Position double clamp approx. 5 mm away from mark A
-arrow 1-.

Note

Mark -A- is valid for vehicles with manual and automatic gear‐
boxes.

1. Removing and installing parts of exhaust system 161


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Installation position of mounting


– Angled side on foot of mounting -arrow- points in direction of
normal travel. Volkswa AG. gen AG
agen does
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ility
ot p

wit
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hole

Separating point on exhaust pipe

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

Special tools and workshop equipment required

do
priv

cum
for

♦ Pneumatic sabre saw -V.A.G 1523A-

en
ng

t.
yi Co
op
– Separate exhaust pipe at right angles at separating point
C py
ht. rig
-arrow 2-.
rig ht
py by
co Vo
by lksw
– Position double clamp -4- (repair solution) when installing at
cted agen
Prote AG.
side markings -arrows 1 and 3-. Specified torque: 40 Nm.
Align rear silencer free of stress
– Mounting pins on exhaust pipe must run parallel to tunnel
bridge (dimension -x- equal on left and right).

1.2 Vehicles with four-wheel drive

1.2.1 Front exhaust pipe and catalytic con‐


verter with attachments, engine code
AJM
Front exhaust pipe and catalytic converter with attachments, en‐
gine codes ARL, ASZ, ATD, AUY, AXR ⇒ page 164 .

162 Rep. Gr.26 - Exhaust system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - From turbocharger
2 - Gasket
❑ Renew
3 - Front exhaust pipe
❑ To remove and install,
unbolt front propshaft
tube from gearbox: ⇒
Rep. Gr. 39
4 - 25 Nm
❑ Renew
5 - Catalytic converter
6 - To front silencer
AG. Volkswagen AG d
7 - Hexagon bolt lksw
agen oes
not
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d by ara
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pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Removing and installing parts of exhaust system 163


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector
en AG. V
o-lkEdition
swagen A08.2009
G ag does
ksw not
Vol gu
1.2.2 Front exhaust pipe and catalytic converter with attachments, engine codesby ara
ed nte
oris
ARL, ASZ,s ATD, AUY, AXR th eo
au ra
c
s

ce
le
un

pt
an
1 - From turbocharger d
itte

y li
rm

ab
2 - Gasket
pe

ility
ot

wit
❑ Renew
, is n

h re
hole

3 - 25 Nm

spec
es, in part or in w

❑ Renew

t to the co
4 - Front exhaust pipe
❑ To remove and install,

rrectness of i
unbolt front propshaft
tube from gearbox: ⇒
l purpos

Rep. Gr. 39
❑ Front exhaust pipe must

nform
ercia

be in contact with turbo‐


charger before securing
m

a
com

t
nuts are tightened

ion in
r
te o

5 - 25 Nm

thi
s
iva

do
❑ Renew
r
rp

cum
fo

en
g

6 - Catalytic converter
n

t.
yi Co
op py
7 - To front silencer
t. C rig
gh ht
pyri by
Vo
8 - Mounting
o
by c lksw
cted agen
Prote AG.
9 - 25 Nm

164 Rep. Gr.26 - Exhaust system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1.2.3 Silencer with mountings

1 - Catalytic converter
2 - Stop plate
❑ For double clamp
3 - Double clamp
❑ Must be pushed onto
stop
⇒ Item 2 (page 165) on
catalytic converter
4 - 25 Nm
5 - Connecting strut
6 - Retainer
❑ Renew if damaged.
7 - Front silencer
❑ Note installation posi‐
tion ⇒ page 161 .
8 - Retainer
❑ Renew if damaged.
9 - Separating point
❑ For repair cases.
❑ Marked by impressions
on exhaust pipe
❑ During production, front
and rear silencers are
installed as a single
component. In repair ca‐
n AG. Volkswagen AG do
ses, the front exhaust lkswage es n
pipe and rear silencer d byV
o ot g
ua
are supplied individually o
ir se
ran
tee
with a double clamp for auth or
ac
connecting together. ss
ce
le

❑ Cut through exhaust


un

pt
an
d

perpendicular to pipe at
itte

y li

separating point using pneumatic sabre saw -V.A.G 1523A-


erm

ab
ility
ot p

10 - Rear silencer
wit
is n

h re
ole,

11 - Mounting
spec
urposes, in part or in wh

❑ With support ring.


t to the co

12 - 40 Nm
13 - Repair double clamp
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Removing and installing parts of exhaust system 165


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Aligning exhaust system


• Engine must be cold.
– Align exhaust system to retainer ( ⇒ Item 8 (page 165) ) whilst
observing dimension -a-. Arrow shows in direction of travel,
dimension -a- = 10 ± 2 mm.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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un

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an
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itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

166 Rep. Gr.26 - Exhaust system


n AG. Volkswagen AG do
lkswage es n
byV
o
Bora 1999ot g

ua , Golf 1998 ➤
ed ran
4-cylinder
horis diesel engine with unit injector - Edition
tee 08.2009
ut or
a ac
ss

ce
le
2 Exhaust gas recirculation system

un

pt
an
d
itte

y li
erm

ab
ility
ot p
Note

wit
is n

h re
ole,
♦ The exhaust gas recirculation system is activated by the diesel

spec
urposes, in part or in wh
direct injection system control unit -J248- via exhaust gas re‐

t to the co
circulation valve -N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
♦ The cone-shaped plunger in the mechanical exhaust gas re‐

rrectne
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.

ss
♦ Pulsed control enables every conceivable valve position.

o
cial p

f inform
♦ Renew self-locking nuts.
mer

atio
m

♦ Vacuum hose schematic diagram ⇒ page 135 .


o

n
c

i
or

n thi
te

2.1 Removing and installing parts of ex‐

sd
iva

o
pr

c
haust gas recirculation system

um
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
2.1.1 Engine codes AJM, ATD, AUY
p by
co Vo
by lksw
cted agen
Prote AG.
Engine codes ARL, ASZ with automatic gearbox ⇒ page 169 .
Engine code ASZ with manual gearbox ⇒ page 170 .
Engine code AXR ⇒ page 171

2. Exhaust gas recirculation system 167


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

1 - Intake manifold
2 - O-ring
❑ Renew.
3 - Intake connecting pipe
❑ Only renew complete.
❑ With exhaust gas recir‐
culation valve (mechan‐
ical) and intake manifold
flap
4 - Exhaust gas recirculation
valve (mechanical) agen
AG. Volkswagen AG d
oes
lksw not
❑ Part of intake connect‐ by
Vo gu
ara
ing pipe rised
nte
ho eo
❑ Can only be reneweds ato‐
ut ra
c
gether with intake con‐
s

ce
e

necting pipe
nl

pt
du

an
itte

y li
5 - 10 Nm
erm

ab
ility
ot p

6 - From charge air cooler

wit
, is n

h re
7 - Gasket
hole

spec
❑ Renew
es, in part or in w

t to the co
8 - 22 Nm
9 - Exhaust manifold

rrectness of i
10 - Connecting pipe
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

168 Rep. Gr.26 - Exhaust system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

2.1.2 Engine codes ARL, ASZ with automatic gearbox

1 - Intake manifold
2 - Intake connecting pipe
❑ Only renew complete.
❑ With exhaust gas recir‐
culation valve (mechan‐
ical) and regulating flap
3 - Gasket
❑ Renew
AG. Volkswagen AG d
4 - Connecting pipe agen oes
olksw not
V gu
by ara
5 - 22 Nm rised
nte
ho eo
ut
6 - Connecting pipe ss a ra
c

ce
e

7 - Exhaust manifold
nl

pt
du

an
itte

y li
8 - To heat exchanger
erm

ab
❑ Coolant hose schematic

ility
ot p

diagram ⇒ page 80 .

wit
, is n

h re
hole

9 - 10 Nm

spec
es, in part or in w

10 - Radiator

t to the co
❑ For exhaust gas recircu‐
lation

rrectness of i
11 - From cylinder head
l purpos

❑ Coolant hose schematic


diagram ⇒ page 80 .

nf
ercia

12 - To expansion tank

orm
m

❑ Coolant hose schematic

atio
m

diagram ⇒ page 80 .
o

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Exhaust gas recirculation system 169


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

2.1.3 Engine code ASZ with manual gearbox

1 - Intake manifold
2 - O-ring
❑ Renew
3 - Vacuum actuator
4 - 5 Nm n AG. Volkswagen AG do
lkswage es n
o ot g
5 - Exhaust gas recirculation
ed
byV ua
ran
valve (mechanical)horis tee
ut or
❑ Part of intake
ss
a connect‐ ac
ing pipe

ce
e
nl

pt
du

❑ Can only be renewed to‐

an
itte

y li
gether with intake con‐
erm

ab
necting pipe

ility
ot p

wit
, is n

6 - Intake connecting pipe

h re
hole

❑ Only renew complete.

spec
es, in part or in w

❑ With exhaust gas recir‐

t to the co
culation valve (mechan‐
ical) and intake manifold
flap

rrectness of i
7 - 10 Nm
l purpos

8 - Gasket
❑ Renew
nf
ercia

orm

9 - 22 Nm
m

atio
om

n in

10 - Connecting pipe
or c

thi
e

❑ To exhaust manifold
t

sd
iva

o
r
rp

cu

11 - Gasket
o

m
f

en
ng

❑ Renew
t.
yi Co
Cop py
❑ Note installation posi‐
t. rig
gh ht
yri
tion. p by
co Vo
by lksw
cted agen
Prote AG.

170 Rep. Gr.26 - Exhaust system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

2.1.4 Engine code AXR

1 - 22 Nm
AG. Volkswagen AG d
2 - Intake manifold wage
n oes
Volks not
gu
❑ With exhaust egas d b recir‐
y ara
nte
culation valvehoris (mechan‐ eo
ut
ical) ands aintake manifold ra
c
flap motor -V157- .
s

ce
e
nl

pt
du

3 - Gasket

an
itte

y li
erm

❑ Renew

ab
ility
ot p

4 - Connecting pipe

wit
, is n

h re
❑ To exhaust gas cooler
hole

spec
bypass flap.
es, in part or in w

t to the co
5 - Radiator
❑ For exhaust gas recircu‐
lation

rrectness of i
6 - 10 Nm
l purpos

7 - Exhaust manifold

nform
ercia

8 - Connecting pipe
m

❑ To exhaust manifold

at
om

ion
c

9 - Bypass flap
in t
or

his
e

❑ When actuated, directs


at

do
riv

exhaust gas via exhaust


p

cum
or

gas recirculation cooler


f

en
ng

t.
changeover valve -
yi Co
op
N345- to exhaust gas
C py
ht. rig
recirculation cooler
rig ht
py by
co Vo
by lksw
cted
10 - Bracket
agen
Prote AG.

❑ For bypass flap.


11 - 5 Nm

2. Exhaust gas recirculation system 171


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

28 – Glow plug system


n AG. Volkswagen AG do
1 Glow plug
yV
olks system
wage es n
ot g
b ua
ed ran
oris tee
th or
au
1.1 Checking glow plug system
ac
ss

ce
e
nl

pt
du

Special tools and workshop equipment required

an
itte

y li
erm

ab
♦ Hand multimeter -V.A.G 1526 A-

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Auxiliary measuring set -V.A.G 1594 A-

Test prerequisites
• Strip fuse for glow plugs in fuse holder on battery OK
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Diesel direct injection system control unit -J248- OK.
Test procedure
– Pull connector off coolant temperature sender ⇒ Overview of
installation positions, page ⇒ page 140 .

172 Rep. Gr.28 - Glow plug system


Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

Note

When the connector is pulled off the sender, a “cold” engine is


simulated and a glow period will be initiated respectively when the
ignition is switched on.

– Pull glow plug connector off glow plug.


– Connect multimeter to measure voltage between one glow
plug connector and vehicle earth.
– Switch on ignition. Approximate battery voltage must be dis‐
played for about 20 seconds.
– If there is no voltage: ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations

1.2 Checking glow plugs


Special tools and workshop equipment required
♦ U/J extension and socket 10 mm -3220-

♦ Adapter set -V.A.G 1594 A-


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

♦ Voltage tester -V.A.G 1527-


t to the co

Test prerequisites
rrectness of i

• Strip fuse for glow plugs in fuse holder on battery OK


l purpos

• The battery voltage must be at least 11.5 V.


• All electrical consumers, e.g. lights and rear window heating,
nf
ercia

must be switched off.


orm
m

atio

Test procedure
om

n in
c

– Pull glow plug connector off glow plug.


or

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo

173
by lksw
cted agen
Prote AG.
1. Glow plug system
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009

– Connect voltage tester -V.A.G 1527- cable to battery positive


(+), using clips from auxiliary measuring set -V.A.G 1594 A- .
– Place test probe of voltage tester -V.A.G 1527- on each glow
plug one after the other. Diode lights up: glow plug OK., diode
does not light up: renew glow plug.
– Remove and install glow plugs using jointed spanner, 10 mm
-3220- . Specified torque: 15 Nm.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

174 Rep. Gr.28 - Glow plug system

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