Documente Academic
Documente Profesional
Documente Cultură
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Workshop Manual
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Bora 1999 ➤
l purpos
Golf 1998 ➤
nform
mercia
a
4-cylinder diesel engine with unit injector
com
tion in
r
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thi
Engine ID
s
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do
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Edition 08.2009
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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.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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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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1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
spec
es, in part or in w
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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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4.1 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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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
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 . . . . . . . .
tee
130
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1.3 Checking charge air system for leaks aut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a. . . . .
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133
1.4 Vacuum hose schematic diagram ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . 135
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3.2 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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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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Prote AG.
1.2 Vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
ii Contents
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2 ssExhaust gas recirculation system . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 167
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2.1
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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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1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
hole
spec
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
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spec
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
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Emissions fulfil EU3 standard EU3 + D4 standards
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Output by c
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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
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1.1 Removing engine
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When doing any repair work, especially in the engine compart‐
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
spec
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fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
rrectne
hot components.
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Procedure
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– Remove air filter.
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– Disconnect connecting pipe between charge air cooler and in‐
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take connecting flange at intake connecting flange.
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– Disconnect fuel supply and return lines at fuel filter. by c lksw
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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!
Note
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Procedure
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– Remove gearbox.
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– On vehicles with automatic gearbox, prevent torque converter
from “falling out” after engine is separated from gearbox.
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– Attach lifting tackle -2024 A- as follows and lift off engine and
gearbox jack -V.A.G 1383 A- using workshop crane.
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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
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belt pulley.
♦ The holes in the hook rails are counted up from the hook.
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Gr. 37 .
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Continuation for all vehicles
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– Remove centre, left and right sound insulation tray ⇒ Rep. Gr.
inform
50 .
mer
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– Carry out a road test and read fault memory ⇒ page 156
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Threaded connection Specified torque
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Bolts, nuts by c
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M8 20 Nm
M10 45 Nm
M 12 60 Nm
Deviations
Front exhaust pipe to turbocharger 25 Nm
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Specified torques for assembly mount‐ ac
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2- Mounting/bracket to body 25 Nm
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1) Renew bolts.
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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°
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2- Mounting to body 25 Nm
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3) Renew bolts.
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Installation sequence:
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1- Pendulum support to subframe 25 Nm
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WARNING
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– Secure air conditioner compressor to towing eye so that the du
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refrigerant lines/hoses are not under tension.
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To prevent damage to bumper protect with adhesive tape.
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13 – Crankshaft group
1 Dismantling and assembling engine
Note
1.1 Overview
l - ⇒ page 13
II - ⇒ page 14
III - ⇒ page 15
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1 - Toothed belt guard - upper
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2 - Toothed belt
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❑ Mark direction of rota‐
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❑ Check for wear.
❑ Do not kink.
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❑ Removing, installing
and tensioning
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⇒ page 37 .
3 - 20 Nm + turn 45° further
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4 - Tensioning roller
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5 - 100 Nm
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❑ With sender wheel.
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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
ce
le
un
pt
an
d
18 - 20 Nm
itte
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rm
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
thi
s
iva
do
r
rp
cum
❑ Check for wear.
fo
en
ng
t.
yi
❑ Do not kink.
Co
Cop py
t.
❑ Removing and installing
rig
gh ht
yri by
⇒ page 16 op Vo
by c lksw
cted agen
Prote
2 - 10 Nm + turn 90° further
AG.
1 - 45 Nm
2 - Screen
3 - Cylinder block
❑ Removing and installing
sealing flange and fly‐
wheel ⇒ page 18
❑ Removing and installing
crankshaft
⇒ page 25 .
n AG. Volkswagen AG do
❑ Dismantling and assem‐ lkswage es n
o ot g
bling pistons and con‐ d byV ua
ran
rods ⇒ page 27 ir se tee
tho
u or
a ac
4 - 10 Nm ss
ce
e
nl
5 - Bracket
pt
du
an
itte
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❑ For vacuum reservoir
erm
ab
ility
ot p
6 - Vacuum reservoir
wit
, is n
h re
hole
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
thi
e
bling ⇒ page 69 .
t
sd
iva
o
r
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 .
ce
e
pt
du
an
itte
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6 - Tighten bolt -F- to 45 Nm
erm
ab
ility
ot p
h re
hole
spec
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
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ng
t.
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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.
Note
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
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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.
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
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
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1 - Seal
erm
ab
ility
ot p
wit
grease the oil seal seal‐
, is n
h re
ing lip.
hole
spec
❑ Before installing, re‐
es, in part or in w
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
at
sleeves.
om
ion
c
in t
or
⇒ page 22
his
ate
do
riv
cum
or
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.
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,
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 .
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
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.
ce
e
nl
pt
du
an
itte
♦ Depth gauge
y li
erm
ab
ility
Loosening and tightening drive plate
ot p
wit
, is n
h re
hole
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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
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
f in
equipment required
form
mer
atio
♦ Toothed belt pulley coun‐
om
n
c
i
or
n thi
e
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
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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 .
Note
ce
e
nl
pt
– Remove sealant residue on cylinder block with a flat scraper. du
an
itte
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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
spec
es, in part or in w
Installing
t to the co
Note
rrectness of i
l purpos
nf
ercia
sealant application.
orm
m
atio
om
n in
c
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.
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
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.
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
h re
hole
(mark).
spec
es, in part or in w
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
at
om
i
❑ Bearing cap 3 with re‐
on
c
in t
or
his
e
ers.
at
do
riv
cum
or
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
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
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rm
ab
pe
ility
ot
wit
, is n
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
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.
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
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ab
ility
ot p
4 - Circlip
wit
is n
h re
5 - Conrod
ole,
spec
t to the co
6 - Bearing shell
ss
f in
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
form
mer
n
c
i
or
sd
a
o
pr
cum
r
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 .
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
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ab
pe
ility
ot
h re
dimensions in mm
hole
spec
t to the co
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
ce
e
nl
pt
1. compression ring 0.06 …0.09 0.25
du
an
itte
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2. compression ring 0.05 …0.08 0.25
erm
ab
ility
ot p
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.
Note
Note
ce
e
nl
pt
du
an
itte
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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
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.
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
nf
ercia
orm
tion:
m
atio
om
n in
or c
thi
e
Note
t
sd
iva
o
r
rp
cu
o
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
Note
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.
15 – Cylinder head,
agen
valve gear
AG. Volkswagen AG d
oes
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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
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erm
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
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
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
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
pt
an
d
itte
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32 - Glow plug
rm
ab
pe
ility
❑ 15 Nm
ot
wit
, is n
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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.
Note
Note
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
an
itte
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Installing
erm
ab
ility
ot p
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
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.
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nl
pt
-arrows- on edges of both sealing surfaces of bearing cap and
du
an
itte
cylinder head at rear of engine.
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erm
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ility
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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
13-.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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nl
pt
du
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Special tools and workshop
itte
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erm
equipment required
ab
ility
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♦ 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
thi
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sd
iva
o
r
sioning system)
rp
cu
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f
en
ng
Note
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.
ce
le
pt
an
d
y li
erm
ab
♦ Wear eye and hand protection when performing any type
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Note
pt
an
d
itte
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
– Lock the hub using diesel injection pump locking pin -3359- .
To do this, slide locking pin through the free elongated hole on
nform
ercia
tio
do
r
rp
cum
fo
Note
en
ng
t.
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Cop py
. rig
The marks on the crankshaft toothed belt pulley and the crank‐
t
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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.
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un
it to press the tensioning roller anti-clockwise in -direction of
pt
an
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erm
ab
with the marking plate -T10008- .
ility
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is n
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Note
ole,
spec
urposes, in part or in wh
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
atio
om
n
c
Installing
i
or
n thi
te
sd
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pr
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Note
fo
en
ng
t.
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op
Always perform adjustment work on toothed belts only on cold
C py
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gh
engines.
ht
pyri by
Vo
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Prote AG.
Note
pt
crankshaft stop -T10050- .
du
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itte
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ility
wit
, is n
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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
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
permissible.
atio
om
n in
or c
thi
sd
a
whether:
iv
o
r
rp
cu
o
en
ng
t.
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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.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
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ss c
ce
le
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
ab
ility
ot p
wit
is n
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
n
c
i
or
n thi
e
sd
va
o
pr
cum
the crankshaft back 1/4 turn so that the crankshaft can again
r
fo
en
ng
– Repeat check.
– Install lower toothed belt guard and vibration damper/pulley.
– Install centre toothed belt guard.
Note
pt
an
d
itte
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ab
ility
ot p
h re
ole,
system
spec
urposes, in part or in wh
t to the co
Note
rrectne
Removing
inform
mer
i
or
n thi
e
sd
iva
o
pr
cum
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).
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!
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
ss c ce
le
un
pt
an
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pe
ility
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wit
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plete.
t to the co
Note
rrectness of i
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a
com
tion in
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te o
thi
do
move.
r
rp
cum
fo
en
ng
t.
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op
Note
C py
t. rig
gh ht
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.
Note
– 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.
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
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– Now turn pin wrench in direction of arrow onto stop and tighten
m
a
com
ti
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
o Vo
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.
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
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
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
nform
ercia
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.
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
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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
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
nform
ercia
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.
– Repeat check.
– Install lower toothed belt guard and pulley vibration damper.
– Install centre toothed belt guard.
Note
an
itte
y li
erm
ab
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.
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
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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.
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
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
nform
ercia
at
om
ion
c
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.
Note
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
– Maintain sequence when loosening and tightening cylinder
head bolts.
rrectness of i
Installing
l purpos
Note
nf
ercia
orm
m
atio
om
n in
c
thi
e
sd
iva
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.
ce
e
nl
pt
– Tighten cylinder head in 4 stages in sequence shown as fol‐
du
an
itte
lows:
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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
nform
mercia
at
om
io
– After tightening cylinder head, turn camshaft so that cams for
n
c
in t
r
his
te
do
riv
cum
for
en
ng
AG. Volkswagen AG d
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olksw not
V gu
d by ara
ise nte
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aut ra
ss c
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nl
pt
du
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itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
Test prerequisite
rrectness of i
Test procedure
nf
ercia
atio
m
n in
or c
thi
te
sd
iva
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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.
Note
ce
Note
e
nl
pt
du
an
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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
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.
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.
pt
an
d
itte
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4 - Washer
rm
ab
pe
ility
wit
, is n
spec
caps.
es, in part or in w
t to the co
5 - Bucket tappet
❑ Do not interchange.
rrectness of i
tion.
❑ Store with cam contact
nform
ercia
surface downwards.
❑ Before installing check
m
a
com
ti
ance ⇒ page 57 .
r
te o
thi
s
do
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rp
cum
en
ng
t.
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6 - Cotters
Co
Cop py
ht. rig
7 - Valve spring plate
rig ht
py by
co Vo
by lksw
cted
8 - Outer valve spring
agen
Prote AG.
❑ 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
ce
e
nl
pt
du
an
11 - Valve guide
itte
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erm
ab
❑ Checking ⇒ page 58 .
ility
ot p
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
n in
or c
thi
te
sd
iva
16 - Bearing shell
o
r
rp
cu
o
m
❑ Do not interchange used bearing shells (mark).
f
en
ng
t.
yi Co
❑ Ensure proper seating of retaining lugs in bearing caps and cylinder head. t. Cop py
rig
gh ht
yri
17 - Camshaft p by
co Vo
by lksw
❑ Checking axial clearance ⇒ page 57 .
cted agen
Prote AG.
❑ 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
Note
Valve dimensions
Note
ce
le
un
pt
an
d
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erm
ab
ility
Valve timing at 1 mm valve lift
ot p
wit
is n
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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
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
Special tools and workshop equipment required
Prote AG.
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
byV gu
ara
ed
2.2 Renewing valve stem seals ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
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
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-
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.
Removing
(With cylinder head installed)
– Remove camshaft ⇒ page 60 .
– 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.
lksw
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AG does
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– Pull off valve stem seals using puller -3047 A- .
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Installing
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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
his
ate
– Oil valve stem seal sealing lip and press carefully onto the
do
priv
valve guide.
um
for
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Cop py
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Prote AG.
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Special tools and workshop du
an
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equipment required
erm
ab
ility
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♦ 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-
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or
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Cop py
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Prote AG.
Removing
– Remove toothed belt ⇒ page 37 .
– Remove securing bolts for camshaft toothed belt pulley -1-.
– Pull camshaft belt pulley off hub.
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nl
pt
du
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– Remove hub from taper of camshaft.
erm
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ility
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– 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
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nf
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orm
m
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– Remove tandem pump ⇒ page 122 .
om
n in
or c
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Cop py
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by
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Prote AG.
Note
Note
– 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.
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spec
t to the co
f inform
mer
atio
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n
c
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te
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
Note
AG. Volkswagen AG d
Note agen oes
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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
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un
pt
an
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rm
ab
2.4 Removing and installing camshaft oil seal
pe
ility
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, is n
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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
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cum
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en
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t.
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Cop py
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pyri by
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by c lksw
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Prote AG.
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♦ 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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spec
urposes, in part or in wh
t to the co
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f inform
mer
atio
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n
c
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fo
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t.
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Cop py
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pyri by
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by
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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.
Note
The oil seal sealing lip must not be additionally oiled or greased.
– 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
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un
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pe
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ot
wit
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hole
spec
es, in part or in w
t to the co
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nform
mercia
a
com
tion in
r
te o
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t.
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Cop py
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by
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Prote AG.
17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
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nl
pt
du
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erm
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ility
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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
engine oil!
b - Oil level within hatched field: Can be topped up with engine
nf
ercia
oil.
rm
m
atio
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c
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sd
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cation system
Co
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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.
1.3.1 Part I
ce
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❑ For oil level/tempera‐
un
pt
an
d
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ness.
rm
ab
pe
ility
4 - Oil dipstick
ot
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❑ The oil level must not be
hole
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
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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.
1.3.2 Part II
pt
an
d
itte
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5 - Seal
erm
ab
❑ Renew
ility
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❑ To turbocharger
spec
urposes, in part or in wh
t to the co
7 - Banjo bolt, 25 Nm
8 - Sealing cap, 25 Nm
rrectne
9 - O-ring
s o
cial p
❑ Renew
inform
mer
n
c
i
or
sd
va
11 - Plug, 25 Nm
i
o
pr
cum
r
fo
en
ng
12 - Gasket yi
t.
Co
op
❑ Renew
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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
pt
du
10 - 10 Nm
an
itte
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ab
ility
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es, in part or in w
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nf
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orm
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a
Assembly sequence
iv
o
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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
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pt
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erm
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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.
n AG. Volkswagen AG do
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a ac
Installing ss
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WARNING
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as follows.
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spec
es, in part or in w
t to the co
– Tighten union nut -2- or banjo bolt -4- on oil filter bracket to
prescribed torque.
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n in
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t.
Special tools and workshop equipment required Cop
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by
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72
Prote AG.
Rep. Gr.17 - Lubrication
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
pt
du
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ab
ility
ot p
– Remove sump.
wit
, is n
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if necessary.
spec
es, in part or in w
t to the co
glasses).
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orm
m
atio
m
Note
o
n in
or c
thi
te
sd
a
o
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cu
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en
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t.
silicone sealing compound.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
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nl
pt
du
an
Note
itte
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erm
ab
ility
ot p
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, 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
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n in
or c
thi
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– Tighten sump/gearbox bolts to 45 Nm.
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t.
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Cop py
t. rig
gh
Note
ht
pyri by
Vo
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by
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Prote
Let sealing compound dry for approx. 30 minutes after installing
AG.
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rm
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pe
ility
ot
wit
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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
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s
Functional check and repair of the visual and acoustic oil pressure
iva
do
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cum
fo
t.
yi
system VAS 5051
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
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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
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
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
19 – Cooling
1 Removing and installing parts of cool‐
ing system
ce
le
un
pt
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
an
d
itte
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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
nform
ercia
a
com
t
only use spring-type clips.
ion in
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do
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cum
fo
t.
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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
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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 - 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
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4 - Cowling horis nte
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aut ra
5 - 5 Nm ss c
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un
6 - Additional fan
pt
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itte
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❑ Only vehicles with op‐
erm
ab
tional equipment.
ility
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is n
7 - Fan ring
h re
ole,
8 - Securing clip
spec
urposes, in part or in wh
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
sd
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fo
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❑ Test pressure 1.4…1.6 bar ht. Cop py
rig
❑ Observe markings ⇒ page 85 Draining and filling coolant rig ht
py by
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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.
ce
le
❑ Check for ease of move‐
un
pt
an
ment.
d
itte
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rm
ab
❑ Note installation posi‐
pe
ility
tion.
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wit
, is n
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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
diagram ⇒ page 80 .
a
com
tion in
6 - To top of expansion tank
r
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thi
❑ Coolant hose schematic
s
iva
do
r
diagram ⇒ page 80 .
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cum
fo
en
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t.
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❑ Clipped into bulkhead of
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rig
plenum chamber. py by
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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 .
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nl
pt
du
an
itte
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erm
ab
ility
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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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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 - 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
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not
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is n
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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
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or
n thi
te
sd
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pr
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
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
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mostat olksw not
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11 - Cylinder head/cylinder horis nte
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block s aut ra
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rm
ab
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ility
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, is n
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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.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
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
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edb ara
nte
7- Upper coolant hose horis
eo
aut ra
8- Radiator ss c
ce
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nl
pt
9 - Lower coolant hose
du
an
itte
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erm
10 - Oil cooler
ab
ility
ot p
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.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
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
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5 - Coolant pipe
erm
ab
ility
ot p
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.
ce
le
pt
an
d
itte
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♦ Spring-type clip pliers -VAS
erm
ab
5024A-
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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Not illustrated:
♦ Cooling system charge unit -VAS 6096-
1.4.1 Draining
– Open filler cap on coolant expansion tank.
WARNING
– Pull off bottom coolant hose retaining clip -arrow- and remove
coolant hose from quick release coupling on radiator.
Continuation for all vehicles
Note
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
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4.2 Filling
Note
ce
le
pt
an
d
y li
cooling effectiveness are reduced again.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
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
nform
4) The quantity of coolant can vary depending upon vehicle equipment.
ercia
a
com
tion in
– Close radiator drain plug.
r
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thi
do
r
rp
cum
en
g
-arrow-.
n
t.
yi Co
Cop py
.
Continuation for all vehicles
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– 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.
ce
e
nl
pt
du
an
itte
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When engine is at operating temperature, coolant level must be
erm
ab
at upper mark of hatched area.
ility
ot p
wit
, is n
h re
hatched area.
hole
spec
es, in part or in w
t to the co
1.5 Removing and installing radiator
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.
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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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
nf
ercia
orm
m
atio
om
n in
c
Removing
or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
On vehicles with engine code “ARL”, connecting hoses on charge
C py
t. rig
gh
oil cooler must be removed ⇒ page 130 Removing and installing
ht
pyri by
parts of charge air cooling system.
co Vo
by lksw
cted agen
Prote AG.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Fill with coolant ⇒ page 85 .
WARNING
Note
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
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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
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.
ce
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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
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.
Removing
Note
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
wage does
no
yV t gu
♦ 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.
ce
le
un
pt
an
d
itte
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Installation is carried out in the reverse order. When installing,
rm
ab
note the following:
pe
ility
ot
wit
, is n
h re
– 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
nform
ercia
a
– Fill with coolant ⇒ page 85 .
com
tion in
r
te o
thi
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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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
Removing
t to the co
Note
rrectness of i
l purpos
ion
c
his
e
do
priv
– Turn thermostat -4- 1/4 turn (90°) to left and remove from con‐
um
for
en
g
nection -2-.
n
t.
yi Co
Cop py
t.
Installing
rig
gh ht
pyri by
Vo
o
by c
Installation is carried out in the reverse order. When installing,
lksw
cted agen
Prote
note the following:
AG.
Note
G. Volkswagen AG d
1.8 Checking cooling system for leaksolkswagen A oes
not
yV gu
db ara
rise nte
Special tools and workshop tho eo
au ra
c
equipment required ss
ce
e
nl
pt
du
an
itte
V.A.G 1274-
y li
erm
ab
ility
♦ Adapter for cooling system
ot p
wit
tester -V.A.G 1274/8-
, is n
h re
hole
spec
tester -V.A.G 1274/9-
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.
Test prerequisite
• Engine at operating temperature.
Test sequence:
WARNING
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
y li
rm
ab
– Find leaks and rectify.
pe
ility
ot
wit
, is n
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
nform
ercia
a
com
tion in
If the pressure relief valve opens prematurely:
r
te o
thi
s
iva
cum
fo
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.
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
op py
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-
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
at
om
ion
c
in t
or
his
ate
do
riv
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.
Note
ce
le
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
nform
mercia
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.
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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
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
thi
te
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
cted agen
Prote
9 - Breather line
AG.
ce
le
un
pt
an
d
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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
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 - 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
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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
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
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.
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
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erm
ab
❑ Blue or with blue marking.
ility
ot p
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
at
om
io
Marking on flange must align with the marking on fuel tank
n
c
in t
or
-arrows-.
his
ate
do
riv
cum
for
en
g
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.
Note
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
pt
an
d
45°: closed
itte
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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
n
c
12 - Breather valve
i
or
n thi
e
sd
iva
cum
r
fo
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
ce
e
nl
pt
du
22 - Clamping washer
an
itte
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erm
ab
23 - Heat shield
ility
ot p
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
atio
n in
or c
27 - Return line
thi
te
sd
a
o
r
rp
cu
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
ce
e
nl
fuel tank -arrows-.
pt
du
an
itte
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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
nf
ercia
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 - 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
pt
an
d
y li
and take control valve
erm
ab
ility
off complete with fuel
ot p
wit
lines.
is n
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ole,
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
i
or
n thi
te
sd
7 - Supply line
iva
o
pr
en
ng
t.
❑ To tandem pump ⇒ Item 25 (page 34)
yi Co
Cop py
ht. rig
8 - Fuel filter rig ht
py by
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❑ Fill with diesel before installing
by c lksw
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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
WARNING
pt
du
an
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ab
ility
h re
spec
t to the co
When working on the fuel supply and injection systems, pay care‐
l purpos
connecting.
m
at
io
fluffy cloths!
n
c
in t
or
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e
do
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cum
for
en
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t.
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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.
Removing
Observe safety precautions ⇒ page 107 .
n AG. Volkswagen AG do
Observe rules for cleanliness ⇒ page 107 . lkswage es n
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byV ua
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ir se tee
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or
Note ss
au ac
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nl
pt
The fuel cooler is located in the return line to the fuel tank. It is
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
– Detach fuel lines from fuel cooler.
hole
spec
es, in part or in w
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
nform
mercia
at
om
ion
c
his
ate
do
riv
cum
for
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
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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
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erm
ab
– Unscrew securing bolt and remove tank flap unit with rubber
ility
ot p
cup.
wit
is n
h re
spec
urposes, in part or in wh
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.
ce
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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
n in
or c
thi
te
sd
iva
o
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rp
cu
Continuation for all vehicles
o
m
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t.
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– 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.
AG. Volkswagen AG d
agen oes
olksw not
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or eo
h
aut ra
ss c
ce
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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
Removing
his
ate
do
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cum
for
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Cop py
– First check whether a coded radio is fitted. If so, obtain anti-
t. rig
gh ht
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theft coding. p by
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by c lksw
cted agen
– With the ignition switched off, disconnect battery earth strap. Prote AG.
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
Note
Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
Note
pt
du
an
Note
itte
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erm
ab
ility
wit
h re
spec
es, in part or in w
Removing
rrectness of i
– 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
at
om
Installing
ion
c
in t
or
– Insert fuel sender into guides on fuel delivery unit and press
his
ate
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.
ce
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un
Special tools and workshop equipment required
pt
an
d
itte
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♦ 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
o
pr
cum
r
fo
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
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– Fold rear seat bench forwards. Prote AG.
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
Note
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
pt
y li
ab
ility
wit
is n
♦ After installing fuel pump flange, check that supply line -2- and
h re
ole,
t to the co
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-
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.
pt
an
d
itte
y li
ab
ility
ot p
h re
spec
t to the co
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
ce
le
un
pt
an
d
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erm
ab
– Renew fuel delivery unit ⇒ page 110 .
ility
ot p
wit
is n
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1.11 Removing, installing and checking suc‐
ole,
spec
urposes, in part or in wh
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
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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♦ Torque wrench -V.A.G 1332-
c by lksw
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Prote AG.
Note
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
pt
carefully loosen connection to release the pressure!
an
d
itte
y li
rm
ab
ility
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
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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
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1.12 Assembly overview - accelerator mechanism ho eo
aut ra
ss c
ce
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un
pt
an
1 - Mounting bracket
d
itte
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rm
ab
2 - Connector
pe
ility
ot
❑ Black, 6-pin.
wit
, is n
h re
hole
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
nform
ercia
4 - 10 Nm
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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Vo
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by c lksw
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Prote AG.
AG. Volkswagen AG d
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ara
d
♦ Torque wrench (5…50 Nm) -V.A.G oris1331-
e nte
eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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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
Test prerequisites
m
at
ion
c
in t
r
his
ate
do
riv
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.
pt
du
Note
an
itte
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erm
ab
must be renewed.
wit
, is n
h re
hole
spec
es, in part or in w
Note
rrectness of i
l purpos
ion
c
in t
or
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.
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
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erm
ab
secure.
ility
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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.
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
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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
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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.
DANGER!
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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un
pt
an
d
itte
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erm
ab
ility
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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
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!
– 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
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note the following: yV
olks ot g
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ed nte
oris e
th or
Note au ac
ss
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nl
pt
du
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itte
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shaft.
erm
ab
ility
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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
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.
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Note
ce
e
nl
pt
du
an
Engine codes AJM, ATD, AUY ⇒ page 125 .
itte
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erm
ab
Engine codes ARL, ASZ ⇒ page 127 .
ility
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wit
, is n
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
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❑ To remove turbocharg‐ d byV gu
ara
er, remove right-hand orise nte
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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
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erm
ab
12 - Pressure unit
ility
ot p
h re
spec
urposes, in part or in wh
13 - Seal
t to the co
❑ Renew
14 - 40 Nm
rrectne
15 - 17 Nm
s
❑ To cylinder block
atio
m
n
c
i
or
❑ Renew
thi
te
sd
iva
o
r
18 - Gasket
p
cum
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fo
en
ng
❑ Renew yi
t.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
❑ Renew
un
pt
an
d
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8 - Intake manifold
erm
ab
ility
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9 - Gasket
wit
is n
❑ Renew
h re
ole,
spec
tion.
t to the co
10 - Washer
11 - 25 Nm
rrectne
❑ Renew
ss
12 - Support
o
cial p
f i
❑ Between turbocharger
nform
atio
m
13 - 40 Nm
o
n
c
i
or
sd
a
hand
iv
o
pr
cum
r
fo
14 - Connecting pipe
en
ng
t.
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❑ Air filter/turbocharger t. Cop py
rig
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15 - Transition piece yri
p by
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by lksw
cted
16 - Turbocharger
agen
Prote AG.
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
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y V gu
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rise nte
tho eo
au ra
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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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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f
en
ng
t.
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Cop py
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Vo
co lksw
by
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Prote AG.
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nl
pt
du
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itte
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5 - 10 Nm
erm
ab
ility
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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
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
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
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
Note
pt
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rm
ab
pe
ility
wit
, is n
h re
hole
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
pt
fold temperature sender -G72-
an
d
itte
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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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
8 - Connecting hose d
itte
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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
atio
om
n
c
i
or
n thi
sender -G71- with intake mani‐
te
sd
va
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.
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
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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
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erm
ab
9 - 10 Nm
ility
ot p
wit
, is n
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
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.
ce
e
with clip.
nl
pt
du
an
itte
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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.
Note
If there is water in the sight glass, drain at water drain screw -6-.
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
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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
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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,
f inform
atio
m
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.
an
itte
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8 - Pressure unit
erm
ab
ility
ot p
control
h re
hole
t to the co
replaced.
9 - Vacuum connection
rrectness of i
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 - 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
ce
e
nl
pt
du
an
itte
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flap changeover valve
erm
ab
⇒ Item 3 (page 137) , to
ility
ot p
wit
, is n
h re
hole
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
at
om
io
in t
or
his
e
do
riv
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.
WARNING
ce
le
pt
an
hot components.
d
itte
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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.
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
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fluid and vacuum) and electrical wiring in their original po‐
erm
ab
sitions.
ility
ot p
wit
is n
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
f in
n
c
i
or
anti-theft coding.
thi
te
sd
va
o
pr
cum
with the ignition switched off, as otherwise the control unit for
r
fo
en
ng
ce
le
al
un
pt
an
d
itte
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B - Brake light switch -F-
rm
ab
pe
ility
❑ In footwell on brake ped‐
ot
wit
al
, is n
h re
hole
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
tion in
flap
r
te o
thi
2 - Change-over valve
s
iva
do
r
rp
en
g
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
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
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.
ce
le
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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
nform
ercia
at
om
ion
❑ For engine control unit.
c
in t
or
his
e
do
riv
cum
for
en
ng
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.
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
h re
hole
spec
es, in part or in w
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
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-
ce
e
nl
pt
du
an
itte
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erm
ab
flap
ility
ot p
wit
, is n
h re
hole
motor -V157-
spec
es, in part or in w
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
do
riv
cum
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
ce
e
nl
pt
du
❑ Note sequence when
an
itte
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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
atio
m
n in
or c
thi
te
sd
a
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
ce
le
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
Special tools and workshop equipment required
rrectness of i
♦ Assembly sleeves -T10056-
l purpos
Removing
– Remove unit injector ⇒ page 149 .
nform
ercia
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.
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.
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
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.
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.
– 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
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
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
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.
Note
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
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further.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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or c
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Prote AG.
– 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).
AG. Volkswagen AG d
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nl
pt
du
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erm
ab
ility
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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
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ate
do
priv
cum
for
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t.
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Cop py
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154
AG.
Rep. Gr.23 - Mixture preparation - injection
Bora 1999 ➤ , Golf 1998 ➤
4-cylinder diesel engine with unit injector - Edition 08.2009
ce
le
un
pt
♦ Test box -V.A.G 1598/31-
an
d
itte
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erm
ab
♦ Auxiliary measuring set -V.A.G 1594-
ility
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wit
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ole,
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
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o
pr
cum
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fo
en
ng
t.
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Cop py
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pyri by
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by c lksw
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Prote AG.
pt
du
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itte
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erm
ab
ility
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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
in t
or
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do
priv
en
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5051/3-
n
t.
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Procedure
t. C rig
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Vo
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– Connect vehicle diagnostic, testing and information system -
c by lksw
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VAS 5051- as follows: Prote AG.
ce
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nl
– Switch on ignition.
pt
du
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itte
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Select operating mode:
erm
ab
ility
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– Press button on display for “Vehicle self-diagnosis”.
wit
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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
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
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do
priv
cum
or
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– Press function “06-End output”. C py
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rig ht
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3.3 Adapting components
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pt
an
d
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pe
ility
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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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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
26 – Exhaust system
ris tee
tho or
au ac
ss
ce
le
un
pt
1 Removing and installing parts of ex‐
an
d
itte
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erm
haust system
ab
ility
ot p
wit
is n
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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
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sd
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o
pr
cum
Vehicles with four-wheel drive ⇒ page 162 .
r
fo
en
ng
t.
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1.1 Front-wheel drive vehicles
Co
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1.1.1 Front exhaust pipe and catalytic converter with attachments
Prote AG.
1 - From turbocharger
2 - Gasket
❑ Renew
3 - 25 Nm wage
n AG. Volkswagen AG do
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❑ Renew d byV
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ran
ir se tee
4 - Front exhaust pipe with cat‐ utho
or
alytic converter ss
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ce
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nl
5 - To rear silencer
pt
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itte
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6 - Mounting
erm
ab
ility
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es, in part or in w
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at
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ion
c
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ate
do
priv
cum
for
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t.
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Cop py
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1 - 40 Nm
2 - From catalytic converter
n AG. Volkswagen AG do
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3 - Double clamp Vol
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d by ua
❑ Note installation oposi‐
ris
e ran
tee
tion ⇒ page 161
au
th. or
ac
ss
4 - 25 Nm
ce
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pt
an
d
5 - Mounting
itte
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ab
❑ Note installation posi‐
ility
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wit
is n
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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
n
c
i
or
n thi
❑ Marked by three inden‐
te
sd
va
tations on circumfer‐
i
o
pr
en
ng
t.
❑ Exhaust pipe and rear
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silencer are fitted as
C py
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gh
standard as one unit. In
ht
pyri by
Vo
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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
Note
Mark -A- is valid for vehicles with manual and automatic gear‐
boxes.
ce
e
nl
pt
du
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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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mercia
at
om
ion
c
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ate
do
priv
cum
for
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ng
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– Separate exhaust pipe at right angles at separating point
C py
ht. rig
-arrow 2-.
rig ht
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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 - 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
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ility
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es, in part or in w
t to the co
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nf
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orm
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Cop py
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Prote AG.
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an
1 - From turbocharger d
itte
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ab
2 - Gasket
pe
ility
ot
wit
❑ Renew
, is n
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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
a
com
t
nuts are tightened
ion in
r
te o
5 - 25 Nm
thi
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❑ Renew
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6 - Catalytic converter
n
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7 - To front silencer
t. C rig
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Vo
8 - Mounting
o
by c lksw
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Prote AG.
9 - 25 Nm
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
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are supplied individually o
ir se
ran
tee
with a double clamp for auth or
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connecting together. ss
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perpendicular to pipe at
itte
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ab
ility
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10 - Rear silencer
wit
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ole,
11 - Mounting
spec
urposes, in part or in wh
12 - 40 Nm
13 - Repair double clamp
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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pr
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t.
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t. rig
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Prote AG.
AG. Volkswagen AG d
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an
d
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ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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pr
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t.
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Cop py
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Prote AG.
ce
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2 Exhaust gas recirculation system
un
pt
an
d
itte
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erm
ab
ility
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Note
wit
is n
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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
n
c
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or
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pr
c
haust gas recirculation system
um
r
fo
en
ng
t.
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Cop py
t. rig
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2.1.1 Engine codes AJM, ATD, AUY
p by
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Prote AG.
Engine codes ARL, ASZ with automatic gearbox ⇒ page 169 .
Engine code ASZ with manual gearbox ⇒ page 170 .
Engine code AXR ⇒ page 171
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
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❑ Part of intake connect‐ by
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ing pipe rised
nte
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❑ Can only be reneweds ato‐
ut ra
c
gether with intake con‐
s
ce
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necting pipe
nl
pt
du
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5 - 10 Nm
erm
ab
ility
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wit
, is n
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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.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
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
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by ara
5 - 22 Nm rised
nte
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ut
6 - Connecting pipe ss a ra
c
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e
7 - Exhaust manifold
nl
pt
du
an
itte
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8 - To heat exchanger
erm
ab
❑ Coolant hose schematic
ility
ot p
diagram ⇒ page 80 .
wit
, is n
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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
nf
ercia
12 - To expansion tank
orm
m
atio
m
diagram ⇒ page 80 .
o
n in
or c
thi
te
sd
iva
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cu
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m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
1 - Intake manifold
2 - O-ring
❑ Renew
3 - Vacuum actuator
4 - 5 Nm n AG. Volkswagen AG do
lkswage es n
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5 - Exhaust gas recirculation
ed
byV ua
ran
valve (mechanical)horis tee
ut or
❑ Part of intake
ss
a connect‐ ac
ing pipe
ce
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nl
pt
du
an
itte
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gether with intake con‐
erm
ab
necting pipe
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
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
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cu
11 - Gasket
o
m
f
en
ng
❑ Renew
t.
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Cop py
❑ Note installation posi‐
t. rig
gh ht
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tion. p by
co Vo
by lksw
cted agen
Prote AG.
1 - 22 Nm
AG. Volkswagen AG d
2 - Intake manifold wage
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Volks not
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❑ With exhaust egas d b recir‐
y ara
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culation valvehoris (mechan‐ eo
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ical) ands aintake manifold ra
c
flap motor -V157- .
s
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nl
pt
du
3 - Gasket
an
itte
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erm
❑ Renew
ab
ility
ot p
4 - Connecting pipe
wit
, is n
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❑ 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
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do
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cum
or
en
ng
t.
changeover valve -
yi Co
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N345- to exhaust gas
C py
ht. rig
recirculation cooler
rig ht
py by
co Vo
by lksw
cted
10 - Bracket
agen
Prote AG.
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nl
pt
du
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ab
♦ Hand multimeter -V.A.G 1526 A-
ility
ot p
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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 c lksw
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Prote AG.
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 .
Note
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
Test prerequisites
rrectness of i
atio
Test procedure
om
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c
thi
te
sd
iva
o
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cu
o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
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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
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.