V5 Agz Golf Jetta Bora Mechanical Workshop Manual

Service.

IN-2r~shop

Manual : Golf 1998'-, Bora 1999 ~,­

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Engine code

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Booklet 5-CyI. in~ection engine., Mechanics

Edition 10.97

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·Service.

List of Workshop Manual Repair Groups

Golf

1998~

IAGzl

Engine code

Booklet

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5-Cy1. injection engine, Mechanics Edition 10.97

When filing a Technical Bulletin enter the Bulletin No. in the adjacent column. When using the Workshop Manual you can then see at a glance whether Technical Bulletins have been published in respect of the particular Repair Group in which you are looking.

Technical Bulletins

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 26 Exhaust system

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Technical Information should always be available to all foremen and mechanics, because their com­ pliance with the instructions given is essential to ensure vehicle roadworthiness and safety. In addition, the normal safety precautions to be observed when working on motor vehicles are also applicable.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 1997 Volkswagen AG

Printed in Germany

KOO.51 07.29.20

Contents 00

Technical data Page Technical data ............................................................................ 00-1 - Engine number .......................................................................... 00-1 - Engine data ......' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-2

10

13

15

11

19

Removing and installing engine

Page

Removing and installing engine . ......... ~ ................................................ , - Notes on removing ........................................................................

- Securing engine to assembly stand ... . . .. . .. . . . .. .. .. .. . .. .. .. . .. . .. . . .. .. .. .. . . .. . . .. . . . ..

- Notes on installing .................... '. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

- lightening torques' ........................ .................. ........................ .....

- Additional information and removal instructions for vehicles with air conditioner ......... . . . . . . . ..

10-1 10-3 10-9 10-11 10-14 10-15

Crankshaft group

Page

Dismantling and assembling engine .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

- Checking valve timing .................................... : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

- Adjusting valve timing ....................................................................

- Removing and installing ribbed belt............................. ...... ........... ...... .....

Removing and installing sealing flange and dual mass flywheel/drive plate .................. , - Renewing crankshaft oil seal -vibration damper end- ..........................................

- Removing and installing drive plate .........................................................

Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

- Piston and cylinder dimensions ............................................................

13-1 13-8 13-11 13-27 13-30 13-33 13-37 13-40 13·45 13-53

Cylinder head, Valve gear

Page;, Removing and installing cylinder head ..................................................... 15.t~ti

- Removing and installing cylinder head. . . .. . . .. . . . . . . . . . . . . . . . .. . . .. . . .. .. . .. . . . . . .. . . .. . . . ..

- Removing and installing cylinder head... ........................................... .... . .. ..

- Checking compression pressures ..........................................................

Servicing vaIve gear ..............,.......................................................

- Reworking valve seats ....................................................................

- Removing and installing camshafts .........................................................

- Checking hydraulic bucket tappets .. . . .. . .. . .. . .. . .. . . .. . .. . . . . .. . . . .. .. . . .. .. .. . . . . . . . . .. ..

- Checking valve guides ....................................................................

- Renewing valve guides ...................................................................

- Renewing valve stem seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

15-9 15-17 15-24 15·27 15-34 15-37 15-42 15-44 15-45 15-47

Lubrication

Page

Removing and installing parts of the lubrication system .....................................

- Dismantling and assembling oil filter bracket . . . . . . .. . . . .. . . . . . . . . .. . . .. . . . . . . . . .. .... . .. . . ...

- Dismantling and assembling oil pump. .. . .. .. . . . . . . . . .. .. . . . . .. . .. . . . . .. . . .. . . .. . . . . . . . . . . ..

- Removing and installing oil sump .. . . . . .. . .. .. . . • . . . . .. .. .. . . .. . .. . . . . . .. . .. . . .. . .. . . . . . . . ..

- Checking oil pressure and oil pressure switch. .. .. . . .. . .. .. . . . . .. .. . . .. .. . .. .. .. . . . . . . .. .. ...

'17·1

Cooling system

Page

Removing and installing parts of cooling system . ......... , . . . . . . . . . . . . .. . ... . . . . . . . . . . . . . . .

- Parts of cooling system body side ..............................'. . . . . . . . . . . . . . . . . . . . . . . . . . ..

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

- Coolant hose connection diagram ..........................................................

- Dismantling and assembling coolant thermostat housing................ ...... ....... .... . ....

- Draining and filling cooling system ............................. :............ . .... ... .... ....

- Removing and installing radiator. .. .. . .. . ... . . . .. . .. .. .. .. . . . . . . .. .. .. .. . . .. . .. . . .. . . .. . .. ..

- Checking continued coolant circulation pump (V51) ...........................................

- Checking radiator fan N7) and (V35) ........................................................

- Removing and installing coolant pump ...................... ~".' . . . .. .... . .. . .. . . .. . .. .. . . . . . ..

19·1

19-2

19-5

19-9

19-11

19-14

19-19 19-22

19-24

19-27

17-8 17-10 17-13 17-16

20

Fuel supply system

Page

Removing and installing parts of fuel supply system ............

20-1 - Removing and installing fuel tank with its attachments and fuel filter ............................. 20-2

- Safety precautions when working on the fuel supply system .. . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-8

- Rules for cleanliness .............'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-9

- Removing and installing fuel delivery unit.. ............................ ........ .............. 20-10

- Removing and installing fuel gauge sender .................................................. 20-13

- Removing and installing fuel tank ..................................... '" . . .. . .. . .. . . .. . .... 20-14

- Checking fuel pump ...................................................................... 20-18

Accelerator mechanism . o. 20-28

- Servicing accelerator mechanism ................................................... , .. . . . .. 20-28

- Adjusting throttle cable ................................................................... 20-30

Activated charcoal filter system ...

20-33

- Servicing parts of the activated charcoal filter system......... ... . . . . . . . ... ... .. .. . . . .. ... .... 20-34

- Checking fuel tank breather.. . . .. .. • . . . .. . . . . . .. . .. .. . . .. . .. .. . . .. . .. . . . . . . . . .. . .. .. . .. .... 20-36

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Exhaust system

Page

Removing and installing parts of exhaust system ........ o. • • • •• •• Secondary air system ............

- Function ................................................................................

- Removing and installing parts of the secondary air system. . . . . . .. . . . . . .. . . . . . . . . . . . .. .. .. . .. ..

- Checking combi-valve ..................................... '" .............. , .. ..... .. ... ..

- Removing and installing combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

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26-1 26-7

26-7

26-8

26-13

26-16

Technical data

Engine number The engine number (engine code and serial number) is located next to the Cylinder head on the cylinder block. It is found by looking down­ wards between the crankcase breather heater element and the throttle valve control part.

Additionally there is a sticker on the cylinder head cover with" Engine code" and "Serial number".

The engine code is also included on the vehide data plate.

00-1--­

Engine data Engine code

AGZ

Manufactured

10.96>­ VRll

Arrangement of cylinders Cylinder angle Displacement

15° Itrs.

2.3

Output

kWat rpm

110/6000

Torque

Nm at rpm

205fJ200

Bore

0mm

Stroke Compression ratio 1} VR

mm

81 90.2 10.0:1

= V-arrangement in compact in-line design

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00-2--­

AGZ

Engine code RON

min.

95 unleaded ll

Injection system

Motronic M3.8.3

Ignition system

Motronic M3.8.3

Firing order

1-2-4-5-3

Knock control

yes

Self-diagnosis

yes

Lambda control

yes

Catalyst

yes

Exhaust gas recirculation system

no

Secondary air system

yes

Charging

no

1)

In exceptional circumstances min. 91 RON, however with reduced performance

00-3--­

Removing and installing en­ gine Special tools, workshop equipment. test and measuring appliances and aux. items required • 2024 A Lifting tackle , • 3395 Engine bracket

• VW 313 Support clamp VW313

• VW 540 Engine and gearbox support • VW 540/1 B Supplementary set • V.A.G 1202 A Workshop crane

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10-1--­

• V.A.G 1306 Drip tray

V..A..G 1331

V.A.G 1306

• VAG 1331 Torque wrench (5... 50 Nm) • VAG 1332 Torque wrench (40...200 Nm) • V.A.G 1383 A Engine/gearbox jack

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• VAG 1921 Spring-type clip pliers • V.A.S 5085 Step ladder V..A..G 1383 A 6f:iIM!i!!i~

V.A..G 1332

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• G 000 100 grease (vehicles with manual gearbox) • Cable tie

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V.A.G 1921

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Notes on removing Note: Check' whether a coded radio is installed as during the forthcoming work sequences the battery earth strap mustbe disconnected. Obtain radio code first if necessary.

- With the ignition switched off disconnect battery earth strap_ , - The engine is removed downwards together with the gearbox.

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- Remove battery and battery retainer.

- All cable ties which are opened or cut open when remOVing engine. must be replaced in the same pOSition when installing engine.

- Remove air cleaner: => Repair group 24; Servicing injection system; Dismantling and as足 sembling air cleaner.

- Pull off supply pipe/hose -1- (with white marking) and return pipel hose -2- (with blue marking) and collect fuel that leaks out with a Cloth.

10-3--足

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Note:

Press buttons on hose couplings to do this.

Warning!

Fuel system is under pt'essum! BeloTe opening the system

place a cIDth around the connection. Then release ",.essure by

carefully loosening the connection.

- Remove centre, left and right insulation tray: , => General body repairs exterior; Repair group 50; Body front; Assem足 blyoverview - Remove ribbed belt => Page 13-27.

- Remove power assisted steering vane pump with bracket and lay to side; hoses remain connected. => Running gear; Repair group 48; Assembly overview: vane pump, reservoir. hydraulic pipes - Remove securing clamps for power steering pressure pipe.

Vehicles with air conditioner - See additional information and removal instructions=> Page 10-15.

10-4--足

Vehicles with manual gearbox - Disconnect selector mechanism from gearbox. => 5-Speed manual gearbox 02J; Repair group 34; ServiCing selector mechanism - Remove hydraulic clutch slave cylinder: => 5-Speed manual gearbox 02J; Repair group 30; Servicing clutch con­ trol

Vehicles with automatic gearbox - Remove selector lever cable from gearbox: => Automatic gearbox 01 M; Repair group 37; Servicing shift mechan­ ism: Dismantling and assembling shift mechanism

Continued for all vehicles - Remove intake manifold upper part => Page 15-9, Removing and in­ stalling cylinder head cover. .

- Disconnect all electric wires from gearbox, alternator and starterand move clear.

10-5--­

- Separate connections on following components: Ignition coil (Nl22) connector.

Continued coolant circulation pump (V51) Hall sender (640) Injectors (N30... N33, N83) Coolant temperature sender (G62) Air conditioning system shut-off thermo switch (Fl63) Engine speed sender (G28) Knock sensor 1 (G61) Knock sensor 2 (G66) Lambda probe 1 (G39).

Fitting locations: => Repair group 24: Servicing injection system; Fitting locations - over­ view - Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.

- Pull vacuum and breather hoses off engine.

- Drain coolant => Page 19-14.

- Pull radiator coolant hoses off engine using hose Clip pliers VAG 1921.

- Remove front exhaust pipe => Page 26-1, Removing and installing parts of exhaust system.

10-6---­

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- Remove right-hand drive shaft and disconnect left-hand drive shaft at gearbox: ~ Running gear; Repairgroup40; Removing and installing drive shafts

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- Disconnect pendulum support -arrows-.

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- Increase size of cut-out on engine bracket 3395 to dimensions as shown: a=32mm b=27mm - Fit engine bracket 3395 onto engine/gearbox jack VAG 1383 A.

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10-7--­

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- Fit engine bracket 3395 onto cylinder block and tighten securing nuts -1- to 40 Nm. - lift engine and gearbox lightly using engine/gearbox jackVAG1383 A.

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- Unbolt engine side of assembly mounting from engine carrier at top -arrows-.

Nate: To remove securing bolts use step ladder VA.s 5085.

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10-8--­

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- Unbolt gearbox side of assembly mounting from gearbox carrier at top -arrows-.

- Carefully lower engine with gearbox.

Note:

Engine with gearbox must be guided carefully when lowering to pre­ vent damage to the bodywork.

Securing engine to assembly stand When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the engine and gearbox bracket VW 540 and supplementary set VW 540/1 B.

Work sequence - Remove gearbox.

Vehicles with automatic gearbox - Secure torque converter against "falling out" after separating en­ gine from gearbox.

Continued for all vehicles . - Bolt engine/gearbox bracket VW 540 with supplementary set VW 540/1 B onto cylinder block.

10-9--­

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- Attach lifting device 2024 A as follows and lift engine out of enginel .gearbox jack using workshop crane.

Pulley end:

2nd hole in hook at position 1

Flywheel end:

2nd hole in hook at position 8

Warning!

The hooksandlocatingpins must be secured with locking pins.

Notes: • The positions marked 1.. .4 on the bar must be towards the pulley end.

• The holes in the hooks are counted up from the hook.

- Rt engine in support clamp VW 313 using workshop crane V.A.G 1202 A.

10-10--­

Notes on installing

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Installation is carried out in the reverse sequence, when doing this note the following: Vehicles with manual gearbox

- Check clutch release bearing for wear; renew if necessary.

- Lightly grease clutch release bearing and splines on input shaft with G 000 100 grease (do not grease release bearing guide sleeve).

Vehicles with automatic gearbox

- Only use nuts approved in parts programme to secure torque con­ verter to drive plate.

Continued for all vehicles

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- Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block. install if necessary.

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- When installing the assembly. ensure sufficient clearance to drive shafts.

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- Align engine mountings stress-free by rocking.

10-11--­ ;

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Vehicles with manual gearbox

- Install hydraulic clutch slave cyliilder: => 5-Speed manual gearbox 02J; Repairgroup30;Servicing clutch con­ trol - Install selector mechanism: => 5-Speed manual gearbox 02J; Repair group 34; Servicing selector mechanism - If necessary adjust gearchange cables: => 5-Speed manual gearbox 02J; Repair group 34; Servicing selector mechanism Vehicles with automatic gearbox

- Install selector cable on gearbox. adjust if necessary: => Automatic gearbox 01 M; Repair group 37; Servicing shift mechan~ ism; Dismantling and assembling shift mechanism Continued for all vehicles

- Installing drive shafts:

=> Running gear; Repair group 40; Removing and installing drive shafts

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- Install front exhaust pipe=> Page 26-1. Removing and installing parts of exhaust system.

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- Install intake manifold upper part => Page 15-9. Removing and instal­ ling cylinder head cover.

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10-12--­

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- Adjust accelerator cable if necessary => Page 20-2S. Servicing accel­ erator mechanism.

- Installing PAS. vane pump: => Runni,ng gear; Repair group 4S; Assembly overview: ,vane pump, reservoir. hydraulic pipes .

- Install ribbed belt => Page 13-27.

- Electrical connections and routing: => Electrical system; Repair group 97 - Install centre, left and right insulation trays: => General body repairs exterior; Repair group 50; Body front; Assem­ bly overview - Filling with coolant => Page 19-14 - Install air cleaner. => Repair group 24; Servicing injection system; Dismantling and as­ sembling air cleaner.

- Carry out a test drive and interrogate fault memory: => Repair group 01; Self-diagnosis; Interrogating and erasing fault memory - Match engine electronics control unit to throttle valve control part: => Repair group 24; Renewing, coding and matching engine control unit; Matching engine electronics control unit to throttle valve con­ trol part

10-13--­

lightening torques lightening torque

Bolted joint

Bolts. nuts

M6

10Nm

MS

20Nm

M10

45Nm

M 12

60Nm

in variation of this Assembly mounting to gear­ box.carrierll

60 Nm + 900 (1/4 turn)

Assembly mounting to en­ gine carrierll

60Nm + 90° (1/4 turn)

Assembly mounting to bodyl)

40Nm + goo (1/4 turn)

Pendulum support to gear­

box1)

40Nm + 900 (1/4 turn)

Pendulum support to sub­ frame"

20Nm +90° (1/4 turn)

1)

Renew stretch bolts

1o-14~--

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Additional information and removal instructions for vehicles with air conditioner Warningl

The air conditioner refrigerant circuit must not be opened.

Note: To prevent damage to condenser also to the refrigerant pipeS/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

To facilitate removing and installing the engine without opening the re­

frigerant circuit:

- Remove retaining clamp(s) from refrigerant pipes.

- Remove ribbed belt ~ Page 13-27.

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- Removing air conditioner compressor.

~ Heating. Air conditioning; Repair group 87; removing and installing

compressor bracket - Secure air conditioner compressor to body so that the refrigerant hoses/pipes are relieved.

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Dismantling and assem­ bling engine

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Notes:

• When stripping and assembling the en­ gine it should be secured to the engine frame with engine and gearbox bracket VW 540 and supplementary set VW 540/18.

• Use assembly tool 3277A only, to pull off and push on the spark plug connector.

• If when repairing an engine, metal shav­ ings or large quantities of small metal par­ ticles caused, for example, by partial seiz­ ure of crankshaft and conrad bearings are fdund in the engine oil, one must apart from thoroughly cleaning oil passages, renewal/ oil spray jets, the oil non-retum valve, the oil cooler and oil filter element to prevent consequential damage.

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• For roller chain item 9 • Removing and installing => Page 15-37, removing and instal­ ling camshafts

2 -Sender wheel • When installing contact surface on timing chain and sender wheel must be dry • For Hall sender (G40) • Removing and installing => Page 15-37, removing and instal­ ling camshafts 3-100Nm • Oil bolt head contact surface when in­ stalling • To remove and install counter-hold with 24 mm open jaw spanner on camshaft => Page 15-37, removing and installing camshafts

20---'

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1 - Camshaft chain sprocket

10

4 - Pivot pin, 18 Nm • For tensioning plate item 7

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5 -Seal • Renew if damaged or leaking

1

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6 • Chain tensioner, 40 Nm • For camshaft roller chain item 9 • Only rotate engine when chain ten­ sioner is installed

7 • Tensioning plate • For camshaft roller chain item 9

8-Sprocket • For roller chain item 15 • Installing => Page 13-11, Adjusting valve timing

9 • Camshaft roller chain • Mark D.O.A. before removing (in­ stallation position) => Fig. 1 • Installing => Page 13-11, Adjusting valve timing

20--./

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18---­ 17---../ 16

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10 -100.Nm • Use counter-hold 3406 when loosen­ ing and tightening => Page 13-11. Ad­ justing valve timing

4

11 - Sprocket • For camshaft roller chain item 9 • Installing => Page 13-11. Adjusting valve timing 12 -10 Nm

13 - Chain tensioner with tensioning plate • For roller chain item 15 • Before installing release locking spline in chain tensioner with a small screwdriver and press tensioning plate against chain tensioner • Only rotate engine with chain ten­ sioner installed

21-----" 20-----"

19------/

18---­ 17---­ 16

1514

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10

I N1:Hl280 I 13-5--­

1

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14 -Crankshaft sprocket • Integral. part of crankshaft • Ground down tooth aligned with main bearing joint =TDC No.1 Cyl. => Page 13-11. Adjusting valve timing

4

15 - Roller chain • Mark D.O.R. before removing (in­ sta lIation position) => Fig. 1 • Installing => Page 13-11. Adjusting valve timing . 16 - Guide rail • For roller chain item 15 • Remove together with roller chain => Page 13-11. Adjusting valve timing

21 20

17 - Locating pin without collar, 10 Nm • For guide rail item 16

19 18 17 16 .

1514

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18 - Locating pinwith collar, 10 Nm • For guide rail item 21

13 12 11

10

I N1~280 I 13-6--­

19-20Nm • Insert with locking fluid "D6"

1

2

3

4

20 -20Nm 21 - Guide rail • For camshaft roller chain item 9

22-10Nm • Insert with locking fluid "D6"

23 -Thrust washer

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24 -Intermediate shaft

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20---'" 19------'

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18----" 17----'

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I N13-0280 I 13-7---­ :-1 ;

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Checking valve timing Special tools, workshop equipment.. testers, measuring instru­ ments and auxiliary items required 3268

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• 3268 Camshaft bar

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• 3277 A Fitting tool

Tee pliE: the

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Iwoo-o468l 13-8--­

Test sequence - Removing insulation tray: ::} General body repairs exterior; Repair group 50; Body front: Assem­ bly overview - Remove cylinder head cover::} Page 15-9. ~

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- Set crankshaft to TDC No.1 Cyl. marks -arrow- by turning crankshaft on the vibration damper securing bolt in engine D.D.A.:

If the TDC No.1 Cyl. setting is correct it is possible to see a notch on the intermediate shaft sprockets -arrow-.

Nate: This condition is only obtained every 2nd TDC position.

If the notch cannot be seen:

- Tum crankshaft 'one full tum further in engine D.D.R.

IN13-G213 I

13-9--­

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- The camshaft jig 3268 must locate in the shaft groove of the longer camshaft and align with the shoulder of the shorter camshaft.

13-10--­

Adjusting valve timing

3268

(Install timing chain) Special tools. workshop equipment, test and measuring appliances and aux. items required

• 3268 Camshaft bar • 3277 A Fitting tool

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VAG 1331

• 3406 Counter-hold • VAG 1331 Torque wrench (5...50 Nm)

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• VAG 1332 (40...200 Nm) Torque wrench

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VAG 1332

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13-11--­

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Work sequence Engine removed

Install roller chain and chain tensioner with tensioning plate: ...

- Set/check position of crankshaft to intermediate shaft.

Ground down tooth on crankshaft sprocket-8­ must align with the main bearing joint (TOC No.1 Cyl.)..

- Install pin without collar for guiderail-2- and tighten to 10Nm. .

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I

....

- Install guide rail-2-with roller chain -l-and both chain sprockets -3­ and -4- (note O.O.A. of roller chain => Page 13-21. Fig. 1)

Marking on roller chain sprocket -4­ must align with the notch -C- or -0- on the

thrust washer.

- Release locking spline in chain tensioner with a small screwdriver -A-.

- Press chain tensioner against tensioner plate and tighten chain ten­ sionerto 10Nm.

I V13-10S21

- Lock vibration damper with counter-hold tool 3406.

I N13-0290 I 13-13--­

lighten intermet:fl8te shaft sprockets 3 and 4

l00Nm.

- Remove counter-hold 3406.

- Check position of crankshaft to intermediate Shaft.

Ground down tooth on crankshaft sprocket -8­ must align with the main bearing joint (TOC No. 1 CyL).

I V13-10S21 Install camshaft roller chain and chain tensionerwith tensioning plate:

- Position both camshafts at TOC No. 1 cylinder.

- The camshaft jig 3268 must locate in the shaft groove of the longer camshaft and align with the shoulder of the shorter camshaft.

- Install tensioning plate locating pins and tighten to 18Nm.

13-14--­

- Install tensioning plale for chain tensioner (camshaft roller chain).

- Install locating pin with collarfor guide rail and tighten to 10 Nm.

Note: With cylinder head removed: - Installing cylinder head => Page 15-17 Removingand installing cylin­ derhead.

- Place guide rail on locating pin. Insert short securing bolt with locking fluid .. 06" and tighten both bolts to 20Nm. ....

- Place camshaft roller chain on intermediate shaft. (Note D.O.A.).

- Fit camshaft chain sprocket and roller chain to camshaft for cylinder bank 1t 3 and 5 (longer camshaft) and pull tight by hand.

- Install camshaft chain sprocket (with sender wheel for Hall sender) and camshaft roller chain to camshaft for cylinder bank 2 and 4 and pull tight by hand.

,~~ ;;

'Ii , I

~

1'[ ,

1: j.

Ji (I III!

I N1:Hl281 I

1

,}

i~!

13-15--­

.I

,

Note:

~ ~

Oil contact surfaces of bolt heads when installing.

- Remove camshaft jig 3268.

- lighten securing bolts for camshaft sprockets to looNm.

Note: Only counter-hoJd with 24 mm open jaw spanner on the camshaft ­ arrow.. The camshaft jig must not be fitted when tightening/Joosening the sprockets.

I N15-0157 I

11I ~i

- Coat sealing surface of sealing flange with AMV 188 001 02 and in­ stall. lighten securing bolt to 10 Nm.

- Renew sealing flange oil seal => Page 13-30, Removing and installing sealing flange and flywheeV drive plate.

t ' - Prepare cylinder head gasket for assembly => Page 15-7, Fig. 2 - Coat sealing surface of cover with AMV 188 001 02.

13-16--­

- Lubricate O-Ring for oil channel seal and insert into cover part.

- Install cover, insert all securing bolts and tighten lightly.

-- First tighten M8 securing bolt to 25Nm then M6 securing bolts to

10 Nm.

- Install chain tensioner for camshaft roller chain and tighten to 40Nm.

Nate:

• Only turn engine with chain tensioner installed! Otherwise cam­ shaft roller chain will jump!

- Turn crankshaft two full turns in engine D.O.R. and check valve tim­ ing ~ Page 13-8.

13-17--­

Engine installed, cylinder head removed

....

-'Set crankshaft to TDC No.1 Cyl. marks-arrow- by turning crankshaft on the vibration damper securing bolt in engine D.O.R.:

....

If the TDC No. 1 Cyl. setting is correct it is possible to see a notch on the intermediate shaft sprockets -arrow-.

If the notch cannot be seen: - Tum crankshaft one full tum in engine D.O.R.

Nate: If the crankshaft is turned with the cylinder head removed, a 2nd mechanic should guide the camshaft roller chain by hand to prevent it jamming.

- Position both camshafts at TDC No. 1 cylinder..

13-18--­

- The camshaft jig 3268 must locate in the shaft groove of the longer camshaft and align with the shoulder of the shorter camshaft.

t

- Prepare cylinder head gasket for assembly

=* Page 15-7, Fig. 2

I

- Install cylinder head =* Page 15-17.

- Place guide rail on locating pin. Insert short securing bolt with locking fluid "06" and tighten bolts to 20Nm.

- Fit camshaft chain sprocket and camshaft roller chain to camshaft for cylinder bank 1. 3 and 5 (longer camshaft) and pu II tight by hand.

- Install camshaft chain sprocket (with sender wheel for Hall sender) and camshaft roller chain on camshaft for cylinder bank 2 and 4 and pull tight by hand.

Note: Lubricate bolt head contact surfaces when installing.

- Remove camshaft jig 3268.

13-19--­

- lighten securing bolts for camshaft sprockets to 100 Nm.

Note: Only counter-hold with 24 mm open jaw spanner on the camshaft ­ arrow-. The camshaft jig must not be fitted when tightening//oosening the sprockets.

- Coat cover sealing flange with AMV 188 001 02.

I N15-0157I

- Lubricate O-Ring for oil channel seal and insert into cover part.

- Install cover; insert all securing bolts and tighten lightly.

- First tighten M8 securing bolt to 25Nm then M6 securing bolts to 10Nm. - Install chain tensionerfor camshaft roller sprocket and tighten to 40Nm.

13-20---

Ul

Note: Only crank engine with chain tensioner installed otherwise the cam­ shaft roller chain will jump.

- Turn crankshaft two full turns in engine D.O.R. and check valve tim­ ing ~ Page 13-8. ~

Fig. 1

Marking roller chains

- Mark roller chains before removing (e.g. with paint arrow pointing in D.O.R.'.

Note: Do not mark chain with a centre punch or any similar means!

I N13-0281 I

13-21---

29

28J~

30

31

1

'-----1 ..

~1IIiI~---2

'---'----3

Pm II 1-10Nm

4 2 - Oil pump drive cover

3 -O-Ring • Renew • Oil before assembling

4 - Oil pump drive

5 - Cylinder block

• Removing and installing sealing flange and dual mass flywheeVdrive plate ~ Page 13-30 • Removing and installing crankshaft ~ Page 13-40 • Dismantling and assembling pistons and conrods ~ Page 13-45

23 - - - - - - : " ' t f t .

21---...../"'-..-.....

6 -Intermediate shaft 7 - Thrust washer 1~F---16

20---"

3

18 17

I N13-0146 I

13-22--­

, lWr"1 .,

- . '. . i

"

29

! 1, \ r

28J~

30 '....- - - - 1

2 7 - - - -..............",.---....

~ ..!""-----2 '-----"'----3 4

8·10 Nm • Insert with locking fluid "06" 9 - Knock sensor 2 (G66) • Checking: => Repair Group 01; Self-diagnosis; Interro­ gating and erasing fault memory 10·20Nm • lightening torque influences the function of the knock sensor 11 - Engine speed sender (G28) • Checking: . => Repair Group 01; Seff-diagnosis; Interro­ gating and erasing fault memory 12 - Coolant pipe • Removing and installing => Page 19-5, parts of cooling system - engine side

i

i

i

21-~"'/

r---._......

.I ~

"

20---'

3

18 17

I N13-0146 I 13-23--­

30 -----'1 ~1IIiiIi!1L----2 '-------:3 1"-,

27--------...

26-----" ~.~\.iii_ .,.~,,~

FF--------,4

13 - Drive .shaft • For oil pump drive 14-0il pump • Dismantling and assembling => Page 17-10 • Coat oil pressure pipe on cylinder block and oil pump housing with AMV 188 001 02 15-25Nm

16-Sump

24

• Removing and installing

=> Page 17-13

3~~~~~l]rJj 23 - - - - " " ' t f l . ; j

17 - Oil drain plug. 20 Nm

22~'­

18-Seal • Renew

!

I

15----·~r-·7""'T

19·15 Nm

21--"""""'"r---._.......

20 - Oil filter bracket • Dismantling and assembling => Page 17-8

n~~-16

20---­

3

18 17

I N13-0146 I 13-24--­

29

30

28~~

r------1 1Iii!JiIIL-----2

"------:3 4

27------...

26------'"

21 • Oil cooler • Coat contact area outside the seal with AMV 188 100 02 • Ensure clearance to adjacent comp(r nents • See note ~ Page 13-1

22 - Fitted bolt, 25 Nm

25~i·,.

(Ii

23 • Compact bracket

24--.1>'

• For alternator air conditioner com­ pressor and P.A.S. vane pump

3 ".

23 - - - - - l o t l t .

24 - Vibration damper • Removing and installing ribbed belt ~ Page 13-27

25 ·120 Nm + '/4 tum (90 0) further

21--..../

• Renew • Counter-hold with 3406 to loosen and tighten ~ Fig. 1 • lighten using torque wrench VAG 1601

.....

~-

9=---18 20-----'

3

18 17

I N13-{)146 I 13-25---

29

28~~

30 26-5Nm

Z1 • Guide tube • For dipstick • Secured with bolt on inlet manifold upper part

27------..

---".-.;;;:

26------'"

28·45Nm 29 - Engine bracket 30 - Dipstick • The oil level must not be above the max. mark!

24 3 ---=~~::::::~~~,~ 23 - - - - " t t l ' .

31 • Oil non-retum valve, 5 Nm • Note fitting position • Clea n if badly soiled • See note '

~ Page 13-1

~--16

18 17

I N13-0146 I 13-26--­

....

Fig. 1

To loosen and tighten the securing bolt hold vibration damper with counter-hold tool 3406

i

Note: Renew securing bolt for vibration damper.

!

I N13-02!1O I

Removing and installing ribbed belt Special tools workshop equipment. testers measuring instru­ ments and auxiliary items required l

l

.6mm0 pin • Straight 16 mm ring spanner

Removing ribbed belt - Removing insulation tray: => General body repairs exterior; Repair group 50; Body front; Assem­ blyoverview - Mark direction of rotation of ribbed belt.

13--27--­

- Swing tensioning roller using a straight 6 mm ring spanner in direc­ tion of arrow until tensioning roller can be locked.

~'

t

•

1 1

t

....

':

I "1:

- Lock tensioning roller using an approx. 6 mm 0 pin -arrow-.

Note: A second mechanic is required for this.

- Remove ribbed belt.

13-28--­

Installing ribbed belt

- Install in reverse order.

Notes: • Ensure, before installing ribbed belt, thataI/ancillaries (altemator, air conditioner compressor, PAS vane pump) are secured tightly.

• When fitting the ribbed belt observe belt direction of rotation and that the belt is seated correctly in the belt pulleys. .... - Fit ribbed belt.

After completing repairs always: - Start engine and check belt running.

I N13-03721

13-29--­

1 2

3 4

5

6

738

Removing and installing sealing flange and dual mass flywheel/drive plate

Notes: For repairs to the clutch: => 5-Speed manual gearbox 02J; Repair.

group 30; Servicing clutch .. When stripping and assembling the en­ gine it should be secured to the engine frame with engine and gearbox bracket VVV 540 and supplementary set VVV

54O!1B.

'1,

1 -100 Nm + tum (90 °)further • Renew • Counter-hold with 3406 to loosen and tighten => Page 13-33. Renewing vibration damper end crankshaft oil seal

3

11

10

9

I N13-0373I

13-30--­

2 • Vibration damper 3·10Nm

1 2

3 4

5

6

738

4 -Oil seal • Renewing ~ Page' 13-33 5 - Sealing flange • Coat sealing surfaces with AMV18800102

6 • Cylinder block • Removing and installing crankshaft ~Page 1340 • Dismantling and assembling pistons and conrods ~ Page 13-45

7 -Sealing flange • Coat sealing surfaces with

AMV18800102

3

11

10

9

I N13-0373 r 13-31--­

1 2

3 4

5

6

8 -Oil seal • Remove with extractor hook 2086 • Lightly oil sealing lip • Install over sleeve 2003/2A • Pull in onto stop with installing tool

738

200313

9 -60 Nm + '12 tum (180 0) further • Renewing 10 - Dual mass flywheel/drive plate • Removing and instalIing drive plate ~ Page 13-37 11-25 Nm

"

, I

Ii

11 .1 J

I' ,

I! .

3

11

10

9

I N13-0373 I 13-32--­

3266

3203

S

~

Renewing crankshaft oil seal ­ vibration damper endSpecial tools, workshop equipment. Wst and measuring appliances and aux. items required

• 3203 Oil seal extractor .3266 Fitting sleeve • 3406 Counter-hold

V.A.G1332

• V.A.G 1332 (40...200 Nm) Torque wrench

W-'­

f'

• VAG 1601 Torque wrench (150...800 Nm)

V.A.G 1601

I W13-00251 13-33--­

Removing

- Remove ribbed belt ~ Page 13-27. ....

- Remove vibration damper. To do this lock vibration damper with counter-hold tool 3406.

- Unscrew inner part of oil seal extractor 3203 three turns (approx. 4 mm) out of the outer part and lock with knurled screw.

I N13-(129() I

....

- Lubricate threaded head of oil seal extractor3203, place it in position and exerting firm pressure screw it as far as possible into oil seal.

- Loosen knurled screw and tum inner part against crankshaft until the oil seal is pulled out.

13-34--­

. ., !f'r

.·1

I'

i .

I '

f ~

I.

Installing

i

- Lightly oil sealing lip of oil seal.

....

- Place guide sleeve from 3266 onto crankshaft journal.

- Slide oil seal over guide sleeve.

....

- Press oil seal in onto stop with press sleeve from 3266. To do this use an old vibration damper securing bolt.

13-35--­

....

- Install vibration damper and lock with counter-hold tool 3406.

- lighten new securing bolt to 100 Nm and then turn 1/4 tum (90°) further.

I N13-0290 I

- Install ribbed belt => Page 13-27.

I

!

.i

f.

I;

13-36--­

VAG 1331

Removing and installing drive plate Special tools, workshop equipment, test and measuring appliances and aux. items required .3406 Counter-hold • VAG 1331 Torque wrench (5...50 Nm) • VAG 1332 Torque wrench (40...200 Nm)

V.A.G1332

• Depth gauge @!"!­

p

• Straight edge

I w13-00281 13-37--­

Removing ...

- Lock vibration damper with counter-hold tool 3406.

- Loosen drive plate securing bolts diagonally and remove.

- Remove drive plate.

I N13-Q!90 I InstaFmg - Fit drive plate onto crankshaft.

- Insert at least 3 old securing bolts and tighten to

3ONm.

...

- Check dimension 08- to cylinder block through the three holes for se­ curing the torque converter using a straight edge and depth gauge and calculate average.

- Compare average with specification (measured distance + thick­ ness of straight edge).

Specification: 15.7 ... 16.5 mm

13-38--­

If the specification is not attained: ...

- Remove drive plate again and fit appropriate shim -1-.

Note: Only one shim of the appropriate thickness may be used.

I V13-1281 I

If the specification is attained: - Insert new securil}g bolts and tighten by hand.

- Tighten securing bolts to 60 Nm and then turn 1800 (1/2 tum) further (turning further can be done in several stages).

13-39

1 2

3 4 4

5

6

8

7 3 8

,,<

Removing and installing crankshaft Notes: • Before removing the crankshaft, that a suitable surface is prepared to sure that the sender wheel (item 6) is damaged or lies against any other item.

• When stripping and assembling the gine it should be secured to the frame with engine and gearbox VW 540 and supplementary set 540/1B. • When changing bearing shells ensure bearing shells of same c%ur code used.

1 - Bearing cap • Bearing cap 1: Vibration damper end • Bearing cap 4 with recesses thrust washers • Bearing shell retaining lugs cyr block/bearing cap must be on same side

<

I N13-0324 I 13-40--­

~-----------1

--2 ....-----3 ...----4

4-----1

;-----5 ,----6

2 - 30 Nm + 1/2 turn (1SOO) further • Renew • 2 x 900 further is permitted

3 -Bearing shells 1 ... 6 • For bearing cap without oil groove • For cylinder block with oil groove

• Do not interchange used bearing shells (mark)

4 - Thrust washer • For bearing cap 4 • Note fixing arrangement

8----..

----7 '----3 ~~~---8

I N13-0324 I 13-41--­ ~----------1

2

-----3 4----.....,

---4 ...-----5 ,----6

---7 '-----3

5 • Crankshaft • See notes before removing ~ Pagel3-40 • Axial clearance new: 0.07 ... 0.23 mm Wear limit: 0.30 mm • Check radial clearance with Plasti­ gage New: 0.02 ...0.06 mm Wear limit: 0.10 mm • Do not rotate the crankshaft when checking the radial clearance • Crankshaft dimensions:

Main journal:

59.958 ... 59.978 mm

Crankshaft journal:

53.958 ... 53.978 mm reworking is not permitted

6 - Sender wheel • For engine speed sender (G28) • Renew • Installing ~ Fig. 1

:::::5!!;;----8

I N13-0324 I 13-42--­

T!I Ii! '

; I

--------------------1

J-l==--2 -----3

-----4 ~--5

4------~

.----6

,!

7 ·10 Nm + '/4 turn (90 0) further • Renew

8 . Oil spray jet • For crankshaft bearings 2...6 • For piston COOling • Opening pressure: 2.0 bar • Removing and installing

=> Page 17-6, Fig. 1

• See note => Page 13-1

;! , i

,!

------7

8---""""

'-------3 ~~----8

I N13-0324 I 13-43--­

~

rig. 1

rltting sender wheel to crankshaft

Ensure crankshafVsender wheel contact surfaces are free of oil and grease.

- For additional security coat reverse side of sender wheel thinly with locking compound 0 000 600.

- Ensure when installing that -VR5- (arrow) is positioned over the individual threaded holes.

- First tighten all securing bolts lightly by hand.

- Then tighten securing bolts to

10 Nm + '/4 tum (goo).

13-44--­ I,

i~htl

i

1

Dismantling and assem­ bling pistons and conrods Note:

9

2

When stripping and assembling the engine it should be secured to the engine frame with engine and gearbox bracket VW 540 and supplementary set VW 540/18.

1 - Piston ring • Offset gaps by 120 ° • Remove and install with piston ring pliers • "TOP" faces towards piston crown • Checking ring gap ~ Fig. 1 • Checking ring to groove clearance ~Fig. 2

3

4

2 -Piston • Checking => Fig. 3 • Mark installation position to conrod and cylinder number • High point of piston crown faces to centre of cylinder block • Install with piston fitting tool 3278 => Fig. 5

5

I N13-02861 13-45

~--'T'--r-----1

3 -Conrod • Only renew as a set • Mark cylinder number -8­ • Installation position: Marks -A- must be above one another

4 • Conrod bearing cap (/,~~ii!------

2

• Note installation position 5-30 Nm + '/4 tum (90 °)further • Renew • Oil threads and contact surface • To measure radial clearance tighten to 30 Nm but not further

&1-------4

rl!------5

I N13->0286 I 13-46--­

6 - Bearing shell

'I ;.' ,

'

--V~---"----

2

,: I,

,l ; i

,

,,

• Note installation position • Do not interchange used

shells

• The lugs on the bearing shells must fit tightly in the recesses • Axial clearance

New: 0.05...0.31 mm

Wear limit: 0.40 mm

• Check radial clearance with Plasti­ gage: New: 0.02...0.07 mm Wear limit: 0.10 mm Do not rotate crankshaft when checking radial clearance 7 - CyrlRder block

3

• Checking cylinder bores

=> Fig. 4

• Piston and cylinder dimensions

=> Page 13-53

.4....L...-----4

e------5 ! N13-02SSI

13-47--­

~-~~----

1

8 - Piston pin • If difficult to remove, heat piston to 6O.()C • Remove and install with drift vw 222a

9 -Circlip P---V-~----2

;r------4

11------5 ! N13-02SS!

13-48--­

~

Fig. 1

Checking piston ring gap

Special tools. workshop equipment. testers. measuring instru­ ments and auxiliary items required • Feeler gauges

Test sequence - Push ring squa rely from above down to approx. 15 mm from bottom end of cylinder. To do this use a piston without rings.

Gap

Piston ring New

Wear limit

Compression ring

mm 0.20...0.40

1.0

Tapered stepped ring

mm 0.20...0.40

1.0

Oil scraper ring

mm 0.25...0.50

1.0

13-49--­

~

Fag. 2

Checldng ring to groove clear8nce

Special tools. WOiIcsllop equipment. testers. measuring instru­ ments and ....., ..... required • Feeler gauges

Clean groove before check.

Piston ring

Clearance

f

New

r

~

Wear limit

Compression ring

mm 0.02...0.07

0.15

Tapered stepped ring

mm 0.03...0.06

0.15

Oil scraper ring

mm 0.02...0.06

0.15

Fig. 3

Checking piston

Special tools, workshop equipment. testers. measuring instru­ ments and auxiliary items required • Micrometer 75...100 mm

I V13-0C1101

Measure pistons approx. 6 mm from the lower edge of skirt. at 90 0 to the piston pin axis.

Deviation from nominal dimension max.O.04mm

13-50--­

....

F'~.

4

Checking cylinder bores

Special tools. workshop equipment. testers, measuring instru­ ments and aQxiliary items required • Internal dial gauge 50...100 mm

Test sequence • Measure bores at 3 locations in both directions ~A-across the engine and -8- in line with crankshaft.

• Deviation from nominal dimension max.0.08mm

Note: Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with adapter bracket 3269" as in­ correct measurements would then be possible,

13-51--­

I ....

Fig. 5

Installing pistons with piston fitting tool 3278

Special tools, workshop equipment testers, measuring instru­ ments and auxiliary items required • 3278 Funnel Note: If a new fitting tool (funnel) is used to install the pistons, first pass pis­ ton with oiledpiston rings twice through the tool and then if necessary remove the resulting metalshavings, Only then install piston with pis­ ton rings.

Work sequence - Oil tool and push piston in by hand. High point of the piston crown must face to the lug on the fitting tool -arrow-, - Hold tool (with piston inserted) on upper edge and press piston in with both thumbs.

- Push piston in until it protrudes approx. 15 mm from the lower edge of the fitting tool.

- Place piston in appropriate cylinder bore. Lug on fitting tool-arrow­ must face to centre of cylinder block.

13-52--­

- Hold fitting tool tight against cylinder block and push piston in.

Piston and cylinder dimensions Honing dimension

Piston-0

Cylinder bore-0

Basic dimen.

mm

80.985

81.01

1st oversize

mm

81.485

81.51

2nd oversize

mm

81.985

82.01

13-53--­

,PITT .

,) [

Removing and installing cylinder head Checking compression pressures ~ Page 15-24.

Notes:

• When installing an exchange cylinder headwith fitted camshaft the contact sur­ faces between bucket tappet and cam must be oiled after installation.

'f

I!

• The plastic protectors fitted to protect the open valves must only be removed im­ mediately before fitting the cylinder head.

• When replacing the cylinder head the complete coolant must be renewed.

22 21 10 20 19 7 18 17 16 6

3

15 14 6

I N15-0078 I 15-1--­

1 -Intake manlold upper part • Removing and installing ~ Page 15-9. Removing and instal­ ling cylinder head cover • First tighten with intake manifold lower part to cylinder head, then tighten the two supportS. • Dismantling and assembling: ~ Repair group 24; Motronic injection and ignition system; Servicing injection part

2 - Throttle valve control part • Heated by coolant • Removing and installing: group 24; Motronic injection and ignition system; Servicing injection part

~ Repair

3-10Nm 4-Cap • Renew seal if damaged

22 21 10 20 19 7 18 17 16 6

3

15 14 6

I N15-0078 I 15·2--­

1

2

4

5

6

6 • Cylinder head cover • Removing and installing

=> Page 15-9

• Renew if damaged or leaking • Before fitting coat cover/cylinder head transitions and the half-moon shaped recesses with D 454 300 A3 6-Bracket

--'0 ---1 -z.4.~~-13 -~3

--..---=:000--7

22 21 10 20.19 7 18 17 16 6

7-26Nm 8 • ~lIIder head bott • Renew • Note installation instructions and se­ quence when loosening and tighten­ ing => Page 15-17 9 - Cylinder head • Check for distortion => Fig. 1 • Removing and installing

=> Page 15-17

• If replaced renew the complete coolant

15 14 6

3

I N15-0078 I 16-3--­

1

4

5

6

10 -O-Ring

• Renew

11-Cover • Can be removed and installed with cylinder head fitted • Coat sealing surfaces with AMV 188 00102 • If only the cover has been removed, prepare cylinder head gasket for as­ sembly => Page 15-7, Fig. 2

. 12 - Chain tensioner, 40 Nm • For camshaft roller chain • Only tum engine with chain tensioner installed

13 -Seal • Renew

14 -Continued coolant circulation pump (V61)

• Checking => Page 19-22

22 21 10 20 19 7 18 17 16 6

3

15 14 6

I N15-0078 I 16-4--­

15 -Ignition coils N, N128, N158, N163, N164 ~

• Checking: Repair Group 28; Servicing ignition part

16 - Thermostat housing • Dismantling and assembling ~ Page 19-11 17 -Gasket • Renew

18 - Cyflllder head gasket • Renew • If replaced renew the complete coolant

19 -Intake rill-lower part 20 - Gasket for intake manifold upper

part • Renew if damaged

21-5Nm

22 21 10 20 19 7 18 17 16 6

3

15 14 6

I N15-007SI 15-5--­

22 - Combi-valve • Checking ~ Page 26-13 • Removing and installing

~ Page 26-16

23 - Gasket for

part

i......

manifold lower

• Renew if damaged

24 - Tensioning element • For ribbed belt

25-5Nm

26 -Bracket • For secondary air inlet valve (N112) and intake manifold change-over valve (Nl56) 27 - Vacuum positioning element • For intake manifold change-over

22 21 10 20 19 7 18 17 16 6

3

15 14 6

I N15-0078 I 15-6--­

.....

~~~~~......I

Fig- 1

Checking cylinder head for alStortion

Special tools. workshop equipment, testers. measuring instru­ ments and auxiliary items required • Feeler gauges Max. permissible distortion: 0.1 mm

.....

Fig. 2

Preparing cylinder head gasket for assembly

Special tools. workshop equipment, testers, measuring instru­ ments and auxiliary items required • Sealant AMV 188 001 02 - Remove old sealant from 3 mm holes in the cylinder head gasket, cover and sealing flange -arrows-.

- Fill 3 mm holes in the cylinder head gasket with sealant AMV 188 001 02 and coat sealing surfaces on cover and sealing flange with sealant.

15-7---

Nate:

With the cylinder head installed the holes are only half v;sible.

15-8--­

Removing and installing cylin­ der head cover

VAG 1331

:1 -I

Special tools, workshop equipment. test and measuring appliances and aux. items required

I

I

I I:

• 3277 A Fitting tool

I

• V.A.G 1331 Torque wrench (5...50 Nml

I

• V.A.G 1921 Spring-type clip pliers

VAG 1921

I W15-00301 15-9--­

Removing Nate:

Check whether a coded radio is installed as during the forthcoming

work sequences the battery earth strap must be disconnected. Obtain

radio code first if necessary.

- With the ignition switched off disconnect battery earth strap.

- All cable ties which are opened or cut open when removing engine, must be replaced in ~he same position when installing engine.

- Remove spark plug connectors with tool 3277 A and unclip ignition cables: => Repair group 28; Motronic injection and ignition system; Servicing ignition part - Remove intake manifold cover.

- Disconnect connector from heater element (N791.

- Remove intake hose between air mass meter (G701 and throttle valve control part (J338). => Repair group 24; Motronic injection and ignition system; Servicing injection part

15-10--­

.....

- Detach connector -1- from throttle valve control part -2-.

- Fit earth connection to throttle valve control unit (J338).

- Open and close the expansion tank sealing cap to release pressure in cooling system.

.....

- Detach the accelerator cable from the support bracket and the throttle valve control part -arrow- (do not remove locating clip).

15·11--­

.....

ft g

- Pull coolant hoses -1- and -2- off throttle valve control part and seal hose ends.

- Now pull off vacuum hose connections -3-, ..4- and -5- as well as the connector for intake temperature sender-6-.

a==4>

1 2

- Unclip secondary air pump pipe/hose as well as all other pipes! hoses/cables from bracket on intake manifold upper part.

- Unscrew dipstick guide tube from intake manifold upper part.

- Now remove the two bolts for the intake manifold support.

- Pull off vacuum hose on intake manifoldchange-overvacuum actua­ tor. .....

- Pull off supply pipe/hose -1- (with white marking) and return pipe/ hose -2- (with blue marking) and collect fuel that leaks out with a cloth.

Note: Press buttons on hose couplings to do this.

15-12--­

Warningl Fuel srstem is under pressurel Before opening the ,system place a doth BI'OUnd the connection. Then release pressure by carefully loosening the connection.

- Seal the pipes so that the fuel system is not contami nated by dirt etc.

i

I

- Remove centre, left and right insulation tray: => General body repairs exterior; Repair group 50; Body front; Assem­ blyoverview - Bring lock carrier into service position: => General body repairs, exterior; Repair group 50; Body, front; Lock carrier service position Vehicles with air conditioner

- Remove ribbed belt => Page 13-27.

- Removing air conditioner compressor: => Heating, Air conditioning; Repair group 87; removing and installing compressor bracket - Remove retaining clamp(s) from refrigerant pipes.

Warningl

The air conditioner refrigerant circuit _1IOt be opened.

Notes:

15-13--­

• The opening ofthe refrigerant circuit can only be carried out in work­ shops, which have trained personnel and the necessary range of tools and workshop equipment.

• To prevent damage to condenser and the refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched. kinked or bent.

Continued for all vehicles

- Remove combi-valve => Page 26-16.

- Remove bracket for secondary airinletvalve(Nll2)and intake mani­ fold change-over valve (N156) => Page 15-6. item 26.

Note: Connections can remain connected to valves.

- Then unbolt intake manifold upper part from intake manifold lower part.

- Take off intake manifold upper part and place on a suitable surface so that the vacuum actuator is not damaged.

15-14--­

Nate: Seal the intake parts in the intake manifold lower part or in cylinder head with a clean cloth.

- Remove the cylinder head cover.

Installing Install in reverse order.

Notes: • Replace cylinder head cover if damaged or leaking.

• Bolt intake manifold upper part to intake manifold lower part, then tighten both bolts for the intake manifold supports.

• Ensue fuel hoses are tight.

- If necessary top-up coolant => Page 19-14 - Adjusting accelerator cable => Page 20-28, SeNicing accelerator mechanism.

- Interrogate fault memory: => Repair group 01; Self-diagnosis; Interrogating and erasing fault memory

15-15--­ lightening torques Bolted joint

lightening torque

Cylinder head cover to cylinder head

·10Nm

Intake manifold upper part to intake manifold lower part

25Nm

Intake manifold upper part to left and right supports

25Nm

Support for intake manifold upper part to cylinder head

25Nm

15-16--­

3268

Removing and installing cylin­ der head

VAG 1306

Special tools, workshop equipment, test and measuring appliances and aux. items required • 3268 camshaft bar • Y.A.G 1306 Drip tray VAG 1331

• V.A.G 1331 Torque wrench (5...50 Nm)

V.A.Gl332

• Y.A.G 1332 (40•..200 Nm) Torque wrench

@!-,­

p

• V.A.G 1921 Spring-type Clip pliers

V.A.G 1921

I Wl5-0031 I 15-17--­

Prerequisites • The engine must be no more than warm to touch.

Removing Note: Check whether a coded radio is installed as during the forthcoming work sequences the batteryearth strap must be disconnected. Obtain radio code first if necessary.

- With the ignition switched off disconnect battery earth strap.

- Remove intake manifold upper part =I> Page 15-9. Removing and in­ stalling cylinder head cover.

- Loosen or separate the following components: • High tension cable terminal 4 from ignition coils • The earth strap on ignition coils - Set crankshaft to TDC No.1 Cyl. marks-arrow- bytuming crankshaft on the vibration damper securing bolt in engine D.O.A.: - Drain coolant =I> Page 19-14.

- Remove the cylinder head cover.

15-18--­

....

- Pull off fuel return pipe -2- (blue marking) and fuel supply pipe -1­ (white marking).

Note:

Press buttons on hose couplings to do this.

Warning!

Fuel supply lines are under pressure! Before removing from

hose connection wrap a cloth IIIOfInd the connection. Then re­

lease pressure by carefully purmg hose off conn~ion.

- Seal the pipes so that the fuel system is not contami nated by dirt etc.

- Separate connector to injectors and pull vacuum hose off fuel pres­ sure regulator.

- Loosen hose clips and pull coolant hoses off coolant thermostat housing.

- Now remove the thermostat housing.

- Then unclip the electric continued coolant circulation pump (V51) from its bracket. Coolant hoses can remain connected.

15-19--­

- Pull 3 pin connector off hall sender (G40), sender remains installed.

- Now remove the ignition coils.

- Remove the bracket and then the camshaft cover part.

- Remove camshaft chain sprocket, hold camshaft with a 24 mm AF open jaw spanner.

I Nl~l571

- Separate front exhaust pipe from exhaust manifold ~ Page 26-1, Removing and installing parts of exhaust system.

....

- Loosen socket head bolts in the sequence given and then remove completely.

- Carefully lift cylinder head off.

15-20--­

Installing

- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. .

- Also prevent dirt and emerycloth particles from getting into tt:le cool­ ant.

- Carefully clean cylinder head and cylinder block sealing surfaces.

Thereby ensuring that no scoring or scratches are formed (when using abrasive paper the grade must not be less than 100).

- Carefully remove metal particles. emery remains and cloths.

If the piston for No. 1 cylinder is not at TOC:

....

- SetcrankshafttoTOCNo.l CyI.marks-arrow- byturning crankshaft on the vibration damper securing bolt in engine O.O.R.:

Notes: • Only remove the new cylinder head gasket from its packing im­ mediately before installing.

• Handle the new gasket with extreme care. Damaging will lead to leaks.

15-21--­

18

-

....

Fit new cylinder head gasket. Lettering (Part No.) must be readable.

- Ensure dowel sleeves are inserted into cylinder block holes 15 and 16. and the cylinder head gasket is located.

- Position the camshafts in cylinder head to TOC No. 1 cylinder.

15

....

- The camshaft jig 3268 must locate in the shaft groove of the longer camshaft and align with the shoulder of the shorter camshaft.

- Now prepare the cylinder head gasket for assembly => Page 15-7 Fig. 2.

- Fit cylinder head, screw cylinder head bolts in and tighten hand tight.

15-22--­

- Tighten cylinder head in tightening sequence as follows: - Pretighten all bolts to 30 Nm.

- Then tighten all bolts to 50 Nm.

- Then tighten all bolts a '/4 tum (90°) further using a ridged wrench.

- Then tighten all bolts again a '/4 tum (90 0) further.

The rest of the assembly is baSically a reverse of the dismantling se­ quence.

Note:

Ensure the O-ring for sealing the oil channel in the cover part is fitted.

Adjusting valve timing => Page 13-11.

Filling with new coolant => Page 19-14.

Note:

There is no requirement to retighten the cylinder head bolts after re- .

pairs.

15-23--­

Checking compression pres­

sures Special tools. workshop equipment, test and measuring appnances and aux. items required

.3122 B Spark plug spanner

1 - - - - - - - - - - - - ­ + - - - - - - - - - - - - 1 .3277 A Fining tool • V.A.G 1331 Torque wrench (5...50 Nm)

V.A.G 1331

• V.A.G 1763 Compression tester

I W15-0032 I 15-24--­

Test conditions • Engine oil tempe~ture at least 30 OC.

Test sequence - Pull con nector off heater element (N79) and remove intake hose be­ tween air cleaner upper pa rt and throttle valve control part (J338) to­ gether with the crankcase breather valve: ~ Repair group 24; Motronic injection and ignition system; Servicing injection part - Remove spark plug connectors with tool 3277 Aand unclip ignition cables: ~ Repair group 28; Motronic injection and ignition system; Servicing ignition part - Remove intake manifold cover.

- Remove spark plugs with spark plug spanner 3122 B. - Pull 6 pin connector (brown) -1- off final output stage -2-.

- Fully open throttle valve.

- Check compression pressure with compression tester VAG 1763.

15-25--­

Note: Using the compression tester ~ Operating instructions.

- Operate starter until tester shows no further pressure increase.

Compression pressure: New: 10...13 bar

Wear limit 7.5 bar

Permissible difference between all cylinders: 3 bar

t :~

~

L

15-26--­

,,-------1

Servicing valve gear

r------2

Note:

----3

Cylinder heads which have cracks between the valve seats orbetween valve seat inserts and the spark plug thread can be used further without reducing service life, pro­ vided the cracks do not exceed a maximum of 0.5 mm in width.

1 - Bearing cap • Installation position ~ Fig. 2 • Installation sequence =* Pagel5-37, removing and instal­ ling camshafts

11---­

2-20Nm

10--~

~----8

~~~--------9

I N15-0161 I 15-27--­

.--------1

r------2

----3

3 - Camshafts • Checking axial clearance =* Fig. 1 • Removing and installing

~ Page 15-37

• Checking radial clearance with plasti­ gage

Wear limit: 0.10 mm

• Run-out: max. 0.01 mm 4 - Camshaft sprocket • Removing and installing =* Page 15-37, removing and instal­ ling camshafts

5 - Sender wheel • For Hall sender (G40) • When installing contact surface on timing chain and sender wheel must be dry .

• Removing and installing =* Page 15-37, removing and instal­ ling camshafts

11----­ 10--~

!~-----8

~~-,--------9

I N15-0161 I 15-28--­

;!rn ,

"

-;f

!

1

1

~

2

3

6-100 Nm • To remove and install counter-hold with 24 mm OJ spanner on camshaft ~ Page 15-37, removing and instal­ ling camshafts • Oil bulkhead contact surface when in­ stalling 7 • Cylinder head height • Minimum height: a =139.5 mm

~

8 - Cylinder head • See note ~ Page 15-27 • Reworking valve seats ~ Page 15-34

. 12 11 10

9-Valves • Do not rework only grinding-in i~ per­ mitted • Valve dimensions ~ Fig. 3

t

>

8 9

I N15-0161 I 15-29

~

}•

1

2

3

10 - Valve guide • Checking ~ Page 15-44 • Renewing ~ Page 15-45 • Service version with collar 11 • Valve stem seal • Renewing ~ Page 15-47

12 . Valve springs • Removing and installing: Cylinder head removed: with 2037 installed: ~ Page 15-47, Renewing valve stem seals

':

13 - Valve spring plate

11 10

14 - Valve cotters

"

'7""'------ 8

~*-~~-----------9

I N15-0161 I 15-30--­

....------1

------2

15 - Bucket tappet

.----3

• Do not interchange • With hydraulic valve clearance com­ pensation • Checking =* Page 15-42 • Store with cam contact surface downwards • Before installing check camshaft axial clearance =* Fig. 1 • Oil contact surface

15-31--­

....

Fig. 1

CaInsIIIIIfts. checking axial clearance

Speen.. tools.. . .bhop equipment" testers, measuring instru­ ments and ....... 'I items required • VW 387 UnNel'sal dial gauge bracket • Dial gauge

Test sequeIIC8 Wear limit: max. 0.15 mm Check with bucket tappets removed and with first and last bearing caps fitted to appropriate camshaft.

....

rig.

2

Fitting position of camshaft bearing caps

The bearing cap markings (arrows) must face towards vibration damper side.

I Nl5-()111 I

15-32--­

...

rig.

3

Valve cfnnensions

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

Dimension

Inlet valve

Exhaust valve

39.0

34.20

6.967

6.96

c

mm mm mm

105.95

106.95

a

L'

45

45

0a 0b

15-33--­

Reworking valve seats Special tools, workshop equipment, testers, measuring instru­ ments and auxiliary items required • Depth gauge

• Valve seat refacing tool Work sequence

Notes:

• When repairing engines with leaking valves, it is not always suffi­ cient to rework orrenew valve seats and valves. It is also necessary to check the valve guides for wear. This is particularly important on high mileage engines.

• The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum permissible reworking di­ mension must be calculated- before reworking commences. If the reworking dimension is exceeded, the function of the hydraulic tappets can no longer be guaranteed and the cylinder head should be renewed.

Calculating max. permissible reworking dimension - Insert valve and press firmly against seat.

15-34--­

Note: If the valve is to be renewedas part ofa repair. use a new valve for the calculation. ~

- Measure distance -a- between end of valve stem and upper edge of cylinder head.

- Calculate max. permissible reworking dimension from measured distance -a-and minimum dimension.

Minimum dimension:

Inlet valve 33.9 mm

Exhaust va Ive 34.1 mm

Measured distance minus minimum dimension

= max. permissible reworking dimension.

Example:

Measured distance -a­ - Minimum dimension

= max. perm. rework dimension 1)

34.8 mm

34.1 mm

0.7 mm

1l=> Page 15-36.

15-35--­

~

Reworking inlet valve seat

a b c Z €X

IS 'Y

~

= 038.3 mm

= Max. permissible reworking dimension 1)

= 1.4mm ... 2.0mm

if necessary rework valve seat insert with 75 0 correction miller

= Cylinder head lower edge

:: 45 0 valve seat angle'

:: 30 0 upper correction angle

:: 60 0 lower correction angle

Reworking exhaust valve seat

a b c Z €X

IS 'Y

:: 033.5mm

= Max. permissible reworking dimension 1)

= 2.0mm ... 2.5mm

if necessary rework valve seat insert with 75 0 correction miller

= Cylinder head lower edge

= 45 0 valve seat angle

= 30 00 upper correction angle

= 73 lower correction angle

15-36--­

Removing and installing camshafts Special tools, workshop equipment.. testers, measuring ments and auxiliary items required 3268

....

• 3268 Camshaft bar

V.A.G 1331

....

• VAG 1331 Torque wrench (5...50 Nm)

Inmrrll.!

@1¢'- •

Iwoo-o427l 15-37--­

Removing

.,

....

! ,{

- Set crankshaft to TDC No.1 Cyl. marks-a~ bvtuming cran on the vibration damper securing bolt in engine D.O.A.: - Remove cylinder head cover => Page 15-9.

i

::... Remove camshaft roller chain tensioner..

- Remove cover part.

- Loosen securing bolts for camshaft sprockets.

Note:

Only counter-hold· camshaft with 24 mm OJ spanner -BffOW-.

camshaft jig 3268 must not be in place when tightening O( tan!'UJn.llJi

the chain sprockets.

- Remove camshaft sprockets.

I Nl5-0157 I

15-38--­

....

Removing bearing caps of camshaft cylinder bank 1, 3 and 5 as . well as camshaft cylinder bank 2 and 4.

Longer camshaft: - First remove bearing cap 1.

- Slacken off bearing caps 3 and 5 alternately and diagonally.

I Nl5-G111 I Shorter camshaft: - First remove bearing cap 4.

- Loosen bearing caps 2 and 6 slowly.

.!

Installing

.'!,

·t

~

- Oil running surfaces of both camshafts.

....

Notes: • When installing the camshafts the recess for the camshaft sprockets -arrows- must be at top.

• When installing bearing caps ensure that the identification mark is readable from the exhaust side of cylinder head and. that the arrow points to vibration damper end.

I Nl5-0112I

15-39--­

....

Installing camshaft cylinder bank 1, 3 and 5 as well as camshaft cylinder bank 2 and 4. .

Longer camshaft: - Tighten bearing caps 3 and 5. to guide camshaft. alternately and diagonally to 20Nm.

I N15-G111 I

- Tighten bearing cap 1 also to

20 Nm.

Shorter camshaft: - "Tighten bearing caps 4 and 6, to guide camshaft, alternately and diagonally to 20Nm.

- Install bearing cap 2 and also tighten to

20Nm.

- Clean sealing surfaces on cylinder head and cover part.

15-40--­

....

- Remove old sealant from 3 mm holes in cylinder head gasket.-ar­ rows-.

Nate: With the cylinder head installed the holes in the cylinder head gasket are only half visible.

- Install camshaft chain sprockets with camshaft roller chain ~ Page 13-11, Adjusting valve timing.

- Fill 3 mm holes in cylinder head gasket with sealant AMV 188 001

02.

- Coat sealing surface of cover with AMV 188 001 02.

Note: Ensure the O-ring for sealing the oil channel in the cover part is fitted.

- Install cover, insert all securing bolts and tighten lightly.

- First tighten M8 securing bolts to

25Nm

then tighten M6 securing bolts to

10Nm.

15-41--­

- Install chain tensioner for camshaft roller chain and tighten to 30Nm.

Note: • When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves will strike pistons).

Checking hydraulic bucket tappets Special tools, workshop equipment, testers, measuring instru·

menta and aUXIliary items required • Feeler gauge • Wood or plastic wedge

Test sequence Notes:

• Irregular valve noises when starting engine are normal - Start engine and run until the radiator fan has switched on once.

- Increase engine speed to about 2500 rpm for 2 minutes.

15-42--­

If the hydraulic tappets are still noisy, locate defective tappets as fol­ lows: -Remove cylinder head cover => Page 15-9.

- Rotate crankshaft clockwise on vibration dampersecuring bolt, until cam of the tappet to be checked is pointing upwards.

- Determine play between cam and bucket tappet.

- If the play is in excess of 0.2 mm, renew bucket tappet. If the play is less than 0.1 mm or no play, proceed with check as follows: - Press bucket tappet down with a wooden or plastic wedge. If free travel in excess of 0.2 mm is felt before tappet opens valve. renew tappet.

Note: After installing new tappets the engine must not be started for approx.

30 minutes. Hydraulic compensation elements must settle (otherwise valves will strike pistons).

15-43--­

Checking valve guides VW387

Special tools. workshop equipment. testers, measuring instru­ ments and auxliary items required

....

• VW 387 Universal dial gauge bracket • Dial gauge

Iwoo-«l37l

_Test sequence

....

- Insert new valve into guide until end of valve stem is flush with end of guide. Due to the slight difference in stem dimensions. ensure that onlyan inlet valve is used in the inlet guideand an exhaust va Ive in the exhaust guide.

- Determine rock.

- Wear limit:

Inlet valve guide = 1.0 mm

Exhaust valve guide = 1.3 mm

15-44--­

Renewing valve guides Special tools, workshop equipment. testers, measuring instru足 ments and auxiliary items required ....

.3120 Reamer and cutting fluid

....

.3121 Drift

Iwoo-oM>l

15-45--足

,J

Removing 3121

- Clean and check cylinder head. Cylinder heads in which the valve seats can no longer be reworked"or cylinder heads which have al足 ready been machined to the minimum dimension (height) => Page15-29. Pos. 7. or already have service version valve guides fitted. are not suitable to have the valve guides replaced.

- Press out wom valve guides with 3121 from the camshaft side.

Installing - Coat new guides with oil and press in with 3121 from the camshaft side (cylinder head cold) until shoulder makes contact. When doing this the cylinder head must be laying flat.

Note: When the shoulder on guide makes contact. the pressure must not exceed 1.0 t otherwise shoulder may break off.

- Ream guides out with hand reamer 3120 using plenty of cutting fluid.

- Rework valve seats => Page 15-34.

15-46--足

I

l~ ,

Renewing valve stem seals (with cylinder head installed)

Special tools. workshop equipment.. test

and measuring appliances and ame. items

required • 2036 Assembly appliance • 3047A Puller 31228

• 3122B Plug spanner • 3129 Fitting tool • WI! 54111 A Valve lever • WI! 541/5 Thrust piece

VW541I1A

VW541J5

I W15-00331 15-47--­

VW65313

.....

• WI! 653/3 Pressure hose

Removing - Remove camshafts => Page 15-37.

- Remove bucket tappets (do not interchange) and store with the con­ tact surface downwards.

- Remove gpark plugs with gpark plug spanner 3122 B.

.

- Set piston of appropriate cylinder to "bottom dead centre". .....

- Fit assembly tool 2036 and adjust mountings to height of studs.

- Screw compressed air hose W.J 653/3 into spark plug thread and apply a continuous pressure of min. 6 bar.

- Remove valve springs with lever WI! 54111 A and press piece W.J 54115.

Note: Tight cotters can be loosened by tapping lightly on the lever.

- Pull off valve stem seals with 3047 A.

15-48--­

:

I

Installing - To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve stem.

- Oil valve stem seal-8-, place it in the tool 3129 and push carefully onto the valve guide.

15--49--­

I~

Removing and installing parts of the lubrica­ tion system

Nates: • If when repairing an engine, metal shavings or large quantities of

small metal particles caused, for example, by partial seizure of

crankshaft and conrad bearings are found in the engine oil one

must apart from thoroughly cleaning oil passages, renew all oil

spray jets, the oil non-retum valve, the oil cooler and oil filter el­ ement to prevent consequential damage.

• The oil level must not be above the max. mark - danger of damage to catalyst!

j

I:

l'

Checking oil pressure ~ Page 17-16

Ii

Oil system capacity":

f'

I·IJ

with oil filter 4.0 Itrs.

1) Up-to-date figures: ~ Exhaust emissions test binder Engine oil specifications:

Use engine oil to VW standard 500 00 or 501 01. Only in exceptional cases: Mu/ti-grade or single-grade oils corresponding to API-SF or SG.

17-1

• ~

1

2

3 4

21 20

5 6 7

1-10Nm

2 • Oil pump drive cover

,

3 -O-Ring

!•

I

i·

• Renew • Oil before installing

I

I

4 • Oil pump drive

I,

5 - Cylinder block

3·

8 9

!

6 . Intermediate shaft 7 • Thrust washer

I f

f

8-10Nm

10 11 12

13

14

15

19

i

I !" i

• Insert with locking fluid "06"

,::,.,1 o

3

,

~

:

, ';J

8

IN17-00291 17·2

,

~ 21 20

1 2 3 4 5 6 7

9 - Oil spray jet • For crankshaft bearings 2...6 • For piston cooling • Removing and installing

~ Fig. 1

• Opening pressure: 2.0 bar • See note

~ Page 17-1

10 - Drive shaft • For oil pump drive

8

3

9 o·

Ii<

10 11 12 13 14 15

19

11 -Oil pump • Dismantling and assembling ~ Page 17-10 • Coat oil pressure pipe at cylinder block and oil pump housing with AMV 188 00102 12-25Nm 13-8Nm

3

I N17-0029 ~ 17-3

,

~

:t

1 2

14 - Baffle plate

3, 15-Sump • Removing and installing

4

21 20

5 6 7

~

Page 17-13

16 -Oil drain plug. 20 Nm 17 -Seal 18 -15 Nm

3

8

9

19 • Oil filter bracIret • Dismantling and assembling ~ Page 17-8 2O·5Nm

•

f

10 11 12 13 14 15

19

f

r' ,

I

,i

l:

21 • Guide tube • For dipstick • Secured with a bolt on inlet manifold upper part

3

8·

I N17-OO29 I 17-4

":''1'1 , ::

'rr ' , 'm , ,

!

,

21

20

1

2

3 4

5

3

8

~

i

22 - Dipstick • The oil level must not be above the max. markl • Markings ~ Page 17-7. Fig. 2

23 - Oil non-retum valve, 5 Nm

• Note fitting position 6

• Clean if badly soiled 7

• See note ~ Page 17-1

I Il i

9

I

iI

II

10

11

12

13

14

15

19

,J"

I

3

I N17-Q029 I

17-5--­

~

rIG. 1

Removing and instalOng oil spray jet

Special toolsr wortcshop equipment, testers, measuring instru­

ments and auxiliary items required

I

I

I.'

.4 mm0drift

I

Note:

"

Oil spray jets are installed in main bearings 2 ... 6.

!

I,

,r:

1

j

• Crankshaft removed

I

1

Removing - Press out oil spray jet out towards bearing using a 4 mm 0 punch. \

Installing

- To install, press in oil spray jet by hand using a 6 mm 0 punch -arrow-.

17-6--­

....

rig. 2

Dipstick markings 1 -max. mark 2-min. ma~ a - Area above hatched field up to max. mark: Do not top-up with en­

gineoil!

b - Oil level within hatched field: can be topped-up with engine oil

c -Area from min. mark up to hatched field: fill with max. 0.5 Itr. of engine oil!

I N17-0037 I

17-7---·

1

2

3

4

3

5

Dismantling and assembling oil filter bracket 1 -1.4 bar oil pressure switch (F1), .

Nm • Black • Checking => Page 17-16 • If sealing ring is leaking nip open replace.

2 - Oil filter bradtet • With non-retum valve Opening pressure: 0.05 bar

3 -0 ring ~~------------

6

I~~~----~----

7

• Renew • Oil before installing

4 • Oil cooler • Ensure clearance to adjacent nents • See note => Page 17-1

3

_J

r-~~----------

8

~-------------

9

N17--Q056 I

17-8-..........

1 2

5

3

4

3

5 - Oil cooler cover, 25 Nm

6-25Nm 7 - Oil filter element • Observe change intervals • See note => Page 17-1

8 - 01 filter lower part 30 Nm • Drain before removing • With by-pass valve Opening pressure: 2.5 bar

9-01 .... ~,10Nm ~--------------

6

r------7

3

N~----8 --3

irell----- 9

I

N17-Q056 I

17-9--­

. Dismantling and assembling oil pump

9---------~

1 - Drive shaft • For oil pump drive

8------------------~

2 - Oil pump housing

3'-25Nm

..-::...-2

:~ ~-.

5 - Oil pump cover with pressure relief

valve

• Opening pressure: 5.3...5.7 bar • Clean strainer if soiled

6

I

4-Gears • Checking backlash . => Fig. 1 • Checking axial clearance => Fig. 2

I N17-00061 17·10-.,--­

.,

1

II ~

i

i

6-10Nm • Renew • Install with locking fluid "06"

9~----------------~

7 • Oil pressure pipe

8----------------~

• Coat cylinder' block and oil pump housing with AMY 188 001 02

8·10Nm

"""--- 2

9·0 ring • Renew if damaged

~+-~-4

I N17-00061 17-11--­

-~----I

..

Fig. 1 Checking oil pump backlash Special tools, workshop equipment. testers, measuring InSltru· ments and auxiliary items required • Feeler gauge Wear limit: 0.20 mm

....

rig. 2 Checking oil pump axial clearance Special tools, workshop equipment. testers, measuring ments and auxiliary items required • Feeler gauge Wear limit: 0.10 mm

li:",

I:

J;

17-12--­

Removing and installing oil sump Special tools. wwbllap equipment,. testers, measuring instru­ ments and . ' T , iIems required • Hand drill with plastic brush • Silicone sealant 0176404 A2 • Flat scraper

Removing - Remove centre. left and right insulation tray: => General bodv repairs exterior; Repair group 50; Body front; Assembly overview

,

- Drain engine oi-

I,

- Remove SOO'1P­ - Loosen surnpwilh rlQht blows of a rubber headed hammer if necess­

ary.

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

17-13--­

....

- Remove sealant residue on the sump with a rotating brush, e.g. a hand driI willi a plastic brush'(wear protective glasses).

- Clean sealing surface, must be free of oil and grease.

I N17~121 NOIIs • Note the use by date of the sealant.

• SurtJJ must be installed wfthin 5 minutes of applying silicone seal­

ing COIIJ1OUIId.

....

- Cut-off tube nozzle at forward marking (nozzle approx. 3 mm 0).

- Apply siicone sealing compound, as shown, to clean sump sealing

surface. Sealing compound bead must be:

• 2...3 mm thick.

I N17~191

• and run on inside of bolt holes -arrows-.

17-14--­

i"

, ' 'f"IjT

Note: The sealing compound bead must not be thicker; otherwise excess sealing compound will enter the sump and may block the oil suction pipe strainer. , ....

- Apply silicone sealing bead as shown to the clean sealing surface of the sump. (The illustration shows the position ofthe sealant bead on the cylinder block).

- Install sump immediately and tighten all sump bolts lightly.

- lighten sump bolts to 15Nm. - lighten sump/gearbox bolts to 45 Nm.

I A17-0041 I

Note: After installing sump the sealant must be allowed to dry for approx. 30 minutes before engine oil is filled .

The rest of the assembly is basically a reverse of the dismantling se.

Quence.

17-15--­ V.A.G 1527 B

V.A.G 1342

~~

Checking oil pressure and oil pressure switch

/'

~

__________________________________

~

______________________

Special tools. workshop equipment, test and measuring appfiances and aux. ~requred

• V.A.G 1342 Oil pressure tester • V.A.G 1527 B Diode test lamp • V.A.G 1594 A Adapter set

I:

I W17-oD011

17-16--.....

Test sequence

Nate: Functional check and servicing the optical and acoustic oil pressure waming: ~ Current flow diagrams, Electrical fault finding and Fitting locations

....

- Remove 1.4 bar oil pressure switch (F1) (black insulation) and screw into test unit.

- Screw test unit into oil filter in place of the oil pressure switch.

- Connect brown wire of tester to earth

I V17-0540 I

H.

- Connect diode test lamp V.A.G 1527 B using aux. cables from VAG 1594A to battery positive (+) and oil pressure switch. LED must not light up.

- If the LED lights up, renew 1.4 bar oil pressure switch (F1) .

When the LED does not light up: - Start engine and run at idling speed

at

1.2... 1.6 bar

17-17--­ the LED must light up, otherwise renew 1.4 bar oil pressure switch (F1 ).

- Increase engine speed further.

At 2000 rpm and an oil temperature of 80 °C the oil pressure ~hould be at least 2.0 bar.

At higher engine speed the oil pressure must not exceed 7.0 bar.

- Replace oil pump if necessary ~ Page 17-10, dismantling and as­ sembling oil pump.

17-18--­

Removing :and installing parts of cooling system Nates: • When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work.

• Hoses are secured with spring-type clips. In cases ofrepair only use spring-type clips.

• v.A.G 1921 pliers are recommended when installing spring-type clips.

• When installing coolant hoses route stress-iree. so that they do not come into contact with other components (observe markings on coolant connection and hose).

Perform cooling system leakage test with cooling system tester VAG 1274andadaptersV.A.G 1274/B and VAG 127419.

Parts of cooling system body side ==- Page 19-2.

Parts of cooling system engine side ==-19-6.

Dismantling and assembling coolant thennostat housing ==-19-11

18-1--­

Parts of cooling system body side 1 - Radiator • Removing and installing

==- Page 19-19

• After replacing renew entire coolant

2 -0 ring • Renew if damaged 3 • Upper caoImd hose • Secured to radiator by a quick release coupling • Check securely seated • Coolant hose connection diagram ==­ Page 19-9 4 • Air ducting

5·10Nm

6 • Radiator fan (V7J 7 • Fan retail,.

10

9

7 8

I N19-0182 I 18-2--­

,

,

1

3

8 • Retaining clip • Check seated securely

9 • Connector 10 • Radiator fan CV35)

15

4

, I'

·-1

11·Bracket • For radiator fan connector

:l "

12 • Lower coolant hose • Secured to radiator bya quick release

coupling

• Check securely seated • Coolant hose,connection diagram :::;> Page 19-9

1

15 14

t

t,

Ii

13 ·0 ring • Renew

9

1:'

; ~

13 12 11

!

5

10

9

7 8

I N19-{)182 I 19-3--­

14 • Thermo switch (F18). 35 Nm • For electric fan • Switching temperatures: Stage 1 ' on: 92...97 °C

off: 84...91 °C

Stage 2

on: 99...105 OC

off: 91 ...98 QC

"

15 -Bracket • For radiator • Note fitting position 16·15Nm

i

I

!

:\

II

10

9

7 8

I N19-{)182 I 19-4--­

1.2 3 4 5

6 7 8

Parts of cooling system engine side .

,.

1 - Sealing cover

4 -------'=:::--1"

• Check with cooling system tester VAG 1274 and adapter V.A.G 1274/9

2 -0 ring • Renew if damaged ~--9

3 - Expansion tank

• Carry out leak test of cooling system with cooling system tester \l.A.G 1274 arKfadapter VA G1274/8 • Test pressure 1.4... 1.6 bar

4-10Nm

3 4

7

5 - Upper coaIMt pipe • Clipped to bulkhead • Coolant hose connection diagram =>

Page 19-9

16

I

N19-0186

I 19-5--­

1 2 3 4 5

6 7 8

6 - To top of . .lilt.

• Coolant hose comection diagram =>

Page 19-9

7 -0 ring • Renew

8 - To heat.- ~t.Rger • Coolant hose connection diagram =>

Page 19-9

~--9

9 -10 Nrn . 10 - Throttle wive control part • Heated by coolant

11 - To top of radiator • Coolant hose connection diagram => Page 19-9 3

4

12 - Gasket

• Renew 13 - To bottom of raal8tor • Coolant hose connection diagram =>

Page 19-9

17----6]~

7

16

I N19-0186 I 19-6--­

1 2 3 4 5

678

14 -Thermostat housing • Dismantling Pagel9-11

and

assembling

~

I

15 - Continued coolant circulation pump

4---~""""'"""

(V51)

• Checking ~ Page 19-22

16 - From heat exchanger

• Coolant hose connection diagram ~ Page 19-9

17 -2SNm

18 - Oil cooler • Removing and installing ~ Page 17-8. item 4

19 - Seali_D9 plug

20 - Coolant pipe

• Coolant hose connection diagram ~

Page 19-9

18---!-~~ \ ""

17~ ....

- -­

7

16

I

N19-0186

I 19-7--­

1 2 3 4 5

678

21 - Coolant pump • Note installation pOSition • Check arm for ease of movement • If damaged and leaking renew com­ plete • Removing and installing ~ Page 19-27

4 ---~,,-..I:J1

22-15 Nm

23 -Pulley • For coolant pump

24-25 Nm

- -­

7

16

I N19-0186] 19-8--....

I

: I

15 16

2

1

3

Coolant hose connection dia­

gram 1 - Heater unit heat exchanger .

2 - Non-return valve 3 - Continued coolant circulation pump

(V51) 4 - ATf cooler • Only on vehicles with automatic gear­

14 +----+-4

box 5 - Upper coolant hose

13

8 -Cooler

12

7 - Lower coolant hose

5

8 - Thermostat housing 9 - Lower coolant pipe 10 - Oil cooler 11-Coolant pump

11

109 8 7

6

I N19-02021 19-9--­

15 16

2 3

1

12 • Cylinder block 13 - Cylinder head 14 - Expansion tank 15 - Upper coolant pipe

18 - Throttle valve control part

14 -I-------+-4

13---tt---t=--..:.-..-l 12--­ 5

11

109 8 7

6

I N19-0202 r 19-10--­

4

12

1m

Dismantling and assembling coolant thermostat housing ____- 1

I

Note: Connecting the coolant hoses to thermostat housing => Page 19-5, parts ofcooling system engine side.

1 - Thermostat housing 2-10Nm

9--+­

3 - Coolant thermostat

j..-...::....------3

:-+------- 4

• Installation position: Breather slot!

valve uppermost

• Checking: heat-up thermostat in

water

• Opening commences approx. 80°C • Ends approx. 105 OC • Opening lift min. 7 mm

----5 "

j

I N19-0125 I

8

19-11--­

8

4

12

1m

11

4 -Seal • Renew .!

5 • Connection

...---1

.,

"

6-Bush 7-10Nm

8'-O-Ring • Renew

9 - Connection

9--+­

10 • Coolant temperature sender (G62)

:---:----- 3 -l------4

.---5

• With coolant temperature gauge

sender (G2)

• For engine control unit • If necessary before removing, re­

lease pressure from cooling system

• Checking: . / => Repair Group 01; Fault memory; Interro­ gating and erasing fault memory

,ill :: i'l ;.,

8

!II

I N19-012SI 19-12---

I i,l

8 11

4

12

11 ·Air concfrtionercut-off switch (F163)

Jm

thermo

• For air conditioning system • If necessary before removing, re­ lease pressure from cooling system

~-1

12 • Retaining clip • Check seated securely

9-->'­

,Ii--:------ 3

-+-------4 .------5

I N19-0125 I

8

19-13--­

Draining and filling cooling system V.A.G 1306

Special tools, workshop equipment.. test8Is, measuring instru· ments and auxiliary items required ....

.• V.A.G 1306 Drip tray

I woo-o5121

V.A.G 1921

....

• VAG 1921 Hose clip pliers • Anti-freeze tester

IWllO-0464I

19-14 --...;-­

Draining - Open cap on coolant expansion tank.

- Remove insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Assem­

. bly overview

....

- To drain coolant from radiator remove drain plug -arrow- in radiator return.

I

....

L

- To drain coolant from engine also remove coolant hose from oil cooler -arrow-. "~I

Note: Observe disposal regulations!

!.

1&-15--­

Filling Notes: • Only use coolant additive G 12 in accordance with TL VW 774 D.

Identification: coloured red .

• On no account must G 12 be mixed with other coolant additives!

• If the fluid in expansion tank is brown, G 12 has been mixed with

other coolant. In this case the coolant must be changed.

• G 12 and coolant additives marked "In accordance with TL VW 774

DN prevent frost and corrosion damage, scaling and also raise boil­ ing point of coolant. For this reason the system must be filled al/

year round with frost and corrosion protection additives.

• Particularly in countries with tropical climates, the coolant due to

the higher boiling point improves engine reliability when heavily

loaded.

• Protected against frost to about -25°C (in arctic climatic countries

to about -35 °CJ.

• The coolant concentration must not be reduced by adding water

even in warmer seasons and in warmer countries. The anti-freeze

ratio must be at least 40 %.

• If for climatic reasons a greater frost protection is required, the

amount of G 12 can be increased, but only up to 60 % (frost protec­ 19-16--­

tion to about -40 °C). as otherwise frost protection is reduced again and cooling effectiveness is also reduced.

• If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

Recommended mixture ratios: Frost

protection

Anti-freeze

G 121)

Water1)

3.61 4.51

5.41 4.51

amouJrt

to -250(; -35OC

40% 50%

1) The quantity of coolant

can vary depending upon the vehicle equip­

ment.

- Screw drain plug into radiator retum.

- Push coolant hose onto oil cooler connection and tighten.

~

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

- Fit expansion tank cap.

19-17--­ - Set heater controls to maximum heat position and switch off air conditioning system if fitted.

- Start engine and maintain an engine speed of about 2000 rpmforap­ prox. 3 minutes.

- Run engine until radiator fan cuts-in.

- Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the coolant level must be on the max. mark. when the engine is cold. between the min. and max. marks.

!

I

l

19-18--­

=

V.A.G 1306

Removing and installing radi­ ator

V.A.G 1331

Special tools, workshop equipment. test and measuring appliances and aux. items

required • VAG 1306 Drip tray

1------------+-------------1 • VAG 1331 Torque wrench (5...50 Nm) • VAG 1921 Spring-type clip pliers

V.A.G1921

• Anti-freeze tester

I W19-0001!

19·19--­

Removing - Drain coolant ~ Page 19-14.

- Removing from bumper: ~ General body repairs, exterior, Repair group 63; Front bumper, Re­ moving and installing front bumper - Pull coolant hoses quick

relea~e

couplings off radiator.

- Pull connectors off thermo switch and radiator fans.

- Bring lock carrier into service position: => General body repairs, exterior; Repair group 50; Body, front; Lock carrier service position - Remove radiator securing bolts and take radiator with fans out downwards.

Vehicles with air conditioner.

- Observe additional information and removal work => Page 19-21.

InstaDing Installation is carried out in the reverse order, when doing this note the following: - Filling with coolant ~ Page 19-14

19·20--­

"

I, "

Additiona. information and removal work on vehicles with air conditioner

1-"

. : 1lte _ _erre!rigerM1t _

mBIt.not be _ e d

Note: To prevent damage to condenser a/so to the refrigerant pipeS/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

- Remove retaining clamp(s) from refrigerant pipes.

- Remove condenser from radiator and secure to lock carrier.

19-21--­

V.A.G 15278

Checking continued coolant circulation pump (V51) Special tools, workshop equipment. testers, measuring instru­ ments and auxiliary items required ~

• V.A.G 1527 B Diode test lamp

~

• Y.A.G 1594 A Auxiliary test set • Current flow diagram

I woo-om I

19-22--­

"

'.:1'.'.':L'1~.,'."

I

ffl •. oj

:: I

,

ii' ,"

Check conartions ....

• Fuse No. 160K.

L

Test sequence ;

- Pull 2 pin connector off continued coolant circulation pump (\151). ....

I

- Connect contacts of continued coolant circulation pump (\151) to bat­ tery using aux. cables from VAG 1594.

Continued coolant circulation pump must run.

If the continued coolant circulation pump does not run: - Replace continued coolant circulation pump (\151).

If the continued coolant circulation pump (V51) runs:

I N19-0175 I

19-23--­

....

- Connect diode test lamp VAG 1527 B to disconnected connector for continued coolant circulation pump (\151) with auxiliary cable from VAG 1594 A LED must rlQht up.

" I

,j i

!

t

Nate: This check must be performed within 10 minutes of switching ignition off.

LED does not light up: - Locate and rectify open circuit using current flow diagram: => Current flow diagrams, Electrical fault finding and Fitting locations

Checking radiator fan (V7) and (V35) V.A.G 1527 B

Special tools. workshop equipment. testers. measuring instru­ ments and auxHiary items required

• VAG 1527 B mode test lamp

19-24--­

f

--"--­

....

• V.A.G 1594 A Auxirlary test set • Current flow diagram

!

I

Check conc:fdions

I

....

!

I

• Fuse No's. 164 and 180 OK. • Radiator fan thermo switch (fUD OK.

I

Test sequence

- Pull 3 pin connector oft radiator fan 1Iamoswitch (F18).

19-,25--­

1 ....

- Bridge contact -1- and contact -2- of conneaor using auxiflary cables from VAG 1594.

1st speed for radiator fans fII7) and (V35J must run.

- Switch on ignition.

I Ntt-Ot9t I

- Bridge contact -2- and contact -3- of connector with auxiliary cables from v.A.G 1594.

2nd speed for radiator fans fII7) and (V35) must run.

If fan 1st or 2nd speeds do not run: - Locate and rectify open circuit using current flow diagram: => Current flow diagrams, Electrical fault finding and Fitting locations

If no wiring open circuit is found:

- Renew radiator fan fII7) or (V35).

19-26--­

Removing and installing cool­ ant pump

VAG 1306

Special tools, workshop equipment test and measuring appliances and aux. items required .3387 Pin wrench

1------------+------------1 • VAG 1306 Drip tray VA.G 1331

• VAG 1331 Torque wrench (5... 50 Nm)

VAG 1921

• v.A.G 1921 Spring~type clip pliers • Anti~freeze tester

I W1!HXJ041 - - _ . 19-27 - - ­

Removing

- Drain coolant ~ Page 19-14

- Remove ribbed belt ~ Page ....

1~27.

- Remove securing bolts ~, ~ for coolant pump belt pulley ~2~ and move belt pulley.

r~

Note: Use pin wrench 3387 when removing and installing coolant pump belt pulley. ....

- Unscrew coolant pump securing bolts -,- and remove coolant pump-2-.

Instalrmg Installation is carried out in the reverse order; when doing th is note the following:

Note: The coolant pump plug faces downwards.

- Moisten new a ring with coolant.

19-28--­

- Insert coolant pump into cylinder block and tighten securing bolts. lightening torque: 15 Nm - Install ribbed belt => Page 13-27.

- Filling with coolant => Page 19-14

.! :

19-29--­

Removing and installing parts of fuel supply system Notes: • Hose connections are secured with either spring-type or clamp-type clips.

• AllNays replace clamp-type clips .With screw-type clips.

• Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw-type clips is not per­ missible.

• VA.G 1921 pliers are recommended when installing spring-type clips.

Observe safety precautions => Page 20-8 .

Observe rules for cleanliness => Page 20-9 Removing and installing fuel tank with its attachments and fuel filter => Page 20-2.

Servicing accelerator mechanism => Page 20-28 Adjusting throttle cable => Page 20-30 Servicing parts of the activated charcoal filter system => Page 20-34.

':

20-1--­

10

Removing and installing fuel tank with its attachments and fuel filter 1 -0 ring • Renew

~---11

~.-----12

2 - Gravity valve . • To remove valve unclip upwards out of support • Check valve for through-flow valve vertical: open, valve tilted 45 0: closed

3 -Yentpipe • Check securely seated • Clipped onto top of fuel tank • To activated charcoal filter => Page 20-34, item 2

4-Cap

18

14 13 I N20-0108 I 20-2--­

5 -Seal • Renew if damaged 6 - Securing screw

7 - Tank flap unit • With rubber cup 8 - Vent valve f 'd • To remove valve unclip out 0 Sl e 4 support .

• Before installing remove ~ap Item • Checking => Page 20-7. Fig. 2

9 - e.th connection • Check securely seated 10 -10 Nm 11-Vent~

.BIacIc • Cf!pped onto side of fuel tan k • Check securely seated .

• Secure with spring-type clips

20-3--­ I I

12 - Fuel tank . k • Supportwithengineandge~rboxJac VAG 1383 A when removing • Removing and installing => Page~14 13 - Clamping ___ 14 - Heat shield • For fuel tank 15-25Nm

16 -Locknut 17 - Fuel tank caver

18 - Securing SInp • Note <frffering length . . .

• Installation po~itio~: FIxing pOint (holes) point in direction of travel

20-4--­

19 • Supply pipe

• Black • Secure with spring-type clips • Check securely seated • To fuel supply pipe on fuel rail: ~ Repair group 24; Servicing injection sys­ tem; Dismantling and assembling fuel rail and injectors

20 - Fuel filter • Fitting position: Arrow points in through-flow direction 21 • Screw-type clip

22 • Sealing ring • Renew jf damaged • Coat with fuel when installing

1

I i

!

.

,. ,

20-5--­

23 - Fuel delivery unit • Removing and installing

~Page 20-10

• Checking fuel pump

=:> Page 20-18

• Clean stra.iner if soiled 24 • Union nut

• Remove and install with spanner 3217 25 -Supply pipe

• Check securely seated 26 - Return pipe

• Blue or blue markings • Clipped onto side of fuel tank • Secure with spring-type clips • Check securely seated • From fuel return pipe on fuel rail ~ Repair group 24; Servicing injection sys­ tem; Dismantling and assembling fuel rail and injectors

l!

i ii

i

:, ii

20-6--­

;I:

'~

....

Fig. 1

Fitting position of fuel delivery unit flange

2

Marking on s~nder must align with the marking on fuel tank -arrows-, Blue or blue marked retum pipe -1- to connection with identification ­ ~

Black supply pipe -2- to connection with identification -V-.

Note:

After installing fuel delivery unit flange, check that the supply, retum

and breather pipes are still clipped onto the fuel tank.

....

Fig. 2

Checking vent valve

Lever in rest position: Closed Lever pushed in direction of arrow: Open

Note: Before installing vent valve remove fuel tank sealing cover.

I '120-1040 I

20-7--­

Safety precautions when· working on the fuel supply system Warningl

Fuel supply lines lITe undet' pteSSUl'eI BefOre removing from

hose eonnection wrap II cloth ..ound the t:OIIIIIHII:ion. Then re­

lease pressure by carefullypuling hose off connection.

When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank the follOwing must be observed: • Before commencing work, switch on exhaust exctraction system and place an extraction hose close to the sender opening in the fuel tank to extract escaping petrol fumes.

If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m3/h can be used.

• Prevent skin contact with petrol! Wear fuel-resistant gloves!

20-8--­

.

mas

in.·.~.:;

'I, , ,,'

i

Rules for cleanliness When working on the fuel supply/injection system, pay careful atten­ tion to the following "5 rules":

,i i

• Thoroughly clean all unions and the adjacent areas before discon­ necting.

• Place parts that have been removed on a clean surface and cover.

Do not use fluffy cloths!

• Carefully cover opened components or seal, if the repair cannot be carried out immediately.

• Only install clean mmponents: Only unpack replacement parts immediately prior to installation.

Do not use parts that have been stored loose (e.g. in tool boxes etc.).

• When the system is open: Do not VtIOrk with mmpressed air if this can be avoided.

Do not move ~icIe unless absolutely necessary.

20-9--­

Removing and installing fuel delivery unit 3217

Special tools. _bIIop equipment.. testers. measuring instru­ ments and ••'7. , items required

....

.3217 Ring nut spanner

....

• V.A.G 1332 Torque wrench (40...200 Nm)

I woo-o2911

V.A.G1332

I W!lO-0428\ I

I l

. i

20-10---

;I,

II

Removing - Note safety precautions before starting work ~ Page 20-8

Note: Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected Obtain radio code first if necessary.

- With the ignition switched off disconnect battery earth strap.

- Remove cover under bench seat.

- Pull4-pin connector as well as supply and return pipes off flange.

Note: Press buttons on hose couplings to do this.

Warningl Fuel supply lines lITe under pressunll ..".. removing from hose t:OIInection wrap a cloth 1ITOfI1III""" f:OIIItfIf:Iion. Then re­ lesse pt'eSSUTe by carefully pulling IJoIe "" COIJIIef:tion.

20-11--­

.... - Remove union nut with spanner 3217.

- Pull fuel delivery unit and seal out of the opening in fuel tank.

Note: If the delivery unit is to be renewed then drain old delivery unit before disposal.

I A20-01OS I Installing - Installing the fuel delivery unit is carried out in the reverse order.

Notes: • Do not bend fuel sender when installing.

• Coat flange seal with fuel when fitting.

• Ensure fuel hoses are seated securely.

• Secure· fuel hoses with sprinrrtype clamps.

• After installing fuel delivery unit, check that the supply. retum and vent pipes are still clipped onto fuel tank.

20-12--­

....

2

f.'.!~

I[

• Note installation position of fuel delivery unit flange: The marking on flange must align with marking on fuel tank ~r­

:!!;

I Itt Li'

rows-. !

1

I: t:

Removing and installing fuel gauge sender Removing - Remove fuel delivery unit

~ Page 20-10.

....

- Release and pull off the terminals for wires -3- and -4-.

- Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sender out downwards -arrows-.

Installing - Insert fuel gauge sender in the guides on the fuel delivery unit and push up until it engages.

I A2IHl1osi

20-13--­

Removing and installing fuel tank V.A.G 1331

Special tools. workshop equipment. testers. measuring instru­ ments and auxiliary items required ....

• VAG 1331 Torque wrench (5... 50 Nm)

....

• VAG 1383 A Engine/gearbox jack

Iwoo-o427l

V.A.G 1383 A ~Mi

20-14--­

,,

Removing - Note safety precautions before starting work => Page 2().8

Note: Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

- With the ignition switched off disoonnect battery earth strap.

- Open fuel flap.

- Remove rear right wheel housing liner: . => General body repairs, exterior; Repair group 66; Removing and in足 stalling wheel housing liner - Drain fuel tank, clean fuel filler neck and surrounding area.

- Unscrew securing bolts and remove 1ank flap unit with rubber cup.

I

- Remove securing bolt on filler necIc..

- Fold rear seat bench forwards.

20-15--足 - Remove fuel gauge sender cover plate and detach connector.

- Remove cover from under the fuel1ank.

Remove rear axle: => Running gear; Repair group 42; Servicing rear axle; Removing and installing rear axle. ....

- Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting point.

Note: Press buttons on hose couplings to do this.

WlITning!

Fuel supply Hnes lITe under ,."...,,1 Before removing from hose connection WTIIP B doth around the connettion. Then re足 lase pressure by t:llrefully pulling hose off connettion.

- Remove tensioning strap. When doing this support fuel tank with engine/gearbox jack VAG 1383 A. -Lower fuel tank.

20-16--足

I' If I

Installing

I:;

Installation is carried out in the reverse order, when doing this note the following: • Breather and fuel hoses are to be installed kink-free.

• Secure fuel hoses with spring-type clamps.

• Fuel hoses are to be installed kink-free.

• Ensure fuel hoses are seated securely.

• Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).

Note: After installing fuel gauge sender, check that the supply, return and

breather pipes are still clipped onto the fuel tank.

V.A.G 1318

3217

20-17--­

I us_I I­

0_•

---==:;l

Checking fuel pump Special tools, workshop equipment, test and measuring appliances and aux. items required • 3217 Ring nut spanner • VAG 1318 Pressure tester

V.A.G 1318111

V.A.G 131811

• VAG 1318/1 Adapter

. .tI-·-·-H--·_·EJ­

• VAG 1318/11 Adapter • VAG1318/17 Adapter • VAG 1318/23 Adapter

V.A.G 1318117 VAG 13141/11-1

VAG 1311111....

VAG 131....7...

VAG 1311117-4

~. ·"iI-~·

I W20-0011 I

20-18--­

!

i

.:i

~:

• V.A.G 1332 Torque wrench (40...200 Nm)·

V.A.G 1332

,

• VAG 1348 Fuel quantity comparison meter @f."'­

p • V.A.G 1466 Test system • V.A.G 1527 B Diode test lamp • VAG 1594 A Adapter set • VAG 1715 Multimeter VAG 1527 B

~~

• Measuring container • Current flow diagram

",

VAG 1715

I W20-00121 20-19--­

Check conditions

• Battery voltage at least 11.5 V ....

• Fuse No. 28 OK. Checking function and voltage supply

- Remove cover from fuel delivery unit.

- Briefly operate starter. Fuel pump must be

heard to run.

- Switch off ignition.

If the fuel pump does not run:

- Remove cover in front of fuse holder. ....

- Pull fuse No. 28 out of fuse holder.

- Connect remote control VAG 1348I3A with adapter cable VAG 1348/3-2 to contact 28a to fuel pump and battery positive (+).

- Operate remote control.

I

20-20--­

Fuel pumps run: - Check activation of fuel pump relay using current flow diagram and

VAG 1466 A:

=> Current flow diagrams, Electrical fault finding and Fitting locations

Fuel pump does not run:

, I,

- Pull 4 pin connector off flange on fuel delivery unit. ....

- Connect diode test lamp VAG 1527 B with aux. cables from V.A.G 1594 A to the outer contacts of the connector.

' :'

- Operate remote control.

LED must light up

LED does not light up: - Locate and eliminate open circuit using current flow diagram: => Current flow diagrams, Electrical fault finding and Fitting locations

LED lights up (vottage supply OK.):

20·21--­

....

- Remove union nut with spanner 3217.

- Check that the electrical wires between flange and fuel pump are connected.

If no open circuit can be found: - Fuel pump defective, renew fuel delivery unit => Page 20-10, Re­ moving and installing fuel delivery unit.

Checking delivery rate

Check conadions

• Voltage supply OK. • Remote control VAG 1348I3A connected.

Test sequence - Remove filler cap from fuel tank filler neck. ....

- Pull off supply pipe/hose -1- (with white marking) and collect fuel that leaks out with a cloth.

Note: Press buttons on hose couplings to do this.

20-22--­

! ; I

Warning!

Fuel system is under pt'fISSUI'fI! Before opening the system

plat:B a cloth Mound the connection. Then l'fllease pressUI'fI by

CIIndully loosening the connection.

V.A.G 1318 V.A.G 13181'11 V.A.G 1318f23 ...

- Connect pressure gauge V.A.G 1318 with adapter 1318123 and V.A.G 1318/17 to the fuel supply pipe.

- Push the hoseV.A.G 1318/1 onto the adapter V.A.G 1318/11 on the pressure gauge and hold hose in a measuring container.

- Open the pressure gauge cut-off tap. The lever then points in the throughflow direction -A-.

- Operate remote control V.A.G 134813Aand slowly close cut-off tap. until pressure gauge shows 1.2 bar.

From this point on do not move position of cut-off tap.

I Na0-01091

- Empty measuring container.

- The quantity of fuel delivered by the fuel pump is dependent upon battery voltage. Therefore connect the multimeter with adapter cables from V.A.G 1594 A to the vehicle battery.

20-23--­ - Operate remote control for

30 seconds

and measure battery voltage

om~3CIs")

,

1000

...

- Compare the quantity of fuel delivered with specification.

lIIIO

.-"'" L.,...--'"

••­

,.....

I

I

10 10,2

11

V""

~I 12

-) Minimum delivery cm 3J30 seconds **)Voltage at fuel pump with engine stationary and pump running (ap­ prox. 2 volts less than battery voltage).

lIIIO

2110

Example:

13 Y"')

I NaO-01&91

During the test a voltage of 12.5 volts is measured at the battery. As the voltage at the pump is approx. 2 volts less than the battery voltage then this will equate to a minimum delivery of 200 cm3/30 s.

If the minimum delivery rate is not attained: V.A.G 13181'11

- Check the fuel pipes for possible restrictions (kinks) or blockages. ...

- Pull the supply hose -1- off fuel filter inlet.

- Connect the pressure gauge V.A.G 1318 with adapter 1318/17 to hose.

- Repeat delivery rate check.

If the minimum delivery rate is now attained:

20-24--­

- Replace the fuel filter.

If the minimum delivery rate is again not attained:

- Remove the fuel delivery unit and check the strainerfifter for soiling.

Only when up to now no fault has been detected: - Replace the fuel delivery unit.

If the delivery rate has been attained but nevertheless you suspect a fuel supply system fault (e.g. intermittent failure of fuel supply sys­ tem): - Check the current draw of the fuel pump as follows: - Reconnect a/l disconnected fuel pipes. .....

- Connect the multimeterV.A.G 1715 using the current clamp to the green/yellow wire of wiring harness.

- Start the engine and run at idling speed..

- Measure the current draw of the fuel pump.

Specification: max. 8 amps.

20-25---

Nate: If the fuel system malfunction is intermittent, you can perform the check during a test drive, to do this a 2nd person is necessary.

If the current draw is exceeded: - Fuel pump defective. renew fuel delivery unit => Page 20-10, Re­ moving and installing fuel delivery unit.

Checking fuel pump non-retum valve

Test conditions • Remote control VAG 1348fJA is still connected.

• Pressure gauge VAG 1318 is still connected.

Test sequence Note:

With this check the fuelsupplypipe connections from the fuel delivery unit to the pointat which the pressure gauge VA. G 1318is connected will be checked for leaks at the same time.

20-26--­

....

- Close pressure gauge cut-off tap (lever at right angles to throughflow direction -position B-).

- Operate reroote control at short intervals, until a pressure of Approx. 3 bar has built up.

Waming!

Danger of spray when opening the cut-off flip, hold container

over the pressure gauge flee connel:fion.

- If pressure builds up too high, lower excess pressure by carefully opening the cut-off tap.

I N20-01091

- Watch pressu re drop on gauge. After 10 minutes the pressure must not drop below 2.5 bar.

If the pressure drops further:

- Check pipe connections for leaks.

If no wiring fault is detected:

- Fuel pump defective, renew fuel delivery unit moving and installing fuel delivery unit.

~

Page 20-10, Re­

20-27--­ ~~~--1

Accelerator mechanism

'H--+---2

Servicing accelerator mechan­ ism 1 - Accelerator cable • Adjusting ~ Page 20-30 • Do not reuse damaged accelerator cable, replace \

I I I

2 -Cable cam

,

• On throttle valve control part

3 -Retainer • Adjusting throttle cable 20-30

~

Page

4 - Support bracket • For accelerator cable 5 - KickdoWn switch (FI) • On bulkhead • Checking ~ Page 20-30, Adjusting throttle cable on vehicles with auto­ matic gearbox

10----..

1 3 - - -...""

12----"""" 11---~

I N20-0t35 I 20-28--­ ,;:,

,

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I

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1

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6 - Connector • Black. 2-pin

2

7 - Balance weight

8 - Accelerator pedal 9 - Spacer sleeve 10 -Bush 11-Washer

i

-'- --- -

.,.-

, I

12 - Stop bolt

I

13-20Nm

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,

,

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10------.

13---

12-------11--~

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I N2<H>1351 20-29--­

Adjusting throttle cable

Vehicles with manual gearbox

Work sequence

...

- Adjust throttle cable by moving the retainer -arrow- at the support bracket. so that the full throttle position is attained at the throttle valve control part.

•

i

20-30--­

IJ

Vehicles with automatic gearbox Special tools, workshop equipment, testers, measuring instru­ ments and auxiliary items required

V.A.G 1526 A

....

• V.A.G 1526 A Hand multimeter

....

• V.A.G 1594 A Auxiliary test set

I WOIHI4311

Iwoo-oml

20-31--­

Work sequence

....

- Adjustthrottle cable by moving the retainer -arrow- at the support bracket, so that the full throttle position is attained at the throttle valve control part.

- Release accelerator pedal.

- Pull 2-pin connector off kick-down switch (FS) in engine compart­ ment (on the bulkhead).

....

- Connect hand multimeter V.A.G 1526 with aux. cables from VAG 1594 to kick-down switch.

- Check resistance at switch.

Specification: 00 n

- Slowly move accelerator pedal in direction of full throttle.

Shortly afterthe kick-down pressure point the resistance must'drop to

On. At this point the accelerator pedal must be just oft the stop_

20-32--­

;. ',I

Th' I;'

Activated charcoal filter system Notes: • Hose connections are secured with either sprlng-type orclamp-type clips.

• Always replace clamp-type clips with screw-type clips.

• 1I.A.G 1921 pliers are recommended when installing spring-:type clips.

Observe safety precautions =* Page 20-8 Observe rules for cleanliness =* Page 20-9

! :

,,

! !, ,

'

ii

20-33--­

2

3 Servicing parts of the activated charcoal filter system ,l ,i

1-10 Nm

1 - -...

~4 t

5

2 - Activated charcoal filter • Location: in engine compartment. right • Secured to body • With solenoid valve 1 for activated charcoal filter (N80) • When the engine is warm the valve will be activated from the engine con­ trol unit (pulsed) • Checking: =* Repair group 01; Final control diagnosis; Performing final control diagnosis

3 - Connector • Black. 2-pin • For solenoid valve 1 ,

I N2D-0170 I

20-34--­

2

3

4-Ventpipe • Black • Check securely seated • From gravity valve on fuel tank => Page 20-2. Item 2

5 -Throttle valve control part

1 - ­ ...

6-T-piece

i-4 t

7 - To heater element (N79)

8 - Breather connection

5

I N20-0170 I

Qaecking fuel tank breather V.A.G 1368

Special tools, workshop equipment.. testers, measuring instru­ ments.and auxiliary items required .....

• VAG 1368 Vacuum tester

.....

• VAG 1390 Hand vacuum pump

, I

20-38--­

~.

,

f. ••••...1;.

Test sequence

1 .A.G.1368

.~

....

- Pull breather pipe/hose -2- from activated charcoal filter -1- off at throttle valve control part -3- T-piece.

- Connect hand vacuum pump V.A.G 1390 to pipe/hose -2-.

6V.:~~~"~·

- Pull breather pipe/hose -5- from fuel tank off activated charcoal filter and connect to -connection A- of vacuum tester V.A.G 1368.

- Connect vacu um tester V.A.G 1368 -connection 8- to breather pipe! hose -4-.

- Set vacuum tester to position -8-.

- Introduce final control diagnosis and select activated charcoal filter solenoid valve (NSO): => Repair group 01; Final control diagnosis; Performing final control di­ agnOSis - Operate hand vacuum pump V.A.G 1390 several times.

Vacuum must not build-up.

If, vacuum builds-up: - Check breather connection -6- on activated charcoal filter -1- for soil­ ing, clean if necessary.

20-37--­

I

If vacuum does not build-up:

, I

I I

- Remove fuel filler cap. ....

! ;

Connect hand vacuum pump VAG 1390 to vacuum tester VAG 1368 -connection 8-.

- Set vacuum tester to -A/8- position.

- Operate V.A.G 1390 several times. Vacuum must

not build-up.

If vacuum builds-up:

- Check gravity valve => Page 20-2, Item 2

- Check pipe/hose -1- from fuel tank for blockage.

If vacuum does not build-up:

- Refit fuel filler cap.

- Operate hand vacuum pump V.A.G 1390 several times.

Vacuum must not

build-up.

20-38--­

Nate: If the fuel level in the tank is low the hand vacuum must be operated at least 20...30 times. \

If vacuum builds-up: - Replace fuel tank cap.

20-39--­

~,

II"

I·

Removing and installing parts of exhaust system Notes:

• Aher working on the exhaust system ensure that the system is not under stress, and that it has sufficient clearance from the body­ work. If necessary, loosen double and single clamps and align si­ lencer and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.

• Renew self-locking nuts.

Special tools, workshop equipment, testers, measuring instru­ ments and auxiliary items required ....

• 3337 Ring spanner for Lambda probe

26-1----­

4 2

1

4 , j

Note: • Components marked with an * are checked by the self-diagnosis: Repair Group 01; Self diagnosis; Interrogat­ ing and erasing fault memory

.---5

16..;.1'.,...;·::.....::-__ 1

.......

;

2-25Nm 3 - Heat shield

4 -Bracktrt

~-10

5 - Lambda probe (G39)*, 50 Nm

..---6

1-

,

• Renew

.---7 .---8 ~- ---9

.

!

1-Seal

.",---.6

17----~·

I

.~t1 I

Xl~~~ ~)

• Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe body • Remove and install with ring spanner 3337 • Checking: => Repair group 24; Checking functions; . Checking Lambda control

I N26-0210 I 26-2--­

,!

4 2

4

6-10 Nm

7 -Clip 8 -Catalyst

.---5 ~--6 ~--7

I

~-8

17 -------.;~ 16 r-- ......

9

I

------10 ---6

9 - Double clamp • Note fitting position:::;. Fig. 3 10-40Nm 11 - Mounting 12 -Centre and rear silencer • As standard. central and rear si­ lencers are installed as a single com­ ponent. In repair cases the central and rear silencer are supplied individ­ uallyand with a double clamp for con­ necting.

• Separating point: :::;. Fig. 1 • Aligning rear silencer free of stress :::;. Fig. 2

I N26-0210 I 26-3--­

4 2

1 2 3

iii-

.

13 - Mounting • With retaining ring

.',

14 - Tunnel bridge

,.,:~:~:,.

'",

19

4

"

...

"""

5

18

6

2

7 8 9

17 16

r--., I

10 6

...... .....

15 - Mounting • Note installation position :::;. Fig. 4 16 • Heat shield • For catalyst 17 - Front exhaust pipe with catalyst 18 -Gasket • Renew 19 - Exhaust manifold

......

I N26-0210 I 26-4 ---....;.­

~ .. : I: '

..... rig. 1

Sep.sting point on exhaust pipe

- Separate exhaust pipe at right angles at separating point -arrow 2-.

- When installing fit repair type double clamp -4- at side markings -ar­ rows 1 and 3-. lightening torque 40 Nm

..... rig.

2

Aligning rear silencer free of stress

- The mounting pins on exhaust pipe must run parallel with tunnel bridge (dimension -x- on left and right the same).

I A2tI-0131 I

26-5--­

..... rig.

3

rltting position of double clamp

- Position double clamp approx. 5 mm away from mark -A-.

AI

Nate: Mark -A- is valid for vehicles with manual and automatic gearboxes.

I N26-021SI i, i

I

Ii

..... rag.

4

Installation position of mounting

- Angled side on foot of mounting -arrow- points forwards.

I

I . ,,

o

I:

I A26-01281

26-6--­

r

Secondary air system Function The secondary air system blows air in behind the exhaust valve for 65 seconds during the cold start (+15 °C ... +35 °C coolant temperature).

This produces an oxygen rich exhaust gas, causes afterburning and re­ duces the heating-up phase of the catalyst. Activation occurs from the Motronic control unit (J220) via the secondary air pump relay (J229) to secondary air inlet valve (N112, change-over valve) and combi-valve.

Additionally after each subsequent engine start (up to max. 85°C en­ gine temperature) the secondary air system will after a 20 second delay switch in for 5 seconds during idling and will be checked by the self-diagnosis.

26-7--­

Removing and installing parts of the secondary air system Notes: • Components marked with an checked by the self-diagnosis:

7 ~--8

9 10

"'"'-----11 '----12 ~----,--13

1

*

are

=> Repair Group 01; Self diagnosis; Interro­ gating and erasing fault memory • Components marked with ** are checked by the final control diagnosis:

=> Repair Group 01; Self diagnosis; Final con­ trol diagnosis • Secondary air pump relay (J299) '* '* => Page 26-12, Fig. 1

1 - Combi-valve • Checking =>Page 26-13 • Removing and installing

=> Page 26-16

2-5Nm

...."~----14 )-------3

1

1

16 15

3

N26-0199 I

26-8--­

3

3 -O-Ring • Renew·

25

4 - Air channel • In cylinder head

3

5 -Bracket • For secondary air inlet valve (N112) and intake manifold change-over valve (N156)

23 22 20

6 - To fuel pressure regulator

9

7 - To intake manifold upper part

10

8 - Secondary air inlet valve (N1121*1**

20

9 - Connector • Black, 2-pin

11 12 13 14 3

19 18 17 16 15

3

N26-0199

10 - Non-return valve • White connection faces towards sec­ ondary air inlet valve (N112)

I 26-9

1

2

3

4

5

6 11 - To vacuum reservoir 12 - To vacuum positioning element for intake manifold change-over

3

1'

13 - To air cleaner upper part 14 -Intalar hose • Ensure seated tightly 15 -Second.y air pump motor "'1011**

9

10

16 - Connector • Black, 2-pin • For secondary air pump motor 17 -Bracket • For secondary air pump motor

11 12 13 14 3

18 17 16 15

3

,i I

N26-0199 \

26-10

18 -Rubber bush

3 25 3

19 ~Housing 20~10Nm

21 ~ Intake manifold change-over valve (N1561

22 - Connection

23

'*---8

22 20

9

10

23 - Pressure hose

• Ensure seated tightly

24·Gasket • Renew

25 • Connection • For combi-valve

---11 "----12

"""-"----13 ...." 'i'-----14 ' N-------3

19 18 17

16 15

3

N26-01991

26-11--­

....

Secondary air pump relay (J299I·1 .

• If tools are necessary to pull relays or control units out of the relay plate. first disconnect battery earth strap•

Fig. 1

• Before disconnecting battery earth strap obtain code for radios with anti-theft coding.

- - - 26-12--­

Checking combi-valve V.A.G 1331

~:::

Special tools, workshop equipment" testers, measuring instru­ ments and auxiliarY items required

.

• VAG 1331 Torque wrench (5...50 Nm)

I WQO-Oot27I

....

• VAG 1390 Hand vacuum pump

I WOO-OS1s1

26-13--­

Check conditions • No fault stored in fault memory => Repair group 01; Self-diagnosis; Interrogating fault memory

• Carry out final control diagnosis => Repair group 01; Self-diagnosis; final control diagnosis • Vacuum pipes and hose connections free of leaks.

• Vacuum pipes not blocked/kinked.

Test sequence - Remove insulation tray: => General body repairs exterior; Repair group 50; Body front; Assem­ blyoverview - Pull vacuum hose from combi-valve off secondary air inlet valve (N112).

Fitting locations: => Repair group 24; Servicing injection system; Fitting locations-over­ view

26-14--­

.....

- Connect hand vacuum pump VAG 1390 to vacuum hose to combi­ valve..

I N:2&-02131 Note:

Do not use compressed air during the following check!

.....

- Detach hose to combi valve at air cleaner upper part -arrow- and pressurize slightly by blowing into hose.

Combi-valve must be closed.

- Operate hand vacuum pump.

Combi valve must open.

If the combi-valve does not open:

I N:2&-0212 I

- Replace combi-valve => Page 26-16. removing and installing combi­ valve.

26-15--­

Removing and installing combi-valve Special tools, workshop equipment" testers, measuring instru­ ments and auxiliary items required V.A.G 1331

.....

• VAG 1331 Torque wrench (5...50 Nm) ~moving

Note: Check whether a coded radio is installed as during the forthcoming work sequences the batteryearth strap must be disconnected. Obtain radio code first if necessary.

- With the ignition switched off disconnect battery earth strap.

- Remove insulation tray: => General body repairs exterior; Repair group 50; Body front; Assem­ blyoverview - Bring lock carrier into service position: => General body repairs. exterior; Repair group 50; Body. front; Lock carrier service position

I

Ii' 1..

~

11

ti,

26-16--­

Vehicles with air conditioner - Remove ribbed belt ~ Page 13-27.

- Removing air conditioner compressor: ~ Heating, Air conditioning; Repair group 87; removing and installing compressor bracket - Remove retaining clamp(s) from refrigerant pipes.

Waming!

The air conditioner refrigerant circuit must not be opened.

Notes:

• The opening ofthe refrigerant circuit can only be carriedout in work­ shops, which have trained personnel and the necessary range of tools and workshop equipment.

• To prevent damage to condenser and the refrigerant pipes/hoses. ensure that the pipes and hoses are not stretched, kinked or bent.

26-17--­

Continued for all vehicles - Remove pressure hose between combi-valve and secondary air pump at combi-valve.

- Pull vacuum hose off combi-valve.

- Unbolt combi-valve from intake manifold lowerpart and pull out with connections.

Installing Install in reverse order.

28-1R_-­

<D

®

®

100-24981

Service. <tP Ii~--------------------------------------------------------

I

Ii

Supplement to Workshop Manual

Golf 1998 ~

r

With this supplement you will receive the new Assembly group

i

,, l'

I:

i'

• S..Cyl. injection engine, Mechanics Edition 10.97 (Art. No. KOO.51 07.29.20 + KOO.51 01.13.20 = KOO.51 00.70.201»)

..

and revised

~

• Side and spine pocket inserts Edition 03.11.97 (Art. No. K03.5100.01.20)

I

~.

Technical information is only of use if it is cared for and kept up-to-date. We will supply you with the latest information ­ please take care to keep it up-to-date and file this supplement.as follows:

~Exchange side and spine pocket inserts in box 1.

~Complete new assembly group folder and file in box 1.

lIArt. No. of the complete Assembly Group including Assembly Group folder

Service Department. Technical Information

~

• ..

---'

'

.......

KOO.5107.29.20