4 cylinder injection engine (1.6 l engine, direct injection) blf

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t.CopyrightbyVolkswagenAG.
Workshop Manual
Jetta 2005 ➤
Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct
injection)
Engine ID BLF
Edition 08.2005
Service
Service Department. Technical Information

en
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
24 - Mixture preparation, Injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007820

en
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Checking and adjusting assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2 Belt drive - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3 Chain drive - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5 Removing and installing control housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 Flywheel end - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Tighten bolt for poly V-belt sprocket - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4 Renewing crankshaft sealing flange -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1 Pistons and conrods - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2 Check piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.1 Cylinder head - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.4 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.5 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.6 Check compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.1 Valve gear - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.2 Parts of the lubrication system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
Contents i

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1.3 Oil cooler - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.6 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.7 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Parts of cooling system - body side - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Parts of cooling system engine side (thermostat side) - Assembly overview . . . . . . . . . . . . 98
1.3 Parts of cooling system engine side (coolant pump side) - Assembly overview . . . . . . . . 99
1.4 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.5 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.6 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 105
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.9 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.10 Check cooling system for leaks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.3 Fuel tank - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.4 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Fuel fliter - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.7 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Repairing fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.3 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.5 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.7 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3 Servicing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Accelerator pedal module - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.1 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.2 Activated charcoal filter system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.4 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.6 Air cleaner/engine cover - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.7 Removing and installing engine cover with air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.8 Intake manifold - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1.9 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.10 Fuel rail with injectors - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.11 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.12 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.13 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.1 Check vacuum reservoir in intake manifold for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.2 Check function of intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.3 Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.1 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.2 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.1 Catalytic converters and attachments - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . 184
1.2 Silencer with mountings - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.3 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.4 Removing and installing pre-catalytic converter with exhaust manifold . . . . . . . . . . . . . . . . 188
1.5 Connecting and disconnecting front and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.1 Assembly overview - Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.2 Removing and installing exhaust gas recirculation valve N18 . . . . . . . . . . . . . . . . . . . . . . 195
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.4 Spark plug test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
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00 – Technical data
1 Technical data
Engine number ⇒ page 1
Engine data ⇒ page 2
1.1 Engine number
Engine code and engine number can be found on the sticker
-arrow- on the control housing.
The engine code is also on the vehicle data plate and on the
crankcase above the gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
If there is no sticker and you need the “engine codes” and the
“serial number”, proceed as follows:
– Removing battery ⇒ Electrical system; Rep. Gr. 27 ; Remov‐
ing and installing battery; Vehicles with petrol engine .
– Open the cover -1- of the electronics box and remove the cable
-2-.
– Remove bolts -arrows- and battery carrier.
– Read the engine code and the serial number on the left of the
cylinder block -arrow-.
Install in reverse order of removal. During this step, observe the
following:
– Install the battery and observe the respective measures after
connecting the battery ⇒ Electrical system; Rep. Gr. 27 ; Re‐
moving and installing battery; Models with petrol engine .
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1.2 Engine data
Engine code BLF
Manufactured 08.05 ▸
Emissions fulfil EU 4 Standard
Displacement cm3 1598
Output kW at rpm 85/6000
Torque Nm at rpm 155/4000
Bore ∅ mm 76,5
Stroke mm 86,9
Compression ratio 12,0
Valves per cylinder 4
RON min. 95 Unleaded
Injection, ignition Motronic MED 9.5.10
Mixture formation homogeneous
Variable valve timing yes
Knock control 1 sensor
Lambda regulation 2 probes
Three-way catalytic converter yes
Exhaust gas recirculation yes
Secondary air system no
Electronic power control yes
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10 – Removing and installing engine
1 Removing and installing engine
Removing engine ⇒ page 4
Fastening the engine to the assembly stand ⇒ page 14
Installing engine ⇒ page 16
Checking and adjusting assembly mounting ⇒ page 20
Assembly mounting ⇒ page 22
Special tools and workshop
equipment required
♦ Hose clamp to Ø 25 mm
-3094-
♦ Multi-point bit 19 mm
-3077-
♦ Multi-point bit 18 mm
-3353-
♦ Torque wrench -V.A.G
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
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1. Removing and installing engine 3

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♦ Spring-type clip pliers -VAS
5024 A-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051-
♦ or vehicle diagnosis and
service information system
-VAS 5052-
♦ Double ladder -VAS 5085-
♦ Drip tray -VAS 6208-
♦ Engine bracket -T40075-
♦ Engine bung set -VAS
6122-
♦ Grease -G 000 100-
1.1 Removing engine
Note
♦ In subsequent work sequences the battery earth strap must
be disconnected. Therefore first check whether a coded radio
is fitted. Obtain radio code first if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ Observe rules for cleanliness ⇒ page 115 .
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
♦ Pull engine coolant hoses off with spring-type clip pliers -VAS
5024 A- .
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Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ All wirings (e.g. for fuel, hydraulic system, activated char‐
coal canister system, coolant and refrigerant liquid, brake
liquid, vacuum) and electrical wirings are to be installed in
the original way.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– With ignition switched off disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
the battery .
– Remove engine cover with air cleaner ⇒ page 161 .
-2-.
– Disconnect rubber bellows -1- from air duct -2-.
– Release both locking devices and take air duct -2- off.
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– Remove warm air collector plate -arrows-.
– Remove pre-catalytic converter with exhaust pipe from ex‐
haust manifold -arrows-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
– Remove right and left front part of wheel housing liner ⇒ Gen‐
eral body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner;
Removing and installing front wheel housing liner .
– Drain coolant ⇒ page 102 .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Lock carrier service posi‐
tion .
For subsequent work sequences the lock carrier must be sup‐
ported on the longitudinal member.
– Support the lock carrier on one side using the multi-point bit
18 mm -3353- .
– Support the lock carrier on the other side using the multi-point
bit 19 mm -3077- .
– Unscrew intake connecting piece on lock carrier -arrows-.
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– Pull coolant hose -1- off expansion tank.
– Pull vacuum hose -2- off activated charcoal canister and wind‐
screen washer system reservoir -arrow- and lay free.
WARNING
The fuel line is under pressure! Wear protective glasses and
clothing to avoid injuries and skin contact. Before loosening
lines, wrap a cloth around the connection. Then release pres‐
sure by carefully removing the line.
– Disconnect fuel supply line -3- (press locking ring inwards) and
collect escaping fuel with a cloth.
– Disconnect breather line -1- (press locking ring inwards).
– Seal the lines so that the fuel system is not contaminated by
dirt etc.
– Loosen bolts -arrows- of assembly mounting on engine just a
bit (less than 1 turn).
– Remove upper coolant hose from radiator.
Models without auxiliary heating
– Remove coolant hoses -3- and -4- to heat exchanger on bulk‐
head.
– Remove connector -2- and hose -5- from active charcoal filter
system solenoid valve 1 -N80- -6-.
– Remove retainer along with active charcoal filter system sol‐
enoid valve 1 -N80- -6- from intake manifold.
Models with auxiliary heater
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– Remove coolant hose -3- to heat exchanger on bulkhead.
– Remove connector -2- and hose -5- from active charcoal filter
system solenoid valve 1 -N80- -6-.
– Remove retainer along with active charcoal filter system sol‐
enoid valve 1 -N80- -6- from intake manifold.
– Remove coolant hoses -1- and -7- on heater coolant shut-off
valve -N279- .
Continuation for all vehicles
– Pull the vacuum hose -arrow- off brake servo.
– Release the front connector on the engine control unit and pull
it off ⇒ page 179 .
– Unlock duct for engine wiring harness -arrow- and pull off up‐
wards.
– Open wiring bracket -arrows-.
– Take engine wiring harness -1- to control unit out of the wiring
guide.
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– Move electrical connector -1- free and disconnect.
– Release underneath bracket -2- of the wiring -arrow-.
– Remove nut -1- and pull earth strap -2- off earth point.
– Take engine wiring harness to control unit off the wiring guide.
– Fit the cable with a cable tie to the engine.
– Remove nut -1- and the earth strap -2- from the assembly
mounting.
– Loosen bolts -arrows- of assembly mounting on gearbox just
a bit (less than 1 turn).
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– Unclip securing clips -1- and -2- on both cables.
– Pull cable end-pieces off gearbox selector lever and relay lev‐
er.
– Remove cable support bracket from gearbox -arrows- and lay
to side.
– Remove clutch slave cylinder -arrows- and lay to side, do not
open pipes.
Caution
Do not operate the clutch pedal anymore after removing the
clutch slave cylinder.
– Unscrew earth wire -1-.
– Remove electrical wirings -2- and -3- on starter and lay to side.
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– Separate electrical connector -1- for Lambda probe -G39- .
– Disconnect electrical connector -3- for reversing light switch -
F4- .
– Lay engine wiring harness on bracket -2- to side.
– Unscrew nut -arrow- and take retainer for electrical wiring off
threaded stud.
Models with an air conditioning system
– Pull activated charcoal canister off the bracket upwards
-arrow-.
Note
To prevent damage to condenser also to the refrigerant lines/ho‐
ses, ensure that the lines and hoses are not stretched, kinked or
bent.
To facilitate removing and installing the engine without opening
the refrigerant circuit:
– Remove bracket -arrow- for refrigerant lines on right longitu‐
dinal member.
– Remove ribbed belt ⇒ page 29 .
– Remove air conditioner compressor from bracket for ancilla‐
ries ⇒ Heating, Air conditioning system; Rep. Gr. 87 ; Repair
work on refrigerant circuit; Removing and installing air condi‐
tioner compressor .
Note
The air conditioning system wiring must not be opened.
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– Fit air conditioner compressor -2- to lock carrier -1-. To do this
pull e.g. a wire through the right air conditioner compressor
mounting.
– Observe that the wiring is not kinked.
– Loosen nut -3-, remove bolt -4- and take exhaust pipe -5- off
auxiliary heater.
– Place drip tray underneath.
– Release spring-type clips of coolant hoses -1- and -2- and pull
coolant hoses off auxiliary heater.
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Alter‐
nator; Alternator 1.6 l FSI engine .
– Separate connector -1- at oil level and oil temperature sender
-G266- .
– Unclip retainer -2- for the line to the oil level and oil tempera‐
ture sender -G266- on subframe.
– Unscrew bolt -1- first.
– Unscrew bolts -2- and -3- and take pendulum support off.
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– Remove bolts -arrows-.
– Remove right-hand drive shaft and left-hand drive shaft ⇒
Running gear, axles, steering; Rep. Gr. 40 ; Servicing drive
shafts; Removing and installing drive shafts .
– Remove bolts -1- and -2- and pull coolant hoses off engine
and gearbox. The coolant hoses remain connected.
– Remove pre-catalytic converter along with exhaust pipe
⇒ page 183 .
– Pull off/disconnect all other electrical connections and hoses
as necessary from engine and lay to one side.
– Fit all electrical wirings and hoses on engine.
– Fit pin of engine bracket -T40075- to engine front first.
– Fit engine bracket -T40075- to the engine and gearbox jack -
V.A.G 1383 A- .
– Fit engine bracket -T40075- to pin.
– Fit the engine bracket -T40075- to the rear side of the cylinder
head -arrows- and tighten to 20 Nm.
– Lift engine/gearbox assembly lightly.
Note
To remove securing bolts for assembly mounting use double lad‐
der -VAS 5085- .
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– Remove bolts -arrows- of assembly mounting from engine
bracket.
– Remove bolts -arrows- of assembly mounting from gearbox
bracket.
Note
♦ Check whether all hoses and wiring connections between en‐
gine, gearbox and body are disconnected.
♦ Engine with gearbox must be guided carefully when lowered
to prevent damage.
– Pull engine/gearbox assembly forwards as far as possible and
carefully lower.
1.2 Securing engine to engine and gearbox
support -VAS 6095-
When working on the engine, the engine should be secured on
the engine and gearbox support -VAS 6095- .
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equipment required
♦ Lifting tackle -2024 A-
♦ Workshop crane -
VAS 6100-
♦ Engine and gearbox stand -
VAS 6095-
Procedure
– Move Engine/gearbox jack -V.A.G 1383 A- to a workbench.
– Lower engine/gearbox assembly so that the gearbox is on the
workbench.
– Remove engine/gearbox connecting bolts.
– Press gearbox off engine.
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– Remove lifting tackle -2024 A- as follows and lift off engine/
gearbox jack -V.A.G 1383 A- with workshop crane -VAS
6100- .
Belt pulley end: 2nd hole in hook rail at position 2
Flywheel end: 3rd hole on support bar in position 7
WARNING
The hooks and locating pins must be secured with locking pins
-arrows- to prevent injuries and damages to the engine.
♦ The positions marked 1...4 on the bar must be towards the belt
pulley end.
♦ The holes in the hook rails are counted up from the hook.
– Pull dowel sleeve -arrow B- out of the cylinder block.
– Secure engine to engine and gearbox support -VAS 6095-
-arrows A- and -arrow B-.
1.3 Installing engine
following:
Caution
tions:
the original way.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
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Note
♦ Install all cable ties at the same place when removing.
♦ Hoses must be locked with clamps ⇒ Electronic parts
catalogue“ETKA” .
♦ When performing repair work, renew self-locking nuts and
bolts.
♦ Renew bolts which are tightened with a swing angle as well as
seals and gaskets.
♦ When swinging the assembly in, ensure that clearance exists
between the drive shafts.
– Fit new dowel sleeves to centralize gearbox on engine block.
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– Ensure that the intermediate plate is attached to the sealing
flange and is slided onto the dowel sleeves -arrows-.
– Check clutch release bearing for wear, renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease -G 000 100- . If
necessary clean and remove corrosion.
– Installing and checking clutch and clutch mechanism ⇒ 6-
speed manual gearbox 0AG; Rep. Gr. 30 ; Repairing clutch
control .
– Rock engine to align engine mounting stress-free, loosen en‐
gine mounting to body if necessary.
Note
♦ Checking and adjusting assembly mounting ⇒ page 20 .
♦ Torque settings for assembly mounting ⇒ page 22 .
♦ Connecting bolts for engine/gearbox ⇒ 6-speed manual gear‐
box 0AG; Rep. Gr. 34 ; Removing and installing gearbox .
♦ Electrical connections and routing ⇒ Electrical system; Rep.
Gr. 97 .
– When installing the engine/gearbox assembly, ensure suffi‐
cient clearance to assembly mountings and radiator.
– Install pendulum support ⇒ page 22 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Servicing drive shafts; Removing and installing drive
shafts .
– Installing pre-catalytic converter with exhaust pipe
⇒ page 188 .
– Install selector mechanism, adjust if necessary ⇒ 6-speed
manual gearbox 0AG; Rep. Gr. 34 ; Servicing selector mech‐
anism .
– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐
box 0AG; Rep. Gr. 30 ; Repairing clutch control; Assembly
overview - hydraulic system .
– Install air conditioner compressor ⇒ Heating, Air conditioning
system; Rep. Gr. 87 ; Repair work on refrigerant circuit; Re‐
moving and installing air conditioner compressor .
– Install ribbed belt ⇒ page 29 .
– Install bulkhead in plenum chamber ⇒ General Body Repairs,
Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .
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– Route engine wiring harness -1- to control unit below and on
the left (in direction of road) of the wiring harness -2-.
– Install battery carrier first and tighten bolts -arrows-.
– Route wiring -2- as shown in the figure and fit to electronics
box -1-.
– Install engine cover with air cleaner ⇒ page 161 .
– Top-up coolant ⇒ page 102 .
– Install noise insulation ⇒ General Body Repairs, Exterior;
– Connect vehicle diagnosis, testing and information system -
VAS 5051- or vehicle diagnosis and service information sys‐
tem -VAS 5052- .
– Interrogate all fault memories and then erase all fault entries
which have been caused when the engine has been removed
and installed.
After erasing the fault memory of the engine control unit gen‐
erate readiness code.
Observe applicable safety precautions during road test.
– Carry out a road test.
– After this, perform a vehicle system test and if necessary, rec‐
tify faults.
Torque settings
Threaded connection Torque setting
Nuts and bolts M 6 10 Nm
M7 15 Nm
M 8 25 Nm
M10 40 Nm
M12 60 Nm
Connecting bolts for engine/gearbox ⇒ 6-speed manual gear‐
box 0AG; Rep. Gr. 34 ; Removing and installing gearbox .
Bolts for assembly mounting ⇒ page 22
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1.4 Checking and adjusting assembly
mounting
Checking settings ⇒ page 20
Adjusting assembly mounting ⇒ page 20
1.4.1 Check settings
The following dimensions must be obtained:
• Between the engine support and the right longitudinal member
must be a distance of -a- = 10 mm at least.
• The edge on the engine support -2- must be parallel to the arm
-1-. Dimension -x- must be the same on top and bottom.
Note
Dimension -a- = 10 mm can be checked e.g. with suitable round
bars.
1.4.2 Adjusting assembly mounting
Special tools and workshop equipment required
♦ Support bracket -10-222 A-
♦ Torque wrench -V.A.G 1332-
If dimension is too small or to large proceed as follows:
ing and installing battery; Vehicles with petrol engines .
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-2-.
– Fit support bracket -10 - 222 A- before the gas pressure damp‐
er for the front flap using adapter -10 - 222 A/8- .
– Attach trigger snap of spindles to lifting eyes.
– Tension engine with both spindles evenly, do not lift.
– Remove bolts -arrows- of engine assembly mounting.
– Remove bolts -arrows- of gearbox assembly mounting.
– Renew all bolts one after the other (if they had not been re‐
moved when the engine was removed) and screw in loosely.
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– Slide the engine with a lever between engine console -1- and
arm -2- until the bolts are centered in the elongated holes:
• Between the engine support and the right longitudinal member
must be a distance of -a- = 10 mm at least.
• The edge on the engine support -2- must be parallel to the arm
-1-. Dimension -x- must be the same on top and bottom.
Note
Dimension -a- can also be checked e.g. with suitable round bars.
– Tighten bolts for engine side assembly mounting
⇒ page 22 .
– Ensure that on gearbox side the edges of the arm -2- and the
gearbox support -1- are parallel with one another. Dimension
-x- must be the same on top and bottom.
– Tighten bolts for gearbox side assembly mounting
⇒ page 22 .
Assembly is carried out in the reverse sequence of removal.
1.5 Assembly mountings
Torque settings
Note
The assembly mounting securing bolts are stretch bolts and must
be replaced.
Engine assembly mounting
A = 20 Nm + 90° (1/4 turn) further
Renew bolts.
B = 40 Nm + 90° (1/4 turn) further
Renew bolts.
C = 60 Nm + 90° (1/4 turn) further
Renew bolts.
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Gearbox assembly mounting
Renew bolts.
Renew bolts.
Pendulum support
Renew bolts.
Renew bolts.
Removing: First remove bolt -B- then bolts -A-.
Installing: First tighten bolts -A- then bolt -B-.
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13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦ If large quantities of metal particles or other deposits (caused,
for example, by partial seizure of the conrod bearings) are
found in the engine oil when performing repairs, clean the oil
passages thoroughly and renew the oil filter in order to prevent
further damage from occurring later.
♦ Oil all contact surfaces before beginning with the assembly
work.
Overview ⇒ page 25
Belt drive - Assembly overview ⇒ page 26
Chain drive - Assembly overview ⇒ page 27 .
Removing and installing poly V-belt ⇒ page 29
Removing and installing control housing ⇒ page 31
Note
When working on the engine, the engine should be secured on
the engine and gearbox support -VAS 6095- .
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1.1 Overview
I - Belt drive - Assembly over‐
view ⇒ page 26
II - Chain drive - Assembly
overview ⇒ page 27 .
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1. Dismantling and assembling engine 25

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1.2 Belt drive - Assembly overview
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Mark D.O.R. with chalk
or a felt tipped pen be‐
fore removing. Reverse
direction of rotation may
lead to destruction with
used belts
❑ Removing and installing
⇒ page 29
❑ Ribbed belt routing in
vehicles with air condi‐
tioner ⇒ page 30
❑ Ribbed belt routing in
vehicles without air con‐
ditioner ⇒ page 30
2 - Bolt
❑ Observe tightening pro‐
cedure ⇒ page 40
❑ Renew
❑ Contact surface of the
securing bolt must be
free of oil and grease
❑ Insert oiled (thread)
❑ Secure poly V-belt
sprocket with counter-
hold -3415- against
turning
❑ The turning further an‐
gle can be measured
with a commercially
available angle measur‐
ing instrument e.g. Ha‐
zet 6690
3 - Poly V-belt sprocket for crankshaft
4 - 20 Nm
❑ To loosen and tighten counterhold with coolant pump wrench -V.A.G 1590- . To do this rework water
pump wrench -V.A.G 1590- ⇒ page 108
5 - Belt pulley for coolant pump
❑ Removing and installing ⇒ page 108
6 - 9 Nm
7 - Coolant pump
8 - 25 Nm
9 - Idler roller
❑ Tightening torque: 40 Nm
10 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. Gr. 27 ; Alternator; Alternator 1.6 l FSI engine
11 - 20 Nm + 90° (1/4 turn) further
❑ Renew
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12 - 25 Nm
13 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, Air conditioning system; Rep. Gr. 87 ; Repair work on refrigerant
circuit; Removing and installing air conditioner compressor
14 - 25 Nm
15 - Bush
❑ Qty. 2
16 - Bracket for ancillaries
17 - Tensioning element for ribbed belt
❑ Turn with open jaw spanner to relieve tension on poly V-belt
❑ Secure tensioning device with a 4 mm hexagon key
❑ To remove, unscrew bolt ⇒ Item 11 (page 26)
1.3 Chain drive - Assembly overview
1 - Cylinder head with cam‐
shaft housing
❑ Sealing surface must
not be reworked
❑ With integrated cam‐
shaft bearings
❑ Remove sealant rem‐
nants
❑ Apply sealing com‐
pound -AMV 188 100
02- before fitting
❑ When installing fit verti‐
cally from above with
the dowel pins into the
holes in the cylinder
head
⇒ page 63
2 - Cylinder block
❑ Dismantling and assem‐
bling cylinder block
⇒ page 36
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 53
3 - Retainer
❑ For tensioning element
and air conditioner com‐
pressor
4 - Sliding rail
❑ For control chain
5 - Chain sprocket
❑ Note installation posi‐
tion: The journal must
engage into the groove of the crankshaft!
❑ For oil pump and control chain drive
❑ Contact surfaces must be free of oil and grease
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6 - Drive chain
❑ Mark D.O.R. before removing (installation position)
7 - 25 Nm
8 - Chain tensioner with tensioning plate and tension spring
❑ For oil pump drive
❑ Is replaced complete only
9 - Oil pan
❑ Clean sealing surface before fitting.
❑ Install with silicone sealing compound -D 176 404 A2-
10 - 13 Nm
11 - 15 Nm
12 - Chain sprocket
❑ Counterhold chain sprocket with counter-hold -T10172-
13 - Cover
14 - 20 Nm + 90° (1/4 turn) further
15 - Piston
❑ For chain tensioner drive chain
16 - Compression spring
17 - Chain tensioner
18 - 9 Nm
19 - Valve gear casing
❑ For a better guide purpose when installing, insert two M6x80 studs into the camshaft housing and the
cylinder block
20 - Bearing bush
❑ Renew if scored
❑ Observe tightening procedure ⇒ page 40
21 - Poly V-belt sprocket
❑ Secure poly V-belt sprocket with counter-hold -3415- against turning
❑ Removing and installing poly V-belt ⇒ page 29
22 - Bolt
❑ Renew
❑ Contact surface of the securing bolt must be free of oil and grease
❑ Secure poly V-belt sprocket with counter-hold -3415- against turning
❑ The turning further angle can be measured with a commercially available angle measuring instrument
e.g. Hazet 6690
23 - O-ring
❑ Renew
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24 - Bolt, 10 Nm
❑ M6x45 mm
25 - 50 Nm
26 - Bolt, 10 Nm
❑ M6x22 mm
❑ Insert with locking fluid
27 - To intake manifold
28 - 10 Nm
29 - Suction relief valve
30 - 10 Nm
31 - Oil separator
32 - Seal
❑ Renew
33 - 40 Nm + 90° (1/4 turn) further
❑ Counterhold chain sprockets with counter-hold -T10172-
❑ Bolt with left-hand thread
❑ Renew
34 - Tensioning plate
35 - 50 Nm + 90° (1/4 turn) further
36 - Camshaft adjuster
❑ Must not be dismantled
37 - Control chain
38 - Chain sprocket
❑ For exhaust camshaft
❑ Lock chain sprockets with counter-hold -T10172-
39 - Guide pins
40 - Bearing bush
1.4 Removing and installing poly V-belt
Removing
– Remove front right wheel housing liner ⇒ General Body Re‐
pairs, Exterior; Rep. Gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Mark direction of rotation of poly V-belt.
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– To relieve tension on ribbed belt, swing tensioning element in
-direction of arrow- using a 16 mm spanner.
– Lock tensioning element using a 4 mm hexagon key -1-.
– Remove ribbed belt.
Installing
Note
♦ Ensure, before installing ribbed belt, that all ancillaries (alter‐
nator, air conditioner compressor) are secured tightly.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.
– Place ribbed V-belt onto crankshaft pulley first. Slide belt onto
tensioning roller last.
Further assembly is basically the reverse of the dismantling pro‐
cedure.
Belt drive with air conditioner compressor
1 - Belt pulley - Coolant pump
2 - Idler roller
3 - Belt pulley - Alternator
4 - Tensioning roller
5 - Belt pulley - Air conditioner compressor
6 - Belt pulley - Crankshaft
Belt drive with no air conditioner compressor
1 - Belt pulley - Coolant pump
2 - Tensioning roller
3 - Belt pulley - Alternator
4 - Poly V-belt
5 - Belt pulley - Crankshaft
After completing repairs always:
– Start engine and check belt running.
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1.5 Removing and installing control housing
equipment required
♦ Support bracket -10-222 A-
♦ Adapter -10 - 222 A/8-
♦ Counter-hold tool -3415-
♦ Pin -3415/1-
♦ Torque wrench -V.A.G.
1331-
1332-
♦ Drip tray for workshop hoist -VAS 6208-
Removing
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pairs, Exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .
– Remove pre-catalytic converter along with exhaust pipe
⇒ page 188 .
– Mark ribbed belt direction of rotation and remove ⇒ page 29 .
– Remove poly V-belt sprocket securing bolt. Lock poly V-belt
sprocket using counter-hold -3415- and -3415/1- .
– Remove bolts -arrows- and take engine lifting eye off.
– Remove coolant pump belt pulley ⇒ page 108 .
– Remove air conditioner compressor with connected coolant
hoses from bracket ⇒ Heating, Air conditioning system; Rep.
Gr. 87 ; Repair work on refrigerant circuit; Removing and in‐
stalling air conditioner compressor .
– Remove tensioning element bracket and air conditioner com‐
pressor.
– Remove alternator and idler roller -2- ⇒ Electrical system;
Rep. Gr. 27 ; Alternator; Alternator, 1.6 l FSI engine .
– Unscrew pressure control valve for crankcase heater element
-arrows-.
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– Remove breather line -1- (press locking ring in).
– Pull activated charcoal canister off the bracket upwards
-arrow-.
dirt etc.
– Remove bracket -3- for activated charcoal canister.
– Remove bolt on filler neck for fluid reservoir -2-.
– On expansion tank, disconnect electrical connection on cool‐
ant shortage indicator sender -G32- and free wiring harness.
– Remove expansion tank -1- and lay on the engine with con‐
nected hoses, tie if necessary.
– Loosen bolts -arrows- of assembly mounting on engine just a
bit (less than 1 turn).
– Remove oil sump ⇒ page 87 .
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– Fit support device -10 - 222 A- using adapter -10 - 222 A/8- as
shown and hook into lifting eye.
– Put engine under slight tension.
– Remove bolts -1- and -2- and remove support.
– Remove bolts from -3- to -6- and remove engine mounting.
– Remove hexagon socket head bolts of the control housing and
the hexagon bolts marked with -arrows-.
– Place drip tray under the engine.
– Remove control housing. To do this raise the engine with the
support device -10 - 222 A- lightly.
Note
Observe that the bearing bush for the crankshaft remains in the
control housing.
– Drive crankshaft seal for poly V-belt sprocket out of the control
housing.
Installing
– Clean sealing surfaces carefully. They must be free of oil and
grease.
Note
Observe that the contact surfaces of the poly V-belt sprocket, the
securing bolt, the bearing bush and the crankshaft pulley sprocket
must be free of oil and grease.
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– Fit new seals -arrows- on the back of the control housing.
– Fit new seal onto dowel pins.
– For a better guide purpose when installing, insert two M6x80
studs into the cylinder head and the cylinder block.
– Fit the control housing at the same time onto the studs and the
dowel pins.
Ensure the camshaft housing does not cant when doing this.
– Tighten control housing securing bolts uniformly using alter‐
nate sequence.
Torque settings:
♦ Bolts M6, 10 Nm
♦ Bolts M10, 50 Nm
– Renew seal for crankshaft poly V-belt sprocket ⇒ page 38 .
– Observe tightening procedure for the crankshaft poly V-belt
sprocket securing bolt ⇒ page 40 .
Further installation is performed in the reverse order of removal.
During this step, observe the following:
– Installing engine bracket ⇒ page 22 .
– Install oil sump ⇒ page 87 .
– Installing pre-catalytic converter along with exhaust pipe
⇒ page 188 .
– Installing coolant pump belt pulley ⇒ page 108 .
– Fit air conditioner compressor with connected coolant hoses
to bracket⇒ Heating, Air conditioning system; Rep. Gr. 87 ;
Repair work on refrigerant circuit; Removing and installing air
conditioner compressor .
– Install alternator with idler roller ⇒ Electrical system; Rep. Gr.
27 ; Alternator; Alternator, 1.6 l FSI engine .
– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. Gr. 66 ; Removing and installing wheel housing
liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
Gr. 50 ; Noise insulation .
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2 Removing and installing sealing
flange and flywheel
Caution
The crankshaft must not be removed. Just loosening the main
bearing caps will cause deformation of the cylinder block bear‐
ing pedestals. This deformation will cause a reduction of the
bearing clearance. Even if the bearing shells are not renewed
bearing damage could occur due to a different bearing clear‐
ance.
If the bearing cap bolts are loosened, the cylinder block must
be replaced complete with the crankshaft.
Measuring the main bearing clearance is not possible with nor‐
mal workshop equipment.
Flywheel end - Assembly overview ⇒ page 36
Renewing crankshaft oil seal - belt pulley end- ⇒ page 38
Tighten bolt for poly V-belt sprocket - crankshaft ⇒ page 40
Renewing crankshaft sealing flange -flywheel end-, vehicles with
manual gearbox ⇒ page 43
Removing and installing flywheel ⇒ page 50
Crankshaft dimensions ⇒ page 52
2.1 Flywheel end - Assembly overview
Caution
ance.
Note
Servicing clutch ⇒ 6-speed manual gearbox 0AG; Rep. Gr. 30 ; Removing and installing clutch
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1 - Bolt
❑ Observe tightening se‐
quence ⇒ page 40
❑ Renew
❑ Contact surface of the
bolt must be free of oil
and grease
❑ Secure poly V-belt
sprocket with counter-
hold -3415- against
turning
❑ The turning further an‐
gle can be measured
with a commercially
available angle measur‐
ing instrument e.g. Ha‐
zet 6690
❑ Contact surfaces must
be free of oil and grease
❑ When removing and in‐
stalling secure with
counter-hold -3415-
against turning
poly V-belt ⇒ page 29
3 - Seal
❑ Renew
4 - Bearing bush
❑ Renew if scored
❑ Observe tightening pro‐
cedure ⇒ page 40
❑ Contact surfaces must
be free of oil and grease
5 - O-ring
❑ Renew
6 - Aluminium cylinder block
7 - 60 Nm + 90° (1/4 turn) further
❑ Renew
8 - Flywheel
❑ To remove and install counterhold flywheel with counter-hold -T10044-
9 - Intermediate plate
❑ Must fit on dowel sleeves
❑ Do not damage/bend when assembling
10 - 12 Nm
❑ Renew
11 - Sealing flange with sender wheel and seal
❑ Only renew sealing flange complete with seal and sender wheel
❑ Renewing crankshaft sealing flange -flywheel end- ⇒ page 43
12 - Engine speed sender -G28-
❑ With attached bolt
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2.2 Renewing crankshaft oil seal - belt pulley end
equipment required
♦ Oil seal extractor -3203-
♦ Pin -3415/1-
♦ Fitting appliance -T10117-
Removing
pairs; Rep. Gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
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– Loosen bolt for poly V-belt sprocket - crankshaft. To do this
counterhold poly V-belt sprocket using counter-hold -3415-
and pin -3415/1- .
– Unscrew bolt and take poly V-belt sprocket off.
– Unscrew inner part of oil seal extractor -3203- three turns (ap‐
prox. 5 mm) out of outer part and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and exerting firm pressure screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against mounting
bush until the seal is pulled out.
– Take the mounting bush off crankshaft journal and clean the
contact surfaces of the crankshaft pulley sprocket and the
mounting bush.
Installing
Note
Observe that the contact surfaces of the poly V-belt sprocket, the
bolt, the bearing bush and the crankshaft pulley sprocket must be
free of oil and grease.
– Renew O-ring ⇒ Item 5 (page 37) .
– Slide the bearing bush with the new O-ring onto the crankshaft
journal.
– Place the sleeve -T10117/2- onto the bush and the seal onto
the bearing bush.
– Take sleeve -T10117/2- off bearing bush.
– Using even blows, press the seal into control housing up to
limit stop using assembly device -T10117- .
– Tighten bolt for poly V-belt sprocket - crankshaft
⇒ page 40 .
cedure.
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2.3 Tighten bolt for poly V-belt sprocket - crankshaft
equipment required
1601-
♦ Pin -3415/1-
– Remove exhaust gas recirculation valve -N18- ⇒ page 195 .
– Unhook wiring harness (not shown in the figure) on the coolant
pipe -4-.
– Remove bolts -5- from coolant pipe -4-.
– Remove bolt -2- from cap -1-.
– Take caps -1- and -3- off. Collect leaking engine oil with a cloth.
Note
Observe that all contact surfaces from the bolt for the poly V-belt
sprocket - crankshaft up to the crankshaft pulley sprocket must
be free of oil and grease.
– Place poly V-belt sprocket to the bearing bush and screw new
bolt into for the poly V-belt sprocket.
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The bolt for the poly V-belt sprocket is spotted on the bolt head
-arrow-.
Always use a new bolt.
– Set the counter-hold -3415- into the openings of the poly V-
belt sprocket using pin -3415/1- , support counter-hold on
wishbone -A- and secure in this position using a cable tie.
Tighten cable tie tightly.
– Tighten bolt for poly V-belt sprocket in the 1st stage as follows:
Tightening torque: 150 Nm
– Now mark position of exhaust camshaft -1- to camshaft hous‐
ing -2- with a coloured pen. The position of the hole -3- is not
relevant for the later check.
– In this position mark the position of the bolt -3- to the poly V-
belt sprocket -1- -arrows-. The marking must not be made on
the washer -2- otherwise it will not turn when turning further.
– Now tighten bolt for poly V-belt sprocket in the 2nd stage as
follows:
Turn bolt 180° (1/2 turn) further.
Turning further can be done in several stages.
– Check exhaust camshaft position.
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• Both markings -1- and -2- must align.
If both markings -1- and -2- align.
– Check timing ⇒ page 67 .
In this way it is checked whether the chain sprocket has turned
on the crankshaft when the bolt for the poly V-belt sprocket
was tightened.
If the markings -1- and -2- do not align.
– Check timing ⇒ page 67 .
If the timing is not OK:
– Adjust timing ⇒ page 69 .
Note
First check whether the journal of the chain sprocket is still in the
crankshaft groove.
– If the journal of the chain sprocket is not in the crankshaft
groove anymore, remove and check it for damage.
Replace a damaged chain sprocket.
If the timing is OK:
The crankshaft has been turned to the poly V-belt sprocket.
– Remove poly V-belt sprocket, seal and bearing bush and clean
thoroughly. They must be free of oil and grease.
– Replace damaged parts.
– Thoroughly clean also the contact surface of the chain sprock‐
et.
– Reinstall parts with a new bolt for the poly V-belt sprocket.
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2.4 Renewing crankshaft sealing flange -flywheel end-
equipment required
♦ Fitting appliance -T10134-
1331-
♦ Socket insert AF 24 -V.A.G.
1332/11-
♦ Three M6×35 mm hexagon
bolts
♦ Feeler gauges
♦ Vernier gauge
Procedure
Note
♦ To show the work sequence more clearly, the sequence is de‐
scribed for a removed engine.
♦ The work sequence is the same when the engine is in the ve‐
hicle and the gearbox removed.
Pressing sealing flange with sender wheel off crankshaft
– Remove the flywheel ⇒ page 50 .
– Remove intermediate plate.
– Position engine at TDC for cylinder No. 1. ⇒ page 67 .
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– Remove bolts -1- and -2- and pull coolant hoses off engine
and gearbox. The coolant hoses remain connected.
– Remove engine speed sender -G28- -arrow-.
– Undo sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
with M6×35 mm bolts.
– Screw three M6×35 mm bolts into the threaded holes of the
sealing flange -arrow-.
– Screw bolts alternately (maximum 1/2 turn (180 °) for each
bolt) into sealing flange and press sealing flange together with
sender wheel off crankshaft.
Pressing sealing flange with sender wheel onto crankshaft
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing
lip support ring. This support ring serves the function of a fitting
sleeve and may not be removed prior to installation.
♦ Sealing flange and sender wheel must not be separated or
twisted after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device -T10134- by a locating pin.
♦ Sealing flange and seal are one unit and must be replaced
together with the sender wheel only.
♦ The assembly device -T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
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Fitting appliance -T10134-
A - Clamping surface
B - Hexagon nut
C - Assembly bell housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
A - Fit assembling seal with sender wheel on assembly appliance
-T10134-
– Screw hexagon nut -B- to just before clamping surface -A- of
threaded spindle.
– Clamp assembly device -T10134- in a vice on clamping sur‐
face -A- of threaded spindle.
– Press assembly bell housing -C- downwards so that it lies on
hexagon nut -B- -arrow-.
– Screw hexagon nut onto the threaded spindle until the inner
part of assembly appliance and the assembly bell housing are
at same height.
– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
twisted.
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– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.
– Push sealing lip support ring -A- downwards in
-direction of arrow- until it lies on flat surface.
– Upper edge of sender wheel and front edge of sealing flange
must align -arrows-.
– Place sealing flange with front side on assembly device -
T10134- that locating pin -B- can be inserted in sender wheel
hole -A-.
Note
Ensure sealing flange lies flat on assembly device.
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– Push sealing flange and support ring for sealing lip -B- against
surface of assembly device -T10134- whilst tightening the
three knurled screws -A-, so that locating pin cannot slide out
of sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains
fixed in assembly device.
B - Attaching assembling tool -T10134- with sealing flange to
crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.
– Screw hexagon nut -B- to end of threaded spindle.
– Press threaded spindle of assembly tool -T10134- in
-direction of arrow-, until hexagon nut -B- lies against assem‐
bly bell housing -A-.
– Align flat side of assembly bell housing towards oil sump side
of crankcase sealing surface.
– Secure assembly tool -T10134- to crankshaft flange using
hexagon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 threads).
– Screw two M6x35 mm bolts -A- into the cylinder block to guide
the sealing flange.
C - Bolting assembly tool -T10134- onto crankshaft flange
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– Push assembly bell housing -C- by hand in
-direction of arrow- until sealing lip support ring -B- contacts
crankshaft -A-.
– Push guide pin for petrol engines (red knob) -F- into threaded
hole in crankshaft. This ensures that the sender wheel reaches
its final installation position.
Note
The guide pin for diesel engines (black knob) -F- must not be in‐
serted in threaded hole of crankshaft.
– Hand tighten both hexagon socket head bolts of assembly
tool.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against assembly bell housing -C-.
D - Pressing sender wheel onto crankshaft flange using assembly
tool -T10134-
– Tighten hexagon nut of assembly tool -T10134- to 35 Nm us‐
ing torque wrench -V.A.G 1331- and 24 mm insert -V.A.G
1332/11- .
Note
After hexagon nut is tightened to 35 Nm torque, a small air gap
must be present between cylinder block and sealing flange.
E - Checking sender wheel installation position on crankshaft
– Screw hexagon nut -E- to end of threaded spindle.
– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Remove assembly tool -T10134- .
– Remove sealing lip support ring.
– The sender wheel is in the correct installation position on the
crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange.
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– Measure distance -a- between crankshaft flange and sender
wheel.
Is measurement -a- too small:
– Press sender wheel further ⇒ page 49
When dimension -a- is achieved:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.
– Install engine speed sender -G28- -arrow- and tighten secur‐
ing bolt to 5 Nm.
– Install intermediate plate.
– Install flywheel ⇒ page 50 .
F - Re-pressing sender wheel
– Secure assembly tool -T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool -T10134- by hand to sealing flange.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against assembly bell housing -C-.
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– Tighten hexagon nut of assembly tool -T10134- to 40 Nm us‐
ing torque wrench -V.A.G 1331- and 24 mm insert -V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again ⇒ page 48 .
If dimension -a- is too small again:
– Tighten hexagon nut for assembly tool assembly device -
T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 48 .
2.5 Removing and installing flywheel
Removing
– Remove gearbox ⇒ 6-speed manual gearbox 0AG; Rep. Gr.
34 ; Removing and installing gearbox .
Note
To avoid damaging the dual-mass flywheel during removal, the
bolts -B- must not be removed using a pneumatic or impact driver.
The bolts -B- must be unscrewed by hand only.
– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
– When removing bolts -B-, make sure that screw heads do not
jam on flywheel.
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– Insert counter-hold tool -3067- in hole on cylinder block.
• Installation position of counter-hold:
A - To tighten
B - To loosen
– Mark position of flywheel in relation to engine.
– Unbolt flywheel.
Installing
following:
– Renew bolts and tighten to 60 Nm and 90° (1/4 turn) further.
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3 Removing and installing crankshaft
Caution
ance.
3.1 Crankshaft dimensions
Honing dimension
dimensions in mm
Conrod bearing
journal-∅
Basic dimension -0,022
47,80
-0,037
1st undersize -0,022
47,55
-0,037
2nd undersize -0,022
47,30
-0,037
3rd undersize -0,022
47,05
-0,037
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4 Dismantling and assembling pistons
and conrods
Pistons and conrods - Assembly overview ⇒ page 53
Check piston ⇒ page 54
Checking cylinder bores ⇒ page 55
Piston and cylinder dimensions ⇒ page 55
4.1 Pistons and conrods - Assembly overview
Note
Oil all contact surfaces before beginning with the assembly work.
1 - Piston
❑ Checking ⇒ page 54
❑ Mark installation posi‐
tion and cylinder num‐
ber
❑ Arrow on piston crown
points to belt pulley end
❑ Install using piston ring
clamp
2 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C
❑ Remove and install drift
-10 - 14-
3 - Retaining ring
4 - Conrod
❑ Renew as set only
❑ Mark cylinder number
-arrows A-
❑ Installation position:
Marking -arrows B-
faces towards pulley
end
❑ Guided axially via piston
5 - Ball socket
❑ Do not interchange
used bearing shells.
❑ Insert bearing shells
centrally
Check radial clearance with
Plastigage:
❑ New: 0.020…0.060 mm
❑ Wear limit: 0.090 mm
❑ Do not rotate crankshaft when checking radial clearance
6 - Cylinder block
❑ Checking cylinder bores ⇒ page 55
❑ Piston and cylinder dimensions ⇒ page 55
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4. Dismantling and assembling pistons and conrods 53

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7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod, this is due to the breaking procedure
(industrially cracking) separating the cap from the conrod
8 - Conrod bolt, 30 Nm + 90° (1/4 turn) further
❑ Renew
❑ Oil threads and contact surfaces
❑ To measure radial clearance, tighten to respective tightening torque, but do not turn further
9 - Oil scraper ring
❑ Remove and install 3-part oil scraper ring carefully by hand
❑ Offset end of upper steel band ring by 120° to adjacent compression ring
❑ Install part ends of the oil scraper ring offset to each other
❑ Checking ring gap ⇒ page 54
❑ Clearance can not be measured
10 - Compression rings
❑ Offset gaps by 120°
❑ Remove and install compression rings using piston ring pliers.
❑ “TOP” faces towards piston crown.
❑ Checking ring gap ⇒ page 54
❑ Checking ring-to-groove clearance ⇒ page 54
4.2 Check piston
♦ External micrometer 75...100 mm
Check piston
– Measure pistons approx. 12 mm from the lower edge of skirt,
at 90° to the piston pin axis. Deviation from nominal dimension
max. 0.04 mm. Nominal dimension ⇒ page 55 .
Checking piston ring gap
– Push ring squarely from above down to approx. 15 mm from
bottom end of cylinder.
Piston ring
dimensions in mm
new Wear limit
1st compression ring 0,20…0,50 1,0
2nd compression ring 0,40…0,60 1,0
Oil scraper ring 0,20…1,10 ---1)
1) No wear limit details
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piston ring-checking ring-to-groove clearance
Clean groove before check.
Piston ring
dimensions in mm
new Wear limit
1st compression ring 0,04…0,08 0,15
2nd compression ring 0,02…0,06 0,15
Oil scraper ring Can not be measured
4.2.1 Checking cylinder bores
♦ Internal dial gauge 50…100 mm
Checking cylinder bores
– Take measurements at 3 positions in both lateral -A- and lon‐
gitudinal -B- planes, as illustrated. Deviation from nominal
dimension max. 0.08 mm.
– Nominal dimension ⇒ page 55 .
Note
Measuring the cylinder bores must not be done when the cylinder
block is fitted to the engine/gearbox bracket -VAS 6095- as in‐
correct measurements would then be possible.
4.3 Piston and cylinder dimensions
Honing dimen‐
sion
Piston ∅2)
Cylinder bore ∅
Basic dimen‐
sion
mm 76,455 76,51
1st oversize mm 76,705 76,76
2nd oversize mm 76,955 77,01
2) Measure approx. 12 mm from the piston lower edge
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4. Dismantling and assembling pistons and conrods 55

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15 – Cylinder head, valve gear
1 Cylinder head
Note
♦ When installing an exchange cylinder head, all the contact
surfaces between the support elements, roller rocker fingers
and the cams must be oiled before installing the camshaft
housing.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
♦ Oil all contact surfaces before beginning with the assembly
work.
♦ Dismantling and assembling intake manifold ⇒ page 162
Cylinder head - Assembly overview ⇒ page 57
Removing and installing camshaft housing ⇒ page 59
Removing and installing cylinder head ⇒ page 63
Checking valve timing ⇒ page 67
Adjusting valve timing ⇒ page 69
Checking compressions ⇒ page 74 .
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56 Rep. Gr.15 - Cylinder head, valve gear

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1.1 Cylinder head - Assembly overview
1 - Cable guide
❑ Fit on camshaft housing
with 8 Nm
2 - 10 Nm
3 - 10 Nm + 90° (1/4 turn) fur‐
ther
❑ Renew
❑ Remove from outside
inwards ⇒ page 61
❑ Tighten from centre out‐
wards ⇒ page 63
4 - 10 Nm
5 - To air cleaner
6 - Hall sender -G40-
7 - O-ring
❑ Renew if damaged.
8 - Retainer
9 - Stud, 6 Nm
❑ For air cleaner
10 - Cylinder head bolt
❑ Renew
❑ Observe installation in‐
structions and se‐
quence when loosening
and tightening
⇒ page 63
11 - Roller rocker finger
❑ Check roller bearing for
easy movement
❑ Oil contact surfaces.
❑ Use securing clip to clip onto support element when installing
12 - Support element
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
13 - Dowel pins
14 - Oil pressure switch -F1- , 25 Nm
❑ Checking ⇒ page 94 .
❑ If sealing ring is leaking, nip open and replace.
15 - Cylinder head
❑ Check for distortion ⇒ page 58 .
❑ Sealing surfaces to the camshaft housing must be free of oil and grease
❑ After renewing, renew entire coolant.
16 - Cylinder head gasket
❑ Renew
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1. Cylinder head 57

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❑ Metal gasket
❑ After renewing, renew entire coolant.
17 - Guide pins
18 - Lifting eye
19 - 20 Nm
20 - Oil strainer
❑ Fitted in cylinder head
❑ Renew
21 - Camshaft housing
❑ With integrated camshaft bearings
❑ Remove sealant remnants
❑ Thoroughly clean sealing surfaces, they must be oil and grease free.
❑ Apply sealing compound -D 188 003 A1- before fitting
❑ When installing fit vertically from above onto studs and dowel pins
22 - Bucket tappet
❑ Renew
23 - O-ring
❑ Renew
❑ Coat with oil before inserting
24 - High-pressure pump
❑ For fuel supply system
❑ With fuel pressure regulating valve -N276-
Checking cylinder head for distortion
Max. permissible distortion: 0.05 mm
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1.2 Removing and installing camshaft housing
equipment required
♦ Dial gauge -VAS 6079-
♦ Puller -T10094-
♦ Dial gauge adapter -
T10170-
♦ Camshaft clamp -T10171-
♦ Counter-hold tool -T10172-
♦ Locking pin -T40011-
♦ Spark plug spanner -3122 B-
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1. Cylinder head 59

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♦ Two M6x80 studs
♦ Sealants -D 188 003 A1-
Removing camshaft housing ⇒ page 60
Installing camshaft housing ⇒ page 61
1.2.1 Remove camshaft housing
Note
♦ The camshafts are mounted in the camshaft housing on this
engine. Therefore, the control housing must be removed be‐
fore the camshaft housing can be removed ⇒ page 31 .
♦ The camshaft housing sealing surface must not be reworked.
– Remove control housing ⇒ page 31 .
– Position crankshaft at TDC for cylinder No. 1. Then turn crank‐
shaft against D.O.R. 45° of engine and remove camshaft
sprockets with the control chain ⇒ page 69 .
– Remove exhaust gas recirculation valve -N18- ⇒ page 195
and remove camshaft sealing caps.
– Pull connector -1- off Hall sender -G40- and connector -2- off
inlet camshaft control valve 1 -N205- .
– Unscrew earth cable -3- from camshaft housing.
– Disconnect connector -4- from high-pressure pump.
– Remove ignition coils. To do this use extractor -T10094-
⇒ page 198 .
– Disassembling the wiring with wiring harness from the cam‐
shaft housing.
WARNING
protective gloves to avoid injuries and skin contact. Before
loosening fuel pipes, wrap a cloth around the connection. Then
release pressure by carefully removing the hose.
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– Pull connector and fuel supply line -arrows- off the high-pres‐
sure pump.
– Remove cable guide -2- and remove clip -4- from the high-
pressure line.
Note
Lock the screwed connections on the high-pressure pump and on
fuel rail when unbolting the union nuts with a spanner.
– Unscrew union nuts -3- and -1- of the high-pressure line.
– Remove dipstick.
– Remove fuel rail ⇒ page 168 .
– Unscrew the left lifting eye.
– Unscrew camshaft housing bolts in the sequence -15 … 1-
.
Note
The bolt -item 9- (below the high-pressure pump) remains in the
camshaft housing.
– Carefully lift camshaft housing off.
1.2.2 Installing camshaft housing
Prerequisites
• The pistons must not be positioned at TDC.
– Remove sealant remnants on cylinder head camshaft housing
with a commercially available sealant remover.
– Prevent dirt and residual sealant from entering cylinder head.
– Clean sealing surfaces carefully. They must be free of oil and
grease.
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– Turn the inlet and outlet camshaft until the camshaft clamp -
T10171- can be fitted into the camshaft openings to limit stop.
The retaining pins -arrows 1- must engage into the holes
-arrows 2-. The inscription “TOP” -arrow 3- must be legible from
above.
– To secure the camshaft -T10171- , hand-tight the M6 bolt
-arrow-, do not tighten.
– Ensure all roller rocker fingers contact the valve ends -1- cor‐
rectly and they are clipped into their respective support ele‐
ments -2-.
– Screw two studs (M6 x 80) into cylinder head before installing
camshaft housing.
– Apply a thin even coat of sealant onto the clean camshaft
housing sealing surface. See hatched area on illustration.
Note
The sealant must not be applied too thick otherwise excess seal‐
ant can enter the oil channels and cause damage to the engine.
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– Renew oil strainer -arrow- and lay it into the cylinder head.
– Carefully fit the camshaft housing vertically onto the cylinder
head studs -arrows- and the dowel pins of the cylinder head.
Note
Ensure no oil remnants drop on the sealing surfaces.
– Tighten new bolts for camshaft housing in 2 steps in the fol‐
lowing tightening sequence as follows:
1. Tighten to 10 Nm using torque wrench.
2. Turn 90° (1/4 turn) further with a rigid wrench.
Ensure the camshaft housing does not cant when doing this.
Note
Sealant must be left dry for approx. 30 minutes after installing
camshaft housing.
cedure. During this step, observe the following:
♦ Install control housing ⇒ page 31 .
♦ Installing fuel lines ⇒ page 139 .
♦ Installing exhaust gas recirculation valve -N18- ⇒ page 195 .
1.3 Removing and installing cylinder head
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Note
To remove the cylinder head it is necessary to remove the engine
with the gearbox. When working on the engine, the engine should
be secured on the engine and gearbox support -VAS 6095- .
Remove cylinder head ⇒ page 64
Install cylinder head ⇒ page 65
1.3.1 Remove cylinder head
– Remove the engine ⇒ page 4 .
– Remove gearbox and fit engine to engine and gearbox bracket
-VAS 6095- ⇒ page 14 .
If the cylinder head must be dismantled, remove the following
components:
♦ Intake manifold ⇒ page 164
♦ Fuel rail ⇒ page 168
♦ Exhaust manifold ⇒ page 186
– Pull retaining clip for coolant pipe out -arrow-.
Note
The thermostat is removed for a clearer illustration.
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– Remove thermostat housing from cylinder head -arrows-.
– Pull thermostat housing off coolant pipe.
– Remove camshaft housing ⇒ page 59 .
– Remove roller rocker finger together with support elements
and place on a clean surface.
– Ensure the roller rocker fingers and the support elements are
not interchanged.
– Loosen socket head bolts in the sequence given and then re‐
move.
– Carefully lift cylinder head off.
1.3.2 Install cylinder head
Prerequisites
• The pistons must not be positioned at TDC.
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.
– Set No. 1 cylinder piston to top dead centre and then turn
crankshaft back slightly.
– Fit new cylinder head gasket. The inscription (Part No.) must
be legible.
– Place cylinder head on. When doing this observe the central‐
izing pins in cylinder block.
– Fit new cylinder head bolts and tighten hand tight.
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– Tighten cylinder head in tightening sequence as follows:
– Tighten all bolts to 30 Nm.
– Then tighten all bolts 90° (1/4 turn) using a rigid wrench.
– Then tighten all bolts again 90 (1/4 turn) further.
– Insert support element in cylinder head and fit roller rocker
finger onto respective valve stem end or support element.
– Renew oil strainer -arrow- and lay it into the cylinder head.
– Install camshaft housing ⇒ page 59 .
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1.4 Checking valve timing
equipment required
♦ Spark plug spanner -3122
B-
1331-
♦ Puller -T10094-
T10170-
Test procedure
pipe -4-.
– Remove spark plug from cylinder No. 1. To do this use puller
-T10094- and the spark plug spanner 3122 B ⇒ page 198 .
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– Turn the dial gauge adapter -T10170- to limit stop into the
spark plug thread.
– Set dial gauge -VAS 6079- with the extension -T10170/1- up
to limit stop and clamp with the clamping nut -arrow-.
– Set crankshaft in engine D.O.R. to TDC cylinder No. 1. Note
the position of the dial gauge indicator.
The holes -arrows- in the camshafts must stand as shown. If nec‐
essary turn crankshaft one turn further (360°).
Note
♦ If the crankshaft was turned more than 0.01 mm past the TDC,
the crankshaft must be turned again approx. 45° against en‐
gine direction of rotation. Then turn the crankshaft in engine
D.O.R. to TDC cylinder No. 1.
♦ Max. permissible deviation of TDC cylinder No. 1: ±0.01 mm.
– Fit camshaft clamp -T10171- to limit stop into the camshaft
openings.
above.
If the camshaft clamp -T10171- can not be inserted up to limit stop
into the camshaft openings the timing is wrong and must be adap‐
ted again ⇒ page 69 .
The timing is OK when the camshaft clamp -T10171- can be in‐
serted into the camshaft openings up to limit stop.
♦ Renew seals for the camshaft sealing caps and lubricate be‐
fore installing.
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1.5 Adjusting valve timing
equipment required
♦ Puller -T10094-
T10170-
♦ Locking pin -T40011-
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B-
♦ Pin -3415/1-
♦ Torque wrench -
V.A.G 1331-
Procedure
– To turn the crankshaft install bearing bush, crankshaft belt
pulley -2- and crankshaft bolt -3- and tighten the crankshaft
bolt. To do this use counter-hold -3415- .
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pipe -4-.
– Remove spark plug from cylinder No. 1. To do this use puller
-T10094- and spark plug spanner -3122 B- ⇒ page 198 .
– Turn the dial gauge adapter -T10170- to limit stop into the
spark plug thread.
– Set dial gauge -VAS 6079- with the extension -T10170/1- up
to limit stop and clamp with the clamping nut -arrow-.
– Set crankshaft in engine D.O.R. to TDC cylinder No. 1. Note
the position of the dial gauge indicator.
– Then turn crankshaft against engine D.O.R. 45° back.
– Press tensioning plate -1- in direction of arrow and lock piston
with the pin -T40011- .
– Mark with a felt tipped pen the direction of road of the control
chain -3-.
Note
Centre bolt of the camshaft adjuster -2- has a left-hand thread.
– Remove bolts -2- (left-hand thread) and -4- and remove cam‐
shaft adjuster -1- with control chain -3-. To counterhold use
counter-hold -T10172- .
– Fit camshaft adjuster -1- again.
– Renew bolts -2- (left-hand thread) and -4- and tighten bolt
-2- to 40 Nm and bolt -4- to 50 Nm (use counter-hold -
T10172- ).
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– Turn the inlet and outlet camshaft until the camshaft clamp -
T10171- can be fitted into the camshaft openings to limit stop.
above.
Note
The camshafts must not be moved axially when turning.
– To secure the camshaft -T10171- , hand-tight the M6 bolt
-arrow-, do not tighten.
– Remove bolts of the camshaft sprockets. To do this is abso‐
lutely necessary to use counter-hold -T10172- .
Caution
The camshaft clamp -T10171- must not be used as counter-
hold.
– Take a camshaft sprocket off.
– Considering direction of road, set the control chain on the
camshaft sprockets and install removed camshaft sprocket
again.
– Screw camshaft bolts into so that the camshaft sprockets can
still be turned on the camshaft.
– Tension control chain by pulling out pin -T40011- .
– Turn crankshaft in engine direction of road to TDC cylinder No.
1. Max. permissible deviation of TDC cylinder No. 1: ±0.01
mm.
Note
If the crankshaft was turned more than 0.01 mm past the TDC,
the crankshaft must be turned again approx. 45° against engine
direction of rotation. Then turn the crankshaft in engine D.O.R. to
TDC cylinder No. 1.
– With the counter-hold -T10172- , hold the camshaft sprockets
-1- and -5- in this position and tighten bolts -2- (left-hand
thread) to 40 Nm and -4- to 50 Nm.
Note
When tightening the camshaft bolts the crankshaft must not turn
and the control chain -3- must remain tensioned on both sides.
– Remove camshaft clamp -T10171- .
– Turn crankshaft two turns in engine direction of road to TDC
cylinder No. 1. Max. permissible deviation of TDC cylinder No.
1: ±0.01 mm.
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openings.
If the camshaft clamp -T10171- can not be fitted:
– Repeat adjustment.
If the camshaft clamp -T10171- can be fitted:
– Remove the camshaft clamp -T10171- , hold the camshaft
sprockets with the counter-hold -T10172- and turn bolt -2- (left-
hand thread) and -4- 90° (1/4 turn) further using a rigid wrench.
Note
♦ The centre bolt of the camshaft adjuster -2- has a left-hand
thread.
♦ The camshaft sprockets must not turn on the camshaft when
tightening.
– Turn crankshaft two turns again in engine direction of road to
TDC cylinder No. 1. Max. permissible deviation of TDC cylin‐
der No. 1: ±0.01 mm.
openings.
If the camshaft clamp -T10171- can not be fitted:
– Repeat adjustment.
♦ Install Poly V-belt ⇒ page 29 .
♦ Renew seals for the camshaft sealing caps and lubricate be‐
fore installing.
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1.6 Check compression pressures
equipment required
B-
1331-
♦ Compression tester -V.A.G
1763-
♦ Puller -T10094-
♦ Vehicle diagnosis, testing and information system -VAS 5051-
♦ or vehicle diagnosis and service information system -VAS
5052-
Test prerequisites
• Engine oil temperature must be at least 30 C.
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Test procedure
– Remove ignition coils. To do this use puller -T10094-
⇒ page 198 .
– Unscrew spark plugs with spark plug wrench -3122 B- .
– Check compressions with compression tester -V.A.G 1763- .
Note
See relevant test unit operating instructions for instructions on
how to use test unit.
– With the accelerator pedal fully depressed, have a second
mechanic to operate the starter until tester shows no further
pressure increase.
Compression pressures:
New: 10…15 bar
Wear limit: 7 bar
Permissible difference between all cylinders: 3 bar
– Install spark plugs with spark plug socket -3122 B- and tighten
to 30 Nm.
cedure.
– Interrogate engine control unit fault memory ⇒ page 178 .
If the fault memory was erased the readiness code must be
generated.
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2 Repairing valve gear
Valve gear - Assembly overview ⇒ page 76
Checking camshaft axial clearance ⇒ page 78
Reworking valve seats ⇒ page 79
Checking valve guides ⇒ page 80
Renewing valve stem seals ⇒ page 81
2.1 Valve gear - Assembly overview
1 - 40 Nm + 90° (1/4 turn) fur‐
ther
❑ Left-hand thread
❑ Renew
2 - 50 Nm + 90° (1/4 turn) fur‐
ther
❑ Renew
3 - Camshaft adjuster
❑ Must not be dismantled
⇒ page 69
4 - Camshaft pulley
❑ Note position when in‐
stalling the control chain
5 - Camshaft variable timing
adjustment valve 1 -N205-
❑ Checking ⇒ Vehicle di‐
agnosis, testing and in‐
formation system -VAS
5051- or Vehicle Diag‐
nosis and Service Infor‐
mation System -VAS
5052-
6 - 10 Nm
7 - O-ring
❑ Renew if damaged.
8 - 10 Nm + 90° (1/4 turn) fur‐
ther
❑ Renew
❑ Tighten from centre out‐
wards
❑ Remove sealant remnants
❑ Apply sealing compound -D 188 800 A1- before fitting
❑ When installing fit vertically from above onto studs and dowel pins
10 - Roller rocker finger
❑ Check roller bearing
❑ Oil contact surfaces
❑ Use securing clip to clip onto support element when installing
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11 - Cotters
12 - Support element
❑ Check oil spray drillings
❑ With hydraulic valve clearance compensation
❑ Do not interchange
❑ Before installing check camshaft axial clearance ⇒ page 78
❑ Oil contact surfaces
13 - Valve spring plate
14 - Valve spring
❑ Removing and installing with removed cylinder head using hold down tool for valve springs -3362-
❑ With cylinder head installed ⇒ page 81
15 - Valve stem seal
❑ Renewing ⇒ page 81
16 - Repair valve guide
❑ With collar
17 - Valve guide
❑ Checking ⇒ page 80 .
18 - Cylinder head
❑ Reworking valve seat ⇒ page 79
❑ Reworking sealing surface ⇒ page 78
19 - Valves
❑ Do not rework. Only lapping-in is permitted
❑ Valve dimensions ⇒ page 79
20 - Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-
21 - Sealing cover
❑ For inlet camshaft
22 - Coolant pipe/bracket
❑ Remove to remove sealing cap ⇒ Item 23 (page 77)
23 - Sealing cover
❑ For outlet camshaft
❑ Remove to remove coolant pipe/bracket ⇒ Item 22 (page 77)
24 - Outlet camshaft
❑ Do not interchange with inlet camshaft
❑ Checking axial clearance ⇒ page 78
❑ Coat with oil before inserting (also axle bearing shoulder)
25 - Inlet camshaft
❑ With cams for high pressure pump -arrow-
❑ Remove to remove bucket tappets of the high pressure pump and renew
❑ Do not interchange with outlet camshaft
❑ Checking axial clearance ⇒ page 78
❑ Coat with oil before inserting (also axle bearing shoulder)
26 - Guide sleeve
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Reworking cylinder head sealing surface
Cylinder head reworking limit:
Dimension -a- = 108.25 mm min.
Note
When the sealing surface has been reworked, the valves must be
set deeper by the same amount (rework valve seats) otherwise
the valves will strike the pistons. When performing this work en‐
sure that the minimum dimension ⇒ page 79 does not remain
under.
2.2 Checking camshaft axial clearance
♦ Universal dial gauge bracket -VW 387-
Perform measurements with camshaft housing removed and
sealing cover fitted.
Checking camshaft axial clearance
Wear limit: max. 0.40 mm
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Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Outlet valve
∅ a mm 29,5 26,0
∅ b mm 5,973 5,953
c mm 100,9 100,5
α ∠° 45 45
2.3 Reworking valve seats
♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient
to reface or renew valve seats and valves. It is also necessary
to check the valve guides for wear. This is particularly impor‐
tant on high mileage engines ⇒ page 80 .
♦ Valve seats should be reworked only enough to produce a
perfect seating pattern. Before beginning to rework valve
seats, calculate the maximum permissible reworking dimen‐
sions. If the reworking dimension is exceeded, hydraulic valve
compensation can no longer be guaranteed and the cylinder
head should be renewed.
The max. permissible reworking dimension is calculated as fol‐
lows:
– Insert valve and press firmly against seat.
Note
If the valve is to be renewed as part of a repair, use a new valve
for the calculation.
– Measure distance between end of valve stem and upper edge
of cylinder head.
– Calculate max. permissible reworking dimension from meas‐
ured distance and minimum dimension.
Minimum dimension: Inlet valve 7.6 mm; Outlet valve 7.6 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
- Measured distance
Minimum dimension
8,0
7,6
mm
mm
= max. perm. rework dimension3)
0,4 mm
3) The maximum permissible reworking dimension is shown on illustrations for
reworking valve seats as dimension “b”.
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Rework inlet valve seat
a = ∅ 28.7 mm
b = max. permissible reworking dimension
c = 1.5…1.8 mm
Z = lower edge of cylinder head
α = 45° Valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
Rework exhaust valve seat
a = ∅ 25.0 mm
b = max. permissible reworking dimension
c = approx. 1.8 mm
Z = lower edge of cylinder head
α = 45° Valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
2.4 Checking valve guides
♦ Universal dial gauge bracket -VW 387-
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Test procedure
– Insert a new valve into the guide. The end of the valve stem
must be flush with the guide. Due to slight differences in stem
diameters, use only an inlet valve in inlet guide and an exhaust
valve in exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded:
– Replace cylinder head.
2.5 Renewing valve stem seals
equipment required
B-
♦ Hold down tool for valve
springs -3362- with press
piece -3362/1-
♦ Extractor for valve stem
seal -3364-
♦ Valve stem seal fitting tool
-3365-
♦ Pressure hose -VW 653/3-
Removing
(with cylinder head installed)
– Remove camshaft housing ⇒ page 59 .
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– Remove roller rocker arms and place onto a clean surface.
When doing this, ensure that the roller rocker fingers are not
interchanged.
– Remove spark plugs with spark plug wrench -3122 B- .
– Set cylinder to “bottom dead centre”.
– Screw hold down tool for valve springs -3362- on with press
piece -3362/1- .
– Now screw pressure hose -VW 653/3- into the spark plug
thread.
– Connect pressure hose to a compressed air system of at least
6 bar and remove valve springs.
– Pull out valve stem seals using valve stem seal puller -3364- .
Installing
– Place the plastic sleeve supplied on the appropriate valve
stem. This will prevent the new valve stem seal being dam‐
aged.
– Place new valve stem seal in valve stem seal fitting tool
-3365- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
– Install camshaft housing ⇒ page 61 .
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17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ Finding metal shavings or a large quantity of small metal par‐
ticles during engine repair could indicate that the conrod bear‐
ings are damaged. To prevent this from causing further
damage, perform the following repairs:
♦ Thoroughly clean oil passages
♦ Renew oil filter
♦ The oil level must not be above the max. mark, danger of
damage to catalytic converter! Markings ⇒ page 83 .
Engine oil (oil capacities, engine oil specification) ⇒ page 83
Parts of the lubrication system - Assembly overview
⇒ page 84
Oil cooler - Assembly overview ⇒ page 86
Removing and installing oil sump ⇒ page 87
Removing and installing oil pump ⇒ page 89
Removing and installing oil cooler ⇒ page 92
Checking oil pressure and oil pressure switch ⇒ page 94
1.1 Engine oil
Oil capacities
With oil filter 3.5 l.
Top up to max. marking if necessary ⇒ page 83 .
Viscosity class and oil specification
⇒ Maintenance ; Booklet 20.1
Markings on dipstick
1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not replenish
with engine oil!
b - Oil level within hatched field: Can be replenished with engine
oil.
c - Area from min. mark up to hatched field: Replenish with max.
0.5 l of engine oil!
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1.2 Parts of the lubrication system - Assembly overview
1 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 83
2 - Seal
❑ Renew
3 - Oil cooler
4 - Coolant pipes
❑ For oil cooler
5 - 8 Nm
6 - O-ring
❑ Renew
7 - 10 Nm
8 - Pressure regulating valve
❑ With breather hose
9 - Seal
❑ Renew
10 - Valve gear casing
control housing
⇒ page 31
❑ For a better guide pur‐
pose when installing, in‐
sert two M6x80 studs
into the camshaft hous‐
ing and the cylinder
block
❑ For a better guide pur‐
pose of the control
housing set the oil sump
with two bolts
11 - Sealing cover
❑ Renew seal if damaged
12 - Seal
❑ Renew if damaged
13 - Oil filter
14 - Oil filter cover, 25 Nm
15 - Valve
❑ With by-pass valve opening pressure: 2.5 bar
❑ With non-return valve
16 - 50 Nm
17 - Bolt, 10 Nm
❑ M6x22 mm
18 - Bolt
❑ Renew
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❑ Contact surface of the securing bolt must be free of oil and grease
❑ Secure belt pulley with counter-hold -3415- against turning
❑ The turning further angle can be measured with a commercially available angle measuring instrument
e.g. Hazet 6690
❑ Contact surfaces of the belt pulley must be free of oil and grease
❑ Removing and installing poly V-belt ⇒ page 29
❑ Secure belt pulley with counter-hold -3415- against turning
20 - Seal
❑ Renew
21 - Bearing bush
❑ Renew if scored
22 - 15 Nm
23 - Chain tensioner with tensioning plate and tension spring
❑ For oil pump drive
❑ Is replaced complete only
24 - Chain sprocket
❑ Note installation position: The journal must engage into the groove of the crankshaft!
❑ For oil pump and control chain drive
25 - 20 Nm + 90° (1/4 turn) further
26 - Chain sprocket
❑ For oil pump
❑ Lock with counter-hold -T10172-
27 - Drive chain
❑ For oil pump
28 - Oil pan
❑ Clean sealing surface before fitting
❑ Install with silicone sealing compound -D 176 404 A2-
29 - Seal
❑ Renew
❑ Lubricate before installing
30 - Oil level/ oil temperature sender -G266-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
31 - 10 Nm
32 - Oil drain plug, 30 Nm
❑ With attached seal
❑ Renew
33 - 13 Nm
❑ Loosen and tighten the bolts on the flywheel end only using socket insert -T10058-
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34 - 45 Nm
35 - Oil pump
❑ Renew complete only
36 - 25 Nm
1.3 Oil cooler - Assembly overview
1 - Oil cooler
⇒ page 92
2 - Seal
❑ Renew
3 - O-ring
❑ Renew
4 - Coolant pipes
5 - 8 Nm
6 - 8 Nm
7 - 8 Nm
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1.4 Removing and installing oil sump
equipment required
♦ Socket -T10058-
1331-
♦ Used oil collection and ex‐
traction unit -V.A.G. 1782-
♦ Silicone sealing compound
-D 176 404 A2-
♦ Hand drill with plastic brush
♦ Flat scraper
♦ Safety goggles
♦ 2 threaded studs M6
Removing
– Removing pre-catalytic converter with exhaust pipe
⇒ page 188 .
– Pull 3-pin connector -1- off oil level and oil temperature sender
-G266- .
– Drain engine oil.
– Unbolt sump sealed with liquid gasket.
– Remove oil sump. Loosen oil sump with light blows of a rubber
headed hammer if necessary.
– Remove sealant residue on cylinder block with a flat scraper.
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– Remove sealant residue from oil sump with a rotating brush,
e.g. a hand drill with a plastic brush attachment (wear protec‐
tive goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe the use by date of the sealing compound.
♦ The oil sump must be installed within 5 minutes of applying the
silicone sealant.
♦ Sump can be offered up easier and with greater security if, for
guide purposes, M6 studs are inserted into the cylinder block
flange at two positions.
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– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of
nozzle).
– Apply silicone sealing compound, as shown, to clean oil sump
sealing surface. Sealant bead must be:
♦ 2...3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealing compound bead must not be thicker, otherwise ex‐
cessive sealing compound will enter the oil sump and may block
the oil suction pipe strainer.
– Install oil sump immediately and tighten the two on the oppo‐
site side oil sump bolts lightly.
Note
♦ When placing the oil sump bolts to the flywheel end, observe
that the oil sump bolts fit into the holes and not between the
cylinder block and flyweel.
♦ If the oil sump bolts have been fitted between the cylinder
block and the flywheel, and can not be removed anymore, the
oil sump must be removed, the sealing surfaces cleaned and
the silicone sealing compound renewed.
– Then tighten both M6 oil sump bolts on flywheel end lightly.
– Tighten both M10 bolts for oil sump/gearbox lightly.
– Tighten remaining oil sump bolts lightly.
– Tighten the oil sump bolts.
Bolts M6: 13 Nm
Bolts M10: 40 Nm
Note
Let sealing compound dry for approx. 30 minutes after installing
oil sump. Only then fill engine oil.
1.5 Removing and installing oil pump
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Removing
– Lock the chain sprocket of the oil pump using counter-hold -
T10172- .
– Remove chain sprocket securing bolt.
Note
Do not remove bolt yet.
– Press chain tensioner in -direction of arrow- using a screw‐
driver.
– Remove chain sprocket securing bolt.
– Take chain sprocket off oil pump and out of chain.
– Loosen securing bolts -arrows- of the oil pump and remove.
– Take oil pump out of the cylinder block.
Installing
– Press chain tensioner in -direction of arrow- using a screw‐
driver.
– Set the chain sprocket into the chain and on the oil pump shaft.
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– Observe correct seat of chain sprocket on oil pump shaft
-arrow-.
– Install chain sprocket securing bolt.
– Lock the chain sprocket using counter-hold -T10172- .
– Place torque wrench -V.A.G. 1331- as shown.
– Tighten securing bolt to 20 Nm + 90° (1/4 turn) further.
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1.6 Removing and installing oil cooler
equipment required
♦ Hose clamp to Ø 25 mm
-3094-
♦ Torque wrench -
V.A.G. 1331-
♦ Torque wrench -
V.A.G. 1410-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Drip tray for workshop hoist
-VAS 6208-
Removing
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– Disconnect coolant hoses on oil cooler using hose clamps
-3094- .
– Remove securing bolts -arrows- for coolant pipes on cylinder
block and on oil cooler.
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Alter‐
nator; Alternator 1.6 l FSI engine .
– Place drip tray underneath.
– Pull coolant pipes out of oil cooler forwards.
– Remove bolts -1- and pull oil cooler -2- off cylinder block.
Installing
following:
Note
Renew O-ring.
– Add coolant or renew if the oil cooler has been removed
⇒ page 102 .
– Install alternator ⇒ Electrical system; Rep. Gr. 27 ; Alternator;
Alternator 1.6 l FSI engine .
Torque settings
Component Nm
Coolant pipes for oil cooler 8
Oil cooler to cylinder block 8
Warm air collector plate to exhaust manifold 10
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1.7 Checking oil pressure and oil pressure switch
equipment required
♦ Oil pressure gauge -V.A.G.
1342-
♦ Voltage tester -V.A.G. 1527
B-
♦ Adapter set -V.A.G. 1594
C-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051-
♦ or vehicle diagnosis and
service information system
-VAS 5052-
Prerequisites
• Engine oil level OK.
• Engine oil temperature at least 80 °C (radiator fan must have
run once).
Note
Functional check and repair of the visual and acoustic oil pressure
display ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations and ⇒ vehicle diagnosis, testing and information system
-VAS 5051- or vehicle diagnosis and service information system
-VAS 5052- .
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Test procedure
– Disconnect electrical wiring on oil pressure switch -F1-
-arrow-.
– Remove oil pressure switch -F1- -2- and screw into the oil
pressure gauge -V.A.G. 1342- .
– Screw tester into the cylinder head in place of the oil pressure
switch.
– Connect brown wire -1- of tester to earth (-).
– Connect voltage tester -V.A.G. 1527 B- using adapter cables
from adapter set -V.A.G. 1594 C- to battery positive (+) and oil
pressure switch.
LED must not light up.
– If the LED lights up, renew oil pressure switch -F1- .
If LED does not light up:
– Start engine and increase speed slowly. At 0.guatda.com/cmx.p3...0.7 bar the
LED must light up; otherwise renew oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be min. 2.0 bar.
At higher engine speeds the oil pressure must not exceed 7.0 bar.
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19 – Cooling system
1 Removing and installing parts of cool‐
ing system
Caution
♦ When doing any repair work, especially in the engine com‐
partment, pay attention to the following due to the cram‐
ped conditions:
the original way.
♦ To avoid damages to the wiring ensure sufficient clear‐
ance to all moving or hot components.
Note
♦ When the engine is warm, the cooling system is under pres‐
sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Hose clip pliers -VAS 5024 A- are recommended for fitting
spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Carry out leak test of cooling system with cooling system tester
-V.A.G. 1274- and adapters -V.A.G. 1274/8- and -
V.A.G. 1274/9- .
Parts of cooling system - body side - Assembly overview
⇒ page 97
Parts of cooling system engine side (thermostat side) - Assembly
overview ⇒ page 98
Parts of cooling system engine side (coolant pump side) - As‐
sembly overview ⇒ page 99
Coolant hose schematic diagram ⇒ page 99
Draining and filling with coolant ⇒ page 102
Removing and installing radiator fan -V7- and radiator fan 2 -
V177- ⇒ page 105
Removing and installing radiator ⇒ page 106
Removing and installing coolant pump ⇒ page 108
Removing and installing thermostat ⇒ page 110
Checking cooling system for leaks ⇒ page 113
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1.1 Parts of cooling system - body side - Assembly overview
1 - Upper coolant hose
❑ From thermostat hous‐
ing on cylinder head
2 - O-ring
3 - Radiator
⇒ page 106
❑ After renewing, renew
entire coolant
4 - Seal
5 - Sealing cover
❑ Check with cooling sys‐
tem tester -V.A.G 1274-
and adapter for cooling
system tester -V.A.G
1274/9- ⇒ page 113
❑ The pressure relief
valve must open at a
pressure of 1.4…1.6 bar
6 - Connector
7 - 3 Nm
8 - Expansion tank
❑ Carry out leak test of
cooling system with
cooling system tester -
V.A.G 1274- and adapt‐
er for cooling system -
V.A.G 1274/8-
⇒ page 113
9 - Retainer
❑ For radiator
10 - 5 Nm
11 - Spacer
❑ For refrigerant pipe tester
12 - Base plate
❑ Fit in lock carrier
13 - 5 Nm
14 - Air ducting
15 - 5 Nm
16 - Radiator fan 2 -V177-
17 - Connector
18 - Connector
19 - Radiator fan -V7-
❑ With radiator fan control unit -J293-
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20 - Lower coolant hose
❑ From connection for thermostat
21 - Retaining clip
22 - Radiator outlet coolant temperature sender -G83-
23 - O-ring
❑ Renew
1.2 Parts of cooling system engine side (thermostat side) - Assembly overview
1 - Pipe union
2 - O-ring
❑ Renew
3 - Compression spring
4 - Rod
5 - 10 Nm
6 - Retainer
❑ For wiring harness
7 - Coolant temperature send‐
er -G62-
❑ If necessary, release
pressure in cooling sys‐
tem before removing
8 - Retaining clip
❑ Check for secure seat‐
ing
9 - Thermostat housing
10 - Seal
❑ Renew
11 - To heat exchanger
❑ Coolant hose schematic
diagram ⇒ page 99
12 - From heat exchanger
❑ Coolant hose schematic
diagram ⇒ page 99
13 - Thermostat
Control range:
❑ Long thermoelement 87 °C…102 °C
❑ Short thermoelement 103 °C…120 °C
14 - Coolant pump housing on cylinder block
15 - Pipe union
16 - To expansion tank
❑ Coolant hose schematic diagram ⇒ page 99
17 - Coolant pipe
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18 - Retaining clip
❑ Check for secure seating
19 - 5 Nm
20 - From bottom of radiator.
21 - To top of radiator
1.3 Parts of cooling system engine side (coolant pump side) - Assembly over‐
view
1 - Coolant pump
⇒ page 108
❑ Check for ease of move‐
ment
❑ With integrated seal
❑ If damaged or leaking
renew complete
2 - 9 Nm
3 - 20 Nm
4 - Belt pulley
❑ To loosen and tighten
use water pump wrench
-V.A.G. 1590-
❑ Change water pump
wrench -V.A.G. 1590-
⇒ page 108
❑ When installing note fix‐
ing arrangement
poly V-belt ⇒ page 29
1.4 Coolant hose schematic diagram
Models without auxiliary heater ⇒ page 100
Models with auxiliary heater ⇒ page 101
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1.4.1 Models without auxiliary heating
1 - Expansion tank
2 - Coolant hose
❑ From exhaust gas recir‐
culation valve -N18-
with exhaust gas recir‐
culation potentiometer -
G212-
3 - Exhaust gas recirculation
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
4 - Heater unit heat exchanger
entire coolant
5 - Coolant hose
❑ To exhaust gas recircu‐
lation valve -N18- with
exhaust gas recircula‐
tion potentiometer -
G212-
6 - Upper coolant hose
7 - Lower coolant hose
8 - Radiator
entire coolant
9 - Engine oil cooler
entire coolant
11 - Cylinder head/cylinder
block
entire coolant
12 - Coolant pipe
13 - Coolant pump
14 - Intake manifold
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1.4.2 Models with auxiliary heater
1 - Expansion tank
2 - Non-return valve
3 - Heater unit heat exchanger
entire coolant
4 - Heater coolant shut-off
valve -N279-
❑ Location: Secured to
engine compartment
bulkhead
G212-
6 - Intake manifold
8 - Radiator
entire coolant
9 - Engine oil cooler
entire coolant
10 - Cylinder head/cylinder
block
entire coolant
11 - Circulation pump -V55-
recirculating pump ⇒
auxiliary heater; Rep.
Gr. 82 ; Removing and
installing auxiliary heat‐
er Thermo Top V
12 - Auxiliary heater Thermo Top V
❑ Removing and installing auxiliary heater ⇒ auxiliary heater; Rep. Gr. 82 ; Removing and installing
auxiliary heater Thermo Top V
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1.5 Draining and filling coolant
equipment required
♦ Refractometer -T10007-
♦ Drip tray -V.A.G. 1306- or -
VAS 6208-
5024 A-
♦ Cooling system charging
unit -VAS 6096-
♦ Adapter for cooling system
tester -V.A.G. 1274/8-
Draining
WARNING
Hot steam can escape when opening expansion tank. Wear
eye protection and protective clothing to prevent eye damage
and scalding. Cover sealing cap with a cloth and open cap
carefully.
– Open sealing cap of expansion tank.
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– Open spring-type clamp -arrow- and pull coolant hose off.
If quick release coupling is pulled off on the lower radiator un‐
ion, much coolant will leak out on the bumper cover.
– Pull coolant hose -arrow- on expansion tank off and guide
completely downwards to drain remaining coolant.
Note
Observe disposal regulations!
Filling
Note
♦ Only use coolant additive G 12 in accordance with “TL VW 774
F”. Identification characteristics: Coloured lilac (purple)
♦ G 12 lilac according to “TL VW 774 F” can be mixed with cool‐
ant additive G 12 red.
♦ G 12 and coolant additives marked in accordance with “TL VW
774 F” prevent frost and corrosion damage, scaling and also
raise boiling point of coolant. For this reason the system must
be filled all year round with frost and corrosion protection ad‐
ditives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection (anti-freeze) must be guaranteed to approx.
-25 °C (approx. -35 °C in countries with an arctic climate) in
the washer system.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The anti-
freeze must be at least 40% of mixture.
♦ If for climatic reasons a higher frost protection is required, the
amount of G 12 can be increased, but only up to 60 % (frost
protection to about -40 °C), as otherwise frost protection is re‐
duced 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 proportions:
Frost
protection to
Anti
freeze proportion
G 124)
Water4)
-25 °C
-35 °C
40 %
50%
2.25 l
2.8 l
3.35 l
2.8 l
4) The quantity of coolant can vary depending upon vehicle equipment.
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– Fit the coolant hose on the union and secure with spring-type
clamp.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
Gr. 50 ; Noise insulation .
– Fit coolant hose -arrow- to expansion tank.
With cooling system charging unit -VAS 6096-
– Fill coolant circuit using cooling system charging unit -
VAS 6096- . ⇒ Operating instructions for cooling system
charging unit VAS 6096 .
Without cooling system charging unit -VAS 6096-
– Fill with coolant up to max. mark on expansion tank.
– Fit expansion tank cap.
– Switch off heater blower.
Models without auxiliary heating
– Start engine and maintain an engine speed of about 2000 rpm
for approx. 3 minutes.
– Run engine until radiator fans cuts-in.
Caution
The auxiliary heater may only be switched on when the coolant
circuit is filled as described in the following.
– Connect the connector of the diagnostic cable -2- of the vehi‐
cle diagnosis, testing and information system -VAS 5051- or
the vehicle diagnosis, testing and information system -VAS
5052- -1- to the diagnosis connection in the driver footwell.
– Start engine and maintain an engine speed of about 2000 rpm
for approx. 3 minutes.
– Let the engine run with the same speed for one minute and
initiate simultaneously in the same minute the selective final
control diagnosis for the heater coolant shut-off valve -N279-
(shut-off valve is supplied with current).
The coolant circuit of the auxiliary heater can be bled only this
way correctly.
– Run engine until radiator fans cuts-in.
Continuation for vehicles with and without auxiliary heater
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– Check coolant level when expansion tank is closed.
• When the engine is at operating temperature, the coolant level
must be on the max. mark and between the min. and max.
marks when the engine is cold.
WARNING
carefully.
– Replenish coolant, if necessary.
1.6 Removing and installing radiator fan -
V7- and radiator fan 2 -V177-
♦ Spring-type clip pliers -VAS 5024 A-
Removing
– Remove upper securing bolts -arrows- of the air ducting.
– Disconnect connector -1- and remove lower securing bolts
-arrows- of the air ducting.
– Take air ducting out downwards.
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– Disconnect connection -1- and place wiring to side.
– Remove nuts -arrows- and take radiator off.
Installing
following:
– Install air ducting from below and tighten bolts to 5 Nm.
1.7 Removing and installing radiator
equipment required
5024 A-
1331-
Removing
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. Gr. 63 ; Front bumper; Removing and installing front
bumper cover .
– Pull coolant hoses off radiator.
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– Remove cowling with radiator fans ⇒ page 105 .
– Remove left and right bumper cover guide ⇒ General body
repairs, exterior; Rep. Gr. 63 ; Front bumper; Front bumper
cover substructure .
Models without air conditioning system
– Remove bolts -1- from radiator mounting.
– Take radiator out downwards.
Models with an air conditioning system
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Lock carrier .
Note
To prevent damage to condenser also to the refrigerant lines/ho‐
ses, ensure that the lines and hoses are not stretched, kinked or
bent.
– Remove bolts -1- from radiator mounting.
– Swing radiator slightly to back.
– Remove securing bolts -2- of condenser.
– Remove bolt -arrow- for fitting refrigerant pipe.
– Take radiator out downwards.
Installing
following:
– Renew coolant if a new radiator has been installed.
– Fill with coolant ⇒ page 102 .
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1.8 Removing and installing coolant pump
equipment required
1331-
♦ Water pump wrench -
V.A.G. 1590-
5024 A-
♦ Drip tray for workshop hoist
-VAS 6208-
Change water pump wrench V.A.G. 1590
– Due to the modified securing bolts for the belt pulley coolant
pump file the three curves for a = 1 mm minimum.
Removing
Note
♦ The integrated coolant pump seal must not be separated from
the coolant pump.
♦ Damaged or leaking coolant pumps must be replaced com‐
plete with seal.
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– Remove bolts -arrows- and take engine lifting eye off.
– Remove the front right wheel housing liner: ⇒ General body
repairs; Rep. Gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
Note
The belt pulley - Coolant pump is removed via the wheel case.
– Unscrew belt pulley - Coolant pump. To do this counterhold
with modified water pump wrench -V.A.G. 1590- .
– Remove bolts -arrows- and remove coolant pump from the
cylinder block.
Installing
following:
– Fit coolant pump into the cylinder block.
– Tighten securing bolts to 25 Nm.
– Tighten belt pulley of coolant pump to 20 Nm.
– Install Poly V-belt ⇒ page 29 .
– Install front right wheel housing liner ⇒ General body repairs;
Rep. Gr. 66 ; Removing and installing wheel housing liner;
Front wheel housing liner .
– Fill with coolant ⇒ page 102 .
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1.9 Removing and installing thermostat
equipment required
♦ Drip tray -V.A.G. 1306-
♦ Torque wrench -
V.A.G. 1331-
♦ Spring-type clip pliers -
VAS 5024 A-
Removing
– With ignition switched off disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
the battery .
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-2-.
– Disconnect electrical connection -arrow- on coolant tempera‐
ture sender -G62- .
– Remove both coolant hoses from thermostat housing
-arrows-.
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– Remove bolts -arrows- and take respective pipe union off.
– Take spring, tappet and thermostat off.
Installing
following:
Note
O-rings; Renew.
– Clean or smooth sealing surface for O-ring.
– Moisten new O-ring with coolant and fit into pipe union.
– Fit thermostat, spring and tappet.
• Installation position: The hole in the tappet for thermostat must
show upwards.
– Tighten bolts -arrows- of pipe union to 5 Nm.
– Install battery carrier first and tighten bolts -arrows-.
– Route wiring -2- as shown in the figure and fit to electronics
box -1-.
– Top-up coolant ⇒ page 102 .
– Install noise insulation ⇒ General Body Repairs, Exterior;
– Install engine cover with air cleaner ⇒ page 161 .
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1.10 Check cooling system for leaks:
equipment required
♦ Cooling system tester -
V.A.G. 1274-
Test procedure
• Engine at operating temperature
WARNING
carefully.
– Open cap on coolant expansion tank.
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– Set cooling system tester -V.A.G. 1274- with adapter -
V.A.G. 1274/8- on coolant reservoir.
– Generate a pressure of approx. 1 bar using the tester hand
pump.
If the pressure drops:
– Search for the leak and eliminate fault.
Check pressure relief valve in sealing cap
– Set cooling system tester -V.A.G. 1274- with adapter -
V.A.G. 1274/9- on coolant reservoir.
– Operate hand pump.
• The pressure relief valve must open at a pressure of 1.4…1.6
bar.
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20 – Fuel supply system
1 Removing and installing parts of fuel
supply system
Safety precautions when working on fuel supply system
⇒ page 115 .
Observe rules for cleanliness ⇒ page 115 .
Fuel tank with attachments - Assembly overview ⇒ page 116
Emptying fuel tank ⇒ page 118
Removing and installing fuel tank ⇒ page 120
Fuel filter with attachments - Assembly overview ⇒ page 123
Removing and installing fuel filter ⇒ page 123
1.1 Safety precautions when working on
fuel supply system
Caution
tions:
coal filter system, coolant and refrigerant liquid, brake
the original way.
The fuel pump is activated when switching on the ignition and by
the driver's door contact switch. Therefore, for safety reasons, the
fuel pump control unit -J538- -2- must be pulled out of the cover
-1- and the electrical connection must be disconnected, before
opening the fuel system, if the battery is not disconnected.
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 beginning work, place an extraction hose close to
sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust extraction
system is available, a radial fan with a displacement greater
than 15 m3/h can be used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.2 Rules for cleanliness
When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules”:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place parts that have been removed on a clean surface and
cover. Use lint-free cloths only!
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♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean parts only: Only unpack replacement parts im‐
mediately prior to installation. Do not use parts that have not
been stored in their packing (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air if
this can be avoided. Do not move vehicle unless absolutely
necessary.
1.3 Fuel tank - Assembly overview
1 - Securing bolt
2 - Sealing cover
❑ Renew seal if damaged
3 - Earth connection
ing.
4 - 10 Nm
5 - Cable guide
❑ For ABS wiring
6 - 25 Nm
❑ Renew
7 - Fuel tank
⇒ page 120
8 - Lock washer
9 - Exhaust system bracket
10 - Securing strap
❑ Note installation posi‐
tion
11 - Heat shield
12 - Supply line
❑ To connecting pipe for
high-pressure pump
ing
13 - Fuel filter
❑ Installation position: Ar‐
row shows in direction of
flow
❑ Fuel filter - Assembly overview ⇒ page 123
14 - Breather line
❑ To activated charcoal filter
❑ Clipped onto side of fuel tank
15 - Seal
❑ Renew
❑ When installing, insert seal "dry" into fuel tank opening
❑ Moisten inner edges of seal with fuel when installing fuel delivery unit only
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16 - Fuel delivery unit
❑ If fuel delivery unit was replaced, adapt the engine control unit to the fuel pump ⇒ vehicle diagnosis,
testing and information system -VAS 5051- or vehicle diagnosis, testing and information system -VAS
5052-
❑ Checking fuel pump ⇒ page 130
❑ Note installation position on fuel tank ⇒ page 117
❑ With fuel gauge sender -G-
❑ Removing and installing fuel gauge sender -G- ⇒ page 129
❑ Clean strainer if soiled
17 - Lock ring, 110 Nm
❑ Remove and install using wrench -T10202-
18 - Supply line
❑ Black
19 - Return hose
❑ Blue
20 - Tank flap unit
❑ With rubber cup
❑ Removing and installing ⇒ General body repairs, exterior; Rep. Gr. 55 ; Fuel tank filler flap unit; Re‐
moving and installing fuel tank filler flap unit
Installation position of fuel delivery unit:
The tab -2- on the fuel delivery unit must lie between the tongues
-1- and -3-.
Note
♦ The -arrow- shows in direction of travel.
♦ The fuel delivery unit can only be installed in this position.
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1.4 Emptying fuel tank
equipment required
1332-
♦ Fuel extractor -VAS 5190-
♦ Wrench -T10202-
– Note safety precautions before beginning work ⇒ page 115 .
– Observe rules for cleanliness ⇒ page 115 .
Empty fuel tank if fuel level is higher than 3/4 ⇒ page 118
Empty fuel tank if fuel level is lower than 3/4 ⇒ page 119
1.4.1 Emptying fuel tank if it is more than 3
/4
full
Caution
Fit earth wire of fuel extractor -VAS 5190- at a bare area of the
body.
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– Remove cotter -2- from shaft piece -1- of fuel extractor -
VAS 5190- .
– Mark hose with insulation tape -arrow- at a distance of -a- =
1180 mm from the suction hose end.
– Remove filler cap from fuel tank filler neck.
– Fit shaft piece -1- of fuel extractor -VAS 5190- to the filler neck.
– Slide suction hose into fuel reservoir until the applied mark
-arrow- has reached the shaft piece.
Note
On the lower end of the filler neck there is a ball valve -2- in the
fuel tank -1- which must not be damaged by the suction hose
-3-. For this reason the hose must only be slid up to the applied
mark -arrow-.
– Empty fuel tank as far as possible.
– Pull suction hose out very carefully.
Note
♦ If no fuel is be sucked anymore, the fuel tank is just sufficiently
vacant to open the fuel delivery unit without danger.
♦ If you must empty the fuel tank completely ⇒ page 119 .
1.4.2 Emptying fuel tank if it is less than 3
/4 full
– Remove seat bench ⇒ General body repairs, interior; Rep.
Gr. 72 ; Rear seats; Removing and installing seat bench .
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– Unclip the cover -1- along with the fuel pump control unit -
J538- -2-.
– Pull connector -1-, black supply line -2- and blue return line
-3- off.
Note
Press locking ring inwards to release fuel lines.
– Open lock ring using wrench -T10202- .
– Pull out the fuel delivery unit a bit.
– Insert suction hose of fuel extraction unit -VAS 5190- as far as
possible into the fuel tank and extract fuel.
If the fuel tank must only be emptied, install fuel delivery unit again
⇒ page 127 .
1.5 Removing and installing fuel tank
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♦ Engine and gearbox jack -V.A.G 1383 A-
Removing
• The fuel tank must not be filled more than 1/4.
Note
♦ If necessary, empty fuel tank with fuel extractor -VAS 5190-
⇒ page 118 .
♦ Note safety precautions before beginning work ⇒ page 115 .
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Open the tank flap and remove filler cap.
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General Body Repairs, Exterior; Rep. Gr. 55 ; Tank flap
unit .
J538- -2-.
Note
In vehicles with auxiliary heater, the connector for the metering
pump -V54- must be disconnected additionally.
– Disconnect connector -1- from fuel supply unit.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. Gr. 66 ; Wheel housing liner; Removing
and installing rear wheel housing liner .
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– Remove tank filler neck bolts -1-.
– Unhook electrical wiring -2- of ABS speed sensor on filler neck
bracket.
– Remove front silencer, separate front and rear silencer first, if
necessary ⇒ page 190 .
WARNING
– Disconnect white breather line -1- and black supply line -2- on
the connection point.
Note
♦ In vehicles with auxiliary heater, the line for the metering pump
-V54- must be disconnected additionally.
♦ Press locking ring inwards to release fuel lines.
♦ A second mechanic is required to assist when supporting the
fuel tank.
– Remove tensioning strap and securing bolts -arrows-. When
doing this support fuel tank with engine/gearbox jack -
V.A.G 1383 A- .
– Remove fuel tank from side.
Installing
Installation is carried out in reverse order of removal. During this
step, observe the following:
♦ Install breather and fuel hoses free of kinks.
♦ Do not interchange supply and return lines (return line blue,
supply line black).
♦ Ensure line connections are tight.
♦ Check fuel tank/body earth connection on filler neck.
♦ After installing fuel tank, check that the supply and return lines
are still clipped onto the fuel tank.
♦ If fuel delivery unit was replaced, adapt the engine control unit
to the fuel pump ⇒ vehicle diagnosis, testing and information
system -VAS 5051- or vehicle diagnosis, testing and informa‐
tion system -VAS 5052- .
Torque settings
Component Nm
Fuel tank to body - M6 10
Fuel tank to body - M8
♦ Renew bolts.
25
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1.6 Fuel fliter - Assembly overview
1 - Fuel filter
❑ With pressure limiting
valve
❑ Flow direction is marked
by arrows
❑ Do not interchange con‐
nections
⇒ page 123
❑ Installation position:
The pin on the air filter
housing must engage
into the recess on the fil‐
ter bracket guide
⇒ page 125
2 - Fuel supply line
❑ Black
❑ From fuel tank
❑ Press locking ring in‐
wards to release fuel
lines
3 - Fuel return line
❑ Blue
❑ To fuel tank
lines
❑ Black
❑ To engine
lines
5 - 3 Nm
6 - Retainer
❑ For fuel filter
❑ Clipped onto fuel tank
1.7 Removing and installing fuel filter
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♦ Drip tray for workshop hoist -VAS 6208-
Removing
– Note safety precautions before beginning work ⇒ page 115 .
– Observe rules for cleanliness ⇒ page 115 .
– Place container under fuel filter.
WARNING
– Pull fuel lines -1-, -2- and -3- off. To do this press securing ring
in.
– Remove bolt -4-.
– Remove fuel filter.
Installing
following:
The flow direction is marked on filter housing with arrows.
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Installation position
The pin -2- on the air filter housing must engage into the recess
on the filter bracket guide -1-.
– Tighten bolt of retaining clip for fuel filter to 3 Nm.
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2 Repairing fuel supply
Note
♦ Fuel hoses on the engine must be secured only with spring-
type clips ⇒ Electronic parts catalogue “ETKA” .
♦ To install spring-type clips spring-type clip pliers -VAS 5024 A-
or hose clamp pliers -V.A.G 1921- are recommended.
Safety precautions when working on fuel supply system
⇒ page 126 .
Note crash fuel shut-off ⇒ page 127 .
Removing and installing fuel fuel delivery unit ⇒ page 127
Removing and installing fuel gauge sender -G- ⇒ page 129
Checking fuel pump ⇒ page 130
Removing and installing high-pressure pump ⇒ page 139
2.1 Safety precautions when working on
fuel supply system
Caution
tions:
coal filter system, coolant and refrigerant liquid, brake
the original way.
The fuel pump is activated when switching on the ignition and by
the driver's door contact switch. Therefore, for safety reasons, the
fuel pump control unit -J538- -2- must be pulled out of the cover
-1- and the electrical connection must be disconnected, before
opening the fuel system, if the battery is not disconnected.
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 beginning work, place an extraction hose close to
sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust extraction
system is available, a radial fan with a displacement greater
than 15 m3/h can be used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
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mantling.
necessary.
2.3 Crash fuel shut-off
Functional check
The crash fuel shut off reduces the danger of a fire in a crash as
the fuel pump is switched off. At the same time the starting char‐
acteristics of the engine are also improved with this system. When
the door is opened the fuel pump is activated for 2 seconds to
build-up fuel pressure.
When opening the fuel system:
Observe safety precautions ⇒ page 126 .
2.4 Removing and installing fuel delivery
unit
♦ Key -T10202-
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Removing
• The fuel tank must not be filled more than 3/4.
Note
♦ If necessary, empty fuel tank with fuel extractor -VAS 5190- .
♦ Note safety precautions before beginning work ⇒ page 126 .
– Switch off ignition and all electrical consumers and pull out
ignition key.
J538- -2-.
Note
In vehicles with auxiliary heater, the connector for the metering
pump -V54- must be disconnected additionally.
WARNING
– Pull 5 pin connector -1-, black supply line -2- and blue return
line -3- off.
Note
♦ Press locking ring inwards to release fuel lines.
♦ In vehicles with auxiliary heater, the suction line for the me‐
tering pump -V54- must be pulled out additionally (open lower
clamp).
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– Open lock ring using wrench -T10202- .
– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
♦ Take care not to bend the fuel gauge sender when removing
fuel delivery unit.
♦ If the fuel delivery unit is to be renewed then drain old fuel
delivery unit before disposal.
Installing
Installation of the fuel delivery unit is carried out in the reverse
order. During this step, observe the following:
♦ Insert new fuel delivery unit seal dry into fuel tank opening.
♦ Moisten inner edges of seal with fuel only when installing fuel
delivery unit.
♦ Take care not to bend the fuel gauge sender when installing
fuel delivery unit.
♦ Note installation position of fuel delivery unit: The tab -2- on
the fuel delivery unit must lie between the tongues -1- and
-3-. The -arrow- shows in direction of travel.
♦ Tighten lock ring to 110 Nm.
♦ Do not interchange the black supply line and the blue return
line (arrows on the flange of the fuel delivery unit).
♦ Ensure fuel pipes/hoses are fitted securely.
♦ After installing the fuel delivery unit, check that the supply and
return lines are still clipped onto the fuel tank.
2.5 Removing and installing fuel gauge
sender -G-
Removing
– Remove the fuel delivery unit ⇒ page 127 .
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– Release line connectors -1- to -3- and pull off.
– Lift up retaining lugs -4- and -5- using a screwdriver and pull
fuel delivery unit -G- off downwards -arrow-.
Installing
– Insert fuel gauge sender -G- in the guides on the fuel delivery
unit and push up until it engages.
– Connect the connectors and check for secure fit.
– Install fuel delivery unit ⇒ page 127 .
2.6 Checking fuel pump
equipment required
♦ Pressure tester -V.A.G
1318-
♦ Adapter -V.A.G 1318/1-
♦ Hose adapter -V.A.G
1318/16-
♦ Double socket -V.A.G
1318/23-
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♦ Key -T10202-
♦ Remote control -V.A.G
1348/3A-
♦ Adapter set -V.A.G 1594C-
♦ Multimeter -V.A.G 1715-
1332-
♦ Measuring container
♦ Voltage tester -V.A.G 1527 B-
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♦ Vehicle diagnosis and service information system -VAS 5052-
Checking function and voltage supply ⇒ page 132
Checking fuel pressure ⇒ page 133
Checking holding pressure ⇒ page 135
Checking delivery rate ⇒ page 136
Checking current consumption ⇒ page 138
2.6.1 Checking function and voltage supply
• Battery charge at least 11.5 V.
• Fuse for fuel pump OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
– Switch ignition on.
• Fuel pump must be heard to run briefly.
Note
The fuel pump runs very quietly.
– Switch off ignition.
Fuel pump does not run
J538- -2-.
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– Pull connector off -1-.
– Connect voltage tester -V.A.G 1527 B- to the outer contacts
of the connector with auxiliary cables from adapter set -V.A.G
1594 C- .
– Switch on ignition.
• The LED must light up briefly.
LED does not light up briefly:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
LED lights up briefly (voltage supply OK):
– Remove the fuel delivery unit ⇒ page 127 .
– Check that the electrical wires between flange and fuel pump
are connected.
If no open circuit can be found:
– Fuel pump is defective. Renew fuel delivery unit ⇒ page 127 .
2.6.2 Checking fuel pressure
WARNING
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– Install the pressure tester -V.A.G 1318- with the adapter -
V.A.G 1318/1- and the adapter set -V.A.G 1318/17- instead of
the fuel supply line.
– Open shut-off tap of pressure tester. The lever then points in
position -A-.
– Switch on ignition repeatedly until fuel pressure does not rise
any more on pressure gauge.
– Read fuel pressure on pressure gauge. Specification: 3.5 to
5.0 bar.
If fuel pressure is OK, check holding pressure ⇒ page 135 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinking
and blockages.
If no fault is detected:
– Pressure limiting valve in fuel filter defective. Replace fuel fil‐
ter.
If the specification is not obtained:
– Check fuel delivery rate upstream of fuel filter. Connect pres‐
sure tester -V.A.G 1318- with adapter set -V.A.G 1318/17-
between fuel filter and supply pipe.
– Open shut-off tap on pressure gauge. The handle points in
direction of flow.
– Start engine and run at idling speed.
Caution
Close the cut-off tap only slowly. At a fuel pressure of 8 bar,
reopen the cut-off tap immediately to prevent damage to the
pressure tester.
– Slowly close cut-off tap of pressure tester. The pressure must
rise to 6.0 bar. When 6 bar have been reached, immediately
reopen cut-off tap.
If pressure has risen:
– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐
tive. Renew fuel filter.
If pressure does not rise:
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2.6.3 Checking holding pressure
• Fuel pressure is OK and pressure tester -V.A.G 1318- is con‐
nected. Checking fuel pressure ⇒ page 133 .
5.0 bar.
– Observe pressure drop on gauge. After 10 minutes, pressure
must not drop below 3.0 bar.
If the pressure drops further:
– Immediately close pressure tester cut-off tap. The lever then
points in direction -B-.
If the pressure drops again:
– Check fuel pipe to high-pressure pump for leaks.
– Renew high-pressure pump ⇒ page 139 .
If pressure does not drop any further:
– Check fuel line to fuel filter for leaks.
If no fault in the fuel line is detected:
– Check the non-return valve in the fuel delivery unit. Connect
pressure tester -V.A.G 1318- with adapter set -V.A.G 1318/17-
between fuel filter and supply pipe.
– Open shut-off tap on pressure gauge. The handle points in
direction of flow.
5.0 bar.
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– After pressure has built up, immediately close pressure tester
cut-off tap.
– Observe pressure drop on gauge. After 10 minutes, pressure
must not drop below 3.0 bar.
If the pressure drops:
– Fuel pump non-return valve is defective, renew fuel delivery
unit ⇒ page 127 .
If the pressure does not drop:
– Pressure limiting valve in fuel filter defective. Replace fuel fil‐
ter.
2.6.4 Checking delivery rate
J538- -2-.
– Connect remote control -V.A.G 1348/3A- to contact -1(+)- of
fuel pump and contact -1(+)- of connector using adapter ca‐
bles.
– Connect contacts -6(-)- of connector and -5(-)- of fuel pump
using an adapter cable from auxiliary measuring set -V.A.G
1594 C- .
– Remove filler cap from fuel tank filler neck.
WARNING
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– Connect pressure tester -V.A.G 1318- with connector -V.A.G
1318/23- and adapter set -V.A.G 1318/17- to the fuel supply
line.
– Push hose adapter -V.A.G 1318/16- onto adapter -V.A.G
1318/11- of pressure tester and hold it in measuring container.
– Close shut-off tap of pressure tester. The lever then points in
position -B-.
WARNING
Danger of spray when shut-off tap is opened. Wear protective
glasses and clothing to avoid injuries and skin contact. Hold
container over free connection of pressure tester.
– Open shut-off tap of pressure tester. The lever then points in
the through flow direction -A-.
– Operate remote control -V.A.G 1348/3A- . At the same time
slowly close shut-off tap until pressure gauge shows 4 bar.
From this point on do not move position of shut-off tap.
– Drain measuring container.
– The fuel pump delivery rate is dependent upon battery voltage.
Therefore connect multimeter -V.A.G 1715- with adapter ca‐
bles from auxiliary measuring set -V.A.G 1594C- to vehicle
battery.
– Operate remote control for 30 seconds and measure battery
voltage.
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– Compare the quantity of fuel delivered with specification.
*) Minimum delivery rate cm3/30 seconds
**) Voltage at fuel pump with engine not running and pump run‐
ning (approx. 2 volts less than battery voltage).
Example:
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, this will equate to a minimum delivery rate of approx. 580
cm3/30 seconds.
If the minimum delivery rate is not attained:
– Check fuel lines for possible restrictions (kinks) or blockages.
WARNING
– Pull fuel supply line -1- off fuel filter inlet (press locking ring
inwards) and collect leaking fuel with a cloth.
– Connect pressure tester -V.A.G 1318- with adapter set -V.A.G
1318/17- to fuel supply line -1-.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter ⇒ page 123 .
If the minimum delivery rate is again not attained:
– Remove the fuel delivery unit ⇒ page 127 and check the filter
strainer for soiling.
Only when up to now no fault has been detected:
– Replace fuel delivery unit.
If delivery quantity has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Measure current consumption of fuel pump ⇒ page 138 .
2.6.5 Checking current consumption
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J538- -2-.
– Connect the current clamp -A- of the multimeter -V.A.G 1715-
or the vehicle diagnosis, testing and information system -VAS
5051- to the cable -B- to contact 1 of the 5-pin connector.
– Check the current draw of the fuel pump.
Specification: max. 9 amps.
Note
If the fuel system malfunction is intermittent, the check can be
performed during a road test, but a 2nd person is necessary.
If the current draw is exceeded:
2.7 Removing and installing high-pressure
pump
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Prerequisites
• Engine must be cold.
Removing
WARNING
The fuel line and the high pressure line is under pressure! Wear
protective glasses and clothing to avoid injuries and skin con‐
tact. Before loosening lines, wrap a cloth around the connec‐
tion. Then release pressure by carefully removing the line.
– Pull connector and fuel supply line -arrows- off the high-pres‐
sure pump.
Note
Collect leaking fuel with a cloth.
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– Remove cable guide -2- and remove clip -4- from the high-
pressure line.
Note
– Remove securing bolts -1-, -2- and -3- evenly.
– Remove high pressure pump -3- and tappet -1- out of the
camshaft housing.
Installing
following:
Note
♦ Moisten tappet of high pressure pump with clean engine oil.
♦ The O-ring of the high pressure pump must always be renew.
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– Slide the tappet -1- into the camshaft housing.
– Fit a new oiled O-ring -2- into the groove of the high pressure
pump -3-.
– Fit the high pressure pump -3- on the camshaft housing.
– Tighten securing bolts -1-, -2- and -3- evenly.
Tightening torque: 10 Nm
– Tighten union nuts of the high pressure line -1- and -3- hand-
tight.
– Install cable guide -2- and press clip -4- onto the high-pressure
line.
Tightening torque of the securing bolt of the cable guide: 10 Nm
Note
fuel rail when tightening the union nuts with a spanner.
– Tighten union nut -1- of the high-pressure line to 30 Nm.
– Tighten union nut -3- of the high-pressure line to 25 Nm.
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– Fit fuel supply line and the connector -arrows- to the high-
pressure pump.
– Connect fuel supply line -3-.
– Install air cleaner ⇒ page 161 .
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3 Servicing electronic power control
(EPC)
Function of EPC system ⇒ page 144
Accelerator pedal module - Assembly overview ⇒ page 145
Removing and installing accelerator pedal module ⇒ page 145
3.1 Function of EPC system
With the electronic power control system (EPC) (also known as
E-gas) the throttle valve is not operated by a cable. There is no
mechanical connection between accelerator and throttle valve.
The position of the accelerator pedal is transmitted to the engine
control unit by two accelerator pedal position senders (variable
resistors together in one housing) connected to the accelerator
pedal.
The position of the accelerator pedal (driver's requirement) is a
main input value for the engine control unit.
The throttle valve is operated over the complete engine speed
and load range by an electric motor (throttle valve positioner) in
the throttle valve module.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit.
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator pedal position sender. That is, when
the accelerator is depressed halfway, the throttle valve positioner
opens the throttle valve by the same amount. The throttle is then
approximately half open.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator pedal position sender.
This means that the throttle valve can already be completely open
even though the accelerator pedal is depressed half way. This
has the advantage of preventing throttling losses at the throttle
valve.
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
opening angle for the respective situation.
This also results in significantly improved consumption and ex‐
haust emission values at certain load conditions.
“EPC” is a system comprising all components which contribute to
determining, controlling or monitoring the position of the throttle
valve, e.g. accelerator pedal position sender, the throttle valve
control module, the EPC warning lamp, the engine control unit
and so on.
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3.2 Accelerator pedal module - Assembly overview
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
-G79- with accelerator position
sender 2 -G185-
❑ Cannot be adjusted
❑ The accelerator pedal
position passes the po‐
sition of the pedal on to
the engine control unit
❑ Openings -A- for re‐
lease tool
⇒ page 145
3 - 10 Nm
4 - Cover
3.3 Removing and installing accelerator
pedal module
♦ Release tool -T10238-
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Removing
– Remove cover for steering column -arrows-.
– Lever off the protective cap ⇒ Item 4 (page 145) using a
screwdriver.
– Unbolt securing bolt ⇒ Item 3 (page 145) .
– Slide the release tool -T10238- as shown into the openings
provided to the stop and take accelerator pedal module off.
– Disconnect connector and pull cable guide off accelerator
pedal module.
Installing
– Fit connector -2- to the accelerator pedal module -5- and slide
the rubber grommet -1- onto the connector again.
– Press the accelerator pedal module onto the securing pins
-6-.
– Fit the centre pin -7- into the hole of the vehicle floor.
– Secure accelerator pedal module with the bolt -3- and fit cover
cap -4-.
– Install steering column cover again.
– If the accelerator pedal module has been renewed, adapt the
accelerator pedal module to the engine control unit⇒ Vehicle
Diagnosis, Testing and Information System -VAS 5051- or
Vehicle Diagnosis and Service Information System -VAS
5052- .
Torque setting
Component Nm
Accelerator pedal module to body 10
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4 Activated charcoal filter system
Function ⇒ page 147
Activated charcoal filter system - Assembly overview
⇒ page 148
Checking fuel tank breather ⇒ page 148
4.1 Functional check
Depending upon the air pressure and ambient temperature, fuel
vapour will form above the level of fuel in the tank.
The active charcoal filter system prevents these HC emissions
escaping to the atmosphere.
Fuel vapours from the highest point in the fuel tank pass through
the gravity valve (which closes at an angle of 45°) and through a
pressure retention valve (in limited quantities) to the activated
charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the Lambda control is active when driving (engine warm),
the activated charcoal filter system solenoid valve 1 -N80- (also
called regeneration valve), is activated (pulsed) from engine con‐
trol unit depending upon load and engine speed. The opening
period depends on the input signals.
Intake manifold vacuum draws fresh air through the vent opening
on the underside of the activated charcoal filter during the purging
procedure (regenerating the activated charcoal). The fuel va‐
pours stored in the activated charcoal and fresh air are fed to
combustion in metered quantities.
The pressure retention valve prevents fuel vapours from being
drawn from the tank when the solenoid valve is open and intake
manifold vacuum is present. It therefore ensures that the evacu‐
ation of the activated charcoal filter has priority.
When there is no electrical signal (i.e. open circuit) the solenoid
valve remains closed. The activated charcoal filter will not be
purged.
Note
♦ Hose connections are secured with either spring-type or
clamp-type clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ Hose clip pliers -VAS 5024 A- are recommended for fitting
spring-type clips.
Observe safety precautions ⇒ page 115 .
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4.2 Activated charcoal filter system - Assembly overview
1 - Activated charcoal filter
❑ Location: In engine
compartment, right
2 - Pressure retention valve
with connecting hose
3 - Connecting hose
ing
❑ From fuel tank
4 - 10 Nm
5 - Activated charcoal canister
solenoid valve 1 -N80-
❑ Valve closed with igni‐
tion switched off
❑ When the engine is
warm the valve will be
activated from the en‐
gine control unit
(pulsed)
6 - Connecting hose
❑ To intake manifold
ing
7 - Retainer
❑ For activated charcoal
filter
8 - Breather hose
4.3 Checking fuel tank breather
♦ Hand vacuum pump -VAS 6213-
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♦ Adapter set -V.A.G 1318/17-
Test prerequisites
• Ignition must be switched off.
Test procedure
– Pull off breather line -1- (press locking ring in).
– Then connect the hand vacuum pump -VAS 6213- with the
adapter set -V.A.G 1318/17- to the breather line -1- to the ac‐
tivated charcoal filter.
– Operate hand vacuum pump -VAS 6213- several times. Vac‐
uum must not build-up.
If vacuum a builds-up:
– Check breather hose ⇒ Item 8 (page 148) on activated char‐
coal filter for soiling and clean if necessary.
If no vacuum builds up:
– Temporarily seal breather connection ⇒ Item 8 (page 148) and
operate vacuum pump again several times. A vacuum must
build up.
If no vacuum builds up:
– Renew activated charcoal filter.
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24 – Mixture preparation, Injection
1 Repairing injection system
Observe general notes on injection ⇒ page 150 .
Safety precautions ⇒ page 151 .
Rules for cleanliness ⇒ page 152 .
Fitting locations overview ⇒ page 153
Technical data ⇒ page 160
Air cleaner/engine cover - Assembly overview ⇒ page 160
Removing and installing engine cover with air cleaner
⇒ page 161
Intake manifold - Assembly overview ⇒ page 162
Removing and installing intake manifold ⇒ page 164
Fuel rail with injectors - Assembly overview ⇒ page 167
Removing and installing fuel rail ⇒ page 168
Removing and installing injectors ⇒ page 170
Clean throttle valve control unit -J338- ⇒ page 173
1.1 General notes on injection
♦ The engine control unit is equipped with self-diagnosis. Before
carrying out repairs and fault finding the fault memory must be
interrogated. Also the vacuum hoses and connections must
be checked (unmetered air).
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips ⇒ Electronic parts catalogue “ETKA” . The
use of clamp or screw-type clips is not permissible.
♦ Disconnect the battery earth strap.only with ignition switched
off. If a coded radio is installed, obtain radio code before dis‐
connecting battery.
♦ Observe procedures after connecting battery ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Connecting and disconnecting battery .
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine, will not be burnt in the engine and dam‐
age the Lambda probe.
♦ During some checks, it is possible that the control unit will de‐
tect and store a fault. Therefore, after completing all tests and
repairs, read the fault memory and erase if necessary
⇒ page 178 .
♦ Models with an airbag are fitted with a crash fuel shut-off sys‐
tem. It reduces the danger of a fire in a crash as the fuel pump
is switched off by the fuel pump relay.
♦ When the driver's door is opened the fuel pump is activated
for 2 seconds to build-up fuel pressure. The starting charac‐
teristics are thereby improved.
Safety precautions ⇒ page 151
Rules for cleanliness ⇒ page 152
Technical data ⇒ page 160
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150 Rep. Gr.24 - Mixture preparation, Injection

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1.2 Safety precautions
WARNING
♦ The fuel line is under pressure! Wear protective glasses
and clothing to avoid injuries and skin contact. Before
loosening lines, wrap a cloth around the connection. Then
release pressure by carefully removing the line.
♦ The fuel pressure in the high-pressure pipe can reach 120
bar! Wear protective glasses and clothing to avoid injuries
and skin contact. Before loosening fuel pipes, wrap a cloth
around the connection. Then release pressure by carefully
loosening the banjo bolts.
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ The fuel pump is activated when switching on the ignition and
by the driver's door contact switch. Therefore, for safety rea‐
sons, the fuel pump control unit -J538- -2- must be pulled out
of the cover -1- and the electrical connection must be discon‐
nected, before opening the fuel system, if the battery is not
disconnected.
♦ Do not touch or pull off ignition wiring when engine is running
or turning at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as measuring instrument
cables.
Caution
tions:
the original way.
Observe following if test and measuring instruments are required
during a test drive:
♦ Test and measuring instruments must be secured to rear seat
and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger's seat and the vehicle is involved in an accident, there is
a possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
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1. Repairing injection system 151

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– Pull all 4-pin connectors -arrows- off ignition coils.
– To do this set the puller -T10094- on the ignition coil with final
output stage -arrow-.
– Pull ignition coil with output stage out a bit.
– Place assembly tool -T10118- as shown.
– Carefully loosen connector lock and pull connector off.
– To install the ignition coil for final output stage fit the connector
until it engages audibly.
– Place puller -T10094- as shown.
– Press the ignition coil with output stage in direction of
-arrow- into the cylinder head.
mantling.
necessary.
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1.4 Fitting locations overview
The components A to K are not shown on the illustration.
1 - Pressure regulating valve
❑ Fitted on control hous‐
ing
2 - Vacuum actuator for intake
manifold flap
3 - Intake manifold pressure
sender -G71- and intake air
temperature sender -G42-
❑ Fitting location
⇒ page 158
♦ Intake manifold flap poten‐
tiometer -G336-
⇒ page 158
♦ Intake manifold flap valve -
N316- ⇒ page 157
4 - Fuel pressure regulating
valve -N276-
❑ Fitting location
⇒ page 157
5 - Motronic control unit -J220-
with ambient temperature
sender
⇒ page 179
❑ Fitting location on rear
intake manifold
⇒ page 157
7 - High-pressure pump
❑ Perform removal and in‐
stallation of the high
pressure pump only
when engine is cold
❑ When installing the high-pressure pump, observe that the fuel system is not contaminated by dirt.
❑ Install lines free of stress
8 - Throttle valve module -J338- , throttle valve drive for electric throttle -G186-
❑ Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for
electric throttle -G188-
❑ When renewing, erase learnt values and adapt engine control unit Vehicle diagnosis, testing and infor‐
mation system -VAS 5051- or Vehicle diagnosis and service information system -VAS 5052- .
❑ Fitting location ⇒ page 156
9 - Exhaust gas recirculation valve -N18- and exhaust gas recirculation potentiometer -G212-
mation system -VAS 5051- or Vehicle diagnosis and service information system -VAS 5052-
10 - Radiator outlet coolant temperature sender -G83-
11 - Coolant temperature sender -G62-
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12 - Connector for Lambda probe -G39-
14 - Lambda probe -G39-
15 - Ignition coils with output stages
❑ Ignition coil 1 with final output stage -N70-
16 - Camshaft variable timing adjustment valve 1 -N205-
❑ Checking ⇒ Vehicle diagnosis, testing and information system -VAS 5051- or Vehicle Diagnosis and
Service Information System -VAS 5052-
A - Fuel pump control unit -J538-
B - “EPC” warning lamp
❑ In dash panel insert
C - “MIL” malfunction indicator lamp
❑ In dash panel insert
D - Accelerator position sender -G79- with accelerator position sender 2 -G185-
❑ In footwell on accelerator pedal (both senders are installed together in a housing)
E - Motronic relay
❑ Motronic current supply relay -J271- ⇒ page 159
F - Injectors
❑ In fuel rail tube
❑ No. 1 cyl. injector -N30-
❑ No.2 cyl. injector -N31-
The injectors are high-pressure injectors which inject the fuel under high pressure (approx. 120 bar max.)
directly into the cylinder.
G - Engine speed sender -G28-
H - Knock sensor 1 -G61-
I - Fuel pressure sender -G247-
J - Intake air temperature sender 2 -G299-
❑ Intergrated in the engine cover
K - Lambda probe after catalytic converter -G130-
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Lambda probe -G39- -arrow-
Connector -arrow- for Lambda probe -G39-
Lambda probe after catalytic converter -G130- -1- with connector
-2-
Fuel pump with fuel pump control unit -J538-
1 - Connector for fuel pump control unit -J538-
2 - Fuel pump control unit -J538-
3 - Fuel delivery unit
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-1- Accelerator position sender -G79- with accelerator position
sender 2 -G185- (in driver's footwell)
Throttle valve module -J338-
Exhaust gas recirculation valve -N18- with exhaust gas recircu‐
lation potentiometer -G212- -arrow-
Coolant temperature sender -G62- -arrow-
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Active charcoal filter system solenoid valve 1 -N80- -arrow-
Fuel pressure regulating valve -N276- -arrow-
Fuel pressure sender -G247- -arrow-
Intake manifold flap valve -N316- -arrow-
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Intake manifold pressure sender -G71- and intake air temperature
sender -G42- -arrow-
Intake manifold flap potentiometer -G336- -arrow-
Intake air temperature sender 2 -G299- -arrow-
Engine speed sender -G28- -arrow-
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Knock sensor 1 -G61- -arrow-
Radiator outlet coolant temperature sender -G83- -arrow-
Hall sender -G40- -arrow-
Relay and fuse carrier in electronics box
R1 - Motronic current supply relay -J271-
R2 - not installed
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1.5 Technical data
Engine code BLF
Idling check
Idling speed 5)
1 rpm 630…730
Engine control unit
System Motronic MED 9.5.10
Engine speed governor 1 rpm from approx. 5700
5) Cannot be adjusted.
1.6 Air cleaner/engine cover - Assembly
overview
Removing and installing air cleaner ⇒ page 161 .
1 - 3 Nm
❑ Observe tightening se‐
quence (figures can be
found on the air cleaner
housing lower part)
2 - Air cleaner housing lower
part
3 - Rubber bush
4 - Filter element
5 - Vacuum line
❑ From camshaft housing
6 - 3 Nm
7 - Intake air temperature
sender 2 -G299-
8 - O-ring
❑ Renew
9 - Air cleaner upper section
10 - Spring clip
11 - Air intake hose
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1.7 Removing and installing engine cover
with air cleaner
Note
The air cleaner is integrated into the engine cover.
Removing
– Unclip air intake hose on the upper part and on the side of the
air ducting -arrows-.
– Pull vacuum line -1- off the actuator for intake air preheating.
– Disconnect electrical connection -2- on intake air temperature
sender 2 -G299- .
– Pull oil dipstick -1- out.
– Pull engine cover off on the marked points -arrows-.
– Fit the oil dipstick -1- again into guide tube to limit stop.
Installing
following:
– Pull oil dipstick out of guide tube.
– Fit the rubber mountings of the cover on the pins fitted on the
engine.
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– Pull cover downwards on the marked points -arrows-.
– Fit the oil dipstick -1- again into guide tube to limit stop.
1.8 Intake manifold - Assembly overview
❑ Secure with spring-type
clips
ing
❑ From fuel filter
2 - Distributor
❑ Clipped on suction relief
valve for crankcase
breather
3 - Fuel supply hose
❑ To high-pressure pump
4 - Throttle valve module -
J338-
❑ Clean ⇒ page 173
❑ When renewing, erase
learnt values and adapt
engine control unit Vehi‐
cle diagnosis, testing
and information system
-VAS 5051- or Vehicle
diagnosis and service
information system -
VAS 5052-
5 - 10 Nm
6 - Vacuum hose
❑ To active charcoal filter
system solenoid valve 1
-N80-
❑ Repairing parts of the
activated charcoal filter
system ⇒ page 147
8 - Seal
❑ Renew
❑ Press in onto limit stop
9 - Vacuum hose
❑ From active charcoal filter system solenoid valve 1 -N80-
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10 - Intake manifold
❑ Check vacuum reservoir in intake manifold ⇒ page 175
11 - 8 Nm
12 - 5 Nm
13 - Connecting pipe
❑ For exhaust gas recirculation system
14 - Fuel pressure sender -G247- , 20 Nm
❑ With attached seal
15 - Union nut, 30 Nm
16 - 8 Nm
17 - High-pressure line
18 - Union nut, 25 Nm
19 - Fuel rail
❑ When renewing, erase learnt values and adapt intake manifold flap potentiometer -G336- to engine
control unit vehicle diagnosis, test and information system -VAS 5051- or vehicle diagnosis and service
information system -VAS 5052-
❑ Before removing and installing, lock the vacuum actuator with a 2.5 mm drill
❑ After installing a new fuel rail, remove the retaining clip of the vacuum actuator
❑ After the installation check the function of the manifold flap with the hand vacuum pump -VAS 6213-
⇒ page 176
20 - Seal
❑ Renew
❑ Note installation position
21 - O-ring
❑ Renew
22 - Intake manifold flap potentiometer -G336-
mation system -VAS 5051- or Vehicle diagnosis and service information system -VAS 5052-
23 - 1.5 Nm
24 - Vacuum actuator
❑ For intake manifold flap
❑ Checking ⇒ page 176
25 - 10 Nm
26 - 20 Nm
27 - Intake manifold pressure sender -G71-
28 - 5 Nm
29 - Intake manifold flap valve -N316-
30 - Vacuum hose
❑ To vacuum actuator
31 - Vacuum hose
❑ From intake manifold
32 - Fuel return hose
❑ Fuel rail from fuel rail
❑ Blue or with blue marking
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❑ Secure with spring-type clips
33 - 20 Nm
1.9 Removing and installing intake manifold
Removing
– Remove engine cover with air cleaner housing ⇒ page 161 .
– Separate electrical connection of active charcoal filter system
solenoid valve 1 -N80- .
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– Separate electrical connection -1- on throttle valve module -
J338- .
– Remove bolts -arrows- and take throttle valve module -J338-
off.
– Remove bolts -arrows- of connecting pipe on exhaust gas re‐
circulation valve -N18- and remove seal.
– Remove vacuum hose -1- to active charcoal filter system sol‐
enoid valve 1 -N80- on intake manifold.
– Unhook active charcoal filter system solenoid valve 1 -N80-
from the brackets and lay to side with connected vacuum
hoses.
– Pull vacuum line -2- off brake servo at intake manifold.
– Unclip coolant line on upper part of intake manifold -arrows-
and lay to front.
– Remove hose -2- for crankcase breather on intake manifold.
To do this press release buttons.
– Disconnect electrical connection -1- on intake manifold pres‐
sure sender -G71- and -3- on intake manifold flap valve -
N316- .
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– Pull vacuum line -arrow- on actuator for variable intake mani‐
fold off.
– Remove securing bolts -1- and -2- for intake manifold and lay
intake manifold to rear.
– Disconnect electrical connection -arrow- on fuel pressure
sender -G247- .
– Remove fuel pressure sender -G247- -arrow-.
– Remove intake manifold upwards to the left.
Installing
following:
Note
♦ Observe that no dirt enters the opened intake manifold or the
fuel rail/cylinder head.
♦ Renew seals and gaskets.
– At first, lay the intake manifold to rear in the engine compart‐
ment.
– Tighten fuel pressure sender -G247- -arrow-.
– Screw the intake manifold on the fuel rail.
Torque settings
Component Nm
Fuel pressure sender -G247- to fuel rail 20
Intake manifold to fuel rail 20
Connecting pipe for exhaust gas recirculation to
exhaust gas recirculation valve -N18-
8
Throttle valve module -J338- to intake manifold 10
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1.10 Fuel rail with injectors - Assembly overview
1 - Retaining clip
❑ Ensure seated correctly
at injector and retaining
plate
❑ Fit with the opened side
to the injector connector
2 - O-ring
❑ Renew
❑ Before installing mois‐
ten with clean engine oil
3 - Injector, cylinder 4 -N33-
❑ Injector, cylinder 1 -
N30-
N31-
N32-
❑ Resistance 12.0…17.0
Ω∼ (at room tempera‐
ture)
⇒ page 170
4 - Seal
❑ Renew
❑ Do not oil or grease
5 - Vacuum hose
6 - Return hose
❑ From the high pressure
pump
❑ Blue or with blue mark‐
ing
❑ Secure with spring-type
clips
7 - Pressure limiting valve
❑ Renew removed valve
❑ Before installing moisten O-rings lightly with clean engine oil
❑ Press in by hand using a 8 mm hexagon socket
8 - 20 Nm
9 - Fuel rail
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1.11 Removing and installing fuel rail
Removing
WARNING
The fuel pressure in the high-pressure pipe can reach 120 bar!
Wear protective glasses and clothing to avoid injuries and skin
contact. Before loosening fuel pipes, wrap a cloth around the
connection. Then release pressure by carefully loosening the
banjo bolts.
– Remove intake manifold ⇒ page 164 .
– Press operating bar of vacuum actuator in direction of actuator
and lock with a ∅ 2.5 mm drill -arrow-.
– Separate electrical connectors -1- to -6-.
– Remove bolts -arrows- and take cable guide off.
– Remove bolt -2- of the cable guide and remove clip -4- from
the high-pressure line.
Note
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– Remove fuel return line -2- on fuel rail.
– Remove bolt -1- for fuel line bracket and unclip line bracket.
– Remove bolts -arrows- and remove fuel rail.
– Removing and installing injectors ⇒ page 170 .
Installing
following:
Note
Renew O-rings and seals.
• The operating bar of the vacuum actuator must be locked with
a ∅ 2.5 mm drill -arrow-.
– When placing the fuel rail on the cylinder head the charging
flaps must be raised lightly.
Note
Otherwise the charging flaps between the fuel rail and the cylinder
head may jam, so that it will not be possible anymore to operate
them when installed.
– Then fit the fuel rail -arrows-.
– Fit the line bracket -1-.
– Connect the fuel return line -2-.
– Check the function of the charging flaps using hand vacuum
pump -VAS 6213- .
– Connect hand vacuum pump -VAS 6213- as shown.
– Pull drill or retaining clip -arrow- out.
– Produce vacuum and check function of vacuum actuator on
operating rod.
Further installation is performed in the reverse order of removal.
– Install intake manifold ⇒ page 164 .
Torque settings
Component Nm
Fuel rail on cylinder head 20
Line guide to fuel rail 7
High-pressure lines to High-pressure pump 30
Fuel rail 25
Line bracket to fuel rail 7
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1.12 Removing and installing injectors
equipment required
1331-
5024 A-
♦ Tool set for FSI engines -
T10133-
Removing
– Remove fuse of fuel pump from fuse holder ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
Note
Removing fuse interrupts the voltage supply to the fuel pump for
reasons of safety, otherwise it is possible that the fuel pump will
be activated when opening the driver’s door.
WARNING
Fuel system is under pressure! Wear eye protection and pro‐
tective clothing to prevent injuries and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
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– Disconnect fuel supply line -3- (press locking ring inwards).
dirt etc.
– Remove intake manifold ⇒ page 164 .
– Remove fuel rail ⇒ page 168 .
– Pull spacer sleeve off injector.
– Place the puller -T10133/1- on the injector -1-. Ensure that the
hooks of the puller engage in the injector recesses -arrows-.
– Tighten knurled nut of the puller hand-tight.
– Fit the slide hammer -T10133/3- on the puller -T10133/1- .
– Pull the injector out of the cylinder head by carefully knocking
it.
Installing
– Clean the hole in the cylinder head using the nylon cylinder
brush -T10133/4- .
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– Carefully clean injector in area of seal -arrow-. Remove resid‐
uals using a wire brush.
– Carefully cut open seal with a knife.
– Clean groove for seal.
– Place the assembly cone -T10133/5- with a new seal -1- on
the injector -2-.
– Slide the seal with the fitting sleeve -T10133/6- on the assem‐
bly cone -T10133/5- .
– Turn the mounting sleeve -T10133/6- and slide the seal into
the seal groove.
– Press calibration sleeve -T10133/7- onto injector to stop by
turning gently (approx. 180°).
– Pull off calibrating sleeve -T10133/7- by turning in opposite
direction.
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– Press calibration sleeve -T10133/8- onto injector to stop by
turning gently (approx. 180°).
– Pull off calibrating sleeve -T10133/8- by turning in opposite
direction.
– Renew O-ring on injector.
– Moisten O-ring with clean engine oil before installing.
Note
The seal must not be oiled.
– Fit the injector into the cylinder head.
Note
The injector must easily be fitted, if necessary wait until the seal
shrinks.
– Install spacer sleeve.
cedure.
– Install fuel rail ⇒ page 168 .
– Install intake manifold ⇒ page 164 .
– If injectors are renewed, erase learnt values and adapt engine
control unit ⇒ Vehicle diagnosis, testing and information sys‐
tem -VAS 5051- or vehicle diagnosis and service information
system -VAS 5052- .
1.13 Cleaning throttle valve module -J338-
Note
♦ If a new engine control unit is installed the throttle valve mod‐
ule must be adapted. Adaption must only be performed with a
new or cleaned throttle valve module, because soiling/coking
in closed throttle valve can lead to incorrect adaption values.
♦ When cleaning the throttle valve housing it must not be
scratched.
– Separate electrical connection -1- on throttle valve module -
J338- .
– Remove bolts -arrows- and take throttle valve module -J338-
off.
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– Open the throttle valve by hand and, with a suitable object (e.g.
a wedge made of plastic or wood) block the throttle valve in its
open position -arrow-.
WARNING
Acetone is highly inflammable. Please observe the accidental
regulations and safety notes when handling with highly inflam‐
mable fluids. Do not use compressed air when cleaning the
throttle valve. Wear protective glasses and clothing to avoid
injuries and skin contact.
– Clean throttle valve union thoroughly, especially in the area
-arrows- of the closed throttle valve using commercially avail‐
able acetone and a brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Wait until the acetone is fully evaporated and reinstall the
cleaned throttle valve module.
– Erase learnt values and adapt engine control unit to throttle
valve control part ⇒ Vehicle diagnosis, testing and information
system -VAS 5051- or Vehicle diagnosis and service informa‐
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2 Checking components
Check vacuum reservoir in intake manifold for leaks
⇒ page 175
Check function of intake manifold flap ⇒ page 176
Checking intake air preheating ⇒ page 176
2.1 Check vacuum reservoir in intake mani‐
fold for leaks
Test prerequisites
Perform visual check, whether all vacuum hoses on the intake
manifold are damaged and seated correctly.
Test procedure
– Remove vacuum hose -arrow- from intake manifold flap valve
-N316- to intake manifold on intake manifold.
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2. Checking components 175

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– Connect hand vacuum pump -VAS 6213- to intake manifold.
– Close the knurled screw on the hand vacuum pump -VAS
6213- .
– Operate the hand vacuum pump until the pressure drop gauge
indicates a pressure of 0.3 bar.
Note
The volume in the vacuum reservoir may require 20 lifts to pro‐
duce a pressure of 0.3 bar.
– Observe pressure for approx. 3 up to 5 minutes.
If the pressure remains at 0.3 bar:
The vacuum reservoir in the intake manifold is OK.
If the vacuum drops.
– Renew intake manifold ⇒ page 164 .
2.2 Check function of intake manifold flap
Test procedure
– After installing a new fuel rail, remove the retaining clip
-arrow- of the vacuum actuator.
– Connect hand vacuum pump -VAS 6213- as shown.
– Produce vacuum and check function of vacuum actuator on
lever arm.
Note
When the intake manifold is removed, the function of the intake
manifold flap can be checked simultaneously.
2.3 Checking intake air preheating
♦ Chilling agent spray (commercially available)
Checking regulating flap
– Remove intake connecting piece of the air cleaner.
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– Check control flap position -1-.
– Spray thermoelement -2- with chilling agent.
• Over +23 °C the flap must close the warm air connection.
• Below +10 °C the flap opens the warm air connection.
Note
The function of the thermoelement can be checked easily by
spraying with commercial chilling agent. To do this the air cleaner
lower part must be removed ⇒ page 160 .
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2. Checking components 177

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3 Engine control unit
Reading and erasing engine control unit fault memory
⇒ page 178
Removing and installing engine control unit ⇒ page 179
3.1 Reading and erasing engine control unit
fault memory
♦ or vehicle diagnosis and service information system -VAS
5052-
Connect vehicle diagnosis, testing and information system -VAS
5051- or vehicle diagnosis and service information system -VAS
5052- as follows:
– Fit the connector of the diagnosis cable -2- to the diagnosis
connection in the driver footwell.
Only when engine does not start:
– Switch ignition on.
Select operating mode:
– Press button on display for “Vehicle self-diagnosis”.
Select vehicle system:
– Press button “01-Engine electronics” on display.
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The display shows the control unit identification and coding -2- as
well as the chassis number and the identification number of the
immobilizer (centre part).
Note
A print-out can be made if needed. Then press key “Print”.
Select diagnostic function:
– Press button “02 - Read fault memory” on display.
– If no fault is stored in engine control unit “0 fault(s) detected”
is displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press the ← key.
– Press button “05 - Erase fault memory” on display.
– Press function “06 - End output”.
Note
If the fault memory was erased the readiness code must be gen‐
erated ⇒ vehicle diagnosis, testing and information system -VAS
5051- or vehicle diagnosis and service information system -VAS
5052- .
3.2 Removing and installing engine control
unit
Removing and installing engine control unit without theft protec‐
tion ⇒ page 179 .
Removing and installing engine control unit with theft protection
⇒ page 180 .
3.2.1 Removing and installing engine control
unit without theft protection
Note
If the engine control unit must be renewed, connect vehicle diag‐
nosis, testing and information system -VAS 5051- or vehicle
diagnosis, testing and information system -VAS 5052- and per‐
form “Renewing engine control unit”.
Removing
– Remove wiper arms and the plenum chamber cover ⇒ Elec‐
trical system; Rep. Gr. 92 ; Windscreen wiper system; Re‐
moving and installing the windscreen wiper system .
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Plenum chamber bulkhead; Plenum
chamber bulkhead - Assembly overview .
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3. Engine control unit 179

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– Release the front connectors -1- from the engine control unit
and pull it off.
– Lever off latching device -2- a bit.
– Continuously slide the engine control unit out of the retainer
-arrow-.
– Unlock the rear engine control unit connector and pull it off.
Installing
– Connect rear connector to engine control unit and lock it.
– Slide the engine control unit onto the retaining plate.
– Push lock -2- against the engine control unit.
– Now fit front connector -1- to engine control unit and lock it in
position.
– Install bulkhead in plenum chamber ⇒ General body repairs,
– Install wiper arms and the plenum chamber cover ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wiper system; Removing
and installing the windscreen wiper system .
3.2.2 Removing and installing anti-theft en‐
gine control unit
♦ Hot air blower from wiring harness repair set -VAS 1978-
♦ Insert injector from wiring harness repair set -VAS 1978-
Note
If the engine control unit must be renewed, connect vehicle diag‐
nosis, testing and information system -VAS 5051- or vehicle
diagnosis, testing and information system -VAS 5052- and per‐
form “Renewing engine control unit”.
Removing
– Remove wiper arms and the plenum chamber cover ⇒ Elec‐
trical system; Rep. Gr. 92 ; Windscreen wiper system; Re‐
moving and installing the windscreen wiper system .
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– Remove bulkhead in plenum chamber ⇒ General body re‐
pairs, exterior; Rep. Gr. 50 ; Plenum chamber bulkhead;
Plenum chamber bulkhead - Assembly overview .
Note
Apply locking fluid to the shear bolts thread. By heating up the
shear head bolts with the hot air blower the inhibitation of the
locking fluid is reduced.
Caution
Cover lines, connectors and control units in the near area of
the engine control unit to avoid damages by burns.
Perform hot air blower adjustments -4- as follows:
– Switch potentiometer for temperature adjustment -2- to maxi‐
mum heating power (600 °C).
– Set the two-stage switch for air mass -3- to position 3.
WARNING
When heating up the shear head bolts, the protective housing
parts will heat up considerably. Wear protective gloves to pre‐
vent injuries.
– Guide the injector of the hot air blower to a shear head bolt.
– Switch on the hot air blower and heat up the bolt for approx.
20 to 25 seconds.
– Remove shear head bolt applying grip pliers at bolt head.
The procedure for the second shear head bolt is the same.
– Insert a screwdriver -A- between the protective housing and
the retaining plate -arrow-.
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– Lever the protective housing out upwards using the screw‐
driver -A- and pull it off sideways from the retaining plate
-arrow-.
– Release the front connectors -1- from the engine control unit
and pull it off.
– Lever off latching device -2- a bit.
– Continuously slide the engine control unit out of the retainer
-arrow-.
– Unlock the rear engine control unit connector and pull it off.
Installing
– Connect rear connector to engine control unit and lock it.
– Slide the engine control unit onto the retaining plate.
– Push lock -2- against the engine control unit.
– Now fit front connector -1- to engine control unit and lock it in
position.
– Slide the protective housing onto the retaining plate.
– Tighten the new shear head bolts -1- evenly until bolt heads
shear off.
– Install bulkhead in plenum chamber ⇒ General body repairs,
– Install wiper arms and the plenum chamber cover ⇒ Electrical
system; Rep. Gr. 92 ; Windscreen wiper system; Removing
and installing the windscreen wiper system .
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26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ After working on the exhaust system ensure that the system
is not under stress, and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and pre-catalytic converter so that sufficient
clearance is maintained to the bodywork and the support rings
are evenly loaded.
♦ The flexible element of the front exhaust pipe must not be bent
more than 30° - otherwise it will be damaged.
♦ Renew self-locking nuts.
equipment required
♦ Lambda probe open ring
spanner set -3337-
1331-
♦ Body saw -V.A.G. 1523 A-
♦ Hot bolt paste -G 052 112
A3-
Catalytic converters and attachments - Assembly overview
⇒ page 184
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1. Removing and installing parts of exhaust system 183

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Silencer with mountings - Assembly overview ⇒ page 186
Removing and installing exhaust manifold ⇒ page 186
Removing and installing pre-catalytic converter with exhaust
manifold ⇒ page 188
Connecting and disconnecting front and rear silencers
⇒ page 190
Aligning exhaust system free of stress ⇒ page 192
1.1 Catalytic converters and attachments - Assembly overview
1 - Warm air collector plate
2 - 10 Nm
3 - Exhaust manifold
⇒ page 186
4 - Seal
❑ Renew
5 - 25 Nm
❑ Renew
6 - 40 Nm
❑ Renew
❑ Note tightening se‐
quence ⇒ page 185
7 - Washer
8 - Retainer
9 - 60 Nm
10 - 25 Nm
11 - Main catalytic converter
with exhaust pipe
12 - To front silencer
13 - Front cross member
14 - Lambda probe after cata‐
lytic converter -G130- , 55 Nm
❑ Connector, black, 4-pin
❑ Fitting location of con‐
nector: On vehicle floor
❑ Lambda probe after cat‐
alytic converter -G130-
with lambda probe open
ring spanner set -3337-
❑ Grease only thread with hot bolt paste -G 052 112 A3- ; hot bolt paste -G 052 112 A3- must not get into
slots in probe body
❑ If sealing ring is leaking, nip open and replace
15 - 25 Nm
❑ Renew
16 - Connector
❑ Black, 6-pin
❑ For Lambda probe -G39- and lambda probe heater -Z19-
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184 Rep. Gr.26 - Exhaust system

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17 - Lambda probe -G39- , 55 Nm
18 - 40 Nm
❑ Note tightening sequence ⇒ page 185
19 - 23 Nm
❑ Note tightening sequence ⇒ page 185
20 - Mounting
21 - Retainer
22 - Pre-catalytic converter with exhaust pipe
❑ Observe tightening sequence when installing ⇒ page 185
23 - Cable guide
❑ For alternator feeder connection
24 - Bellows
Tightening sequence for pre-catalytic converter on exhaust mani‐
fold and engine
– Fit pre-catalytic converter -7- and bracket -2- and tighten nuts
-1- on threaded studs by hand.
– Tighten nut -3-.
– Tighten nuts -1-.
– Slide bracket -4- to cylinder block to limit stop and tighten bolts
-6-.
– Tighten bolts -5-.
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1.2 Silencer with mountings - Assembly overview
1 - Mounting
2 - 25 Nm
3 - Retaining ring
4 - Separating point
❑ For repair cases
❑ Marked by three impres‐
sions on circumference
of exhaust pipe
❑ As standard, front and
rear silencers are instal‐
led as a single compo‐
nent. In repair cases the
front silencer and rear
silencer are supplied in‐
dividually with a repair
clamp for connecting to‐
gether
❑ Connecting and discon‐
necting front and rear si‐
lencers ⇒ page 190
5 - Front and rear silencers
❑ Front and rear silencers
❑ Connecting and discon‐
necting front and rear si‐
lencers ⇒ page 190
❑ Aligning exhaust sys‐
tem free of stress
⇒ page 192
6 - Mounting
7 - Rear cross member
8 - Retaining ring
9 - 25 Nm
10 - Clamp
1.3 Removing and installing exhaust mani‐
fold
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♦ Torque wrench -V.A.G. 1331-
Removing
Note
The flexible element of the pre-catalytic converter must not be
bent more than 30° - otherwise it will be damaged.
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– Remove bolts -arrows-.
– Remove nut -1- from exhaust manifold/gearbox bracket. Take
bracket off.
– Remove exhaust manifold from cylinder head -arrows-.
– Take exhaust manifold and seal for exhaust manifold off from
above.
Installing
following:
Note
Renew seals and self-locking nuts.
– Grease threaded studs thread on cylinder head using hot bolt
paste -G 052 112 A3- .
Torque settings
Component Nm
Exhaust manifold to cylinder head 256)
Pre-catalytic converter to exhaust manifold 406)
Pre-catalytic converter to cylinder block 23
Bracket for exhaust manifold to gearbox 60
6) Renew
1.4 Removing and installing pre-catalytic
converter with exhaust manifold
Removing
Jetta 2005 ➤ , Bora 2006 ➤

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– Take electrical connection -1- for Lambda probe -G39- out of
bracket -2- and disconnect.
Jetta 2005 ➤ , Bora 2006 ➤

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– Remove bolts -1- and -5-.
– Remove mounting -4- for exhaust system from pins on pre-
catalytic converter.
– Remove nuts -2- and -3- on exhaust system flange.
– Disconnect the exhaust system on flange.
– Unscrew bolt -1- first.
– Unscrew bolts -2- and -3- and take pendulum support off.
Note
The flexible element of the pre-catalytic converter must not be
bent more than 30° - otherwise it will be damaged.
– Remove nut -1- and take bracket off exhaust manifold/gear‐
box.
– Remove bolts -arrows- and take bracket off with pre-catalytic
converter.
– Swing pre-catalytic converter out forwards.
Installing
following:
– Grease threaded studs thread on pre-catalytic converter with
hot bolt paste -G 052 112 A3- .
– Observe tightening sequence ⇒ page 185 .
Torque settings
Component Nm
Pre-catalytic converter to cylinder block 23
Pre-catalytic converter to main catalytic converter 257)
Pre-catalytic converter to exhaust manifold 407)
Exhaust system bracket to subframe 25
7) Renew
1.5 Connecting and disconnecting front and
rear silencers
♦ To renew the front and rear silencers individually there is a
separating point provided in the connecting pipe.
♦ The separating point is marked by an impression on the ex‐
haust pipe circumference.
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♦ Body saw -V.A.G. 1523 A- or
♦ Chain pipe cutter -VAS 6254-
♦ Safety goggles
Separate
WARNING
To prevent damage by metal particles, wear protective goggles
and protective clothes.
– Cut through exhaust pipe -arrow 2- at right angles, e. g. using
body saw -V.A.G. 1523 A- or chain pipe cutter -VAS 6254- .
Connect
Note
A second mechanic is required to tighten the repair clamp-type
clip.
– Fit front silencer into retainers. Front socket remains fitted
loosely on the pipes.
– Align rear silencer horizontally and hold in this position.
– Position the repair clamp-type clip at the side markings
-arrow 1- and -arrow 3-.
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– Turn the repair clamp-type clip -A- as shown and tighten to
25 Nm.
– Then align exhaust system free of stress ⇒ page 192 .
1.6 Aligning exhaust system free of stress
• The exhaust system must be aligned when it is cold.
– Loosen threaded connections on front clamp-type clip -1-.
– Position clamp-type clip -1- so that the distance -a- to the
marking on the pipe (-2-) is 5 mm and tighten front bolt by
hand. The -arrow- shows in direction of travel.
– Move the exhaust system forwards until the dimension -a- =
9…11 mm is reached on the outer hand hold straps of the front
silencer. The -arrow- points forwards.
– In this position, tighten front clamp-type clip evenly to 25 Nm.
Align end pipe
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– Align rear silencer so that dimension -x- between bumper cut-
out and end pipe on the left and right-hand sides are the same.
– To align the end pipe, loosen rear silencer mounting if neces‐
sary.
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2 Exhaust gas recirculation system
Assembly overview - Exhaust gas recirculation system
⇒ page 194
Removing and installing left brake pad wear indicator shear ele‐
ment -N18- ⇒ page 195
2.1 Assembly overview - Exhaust gas recirculation system
1 - Cylinder head
3 - Connector
❑ Gray, 6-pin
4 - Intake manifold
5 - Seal
❑ Renew
6 - 8 Nm
7 - Connecting pipe
❑ Bolt stress free
8 - 5 Nm
9 - Seal
❑ Renew
❑ The lug must show
downwards
10 - 10 Nm
G212-
❑ When renewing, erase
learnt values and adapt
engine control unit Vehi‐
cle diagnosis, testing
and information system
-VAS 5051- or Vehicle
diagnosis and service
information system -
VAS 5052-
⇒ page 195
12 - Connecting pipe
❑ Install free of stress
13 - 18 Nm
14 - Seal
❑ Renew
❑ Note installation position ⇒ page 195
15 - To expansion tank
16 - From T-piece on cooler inlet
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Installation position of seal on cylinder head
The lug on the seal -1- must align with the recess on the con‐
necting pipe -2- -arrows-.
2.2 Removing and installing exhaust gas re‐
circulation valve -N18-
♦ Hose clamp to Ø 25 mm -3094-
Removing
Note
To remove exhaust gas recirculation valve -N18- complete, cool‐
ant hoses must be clamped off and pulled off first.
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2. Exhaust gas recirculation system 195

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– Remove connecting pipe -1-.
– Remove connecting pipe -3-. When doing this swivel out of
intake manifold upwards.
– Remove exhaust gas recirculation valve -N18- -4- from cam‐
shaft housing and lay to side with connected coolant hoses.
Installing
following:
♦ Renew seals and gasket in intake manifold.
♦ The lug of the seal connecting pipe/ exhaust gas recirculation
valve must show downwards.
♦ Observe installation position of seal on cylinder head
⇒ page 195
♦ Connect connecting pipes free of stress. Before tightening all
bolts screw in hand-tight.
♦ Torque settings ⇒ page 194 .
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28 – Ignition system
1 Repairing ignition system
General notes on ignition system
♦ The engine control unit is equipped with self-diagnosis.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ During some checks, it is possible that the engine control unit
will detect and store a fault. Therefore after completing all
checks and repairs the fault memory must be interrogated and
if necessary erased.
♦ If the engine starts only for a short period of time after per‐
forming fault finding, repairs or component tests and then
stalls, it could be that the immobilizer blocks the engine control
unit. In this case, the control unit must be adapted. ⇒ vehicle
diagnosis, testing and information system -VAS 5051- or ve‐
hicle diagnosis and service information system -VAS 5052- .
Safety precautions ⇒ page 197 .
Assembly overview - ignition system ⇒ page 198 .
Removing and installing ignition coils with output stage
⇒ page 198 .
Test data, spark plugs ⇒ page 199 .
1.1 Safety precautions
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or pull off ignition wiring when engine is running
or turning at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as measuring instrument
cables.
Observe following if test and measuring instruments are required
during a test drive:
♦ Test and measuring instruments must be secured to rear seat
and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger's seat and the vehicle is involved in an accident, there is
a possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
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1. Repairing ignition system 197

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1.2 Assembly overview - ignition system
1 - Connector
❑ Black, 4-pin
❑ Unlock with assembly
tool -T10118-
2 - Ignition coil 3 with final out‐
put stage -N291-
❑ Ignition coil 1 with final
output stage -N70-
output stage -N127-
output stage -N292-
⇒ page 198
3 - Connector
❑ Black, 2-pin
❑ For knock sensor 1 -
G61-
❑ Gold-plated connector
contacts
4 - Knock sensor 1 -G61-
❑ Gold-plated connector
contacts
5 - 20 Nm
❑ The torque setting influ‐
ences the function of the
knock sensor
6 - Connector
❑ Black, 3-pin
❑ For Hall sender -G40-
8 - O-ring
9 - 10 Nm
10 - Spark plug, 30 Nm
❑ Remove and install with spark plug spanner -3122 B-
❑ Type and electrode gap ⇒ page 199
11 - Cable guide
❑ Fit on camshaft housing with 8 Nm
12 - Earth wire
❑ Loosen or tighten when the ignition is switched off
13 - 10 Nm
❑ Loosen or tighten when the ignition is switched off
1.3 Removing and installing ignition coils
with output stage
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198 Rep. Gr.28 - Ignition system

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♦ Assembly tool -T10118-
♦ Puller -T10094-
Removing
– Fit puller -T10094- on the ignition coil with final output stage
-arrow-.
– Pull ignition coil with output stage out a bit.
– Place assembly tool -T10118- as shown.
– Carefully loosen connector lock and pull connector off.
Installing
– Fit puller -T10094- on the ignition coil with final output stage.
– Slide the connector on the ignition coil with output stage until
it audibly engages.
– Press the ignition coil with output stage in direction of
-arrow- into the cylinder head.
1.4 Spark plug test data
Engine code BLF
Firing order 1-3-4-2
Spark plugs
VW/Audi 101,000,068 AA
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1. Repairing ignition system 199

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Engine code BLF
Manufacturer's designation FGR 6HQ E0
Electrode gap 0.9…1.1 mm
Torque setting 30 Nm
Change interval 60,000 km
Jetta 2005 ➤ , Bora 2006 ➤
200 Rep. Gr.28 - Ignition system

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