Service. Workshop Manual Audi 100 1991 > AAN ce 5 Cyl. Fl. eng Booklet (4 \aive, turbo) Mechanics Edition 07.91 Service Department. Technical InformationService. List of Workshop Manual Repair Groups Audi 100 1991 > AAN 5 Cyl. Fl. Engine (4-valve, Turbo), Mechanics Booklet esition 07.91 When fing a Technical Bulletin enter the Bulletin No. in the adjacent column. When using the Workshop Manual you can then see at a glance whether Technical Bullets have been published in respect ofthe particular Repair Group in which you are looking Repair Group Technical Bulletins (00 Technical Data 10 Removing and instaling engine 13 Crankshaft group 15 Cylinder head, Valve gear | 17 Lubrication [ | 19 Cooling | | 20 Fuel supply system 21 Charging i 26 Exhaust system Technical Information should always be available to all foremen and mechanics, because their ‘compliance with the instructions given is essential to ensure vehicle roadworthiness and safety. In addition, the normal safety precautions to be observed when working on motor vehicles are also applicable. This Workshop Manual is only intended for use within the Volkswagen and Audi organisation, passing on to third parties is not permitted Printed in Germany © 1991 Volkswagen AG (000 5261.29.2010 5 v 9 Technical Data = Engine code = List of engines Renoving and Installing Engine = ules for cleanliness = Safety neasures = Removing ~ Securing engine to repair stand = Installing ~ Tightening torques Crankshaft: Group Dismantling and assenbling engine = Renaving and installing ribbed belt = Removing and instaiting toothed belt Dismantling and assembling cylinder block, crankshaft and Flywheel = Weasuring distance From lug to ignition firing point sender (-G8) and distance from flywhee) to engine spees sender (-628) = Crankshart dimensions = Checking crankshaft radial clearance Dismant1ing and assent’ ing pistons and conrods = Piston and cylinder dimensions = Checking conrad radia? clearance Checking basic mechanical adjustnent of engine Cylinder Head, Valve Gear Removing and instal Ting cylinder head = Installing cylinder head = Checking compression pressure Servicing valve gear = Checking hydraulic bucket teppets = Renewing camshaft oi! seal = Removing and installing canshafts = Reworking valve seats = Renewing valve guides = Renewing valve-sten of] seals (with cylinder head instal ies) = Renexing valve-sten ofT seals (with cylinder head renoved) Lubrveat fon Removing and installing lubrication system components = Checking of1 pressure switch and oi] pressure = Checking of] pressure sender (-519) = Reroving and installing of) sump = Renoving and installing of] pune Cooling Renoving and instatTing cooling systen components = Draining and f411ing coolant ~ Checking ccolant systen for leaks = Checking pressure relief valve in cap = Checking viscous fan Checking turbocharger thermoswitch ~F98 and cooTant pump0 a 6 Fuel Supply System Removing and instalTing fuel system conponents = fules for cleanliness when warking on fuel suppTy/injection system = Safety seasures when working on fuel tank = Reneving and installing fuel gauge sender = Revoving and instal ing fuel ounp = Renoving and installing fuel tank Dismant]ing and assenbling fuel punp = Checking fuel punp = Checking non-return valve of fuel pun Servicing fuel tank ventilation with activated charcoal fvIter Servicing thrattle Tinkege = Adjusting throttle cable Turbockarging Removing and installing turbocharger components = Rules for cleanliness when working on turbocharger = Removing and installing turbocharger = Checking turbocharger and waste gate = Checking overrun cut-off valve with vacuum pump ¥.A.6 1390 Removing ard installing intercooler components = Rencving and installing intercooler Exhaust System Removing and installing exraust systen components = Aligring exhaust system ension-free = Checking exhaust syste for leaks Page 20-1 20-8 20-5 20-6 20-8 20-11 20-1 2013 20-17 20-19 20-22 20-23 Page att 215 21-10 2-13 ail n-l6 Page 26-1 26-1 26-8‘egancal Ta east cone rahe cose ans serial mater are stamped on ipteane ide 2 pea ot line se oo LS.oF vats Inala ate ™ one ae a Cosine ceraiteriates mestetaree fron or Yate toes for weal ite Inlet pas aftr Te x re. oF eines ‘ Ine clones after fe s ee en & apc hr 2206 Sat loner sear fis ° cate Wirm —tarso o* stout 38 Trae resem opto sa tapeeion ten verre fore men, at oust ges rcinclatan oy seote ™ cota a Compression aio sa Lent cat ® ast trecharger * es fon was omeues 2 cca sess 2 TYarvgny cle a) unors and surrounding at ttre Srecarnest Blot remved gars ov ean surface an ever vin file or pers fp ot ae iat” 1 GreFbly etn or sea! opel components igi ct el oat ay tal cnn es, i Peay roach venient parts meciately ibe iaatatin = Boot ve arte that have teen stored Tote engin teal howe ete 6 apen ful Sper 8 oe (PEL tot ene wich empress 20710 ola «Irae aie venice unons absoutely reciay. ‘seen mass in eda aaa nue o ens ler StfeSadn futon ans bt Taection Shitty saree aller nge. Tin drecinect ond comet wires of Wan someon ase ye. nestor Syste arg neasiring wives, wah ignition seeks Sih serous Engin ts revved pura wou gearox, OAs) ible Sheree rte ose tuts fipite rma! mgt be eit ale ‘Tintagel Ts TRAE ian ancotetsseerity cota 65 ‘esas seertetn coe mace before GrSanieting tater. + biscmnet battery earthing strap. totes, Tibices without fresh ete flter or air nation, eettery Te vozate 'nplena ‘force on sont, On eect with redhat EMferon al cecteorer Iv [o estafoa tier rr eet ease‘ NOYLEYS HR (0 IRS ~ ¢ he | A = aA ps Aionwe oaton genre epport asinesearton flanges User 1st = Ramet gute a 11 woe ct oF expe ear ute at in vinpag hte Dy isles with sdmatic sears ~ Metete te paranoia sand wth gin ant wits, esune cylinder bores (eps ro 15] te erpne noone on reat stdTALL Inatell engine im reverse order ard observe faivaving puree! © Cheah soener loeating seaves for centrin fengitegenrtoc ave Iatallad in eylinger Taek Te tienes SF necessary Always renew self-Tocking ats, 1 Aiaye rene cose. © Et necessary, check centring of eluten rive plate i Coan santhing of gesebon {apt shaft. Tiny Seat Casthing nd clot talenae earing witn 000 fo, Go not presse, ite sieeve for relaace bea'ng ke sure the support tab of seolantptpe 1 tot pinoned betwen angie ate garb stsie planing ease sagetber lnstall engine nunting tosve-tre by al grtegentne wth anatong movements AetOre tightening engine neste. Ingeat! coolant pipe, retaining clip for rertigersnt pipe an AJe corpressor ‘gether al ez ren tightening extaut down pize oe Eurecharge, ensure Teeion Of navetnt ictaten ethule! eave pipe and subtree Align exhaust systen tensioner = Spat Gratp ia Asst ott cable = see Retr ‘Group 20. bs Do not race grat coolant. F12) coolant sence Group 9. © heck) level before starting enaine ‘Seéure aif case tet tan out ching Forel at same Toston sin ‘petal lations * o Scie ring eggdeng reel ‘naeaiTatin. qa o.20‘Sarena os ules/nuts = general Fwalonss Cant Som pipe to turbecharger mm anaust con pipe ta corasited eipe host con pipe ta caalyst acalyst to gearios suport AJC cnpressor ts bracket Torave comerter do drive plate Viscous fan to carrier 028 1m Die ake 25 un ue tte 20SHAUL A ASSTOLING cau eNO STIL HED BELT 4 567890 pie, tied ve shoes version wt ate » te RDA marking on eater rng rust pels n'drecticn ef sel 2 Wigs ca ovation tegeratare: Te + 4% Jean teeta ai incas Een = son Rape Group 29 5 Rey» See. orig robes Ser! rage ia o Teettran of yaa cat a ieersetrenad 5 ied wt Pare ection of travel before Fetevieg neh oa ar fel pen a ewe wr inte inp. o sprite siecton af Seve on ad bate Tens fo Sts cern 23 220-2120 191817 %6 (3093) om 5 satgon Canae en oe feet et Walle ae sty open-end spamer ta Seu. itn pina ome Andale po brace mo ae © felt essen GFTe stacker ited belt, ohne! tet de gaat ee for pow Seering 23 22° 212019 1817 %6scout clutch te sek Yor este of vere 4 56789 101 eam % Sai tbe aa ot aor and ist ng ied belt ware be a 21 eaten aol SRGReniny torque ~ see "enor ing ad inatelling vibration tamper" Fae Bas ctr 2 ok aig eosin direction Pitre Vee 2 ote feersng ack ate = see Mrkhp Muah 10)"erers Boy apa, Repate Goup 93 = 1 necessary, velip lower wleing Yeon fron fin eae = esc te et apm from reator appl? ‘eh viscous fant Delt by sytrang tension 3 arvoandsnsorting im4 heating of ried belt vices witbat ce tne LI ow e716 1 4 «13 2 109 56 Ader utten Sieatay eoohed belt «see amgeg en este 0p eothed age nib oy tooth tet with 1 SPARE tor case of eovenent 9A al yee 2 lrg nd uting se wt nits te Me toner ote be aa 1 Tmaise 6 10s 9 Ds tele ater toothed belt at ep among td Snot ited bee shige ht zation danger, Hee oP tate mes et vt aay on casted ae pulley Of evanesart ony posible In one psition shales ocfset, ce Fenoving sof inet ong = Figs 1s Pane 1s Sts sn 2) Cental pt START ay tongue ~ cee ering aed octal iag oration dager" = Fi. ts age bs 201918 1716 «15 TN 109Tightentay torque ith spamer for ration anger 9 Tighteniog tore asta, spamar or bratlen ampere som © tae brace 3256 © Gove threats an contact surfaces of bolt Fead wich sealing ste AN 165 tol oP mee {Biter for waraton dame as aig sith = Reve front orashoe Manu Fad a0 “Geverat Soy Repay agar Srp fenove1oek carrie plate - ne Yoiahop nn at Sab ape tnscreebracat for trim plate -2- fron EGHE te ele cee Unsere right an Taft wadtator bolts 2 Unsores left ate guide from raster ae + Banove upper abr dct tran raiatr.na120nat4 ig. 5 _riving out oeete aearion © yee ove = Drive aut bearing wity 20m dia. crit ran bckse af heel ¢ uu hte nate ering Sots of sarig sms tr = este oF rig oes, = Dei in flan oth hyteel (clutch ei) aah ert Shs tnd Breseing tw! Tossa a ug 2 ei ost in Ce = Suite ase tice 10-201 an totale 1 Tishesing traits 32m #14 tum (9 t pe ‘ipen con amy be tote sn ne position = flr for secivitg toils ae foe 4g. 2 vesuuron crate aia leanne = Hoasute ania) clearence ato. # Bearing (Ghee bari) News 0.07 0028 Ue vnite 0°33 atoon F ree i ns‘usu DENN (Oiseniore in mm) Cerdion | Semel ats? | Satan ei, Ca noe “ee understze | 57-75 a CAIN RAMSAY ADL CERNE 1 Check rata clearance with Plasgée oar | te ae | foi fe | A ~ fenove craks Seeing xp = Clean beareg shell ant erantsat, journal fearing ye strip corresponding to o% rea ae arg + Instat 9 and sell and tighten to 65 foe BEd rotate cantata. = Herve Bearing cap again + Cenpane wth of Plaeigage strip itn rensring seats fers 018. 9.058 Se tives 9:26 228DiSMMTLINS aD ASSEGLG FISTING ‘ees eign rin 8 Defeat gas ay 120" mein ties ta psn om Fig y fae Lie os femoing 23 ttalling = ig. 6, faye ie ese sige clearance «rig. 7, 0 Ghechag Fins ga = Fin 8 Ege 138 finger numer ig. 1 Ghesing = Fig. 8, tape 1338 Roving aod faetining = Ths. 25 fege 122 efor on ister crow potts tor puly eo Pisteh Smersions ~ age 13-97 % sams lweys weno 35 set fan cyliner rater wigh pur 8 Tratallatton sorter srk point tonrd pulley ed MS ca ok ‘8 Installatfon position: Warkings ain round Bley od SM a only Tenge aan eae Is fouletety Stared f Tolmasute radial cleernce, ight t 30 My Buna arth Tevet out «Fig. 35 age 1-38 tity Fer wan angine is upiately Startle 5 tins ST mck ender bores = 9. 9, fae ae Piston ap yin enensione Page 2 new1 Baaring shel Mote rasta ation position 2 aires se Bearing 1 Obartemarkog (original Airersionsonestze. Figs 10, Page 33 thee adi Plastigage = Page Ban wth tacking concer 06 ee pat 4 Fis. 1_Moshingpistin {ostallason gsttion oven an ptten roan pointe cose puley Gms Nar epinger atten 1 60 Be 6 Clearly mar sequence on piston crown vith steratct tet pe Iwoarcarti Drak se puch, as pistor cram is Fat 4 fsa, 2 teagan tntaing psion Tost wih pian ring compressor. 1 Mey i esl4 ea ow " Yeasre appro. 20m fr satan of kt Eb effet ca ploton pin fa 9 focinn deviation fron spscifieg divertor “TOP mast face ttwerd piston con 1 Ganfor on slane ving must face ter See stad Step on stepped ring mist face contd nsdn ain 4 Fig. enoring ant uastallig sistan rings 2: Henove and Grail with fatonelng sera. nae(oinerstons 1m re) Toning oy, bore Tne the wie cy Sst oversize) 21.22 an rs oversae| 1:88 ast nar HEC cw api Lez © heck radia? clearance with Pastigae fetes ICTS also pussiole to erec radial clenance ith gine tna Weasuring rage of | Calor] tine Patong ets 2.085... 2.6m | areen | Ped Oca ac060m | Fer” | octia 2 280m | bse + Clear bearing tre erank Journal. ~ Lay Plastiage strip corresonting to with of rants aura in ate! ection Joumal erin Bearing shell = 3201 conrad beerig cap with baring shel and rahe fo 0h, tut an duroge foes Peter rotate carta, ~ fenoveconr being cap an, “= compare sty ot Pastigage strip with enr'ng sate, Si 06 om, NED vinit OC1 m ieToot be teston eno uper tothe tel es OP Benen lage (8 32) haranic for So rseat of 0 at Fiji TE = Tre crm te inter Tespdtion ale © : % sean marking on cmmhtt sprocet and {liner nad over 2g eg OF eweiras on conta are ofect, y {ietture tar Sranchatt ane aetna) a itn asthe Be seta are pones Ee Fhinder heed ean be renved od Sta iet th ensine neta tes fo fapaying arose ng tated elt = fee fesse trap 33 Renan ard “ostall ne ingestors = see oreshop Haat At 169 “Bocrome Infect and Ighition Syste fying tans nit eres Outen valve Shee oe Bua ei at ner Le SRilig dene Inf; groves cra Soot See! ex. OS fin width, OF ‘ora nove than frat apone plus ‘hraae ore creve 1 hen instal ig reiacenent cytnger hg with f tte compat contact Sovfetes between Suck tigpets en can feefeces muse ae ed afte instal ing ie oe sca ting hese peat, reser al conan, co heckng caigrecston = Page 157 11 i Sere 1 fraute correct Instat ation postion "OBE marking 9 part Farber rst fave eyltaer hea o Fit gate over certring pion in ‘litter bnace nD 3 Gaset ie ovlnder beas Street for distortion - Fig. 1, ieee es 2 Belin ating Fi. 2 1 Hnete ing Pose 18 © Servicing atee train's Page 15:9 sm 6 inter teat tots Shtesee 2 FEM aetaatontetractene nt Sequence wee Toston Elptening = Age 158 at sti & se ae+p in Pia oe le Sorin with 1s 10.0 Soe Brith ignition cals O'Daly renew tf aged Insert Te gree ta cover 8 (otis dos som sa Beata P Fer acum noses 2 later tend cane Sans ene 1? danger 6 Insert tr grove on er nder head Ty rene if dna > Inaba mantle aTtee Aen soe: ¥.AG 1649 to ‘stall i" fal: for fl dipstick stde tbe © 10m sates oie ‘ering ean 28. onlan nine se 0 30 os]< hacking cinder head far distortion fstortions nat. 0.1 mn. Ha, 2 fetinishing cinder bat © Hetinishing cylinder hea (grinding fat) {sperma ele upto aininun dimension SCTE im feusored throogh Bolt ote) {MSTALING cane aio tes Oh eey cylinder heat bolts. 8 het att eo econ in Bind foies of ey ingen nad bees tn epider Site : + Before Tuting tinder hese, set ranspatt and cana‘s In einer head to Saeeincer 1. = Fit evlinger ead gatet over conti Pits: OBEN Gr pat ramber mst face pliner bad (arth Foe patter = Install cytinder hea fit eynaer he tots an iaten by had = Tighten cylinder head bolts én total of ‘nee sta = Ta ee dagen 7 {eoaine co) o Stage stage 11 = Ske Stage 111 = 12 Gurn_Gao.turther with gid spamer without $dpping (2 SOPs also bertertoe) Notes 2 tabaen cylinder hexs bolts in reverse ser © ART Clonal retighening of Bolts fs not FeauiredeAEGNG oWPRESSLON PRESSE > Eaglue gam {Coolant terperature gauge et opprars 8). caver on rear engine compartnent bulkhead So te iefeard rove cover 4 mack ant separate somnectors Sand -E- Cogieion carl ove bape Pd. ~ tnscrew al spark plugs with spark plug Sanmer S22 8 = cheek conpransionpreseure with compression Bese Fecerer hc 18h nd ait = Operate starter sntit ga further pressure esse is indiceted by tester, onression aressures (in br) «Specified value FRB gee 10 fhatwieusl gtineers = RDSHRUG Wa at es Cylinder nude with cracks between valve fr iten na aare tan FSP Spare pla heegs are erected, es PM SMe uta ation position and uaberiny= Figs band 2, payee Htatalation sewaence = see Heer ane eta ag sihatis? ie EST it tm iL seal here Fase 8-18 Bei chain ‘ute sale sping Siberia eal ing = see ten i Sooge naive saring mann a2 ing = se ‘ele it 6a Lover anivessocing eat seravig and Totaling = see Possible tot ale ste se ist off fear vero age ibe lve stom sal 2 eran With cy! nger tone inctalied = Pages 2 Bepering vith ey ter heed rerovee Shee Isat sate guide O'Ghcking ~ Fa. 5, Fage 1615 9 Renewing = Page 18.27 ‘Satur tea 2 astalling ~ fage 15-6 evoking valve sents = Page 2526 3 Gheting or duetortion, owotieg - Yale SERTy grin ny 40 gt reer 012> antes Oita estoy cates, goat iheiee serve ptm] tor tae raha 2 ration o Bek eel arc ot Sopete rnvne) “Tg 3 pais emg. neta = Faget Shek rato} lence with Flastigige facet tapes reeves) 1 Suda caper foal) Ser al ke tres, ‘pian caus ones rite tar), he turn crane Prsttioon i rowing surfaces wot ntechnge far © Mer reovng, set alee tages oh Fog Sure tees Jarre o theking rage 1516 oe abve ters Rong ad asta og iitn fina tea ett, in ve tet an) 286 ne ne ever Wt f= see repeal « et = WEB timer ne rane = Boge be cari ee alu-saring cat oe ag a Hew at 4 fig. 1_tnatataton gation ot “ant ezine ce © fecesses a comers of bearing caps mst Fein teat ake Se oy oer Pet © Insta baring caps acorns te mmmerng ata an ca a saw In arom, « a, 2_ stallion poston fet Abc offset. efor iatling cma {abating ag etre tt aten posite waeoan e Seroeunivorst] maturing guuge bractet, “wae arto geniing sutace of tine ond ond nsere ane = Insert nat valve Sno guide, Tae sten rd st eal eth ule. 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"eectrial Seton's (saite station + Remove of pressure sich 2 and seree Hite o1 pressure tester WAG 382 = Seen shea caoaction Daf oi Buco ol prenire ite = Cnrec rom ave oI of tester to eat, = onnect sate testa Yh. 1827 batery pouiuve (ean to ofl pressure Seite i tester with nue ilar Pes ram Waste lace test arp mis rat wy ttherlse renew aif pasar oth = Start engine ant slowly teres ope. 0 Ae Joh. 20 ar ode test Ianp mist ativan renew 1-8 bar a prestte seitse engine soe (At 2000 raven of! erperatre af 9 °C, pressive mist be 2 east 2.0 89 Farther increase engine peat pening pee of arse elit va: This preare y’ Be ily aialiy es TSH pressure is cessive (pressure relter lve st iecing of tncaresty rgeeede Syossite tapdets ett Se subjected Dressive sreetare” Engine wil eutaut sn fer staring an turn cner nocssenty tat, fring subseatens starting aue to Tack of a9 HECKIMG OL PRESSE SEES, ese combing: oro evel © Engine ot} tenperatyre at lest 60 1 Alga chek Speen Gk esi op syels) ote. Pi thecking and servicing Aute chuck Systen — es todsa ra Wal i Mica © Irate tian position of of) sressire sender {60)"= Page 19 2nd + Pull wie off contac 6 of oT pressure Senet (ig). = cone tan multimeter Vol 1526 ta ast fof oi pressure sonier ant engine Srirwite atti wine fon Fag = Set YA 156 20 2000 measuring range (Gaui ytched et) Specified whut: $s. 190 = Start engine and ran at se Specified vate: 70... 1200 ~ Inerease engine speed te 3009 re. Specified vlaes 270... 2008 04 = pal oth ice tram gatas of of pressare sender (ld) ~ Seek fad ater YA 158 Enact a all Pressure ence ane oe ch afth entity ae tr WAS + fun egine at ile lt eae: 9 = switch off engine. Specltiag value: 8 05.0 1 speed valugt ane rr cotairad, renew On rant Seeder (510) ai Gree Syste. EMOUNG AND IASTALING LL IME sans STH Bie oft ips “ unre retaining e1Ips arrows. = Unncrew wir guide Ie. = unscren two fren bolts of subfrare 2 ‘apart Fer tho Frne bolts of subframe Secrve ira eat en Po There are tae cutouts on flyweel cover and on Fy! <= tum coda wt to seyret ‘roas: aF aif sang ate vise = rove oT am, wegaia Seren sake een susrace bots, Tightening torqe: Lo on. tumn (a0 enve tothed bet - see Repair Group 12. Page 27-12, Unscres oil pnp ent pull off crarhsart ab es gases sleeve fron of seal puller 2080 to vaishet Journal prokece fT Bae en test} ina oil pure rake sare ‘riaotet ore ge enue. Insta)! toothed belt - se Repair Grup 13refiltiogcaoont = i foe o Checking coolant systen fer lens — gets z » ‘oolat sine fomecior Far eglare shortage inlleator elton P65 ih exgenson tank SARS EST enone rteator vite en, oO Rhecking = Page 1-36 ose wa SR RR or aier ta suse polrt indirection of tee 1 Sitching temperature Jes 428 imole iepertare st vinous 0 Erecting ~ Page 2915, 4 Roving» set theovingritbet Bete" heoatr reap 0 Tiattesrg torque 9 viscous clutch ea o faverse rene ote 8 2 nt stage on 99 Sas 8c aio ae + Soply om actin Soni. mabe bas weplate astro bape feist Renan Aad 0 “Engen fear ple. ge sop 30 ot Lever costars hoses Installation anion = gr eer armas For angle sracker 1 ig ale ute 2 Lovee aut OF Ettore: ves tena! a Lesk.mster Oars ito fe 5 ee over one vaeth tn Took ut 2 be ey & & ae ERE la tea for eteetrie fan tom cup Sifor vine to fan nator we7 18 19 20 2) 2 Testelloien prttion of lover feolart hse Tig. Tage Tet FEE Fat themostat z Mermstat OhTpsta ation position = Fi 25 Page 83 esha: fest termetat fm agter Byars at apron. 8) © closest approa. tone 1 Opening stroee #2 east § me PBEL or cose of overt enw cols pup 3 aamged ot Issetng ar 195 1+ Goring oes 1 BESS an sooth suing srtace for O-ring i 8 Moorted Tere Engine aor De seelst_ oa, Soe roonaroer 9 Checting'» #58 13-16 Elegtronic thesmuseich 276 heating = see Hresop Hawa) st 1) "rlecrveal Scere oBte ogra £38 otto turodtarger cxoant pup © Stating teperstures: oe ies ieee ate St os 2 ste 8 Ghetting ~ Page 18-16 > Ta-eadtatar (soa, Taepaneion sak7 18 19 20 21 + Salant gol aice ae uae Socant_tebectare sede 652 oe © Cheching = see Norkshp Haas) ass 103: einige tion sn Injection Sten" a ti - os 3° hechng - see dartsnon Nou] ast 5D tear ha hie Condi anar” oie oeeroemvnge must be tigre 4 6a. themgsat natal ao me fing ante see a sett Samed meeecete nlite, ETH rl gf ere oh ‘pcrtenaate aman alii, ‘fay le Cling uttg pin fore tale estan hate ified a ene ind th an strene and ante cotroton ine 0p ating pint conta 16a a 1 operation efficteny wien erpite 1 Sealing ll Tattle th cee htt fecomodedwinture ratios for 9.9 Tt. rest wwe | weer prstection iy | guemity Boots xg Bein | a ie Tae wim] een 11 For cours with cod clieies isoestat stress with ono tallattonpotiton» Fi. 2, Fage 194, = Fit win (50. Insta coon hase enperature gauge at THe between “HE a ANT SSE £08 LS no oly hen engine ie a opereting aertere Ft coding spstam Center 1274 ‘apnsion Bantry adagter W103. frie psa of pot 1.0 ba wth ane pare a Mpg ges ete sar, tte cress (0 1 + Sere cap ante ng syste tester whan + Produce ressune wth hand pup of teste = Presure cele valve mst open at 1.2 iSsca sos ay bei citch fro et felase of itch tauing ate leer = Grech ase af moyen af fen with engine Stead ff, “Thrust be psi totum ar Stat ntinale retane, + Check atl clenrance. Clearance should = maine a ooer i rcaterene offen rot eee agro. iF Beton of wscous tan ch ected erent ST hes teeny viens cluth, watch ‘niteletton seeion fn ge 2 was cas upcumscn THEME 138 AND ar ae = fun eogine wt) conlant temerstare gee Spee me tn Ee laa = Seieh ott engine, After appro. ances, electric colart Dano raator fen risk xi on 1 electri coat pep and rstoter fan omic femect 9 bos ther Ulectre coolant pimp an vatiator fan rast 1 eelant pap on rsiator fore 1 celane jmp an raster far do oat teiate aut ung caret tow haga, ma‘oxea Bees tat onten Fegan etd ante Pls at be Sie. deg. Mnys renew gestess, fl sees an ase cciptarirg feu tre. ‘fae cemeton te sired woh een ering eli Lees Fete air = Fis Fag 20 1 Gertig i gar relay «se orkaop Fare oc cin a er reread nti fal gue fences ae sue hat eae ae Gave tes tr cleiness ~ age 2 Sul tae PacaroRrTs 1 et iatenporiton of fe) Mier Fg tape 2 tum sie rater sie PSPs corel Filter 4 Posse naan ule vie athe 2 Pree ie ror rakirg tiated ehreanl fier oF tank Serine © MReeig ot tating = regain pret Street nang saul salt ote Sarg! ne 0) 1+ fuel pe ener iris aa italy = Page 26 1 ene wewench “Pull fone No A aut of ose holder. + comet vemte anton .5 108/3 ta mace or fuse soetet of fase 40.17 B} Piste = Gomeet lip termina) te battery (1) iu enlcs wth ate confers = tomect tip terminal to starting aid fecha (1 4/£ig,.2_lntalationsnstion of ful iar arrov« inection of flow te engine. ae AES. LNs INGO EEL ‘SHPBULUMeeHin sate © Tforouhly clean 40] asons and surroubins ‘en Brie Sscoettiog. oe reed prs acti safes on fiefs 1 Careftly cover ae pal apenas enpnents HW vapite cane! be cartes ot stowttaey ‘9 Ony insta cles parts Teh unpack veplecner: parts temesiately prior to instal lstone = Ebise Ce'sarte iat nave teen stores Teoge (eg. in tolboces ete} owe oe agit i ape 2% ate wh cages ar 6 = Borat note vebile unless abseatelySAE MEASURES EN WORKING 8 UE. Tame ten resoving and instal ing uel pane er fal apes fran cnatly or pariny File tee cans Ge foto Rast be ste 2 Before begloningrepals, suckin pipe of fxlate struction anit ture be Toca oe rape opening of fuel ark sa tt fet ensue een escape ater epn'ag ap en pe ieestately suciee aff iP exes eattact nya fs ave ee, a'rgal Yan (potor 3 loeteeoteide Sivflog) sh tune of mre thn 15 br Tate re nts fo a Tenving Sr inet ing foe pay fe! Fevintare stoves st be sores as MOVG AND ASTALLING FUEL ca SEER 0 gerne safety measures - Fase 20-5. “ean FeeTakimast ot te wre than 2/8 fu. « ene ovr (ite sn tt Har overing) = Full off comector for fue) geuge and fuel are. “= Loosen tins of sappy pipe te, rezura Dlpe-B> and breather plop =o dnd pull off = Wace neta Ition position of fuel gouge ener" are tf naceff lectricalcomection to fae Toteh nial lation portion of fuel suse fener. ar DUNG NST FEL Uber safety neasues » Fogo 205 “rai iors pot be mre tan 2/9 fu. fall of? comector for fel sage ar fu cefe wich sumer for Th reoving a seta ing Soe tank seder, thsare tates ae nO dap = Fa saply an return pes off er sice of cent ati = full off etetricat conection to fue 4 Ft fue pnp sumer 3218 to tut ure in Sofrte tasty nd Care pimp appent m tsar fet. + Pall ext pap apr fr Til pip ito ote tousing 22 that trang cat igne meh mean ok = Fis fuel pup soemer 321 te fue! pa = lum fue pap clecatce art) Yoranking SeT algae sttnneieg =a (Fan pany enone Mote itl ation position of fuel see ner.ous) nssructienss Spy fuel Ta Before veoving with fl etiretar AE 1 + Regove cover plenum career at right ant stated baltey eotning strap.” (On Neaieies with fresher ser oath {Srey aay 1 oct eter ear = Serve rar Fira deve «sce Uoristop fant fos 10 "Spee Winal Gear ORK the! Oree! = tga Srauy = 1p sagpart, position npinegearbn Vtter Wek@ aes Winer fel ark int mae ae ee |Risements an Fev Tue ton org removed ne ena sade Hratell ear tinal grive «ge rtsoe Noma at 100. Spen fuel Gearbox OIA Tope Orie" Regie Group 3 mou UMMM a ASEORLING uh uN |RSS re two bate tesing vests 2 sei hoasig carmecies tse 5 Sees with ones 88 Bite faerie wide fo titer Sor fae sl poe 3 pffle si 4 ilies Sapte aiseeons rk me Shackinn cover sunle least 18) Hiter Ie geo eon ton amc: reote contra ey Se ao nays a Operate reote control. Fee pap must (ere sity. Tequired to" Tisten for puap operating noises Under venice near fuel ean mp nas Shack fue} pum relay «see worktop anal (RcC'ago"oetrele Ineciton and Tarton Spt", tow breun Ot ue) pump cogs oat “4 tnscrn coer for fuel swage sender and et pon (onder Igage st oor ah ult off comecsar for feel pup and fuel gua mens hand multnoter VA. 1525 to T"igreenyeliw) an € Tore) stn i0ty wltes rom VA 1588 = thera rnete cont Soecitied value: appr. battery wetage 1 If specified value 11 not obi viicate sneak tn virtng wing current Foe lagen 1 specified value 1s tains: Hove (uel gauge sender = Pape 20-8, 4+ crack ines from sender housing te foe ang for saneinray eh mt ml inter Te ateany ne innate bree fn wiring 4f necessary fo brsk in wiring 4& pete, renew n feroving ard netting foe pa = Pee 208aneCH AO FERN LYE OF FL AM oSTrgstare Rietatan, fuel pay, injectors King ater Feed ate of pow 0%, checking = ne As tet Ty charged at Teo 12 fonmect rete contrat WA,5 148/3A with elpler wire Act THGIS2 5. Ip eat RNeR tesserae ipter (4.6 Ly:0, Vk iter te COR af ie. Lear's pein gua tn Soper pa tn ‘erat cence conte for sane reste ove tore on prevtee ou te sles? ; Fealtion PAE i RSoeee ase: HeSSune gauge lever ust comin i ered easton fering ecureg proce oar = Evtetly operate geete control unt noes Eris Seton Wath pressre trp after 1 ins mee a Bar 11 pressure Sop 1s greater, carry cot Feito" the ithe prcture gue comectiens for 5 Ghee rel as er Te, = 11 eas are prser, reereturn vee In Pol gs Bete = fer Hel iro = Page 20-6, ats(a3 seLfeapoing scr Splat valve for activate charcoal kee och mas a tog 10 tose ° Garena rier AE abe entiation of actvatet 35h water from racking Siotee hare fer aa. ued cama af aad 2 Te fuel guage sede. wot SECM. mpTT Lat » clip » io acto ie i Tor adsting throtne cate Tirgtle cable a austing = age 2-23 5+ Suare becieg faa] neatenue tone ca Proete cane say scp Piifrcete cable is tighlycutceptible to {inking apd rust theretene oe Carefully enced wee tne eg Singles Shen Fine clea to break IMer” increta, rsa ble wen hat beer inte aay nit eta Te o Aen Insta Ving, erste thatthvatrie coe Ageteetiepor eet arth equate contin: Throttle eane-crmects to tctle pel fd fast die ca a tari 1 pls ott chet cate = Depress thottle pedo to full ehotete pelea = Pull back trate cable sleeve unit Shrxtle valve ever eentoee sll ehotsle Bop * Srsert securing clip behind support bracket 4 ech heer of troste bleAga acer Sfierye ples tor clesnionss- nay : tole einection ae scuee wth eos. 5 Always reve sea. 2 lg erechrr wth tt = & + ‘ ray pi aturn pine so \-- Solan return eine See 8 fealvith pprooriate olay etter oe BEERS sue 10 8 dimoving ans Tneai tag = page 218 ah at oa P iten ‘tut to aoe 2 aving ad Totaling» see eal ep 28 Sealant aise 5 Sel wen appropriate plug atten oheereatre 1-10. Bp Peron ang nate oe FREESE ation pvition «see Repate Geesp 25” Him 2 ke otee ee gate Phat Page 2 oving an Titel ng = Page 2-8om Pietew ‘Me O81 sys ang tore Srerirg ont! at hate fr sursacharger wth ergie ct ge 2I 2 tose for crankcase entation 2 Tolclinder fead cter ee Abe teen P Toit vane sensor 7 Qurein catcoft valve SMtbeeieg = Page 213 oa tagun base SEE coe orate 2 tone % ings 2 testy = ee ert Yl ah oti tion Inecton yar? Tharashly cleen all anions ont surrounding Fs ete che a He ees ert in ln ute et sey wihinet per Bo Clrety cover or set apenee cenponents ‘fraps coat be carve aut Simectecely. Only install clean ports ny aac repli: ports (estey ~ Batre arts that "hve see stored Toone fess in toobones 30°).+ full solenoid valve for boost pressure Iinteing bs oat 3 bracket Sonat pessune Tf sing ard sarbchorger = trscray four nts on turoshorger/extaust ow pipe tlanje stro oe Flange, fat Bhan int oat efebeus: com pipe ‘Tange are seemer 126 ~ hero exhaust dow pipe = see Repair ro 2 ve " + inser cooant sappy pe Coan 21 Seply ape ts fn fateenrger4 sera turncterger trom exaust mente Italics Se trae ro tas + Sete to capa Ties tot) return oe ~ Seforeseroing 2928] sal pie, f81 sii pesage on tortor veh al rater esa iacion positon a coraatee ive = see Rest run 26. = fun eogire at le for approt. 1 airate ier rca ling terochnger: ore rev Spe oi oply of turbans In ra as oceTNs TaN MD ‘eat sodtion Sires felt rma «se orkep at a 18 'sptraicTenesen an Irgection Syste Cavey.ete Hin cortzaletaer aiagtase = Se dociop Wart hats It Woestie Igevtan gr inleticn Span” 5 Ergre oi tewersture at esst 90% © No esting vat crmetion = tam gee tetenere arrose on comector foyer ear erpne cmaraent ultheat Sete Tet ta nove cover 4 scanert n'sture separator -I- ron raat sed pul off ose ~ Ft Tepece wien nesaring hose of fipartorsie and avsesomctee hae ato|-—-VWAG 1397] Seater ais ~ Switch an turbochnger cesta, itch ‘easing range sulteh a posit tach measuring ose to alo = “Ae Yl wc eco ty aoe tae tt et Shia Meg On Se cay nan of eeral poe i atopy. ° Fe Siete Lagat ets crnerothwnars iy. Aetore eck, drive whlcle briskly for Ee least Bar fio tatehe eee eee} fe oust gresure ig nerateldarog frvving, fecendnethante must Se prerent to ert etetnrger tear for set at Fully dpress accelerator in th ger ten Wal is pot tah an ere ~ Frees reney buttor Won tarbotarer tester at at ae sect tiet wa Atte fo) outsice Roost pressure eersture TER Tee me D> tesa 00 Ds teen 5 0 Sea level fm meeting as of ate ante Tigtl cm =F spcstted value 1s obtained Out path berfomerce vs oticet in soe rege Sow oD ran cheek over ato eas = Page 2ris. If specitied value ts ot cteinedy iar rt ite ae pet = 18 specified vale ts 58411 aot etal, reser turbocharge.Heater 2 verran cut-oft valves Vaated front eProp op oer se wich acuan pressure, thos Peleg Cxisting tose pessire fn Tent of hrete'2 sive smorer to prevent ae Soc during eeetertenstceeration 0 SPperormance ts comm or shock tals cur airing Tong ehangesy everran cutoff valve rust be creck fatett sve. se VAS 1390 to oerre Operate eum pa 6 Overan cutott fslve must open arto Atger appr. 20 seconds, operate venting volve BF vasue a overran cut-off valve must clase are ff valve des not open or ie plate sea ogvith eseraslee. Secure Soest ions ef overrun cuesst rive th ary sus a SALLIE LERCH ‘nme ates HiFiase conection: ave secured with assure aise Pe toonager oh Sich oer tot Se frock angle basses, 6 tbe Oar Pore angle racket 7 terse 5 aber eames BASE Reese bracet 10> Shgesetend bolt wisn callatom ‘ee fetta sere ee dcary a ote 1 eat Me selenite cme 2 or caring a gulde mirage Sg itercanier am ets Rove front tamer «see ria Maal AOS on "Cnr ody ears Bele Grae, = hseev seer for myaraite fas fon fire coparin: stella tase Sethe sete ~ there wna saser ster reer = Shscnet the a use at ntersoler 4 tone tts fom front arc arse > thcr rea searing a From ‘niece = Tete officers denna nas2 Doe oe ca Seen tar anicrewg ce Bo: f Sernitation postion ge re ees 26 nay stunc a isbiees with aon steve 20 form 3 } a. 2 teaches © foranginent of parts eet es oe amt4 rig, te pipe cla Install Moe tae tee doable pipe clay cach ti fester is feovense 4 Fig, forested sie 4 natallation go Dieceion oF flow carr: ron exhaust orale to ethaeee sya Shreian 6 = 130manaes: sytem is aligned wae cold. = aura suficient clearance between al parts of east systen and Dat 4 shen exist syst ts correctly fitted, Dretersion et reir nouts of cate shiewer ast be ot" approx 10 SHECMG WAST S104 se ens Leads exasst system vpstreny of Ls abe ay lead te fa aving sal factors € Starting prabens Stig tise © Uneven eeeleration bor pagerten Inge: wea Insert compressed afr gun into ont etust -ytun tipi a seal Cho Also sea) sestécailpipe with ran. sare of compressed air ron 8 ar + Operete compressed atr gun conirauslys “Spray camacton pints of eine teat, sivl fant ernest Stee eee PHoefeatiyat, cameron 20 ts etn fetatye ef vith ieaecetect len Spey {opel Baha St a Shier = Hepa any Tels Fon Only we canting congount tn spectal cases