Beruflich Dokumente
Kultur Dokumente
V.A.G 1202 A
V.A.G 1306
Notes:
All cable ties which are opened or cut open when removing
the engine must be replaced in the same position when
installing the engine.
Warning!
Hot steam can escape when the cap on the expansion tank
is opened. Cover the cap with a cloth, and open it carefully.
- Remove V-belt.
900058 Type
4A
Õ - Unbolt vane pump for power steering and bracket (at rear)
-arrows-. Do not disconnect hydraulic connections.
All models
Õ - Remove air intake pipe -arrow- between lock carrier and air
cleaner housing.
900058 Type Type description
4A
Õ - Unscrew earth connection to fan motor at earth point -arrow- at
front left of engine compartment.
Warning!
The air conditioner refrigerant circuit must not be opened.
All models
1 -Injection pump
2 -Injection pump
Note:
Support bar must be positioned behind gas strut for bonnet, and
spindles must face forwards.
Notes:
The height of the gearbox can be adjusted via the wing nut on
the lifting hook.
Warning
The hook attachments and locating pins on the lifting tackle
must be secured with locking pins (arrows in illustration).
Note:
Check that all hoses and other connections between engine and
body have been detached.
Notes:
Secure all hose connections with the correct hose clips (same
as original equipment)
- Check whether the two dowel sleeves for centring engine and
gearbox are in the cylinder block, install if necessary.
- Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease G 000 100 to the splines. Do not grease
guide sleeve.
- To secure the torque converter on the drive plate only use the
correct nuts as specified in the parts catalogue.
=> Parts catalogue
All models
- Then operate all electric window switches again for at least one
second in the "close" direction to activate the automatic one
-touch function.
Notes:
A: centering sleeves
Õ Engine/gearbox mountings (automatics)
A: centering sleeves
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Except for the following:
Engine mount to subframe 25
Engine support to engine mount 25
Torque reaction support M8 20
M10 40
Drive plate to
torque converter M10 x1 85
A/C compressor to compressor bracket 25
Power steering pump to bracket 25
Catalytic converter to turbocharger 25
Hose clamps 2
Dismantling and assembling engine
Notes:
2 - 25 Nm
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
3 - Bolt
Bolt with strength rating 8.8:
tighten to 25 Nm
Bolt with strength rating 10.9:
tighten to 35 Nm
=> Parts catalogue
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
4 - Pulley
For vibration damper
V-belt version
5 - Ribbed belt
Check for wear
Removing and installing
=> Page 13-11
6 - Cover cap
Prise off with screwdriver
7 - Tensioning roller
For ribbed belt
Removing and installing ribbed
belt => Page 13-11
8 - 65 Nm
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
9 - Pulley
For alternator
For ribbed belt
10 - 25 Nm
11 - Alternator
Removing:
- Disconnect battery earth strap
- Remove ribbed belt
- Loosen bolts on alternator (top and
bottom)
- Detach alternator and unscrew
wiring connections
To facilitate positioning of
alternator, knock back bush for
bottom retaining bolt on bracket
slightly
12 - Lever
For tensioning roller
Engage flats on end of lever in
tensioning element -Item 17-
13 - 25 Nm
14 - Seal
15 - 25 Nm
16 - 10 Nm
17 - Tensioning element
Removing:
- Remove ribbed belt
=>Page 13-11.
Engage on flats on lever for
tensioning roller -Item 12-
18 - Bracket
For alternator
19 - 25 Nm
20 - Vibration damper
For ribbed belt
With pulley for V-belt
Can only be installed in one
position. Holes are off-set
21 - Coolant pump
Check that pump runs freely
Removing and installing
=> Page 19-11
22 - Bolt
Bolt with strength rating 8.8:
tighten to 25 Nm
Bolt with strength rating 10.9:
tighten to 35 Nm
=> Parts catalogue
23 - Bracket
For vane pump
24 - Bolt/nut
Bolt with strength rating 8.8:
tighten to 25 Nm
Bolt with strength rating 10.9:
tighten to 35 Nm
Tighten nut to 25 Nm
=> Parts catalogue
25 - 25 Nm
26 - Rear bracket
For vane pump
27 - Vane pump
For power steering
Removing and installing:
28 - 25 Nm
29 - Frontbracket
For vane pump
30 - Retainer
31 - 25 Nm
32 - Bolt - 25 Nm
With tensioner nut
33 - Pulley
For vane pump
V-belt version
34 - 25 Nm
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
35 - 25 Nm
36 - Pulley
For coolant pump
V-belt version
Ribbed belt drive for alternator, V-belt drive for coolant
pump and vane pump
Notes:
2 - 25 Nm
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
3 - Bolt
Bolt with strength rating 8.8:
tighten to 25 Nm
Bolt with strength rating 10.9:
tighten to 35 Nm
=> Parts catalogue
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
4 - Pulley
For vibration damper
V-belt version
5 - Ribbed belt
Check for wear
Removing and installing
=> Page 13-11
6 - Cover cap
Prise off with screwdriver
7 - Tensioning roller
For ribbed belt
Removing and installing ribbed
belt => Page 13-11
8 - 65 Nm
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
9 - Pulley
For alternator
For ribbed belt
10 - 25 Nm
11 - Alternator
Removing:
- Disconnect battery earth strap
- Remove ribbed belt
- Loosen bolts on alternator (top and
bottom)
- Detach alternator and unscrew
wiring connections
To facilitate positioning of
alternator, knock back bush for
bottom retaining bolt on bracket
slightly
12 - Lever
For tensioning roller
Engage flats on end of lever in
tensioning element -Item 17-
13 - 25 Nm
14 - Seal
15 - 25 Nm
16 - 10 Nm
17 - Tensioning element
Removing:
- Remove ribbed belt
=>Page 13-11.
Engage on flats on lever for
tensioning roller -Item 12-
18 - Bracket
For alternator
19 - 25 Nm
20 - Vibration damper
For ribbed belt
With pulley for V-belt
Can only be installed in one
position. Holes are off-set
21 - Coolant pump
Check that pump runs freely
Removing and installing
=> Page 19-11
22 - Bolt
Bolt with strength rating 8.8:
tighten to 25 Nm
Bolt with strength rating 10.9:
tighten to 35 Nm
=> Parts catalogue
23 - Bracket
For vane pump
24 - Bolt/nut
Bolt with strength rating 8.8:
tighten to 25 Nm
Bolt with strength rating 10.9:
tighten to 35 Nm
Tighten nut to 25 Nm
=> Parts catalogue
25 - 25 Nm
26 - Rear bracket
For vane pump
27 - Vane pump
For power steering
Removing and installing:
28 - 25 Nm
29 - Frontbracket
For vane pump
30 - Retainer
31 - 25 Nm
32 - Bolt - 25 Nm
With tensioner nut
33 - Pulley
For vane pump
V-belt version
34 - 25 Nm
If necessary, brace pulley with
strap wrench (oil filter wrench) when
loosening and tightening.
35 - 25 Nm
36 - Pulley
For coolant pump
V-belt version
Removing and installing V-belt
- Remove V-belt.
Installation is performed in the reverse order.
V-belt for coolant pump and and vane pump Belt yield (max.)
New V-belt 2 mm
Used V-belt 5 mm
Tightening torques
Component Nm
Vane pump to bracket 25
Vane pump to tensioning bar 25
Removing and installing ribbed belt
Removing
Note:
- Detach cover cap -Item 6-, Page 13-3, from tensioning roller.
Ensure that the ribbed belt is properly seated in the pulleys when
installing.
- Press on cover cap -Item 6-, Page 13-3, for tensioning roller.
Note:
2 - Toothed belt
Mark direction of rotation with
chalk or felt pen before removing
Check for wear
Removing=>Page 13-20
Installing=>Page 13-26
3 - 20 Nm
4 - Tensioning roller
Checking semi-automatic toothed
belt tensioning roller
=> Page 13-30
Position
=>Fig.1, Page 13-18
5 - 45 Nm
Counter-hold with 3036 to loosen
and tighten
6 - Camshaft sprocket
Release from camshaft taper by
tapping with a hammer (using a drift
through toothed belt guard opening)
7 - 25 Nm
8 - Idler roller
9 - 10 Nm
12 - 25 Nm
13 - Woodruff key
Check proper seating
16 - Crankshaft sprocket
Contact surface between sprocket
and crankshaft must be free of oil.
Can only be installed in one
position.
17 - 90 Nm + 1/4 turn (90 °) further
Renew
Do not use oil
Use counter-hold tool 3099 or
3415 to loosen and tighten
Bolting on counter-hold tool 3099
=> Page 13-39
18 - 45 Nm
Use counter-hold tool 3036 to
loosen and tighten
19 - 45 Nm
20 - 10 Nm
22 - Spreader clip
900058 Type Type description
4A 1Z
Õ Fig.1Position of semi-automatic CUT
tensioning roller
The retaining lug must fit in the opening in the rear toothed belt
guard.
Mandrel 2064
Retainer 3036
Notes:
- Fit camshaft sprocket together with toothed belt and locate with
securing bolt (camshaft sprocket can still turn).
If the eccentric mounting is turned too far to the right (by mistake)
, slacken completely before re-tensioning.
Note:
Tightening torques
Component Nm
Toothed belt sprocket to camshaft 45
Idler wheel to console 25
Semi-automatic tensioning roller to cylinder block
20
Bottom section of toothed belt guard to cylinder block
10
Vibration damper with 8.8 25
pulley to crankshaft 10.9 35
Checking semi-automatic toothed belt tensioning roller
Test requirements
Test sequence
TDC marking "0" is stamped into the cylinder block side of the
drive plate.
Removing and installing sealing
flanges and flywheel/drive plate
Note:
1 - Oil seal
To remove, remove sealing flange
-Item 27-
Install with 10-203
Lightly oil sealing lip
4 - 25 Nm
5 - Oil seal
Renewing => Page 13-39
Lightly oil sealing lip of oil seal
6 - 10 Nm
8 - Gasket
Renew
900058 Type Type description MY
4A
9 - Cylinder block
Removing and installing crankshaft
=> Page 13-48
Dismantling and assembling
pistons and conrods
=> Page 13-57
10 - Vacuum pump
For brake servo
11 - O ring
Renew
12 - Cover
13 - 10 Nm
14 - 20 Nm
15 - Bracket
For exhauster
16 - O ring
Renew
900058 Type Type description MY
4A
17 - Oil seal
Renew
18 - 10 Nm
20 - Gasket
Only install gasket if sealing flange
has no sealing lip on cylinder block
side
21 - Flywheel/drive plate
Removing and installing flywheel
=> Page 13-44
Removing and installing drive plate
=>Page 13-45
900058 Type Type description MY
4A
22 - 60 Nm + 1/4turn (90 °) further
Renewing
23 - Intermediate plate
Must be located on dowel sleeves
Do not damage orbend when
assembling
24 - Intermediate shaft
Axial clearance max. 0.25 mm
25 - Woodruff key
Check that Woodruff key is fitted
correctly
26 - O ring
Renew
28 - 25 Nm
900058 Type Type description
4A 1Z of intermediate
Õ Fig.1Installation position CUT shaft sprocket
z Engine in vehicle
- Unscrew inner part of the oil seal extractor 2085 two turns
(approx. 3 mm) out of the outer part and lock with knurled
screw.
900058 Type Type description
4A
Õ - Lubricate threaded head of oil seal extractor, place it in position
and, exerting firm pressure, screw it as far as possible into oil
seal.
- Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
Tightening torques
Component Nm
Toothed belt sprocket to crankshaft 90 + 90°1)2)
Torque reaction support M8 20
M10 40
1)Renew bolt
Flywheel
Work sequence
- Renew bolts.
Tightening torque
Component Nm
Flywheel to crankshaft 60 + 90°1)
1)90°= 1/4turn
Drive plate
Special tools and workshop equipment required
900058 Type Type description
4A
Counter-hold tool VW 558
Depth gauge
Removing
Tightening torque
Component Nm
Drive plate to crankshaft 60 + 90°1)
1)90°= 1/4turn
Removing and installing crankshaft
Note:
1 - Thrust washers
For bearing 3
Different versions for cylinder
block and bearing cap
Note fixing arrangement
2 - Bearing shell
Bearing shell with oil groove for
cylinder block
Do not interchange used bearing
shells (mark with waterproof pen)
3 - Crankshaft
Axial clearance new: 0.07...0.17
mm
Wear limit: 0.37 mm
Check radial clearance with
Plastigage
New: 0.03...0.08 mm
Wear limit: 0.17 mm
Do not rotate the crankshaft when
checking the radial clearance
Crankshaft dimensions
=> Page 13-56
4 - Bearing shell
Bearing shell without oil groove for
bearing cap
Do not interchange used bearing
shells (mark with waterproof pen)
5 - Thrust washers
For bearing 3 bearing cap
Different versions for cylinder
block and bearing cap
Note fixing arrangement
6 - 65 Nm + 1/4turn (90 °) further
Renewing
When measuring radial clearance
of crankshaft, tighten to 65 Nm but
do not turn further
7 - Bearing cap
Bearing cap 1: Pulley end
Bearing cap 3 with recesses for
thrust washers
Bearing shell retaining lugs
(cylinder block/bearing cap) must be
on the same side
10 - Sender wheel
For engine speed sender (G28)
Can only be installed in one
position. Holes are off-set
Always renew sender wheel if
securing bolts have been
unscrewed
Removing and installing
=>Fig. 1, Page 13-52
11 - Fitted pin
Checking projection from
crankshaft=>Fig. 2, Page 13-52
4A 1Z
Õ Fig.1Removing and installing senderCUT
wheel
- Always renew sender wheel -2- if securing bolts -1- have been
unscrewed.
Notes:
If the securing bolts are tightened a second time, the seats for
the countersunk bolt heads in the sender wheel will be distorted
to such an extent that the bolt heads will come into direct
contact with the crankshaft -3- (-arrows-) and the sender wheel
will only fit loosely under the bolts.
Tightening torque
Component Nm
Sender wheel to crankshaft 10 + 90° 1)2)
1)Renew bolts
a =2.5...3.0 mm
Removing and installing needle bearing in crankshaft
Drift VW 207 C
Installing
Distance a = 1.5 mm
Crankshaft dimensions
(in mm)
-0.022 -0.022
Basic dimension 54.00 47.80
-0.042 -0.042
-0.022 -0.022
1st undersize 53.75 47.55
-0.042 -0.042
-0.022 -0.022
2nd undersize 53.50 47.30
-0.042 -0.042
-0.022 -0.022
3rd undersize 53.25 47.05
-0.042 -0.042
Dismantling and assembling pistons
and conrods
Note:
1 - 7 Nm
Version fitted>06.96
Apply sealant AMV 188 001 02
when installing
5 - Bearing shell
Note installation position
Do not interchange used bearing
shells (mark with waterproof pen)
Ensure retaining lugs fit tightly in
recesses
Axial clearance
Wear limit: 0.37 mm
Check radial clearance with
Plastigage:
Wear limit: 0.08 mm
Do not rotate crankshaft when
checking radial clearance
6 - Cylinder block
Checking cylinder bores
=>Fig. 4, Page 13-64
Piston and cylinder dimensions
=>Page 13-68
7 - Bearing shell
Note installation position
Do not interchange used bearing
shells (mark with waterproof pen)
Ensure retaining lugs fit tightly in
recesses
Axial clearance
Wear limit: 0.37 mm
Check radial clearance with
Plastigage:
Wear limit: 0.08 mm
Do not rotate crankshaft when
checking radial clearance
8 - Fitted pin
See note
=>Page 13-57
The fitted pin must seat securely in
the conrod, not in the bearing cap
9 - Conrod
See note
=>Page 13-57
Only renew as a set
Mark cylinder number -A-
Installation position:
Marking -B- faces towards pulley
end
10 - Circlip
11 - Piston pin
If difficult to move, heat piston to
approx. 60 °C
Remove and install with VW 222a
12 - Piston
With combustion chamber
Checking=>Fig. 3, Page 13-64
Mark installation position/cylinder
number=> Fig.5, Page 13-65
Renew piston if there are cracks in
piston skirt
Arrow on piston crown points to
pulley end
Install using piston ring clamp
Checking piston projection at TDC
=>Page 13-66
Piston and cylinder dimensions
=>Page 13-68
13 - Piston ring
Offset gaps by 120 °
Remove and install with piston ring
pliers
"TOP" must face towards piston
crown
Checking ring gap
=>Fig. 1, Page 13-63
Checking ring-to-groove clearance
=>Fig. 2, Page 13-63
Note:
Holes = arrow 2
Notes:
Notes:
2 - 25 Nm
3 - Lifting eye
8 - Dished washer
9 - 10 Nm
10 - Cover cap
11 - Gasket
Renew if damaged or leaking
12 - Fillercap
13 - Breather hose
14 - Hose clip
After fitting hose clip on hose,
engage in retaining tab on cylinder
head cover
15 - Pressure regulating valve
For crankcase breather
16 - Gasket
Renew if damaged
18 - Injector pipes
Tighten to 25 Nm
Remove with 3035
Always remove pipework complete
Do not alter shape
19 - 10 Nm
20 - Coolant flange
With coolant temperature sender
21 - O ring
Renew
22 - Coolant flange
23 - 10 Nm
24 - Connector
For needle lift sender -G80
25 - Return pipe
To injection pump
Note:
Holes = arrow 2
Notes:
Removing
- Take off dished washer -5- and upper sealing washer -4-.
Component Nm
Cylinder head cover to cylinder head 10
Removing and installing intake manifold
Removing
Tightening torques
Component Nm
Intake manifold to cylinder head 25
Heat shield to exhaust manifold 25
Mechanical exhaust gas recirculation valve to intake
manifold 25
Removing cylinder head
Mandrel 2064
V.A.G 1306
Work sequence
z Engine in vehicle
Note:
All cable ties which are released or cut open when removing
must be fitted in the same position when installing.
Warning!
Hot steam can escape when the cap on the expansion tank
is opened. Cover the cap with a cloth, and open it carefully.
- Remove air pipe -1- between charge air cooler and intake
manifold.
Notes:
- Unscrew guide pins with removal tool from 3070 through bolt
holes in cylinder head and install remaining cylinder head bolts.
Note:
=>Page 13-20.
- Then operate all electric window switches again for at least one
second in the "close" direction to activate the automatic one
-touch function.
Tightening torques
Component Nm
Catalytic converter to turbocharger 25
Oil return pipe to cylinder block 30
Injector pipes to injectors/
injection pump 25
Idler wheel to console 25
Toothed belt sprocket to camshaft 45
Hose clamps 2
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZChecking compression
CUT MICLEF
pressure -1-
V.A.G 1763
V.A.G 1381/12
Compression pressure:
Note:
Tightening torque
Component Nm
Glow plugs in cylinder head 15
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Servicing valve gear 1Z CUT MICLEF -1-
Notes:
2 - Oil seal
To remove and install, remove
bearing cap and camshaft sprocket
Removing and installing toothed
belt =>Page 13-20and13-26
3 - Camshaft sprocket
Take off toothed belt before
removing and installing =>Page
13-20or 13-26
Drive off camshaft taper using
hammer and drift through toothed
belt guard openings
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
4 - 45 Nm
Counter-hold with 3036 to loosen
and tighten
5 - 20 Nm
6 - Bearing cap
Installation position
=>Fig. 1, Page 15-38
Installation sequence
=> Page 15-40, removing and
installing camshaft
Before installing first bearing cap,
apply a thin coat of sealant "D 454
300 A2" to contact surfaces
ApplyAMV 174 004 01at sealing
points=>Fig.3and Fig.4, Page 15-7
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -4-
7 - Camshaft
Checking axial clearance
=> 15-39
Removing and installing
=> Page 15-40
Check radial clearance with
Plastigage
Wear limit: 0.11 mm
Run-out: max. 0.01 mm
14 - Valve guide
Checking => Page 15-54
Renew cylinder head if wear limit
is exceeded
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -6-
15 - Lower valve spring plate
Use puller 3047 A to remove and
install
16 - Valve
Do not rework; only lapping-in is
permitted
Valve dimensions
=>Fig. 2, Page 15-38
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Õ Fig. 1Fitting position1Z CUT caps
of camshaft bearing MICLEF -7-
Note:
Dial gauge
Mandrel 2064
Note:
Notes:
Tightening torque
Component Nm
Bearing caps to cylinder head 20
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z
Checking hydraulic bucket tappets CUT MICLEF -1-
Feeler gauge
Notes:
Note:
Puller 3047 A
Removing
- Adjust shaft of fitting tool so that it is level with the studs for the
bearing caps.
Installing
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
Õ - To prevent damage to the new valve stem seals -B-, place
plastic sleeve -A- on valve stem.
- Insert valve stem seal in the tool 3129 and push it down
carefully onto the valve guide.
Note:
Depth gauge
Notes:
Note:
Example:
a = 35.7 mm ш
b = 1.6 mm
45 ° = Valve seat angle
Note:
a = 31.4 mm ш
b = 2.7 mm
45 ° = Valve seat angle
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z
Checking valve guides CUT MICLEF -1-
Dial gauge
Õ - Insert valve into valve guide until end of valve stem is flush with
end of guide. Due to the slight difference in stem diameters,
ensure that only an inlet valve is used in the inlet guide and an
exhaust valve in the exhaust guide.
Wear limit
Notes:
Amount of sideways play: not more than 1.3 mm If the valve is to be renewed as part of a repair, use a new
valve for the calculation.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z parts of theCUT
Removing and installing MICLEF
lubrication system -1-
Notes:
The oil level must not be above the max. mark - danger of
damage to catalytic converter.
=> Maintenance
2 - Gasket
Renew
3 - 18 Nm
Tighten in stages and in diagonal
sequence
4 - Gasket
Renew
Install dry
Apply a small amount of sealant
"AMV 174 004 01" only to sealing
points between sealing flange and
cylinder block (front and rear)
5 - 10 Nm
6 - Suction pipe
Clean strainer if soiled
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
7 - O ring
Renew
10 - Gears
Checking backlash
=>Fig. 1, Page 17-8
Checking axial clearance
=>Fig. 2, Page 17-8
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
11 - Oil pump cover with pressure
relief valve
Opening pressure: 5.7...6.7 bar
12 - 10 Nm
13 - 25 Nm
14 - Sump
Removing and installing
=> Page 17-9
Clean sealing surface before
installing
Before installing sump, apply a
small amount of sealant
"AMV 174 004 01" to sealing points
between sealing flange and cylinder
block
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -4-
15 - Engine/gearbox support
Remove support in order to
remove sump => Page 17-9
When installing engine/gearbox
support with engine removed from
vehicle, ensure that support is
positioned flush with intermediate
plate at flywheel end (i.e. engine/
gearbox support should protrude 0.8
mm from cylinder block).
16 - 45 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZPart II CUT MICLEF -1-
1 - Oil filter
Observe change intervals
=> Maintenance manual
Loosen with strap wrench
Observe installation instructions on
oil filter
2 - 25 Nm
3 - Oil cooler
See note
=> Page 17-1
Coolant hose connection diagram
=>Page 19-2
4 - 25 Nm
6 - Gasket
Renew
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
7 - 0.9 bar oil pressure switch -F1
- 25 Nm
Grey
Checking => Page 17-15
8 - Seal
If seal is leaking, cut open and
renew.
10 - Seal
If seal is leaking, cut open and
renew.
11 - O ring
Renew
Engage in projections on oil cooler
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z backlash CUT
Õ Fig. 1Checking oil pump MICLEF -3-
New: 0.05 mm
Drip tray
Õ When installing the engine and gearbox support -3- with the
engine removed from the vehicle, make sure that the support is
positioned flush with the intermediate plate -1- at the flywheel
end. In other words, the engine/gearbox support should
protrude by 0.8 mm (distance a) from cylinder block -2-.
- Lightly coat the sealing points for the sump between sealing
flange and cylinder block (at front and rear) using AMV 174 004
01.
- Installsubframe
Tightening torques
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Õ Attachments of engine/gearbox
1Z supportCUT MICLEF -5-
Component Nm
Sump to cylinder block1) 18
Oil drain plug 30
1)Special
bolts; use only correct type (same as original
equipment)
Removing
Tightening torque
Component Nm
Oil pump to cylinder block 25
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZTesting oil pressure
CUT and oil pressure
MICLEF -1-
switch
V.A.G 1342
V.A.G 1527 B
V.A.G 1594 A
- Start engine
Note:
If test lamp does not light up, renew oil pressure switch.
- Pressure relief valve or oil pump defective; renew oil pump =>
Page 17-14.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Engine oil 1Z CUT MICLEF -1-
=> Maintenance
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Checking oil level 1Z CUT MICLEF -1-
z After switching off the engine, wait a few minutes to allow the
oil to flow back into the sump.
Test sequence
- Pull out the dipstick, wipe off with a clean cloth and insert it
again as far as it will go.
- Pull out the dipstick again and read off the oil level.
b -Oil can be topped up. The oil level may rise as far as area -a-
after topping up.
Note:
The oil level must not be above marking -a- on the dipstick.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z parts of cooling
Removing and installing CUT system MICLEF -1-
Warning!
Hot steam can escape when the cap on the expansion tank
is opened. Cover the cap with a cloth, and open it carefully.
Notes:
Secure all hose connections with the correct hose clips (same
as original equipment)
1 - Radiator
Removing and installing
=> Page 19-18
After replacing, fill system with
fresh coolant
2 - Return pipe
To expansion tank
3 - Expansion tank
4 - Fillercap
With pressure relief valve
Testing pressure relief valve
=>Page 19-23
5 - Oil cooler
Removing and installing
=>Page 17-6, item 3
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
6 - Return pipe
From heat exchanger (for heater)
8 - Supply pipe
To heat exchanger
Note:
Warning!
Hot steam can escape when the cap on the expansion tank
is opened. Cover the cap with a cloth, and open it carefully.
Notes:
Caution
The two different coolant additives G
1)Cooling
system capacity: 6.5 litres (may vary according to
equipment fitted on vehicle)
- Start engine.
Warning!
Hot steam can escape when the cap on the expansion tank
is opened. Cover the cap with a cloth, and open it carefully.
- Stop engine.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z coolant pump
Removing and installing CUT MICLEF -1-
Removing
- Remove V-belt.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
Õ - Unbolt vane pump for power steering complete with rear
bracket -arrows-. Do not disconnect hydraulic connections.
Õ - Detach bracket for engine cover panel below injection pump -2-.
Tightening torques
Component Nm
Bearing housing to pump housing 10
Pump housing to toothed belt guard 10
Vane pump bracket to cylinder block 25
Bracket for engine cover panel 25
Hose clamps 2
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z checking coolant
Removing and installing, CUT MICLEF
thermostat -1-
Removing
Tightening torques
Component Nm
Connection to pump housing 10
Hose clamps 2
1)cannot be tested
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z radiator
Removing and installing CUT MICLEF -1-
Removing
Warning!
The air conditioner refrigerant circuit must not be opened.
Note:
- Pull condenser out of its bracket, pivot towards the side and
900058 Type Type description secure
MYwith wire. Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
All models
- Detach air cowls from radiator -1- and -3- (left and right).
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -4-
Õ - Unscrew nuts -2- on bonded rubber mountings.
- ... and pull downwards out of top bracket -arrow- (if necessary,
unscrew bolt -1- on radiator support).
Installing
Tightening torque
Component Nm
Radiator to front end M6 10
M8 20
Condenser to radiator 10
Hose clamps 2
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z for leaks CUT
Checking cooling system MICLEF -1-
Test requirement:
Test sequence
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
Warning!
Hot steam can escape when opening cap on expansion tank:
Cover cap with a cloth and open carefully.
When removing and installing the fuel gauge sender from a full
or partly full fuel tank, note the following points:
Drain the fuel tank before removal from the vehicle in order to
reduce weight.
When removing and installing the fuel gauge sender from a full
or partly full fuel tank, note the following points:
Drain the fuel tank before removal from the vehicle in order to
reduce weight.
Also ensure that no Diesel fuel runs onto the coolant hoses. If
necessary hoses must be cleaned immediately. Affected hoses
must be replaced.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZOverview of components:
CUT MICLEF
fuel tank -1-
with attachments
Notes:
1 - Securing strap
For fuel tank
2 - Fuel tank
Removing and installing
=> Page 20-7
3 - Vent pipe
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
4 - Hose for filler pipe
6 - Filler pipe
7 - Overflow hose
9 - Clamp
10 - Union nut, 60 Nm
Remove and install with spanner
3217
13 - Clamping washer
14 - Heat shield
For fuel tank
Ensure proper seating on rubber
plugs
Engage on retaining pins on fuel
tank and secure with clamping
washer
15 - Collar nut - 20 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Draining fuel tank 1Z CUT MICLEF -1-
Removing
Note:
The fuel tank must be empty when it is removed from the vehicle
in order to reduce weight.
- Detach cover for fuel gauge sender unit under floor trim in
luggage compartment.
Õ - Disconnect return pipe -2- and supply pipe -3- from fuel gauge
sender.
Installing
Notes:
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Secure all hose connections
1Z with theCUT
correct hose clips
MICLEF
(same -3-
as original equipment)
Tightening torque
Component Nm
Securing straps for fuel tank to body 20
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Checking fuel gauge1Z
sender -G CUT MICLEF -1-
- Detach cover for fuel gauge sender under floor trim in luggage
compartment.
Notes:
When the sender is removed from the tank the float travel is
greater, so the resistance readings will differ slightly from those
given in the table.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z fuel gauge CUT
Removing and installing sender MICLEF -1-
Removing
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
- Detach cover for fuel gauge sender under floor trim in luggage
compartment.
Õ - Disconnect fuel return pipe -2- and supply pipe -3- from fuel
gauge sender.
- Take out fuel gauge sender and seal from opening in fuel tank.
Installing
Note:
Secure all hose connections with the correct hose clips (same as
original parts)
- Fit new seal for fuel gauge sender (dry) in opening in fuel tank.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
Õ - Insert fuel gauge sender in fuel tank; note correct installation
position:
- Notch -2- on flange must be aligned with marking on fuel
tank -1-.
Note:
Notes:
2 - Seal
Renew if damaged
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
3 - Fuel filter
Loosen with strap wrench
Lightly lubricate seals with diesel
before installing
Fill with clean fuel before installing
Tighten by hand
4 - Seal
Renew if damaged
5 - Supply pipe
From fuel tank
6 - Supply pipe
To injection pump
7 - O-Ring
Renew
8 - Return pipe
From injection pump
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
9 - Control valve
Installation position: arrow points
towards fuel tank
10 - Retainer plate
11 - 5 Nm
12 - Return pipe
To fuel tank
13 - Non-return valve
Installation position: arrow points
towards fuel tank
14 - Vent screw - 10 Nm
Loosen in order to drain water
15 - Seal
18 - Heat shield
19 - 10 Nm
20 - Bracket
21 - 10 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZBleeding fuel CUT
system MICLEF -1-
Note:
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Õ At temperatures below1Z CUTvalve for fuelMICLEF
+ 15 °C the control pre -3-
-heating opens the passage from the fuel return hose to the filter.
If this is the case, clamp off the return hoses on both sides of the
control valve using hose clamps 3094.
Important:
Empty the bleeder container it becomes completely full. No
fuel must be allowed to enter the hand vacuum pump.
Note:
Replace seals.
- Start the engine and check fuel system for leaks (visual check).
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Zfor leaks
Checking fuel system CUT MICLEF -1-
Starting problems
Work sequence
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
Õ - Attach adapter 1274/2 to cooling system tester V.A.G 1274.
By moving the hose clamps from the filter to the fuel tank
connections it is also possible to test the fuel hoses.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZServicing accelerator
CUT linkageMICLEF -1-
1 - Bush
2 - Circlip
3 - Accelerator pedal
4 - Torsion spring
5 - 10 Nm
6 - Spring washer
7 - Cable cam
8 - Square nut
9 - Mounting
11 - 10 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZTesting accelerator
CUT position MICLEF
sender -1-
-G79
V.A.G 1526 A
V.A.G 1594 A
V.A.G 1598/18
or
- Switch on ignition.
- Switch on fault reader printer with the print key. The warning
lamp in key should light up.
028906021A 1.9l R4 EDC SG D .. ⇒Õ The display on fault reader V.A.G 1551 will show the control unit
Coding 00000 WSC 00000 identification, as in thisexample.
- If the specifications for the initial and/or final readouts are not
obtained, adjust accelerator position sender -G79 => Page
20-35.
- Switch on ignition.
- Specification: approx. 5 V
If the specification is obtained:
Testing wiring
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -5-
Õ - With the ignition switched off, connect test box V.A.G 1598/18
to connector -1- (the control unit -2- remains disconnected).
Note:
Work sequence
- Fit eye from cable cam -7- onto stud on accelerator pedal -3-
(pedal is already in position).
- The eye must be properly seated in the slot on the cable
cam.
- The cable cam must be able to turn freely on the shaft of the
accelerator position sender.
- Pull apart the setting jig and lock it in position with the pin
-arrow-.
Notes:
Secure all hose connections with the correct hose clips (same
as original equipment)
2 - Pressure unit
For charge pressure control
Testing =>Page 21-12
3 - Pressure connection on
turbocharger
Pressure supply for charge
pressure control
Safety notes
Warning
=> Diesel direct injection and glow plug system (4-cylinder TDI);
=> Diesel direct injection and glow plug system (4-cylinder TDI;
Test sequence
=> Diesel direct injection and glow plug system (4-cylinder TDI);
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
=> Repair group 01; Reading measured value block=>
- Accelerate from 1500 rpm at full throttle in third gear (or with
selector lever at position 2), and watch rev counter.
- Press PRINT key on V.A.G 1551 and the memory key -M- on V.
A.G 1397 A simultaneously at approx. 3000 rpm.
Specifications:
Read measured value block 11 ⇒ Õ Specification for display zone 3 on V.A.G 1551:
3040 rpm 1846 mbar 1693 mbar 39 %
1550 ... 1750 mbar
Note:
Note:
A fault was stored in the fault memory when the connector for
charge pressure control solenoid valve -N75 was disconnected.
=> Diesel direct injection and glow plug system (4-cylinder TDI);
- Accelerate from 1500 rpm at full throttle in third gear (or with
900058 Type Type description selector
MY lever at position
Engine
2), and
ID watch
Gearbox
rev counter.
ID User Workshop Manual
4A 1Z CUT MICLEF -5-
- Press PRINT key on V.A.G 1551 and the memory key -M- on V.
A.G 1397 A simultaneously at approx. 3000 rpm.
Specifications:
Read measured value block 11 ⇒ Õ Specification for display zone 3 on V.A.G 1551:
3090 rpm 1866 mbar 1917 mbar 62 %
1800 ... 2050 mbar
Test requirement:
Õ - Remove air intake pipe -arrow- between lock carrier and air
cleaner housing.
If the operating rod does not move, even though the lever is free
to move:
Note:
A fault was stored in the fault memory when the connector for
charge pressure control solenoid valve -N75 was disconnected.
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZTesting charge
CUT MICLEF
pressure control valve -1-
-N75
V.A.G 1526 A
V.A.G 1594 A
V.A.G 1598/18
- Switch on ignition.
- Specification: approx. battery voltage
If the specification is not obtained:
Õ - With the ignition switched off, connect test box V.A.G 1598/18
to connector -1- (the control unit -2- remains disconnected).
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -5-
Õ - Test for open circuit and short to positive or earth in the
following wiring connections:
Test sequence
=> Diesel direct injection and glow plug system (4-cylinder TDI);
Õ Indicated on display:
1 - Pressure unit
For charge pressure control
2 - Bracket
3 - 10 Nm
4 - 10 Nm
Lock nut for operating rod -Item 6-
Adjusting=>Page 21-27
5 - Securing clip
6 - Operating rod
For charge pressure control valve
Adjusting=>Page 21-27
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
7 - 10 Nm
Install with locking fluid D 000 600
A2
8 - Gasket
Renew
9 - 25 Nm
Renew
10 - 25 Nm
12 - Banjo bolt, 25 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
13 - Seals
Renew
14 - Exhaust manifold
With connection for exhaust gas
recirculation
15 - Intake manifold
Removing and installing
=> Page 15-11
16 - Cap
For charge pressure test
connection
Secure with hose clamp
17 - Gasket
Renew
19 - 25 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -4-
20 - 30 Nm
Renew
Coat threads and bolt head
seating surface with high
-temperature lubricant "G 052 112
A3"
21 - Gasket
Renew
Note installation position
22 - 25 Nm
Renew
23 - Heat shield
24 - 25 Nm
Renew
25 - Turbocharger
Checking => Page 21-3onwards
Removing and installing
=> Page 21-29
Fill with engine oil at connection
for oil supply pipe
28 - 40 Nm
29 - Seal
Renew
31 - Seal
Renew
32 - Banjo bolt, 30 Nm
Removing
- Apply locking fluid D 000 600 A2 to bolts -2- for pressure unit -6
-, install on turbocharger and tighten to 10 Nm.
- Adjust rod length -3- so that the rod eye will fit easily on lever
pin -5-. (Lever lies against stop with no play).
Removing
Õ - Remove air intake pipe -arrow- between lock carrier and air
cleaner housing.
- Unbolt bracket -2- for oil supply pipe from exhaust manifold.
Notes:
Secure all hose connections with the correct hose clips (same
as original equipment)
Tightening torques
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Component 1Z CUT MICLEF
Nm -4-
Turbocharger to exhaust manifold 30
Turbocharger to catalytic converter 25
Oil return pipe to cylinder block 30
Oil supply pipe to turbocharger 25
Hose clamps 2
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZRemoving and CUT MICLEF
installing parts of -1-
charge air cooling system
Notes:
1 - Air ducting
2 - 20 Nm
3 - Washer
5 - Rubber grommet
For front retaining bracket
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
6 - Charge air cooler (intercooler)
Removing and installing
=> Page 21-37
7 - 20 Nm
9 - Rubber grommet
For rear retaining bracket
14 - Self-tapping screw
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z charge air cooler
Removing and installing CUT (intercooler)
MICLEF -1-
Removing
Õ - Remove air intake pipe -arrow- between lock carrier and air
cleaner housing.
Õ - Remove air duct -1- between charge air cooler and intake
manifold.
Tightening torques
Component Nm
Charge air cooler to retaining bracket
20
Hose clamps 2
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z parts of exhaust
Removing and installing CUT system MICLEF -1-
Notes:
2 - Clamp
3 - Seal
Can be damaged by knocks; do
not drop on the floor
4 - Clamp
5 - Rear silencer
Aligning exhaust system free of
stress => Page 26-10
6 - Front silencer
Aligning exhaust system free of
stress => Page 26-10
7 - 40 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -3-
8 - Clamp
Align exhaust system so it is free
of stress before tightening clamp
=> Page 26-10.
Installation position:
bolted connection on the right
Position of bolts => Fig.4
Tighten bolted connections evenly.
9 - Catalytic converter
With flexible connection (de
-coupling element)
Do not bend flexible connection
more than10°- otherwise it can be
damaged
Protect from damage by knocks
and impact
Removing and installing
=> Page 26-8
10 - Gasket
Renew
11 - 25 Nm
Renew
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z
Õ Fig.1Bending back retaining tabs onCUT
front exhaust MICLEF -4-
mountings
z Rear silencer
Tightening torque: 20 Nm
Removing
Installing
Note:
Tightening torques
Component Nm
Exhaust manifold to cylinder head 25
Heat shield to exhaust manifold 25
Exhaust gas recirculation pipe to exhaust manifold
25
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z front exhaust
Removing and installing CUT MICLEF
pipe with catalytic -1-
converter
Removing
Note:
- Slide the clamp towards the rear and remove the exhaust pipe.
Installing
Note:
Component Nm
Catalytic converter to turbocharger 25
Clamp for exhaust pipe 40
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Stress-free alignment1Zof exhaust system
CUT MICLEF -1-
Notes:
Secure all hose connections with the correct hose clips (same
as original equipment)
1 - Intake manifold
2 - Gasket
Renew
4 - 25 Nm
5 - Gasket
Renew
6 - 25 Nm
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -2-
7 - Exhaust gas recirculation pipe
When installing, just nip all bolts
(parts must be just free to move),
then tighten stress free
8 - 25 Nm
9 - Gasket
Renew
10 - Exhaust manifold
Removing and installing
=> Page 26-6
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1ZDiagram of vacuum
CUT hose connections
MICLEF -1-
1 - Brake servo
2 - Vacuum connection
6 - Air cleaner
7 - Breather pipe
To air cleaner
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A Checking mechanical1Zexhaust gas recirculation
CUT MICLEF
valve -1-
V.A.G 1390
Test sequence
- Operate pump.
- The diaphragm rod should move towards the vacuum
connection.
Note:
or
Test sequence
=> Diesel direct injection and glow plug system (4-cylinder TDI);
Õ Indicated on display:
Note:
=> Diesel direct injection and glow plug system (4-cylinder TDI);
V.A.G 1526 A
V.A.G 1594 A
V.A.G 1598/18
- Switch on ignition.
- Specification: approx. battery voltage
If the specification is not obtained:
Õ - With the ignition switched off, connect test box V.A.G 1598/18
to connector -1- (the control unit -2- remains disconnected).
900058 Type Type description MY Engine ID Gearbox ID User Workshop Manual
4A 1Z CUT MICLEF -5-
Õ - Test for open circuit and short to positive or earth in the
following wiring connections: