V5 Workshop Manual 1998 Onwards PDF

Service.
IN-2r~shop
Manual
: Golf
1998'-,
Bora 1999 ~,
,L
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AGZ
Engine
code
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Booklet 5-CyI. in~ection engine.,

Mechanics
Edition 10.97
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Service.
List of Workshop Manual Repair Groups
Golf
1998~
IAGzl
Engine
code
Booklet
5-Cy1. injection engine, Mechanics Edition 10.97
When filing a Technical Bulletin enter the Bulletin No. in the adjacent column. When using the Workshop
Manual you can then see at a glance whether Technical Bulletins have been published in respect of the
particular Repair Group in which you are looking.
Technical Bulletins
Repair Group
00 Technical Data
10 Removing and installing engine
13 Crankshaft group
15 Cylinder head, Valve gear
17 Lubrication
19 Cooling
20 Fuel supply system
26 Exhaust system
..
-~-.
--,-
_ J __
..
..
Technical Information should always be available to all foremen and mechanics, because their com
pliance with the instructions given is essential to ensure vehicle roadworthiness and safety. In addition,
the normal safety precautions to be observed when working on motor vehicles are also applicable.
All rights reserved.
No reproduction without prior agreement from publisher.

Copyright 1997 Volkswagen AG
Printed in Germany
KOO.51 07.29.20
Contents
00
Technical data
Page
Technical data ............................................................................ 00-1
- Engine number .......................................................................... 00-1
- Engine data ......' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-2
10
13
15
11
19
Removing and installing engine
Page
Removing and installing engine . ......... ~ ................................................ ,

- Notes on removing ........................................................................
- Securing engine to assembly stand ... . . .. . .. . . . .. .. .. .. . .. .. .. . .. . .. . . .. .. .. .. . . .. . . .. . . . ..
- Notes on installing .................... '. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
- lightening torques' ........................ .................. ........................ .....
- Additional information and removal instructions for vehicles with air conditioner ......... . . . . . . . ..
10-1
10-3
10-9
10-11
10-14
10-15
Crankshaft group
Page
Dismantling and assembling engine .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

- Checking valve timing .................................... : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
- Adjusting valve timing ....................................................................
- Removing and installing ribbed belt............................. ...... ........... ...... .....
Removing and installing sealing flange and dual mass flywheel/drive plate .................. ,
- Renewing crankshaft oil seal -vibration damper end- ..........................................
- Removing and installing drive plate .........................................................
Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
- Piston and cylinder dimensions ............................................................
13-1
13-8
13-11
13-27
13-30
13-33
13-37
13-40
1345
13-53
Cylinder head, Valve gear
Page;,
Removing and installing cylinder head ..................................................... 15.t~ti
- Removing and installing cylinder head. . . .. . . .. . . . . . . . . . . . . . . . .. . . .. . . .. .. . .. . . . . . .. . . .. . . . ..

- Removing and installing cylinder head... ........................................... .... . .. ..
- Checking compression pressures ..........................................................
Servicing vaIve gear ..............,.......................................................
- Reworking valve seats ....................................................................
- Removing and installing camshafts .........................................................
- Checking hydraulic bucket tappets .. . . .. . .. . .. . .. . .. . . .. . .. . . . . .. . . . .. .. . . .. .. .. . . . . . . . . .. ..
- Checking valve guides ....................................................................
- Renewing valve guides ...................................................................
- Renewing valve stem seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
15-9
15-17
15-24
1527
15-34
15-37
15-42
15-44
15-45
15-47
Lubrication
Page
Removing and installing parts of the lubrication system .....................................

- Dismantling and assembling oil filter bracket . . . . . . .. . . . .. . . . . . . . . .. . . .. . . . . . . . . .. .... . .. . . ...
- Dismantling and assembling oil pump. .. . .. .. . . . . . . . . .. .. . . . . .. . .. . . . . .. . . .. . . .. . . . . . . . . . . ..
- Removing and installing oil sump .. . . . . .. . .. .. . . . . . . .. .. .. . . .. . .. . . . . . .. . .. . . .. . .. . . . . . . . ..
- Checking oil pressure and oil pressure switch. .. .. . . .. . .. .. . . . . .. .. . . .. .. . .. .. .. . . . . . . .. .. ...
'171
Cooling system
Page
Removing and installing parts of cooling system . ......... , . . . . . . . . . . . . .. . ... . . . . . . . . . . . . . . .

- Parts of cooling system body side ..............................'. . . . . . . . . . . . . . . . . . . . . . . . . . ..
- Parts of cooling system engine side ........................................................
- Coolant hose connection diagram ..........................................................
- Dismantling and assembling coolant thermostat housing................ ...... ....... .... . ....
- Draining and filling cooling system ............................. :............ . .... ... .... ....
- Removing and installing radiator. .. .. . .. . ... . . . .. . .. .. .. .. . . . . . . .. .. .. .. . . .. . .. . . .. . . .. . .. ..
- Checking continued coolant circulation pump (V51) ...........................................
- Checking radiator fan N7) and (V35) ........................................................
- Removing and installing coolant pump ...................... ~".' . . . .. .... . .. . .. . . .. . .. .. . . . . . ..
191
19-2
19-5
19-9
19-11
19-14
19-19
19-22
19-24
19-27
17-8
17-10
17-13
17-16
20
Fuel supply system
Page
Removing and installing parts of fuel supply system ............

20-1
- Removing and installing fuel tank with its attachments and fuel filter ............................. 20-2
- Safety precautions when working on the fuel supply system .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-8
- Rules for cleanliness .............'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-9
- Removing and installing fuel delivery unit.. ............................ ........ .............. 20-10
- Removing and installing fuel gauge sender .................................................. 20-13
- Removing and installing fuel tank ..................................... '" . . .. . .. . .. . . .. . .... 20-14
- Checking fuel pump ...................................................................... 20-18
Accelerator mechanism .
o. 20-28
- Servicing accelerator mechanism ................................................... , .. . . . .. 20-28
- Adjusting throttle cable ................................................................... 20-30
Activated charcoal filter system ...

20-33
- Servicing parts of the activated charcoal filter system......... ... . . . . . . . ... ... .. .. . . . .. ... .... 20-34
- Checking fuel tank breather.. . . .. .. . . . .. . . . . . .. . .. .. . . .. . .. .. . . .. . .. . . . . . . . . .. . .. .. . .. .... 20-36
26
,'
Exhaust system
Page
Removing and installing parts of exhaust system ........

o.
Secondary air system ............
- Function ................................................................................
- Removing and installing parts of the secondary air system. . . . . . .. . . . . . .. . . . . . . . . . . . .. .. .. . .. ..
- Checking combi-valve ..................................... '" .............. , .. ..... .. ... ..
- Removing and installing combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
0
00
00.
26-1
26-7
26-7
26-8
26-13
26-16
Technical data
Engine number
The engine number (engine code and serial number) is located next to
the Cylinder head on the cylinder block. It is found by looking down
wards between the crankcase breather heater element and the
throttle valve control part.
Additionally there is a sticker on the cylinder head cover with" Engine
code" and "Serial number".
The engine code is also included on the vehide data plate.
00-1--
Engine data
Engine code
AGZ
Manufactured
10.96>
VRll
Arrangement of cylinders
Cylinder angle
Displacement
15
Itrs.
2.3
Output
kWat rpm
110/6000
Torque
Nm at rpm
205fJ200
Bore
0mm
Stroke
Compression ratio
1} VR
mm
81
90.2
10.0:1
= V-arrangement in compact in-line design
00-2--
AGZ
Engine code
RON
min.
95 unleaded ll
Injection system
Motronic M3.8.3
Ignition system
Motronic M3.8.3
Firing order
1-2-4-5-3
Knock control
yes
Self-diagnosis
yes
Lambda control
yes
Catalyst
yes
Exhaust gas recirculation system
no
Secondary air system
yes
Charging
no
1)
In exceptional circumstances min. 91 RON, however with reduced performance
00-3--
Removing and installing en

gine
Special tools, workshop equipment. test
and measuring appliances and aux. items
required
2024 A Lifting tackle ,
3395 Engine bracket
VW 313 Support clamp

VW313
VW 540 Engine and gearbox support

VW 540/1 B Supplementary set
V.A.G 1202 A Workshop crane
! W1 ()-()()()8!
10-1--
V.A.G 1306 Drip tray
V..A..G 1331
V.A.G 1306
VAG 1331 Torque wrench (5... 50 Nm)

VAG 1332 Torque wrench (40...200 Nm)
V.A.G 1383 A Engine/gearbox jack
VAG 1921 Spring-type clip pliers

V.A.S 5085 Step ladder
V..A..G 1383 A 6f:iIM!i!!i~
V.A..G 1332
fIG ,
"
G 000 100 grease (vehicles with manual

gearbox)
Cable tie
V.A.G 1921
n.<,:
I
W10-00091
10-2--
..
Notes on removing
Note:
Check' whether a coded radio is installed as during the forthcoming
work sequences the battery earth strap mustbe disconnected. Obtain
radio code first if necessary.
- With the ignition switched off disconnect battery earth strap_ ,

- The engine is removed downwards together with the gearbox.
I
I
- Remove battery and battery retainer.

- All cable ties which are opened or cut open when remOVing engine.
must be replaced in the same pOSition when installing engine.
- Remove air cleaner:
=> Repair group 24; Servicing injection system; Dismantling and as
sembling air cleaner.
- Pull off supply pipe/hose -1- (with white marking) and return pipel
hose -2- (with blue marking) and collect fuel that leaks out with a
Cloth.
10-3--
Note:
Press buttons on hose couplings to do this.
Warning!
Fuel system is under pt'essum! BeloTe opening the system
place a cIDth around the connection. Then release ",.essure by
carefully loosening the connection.
- Remove centre, left and right insulation tray:

, => General body repairs exterior; Repair group 50; Body front; Assem
blyoverview
- Remove ribbed belt => Page 13-27.
- Remove power assisted steering vane pump with bracket and lay
to side; hoses remain connected.
=> Running gear; Repair group 48; Assembly overview: vane pump,
reservoir. hydraulic pipes
- Remove securing clamps for power steering pressure pipe.
Vehicles with air conditioner

- See additional information and removal instructions=> Page 10-15.
10-4--
Vehicles with manual gearbox

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

- Remove selector lever cable from gearbox:
=> Automatic gearbox 01 M; Repair group 37; Servicing shift mechan
ism: Dismantling and assembling shift mechanism
Continued for all vehicles

- Remove intake manifold upper part => Page 15-9, Removing and in
stalling cylinder head cover.
.
- Disconnect all electric wires from gearbox, alternator and starterand
move clear.
10-5--
- Separate connections on following components:

Ignition coil (Nl22) connector.
Continued coolant circulation pump (V51)
Hall sender (640)
Injectors (N30... N33, N83)
Coolant temperature sender (G62)
Air conditioning system shut-off thermo
switch (Fl63)
Engine speed sender (G28)
Knock sensor 1 (G61)
Knock sensor 2 (G66)
Lambda probe 1 (G39).
Fitting locations:
=> Repair group 24: Servicing injection system; Fitting locations - over
view
- Pull off/disconnect all other electrical connections as necessary
from engine and lay to one side.
- Pull vacuum and breather hoses off engine.
- Drain coolant => Page 19-14.
- Pull radiator coolant hoses off engine using hose Clip pliers VAG
1921.
- Remove front exhaust pipe => Page 26-1, Removing and installing
parts of exhaust system.
10-6---
....
:1
;;
- Remove right-hand drive shaft and disconnect left-hand drive shaft

at gearbox:
~ Running gear; Repairgroup40; Removing and installing drive shafts
4
\.F~4-..-f=:::::.::::~.....
"1
- Disconnect pendulum support -arrows-.
:~
,1
Ii
..
V
1\
p
.....
- Increase size of cut-out on engine bracket 3395 to dimensions as

shown:
a=32mm
b=27mm
- Fit engine bracket 3395 onto engine/gearbox jack VAG 1383 A.
I N1G-01<121
10-7--
.....
- Fit engine bracket 3395 onto cylinder block and tighten securing
nuts -1- to 40 Nm.
- lift engine and gearbox lightly using engine/gearbox jackVAG1383
A.
I N10-0a70 I
.....
- Unbolt engine side of assembly mounting from engine carrier at top

-arrows-.
Nate:
To remove securing bolts use step ladder VA.s 5085.
li
P
it
,
-,I
10-8--
....
- Unbolt gearbox side of assembly mounting from gearbox carrier at

top -arrows-.
- Carefully lower engine with gearbox.
Note:
Engine with gearbox must be guided carefully when lowering to pre

vent damage to the bodywork.
Securing engine to assembly stand

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

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

. - Bolt engine/gearbox bracket VW 540 with supplementary set VW
540/1 B onto cylinder block.
10-9--
....
- Attach lifting device 2024 A as follows and lift engine out of enginel
.gearbox jack using workshop crane.
Pulley end:
2nd hole in hook at position 1
Flywheel end:
2nd hole in hook at position 8
Warning!
The hooksandlocatingpins must be secured with locking pins.
Notes:
The positions marked 1.. .4 on the bar must be towards the pulley
end.
The holes in the hooks are counted up from the hook.
- Rt engine in support clamp VW 313 using workshop crane

V.A.G 1202 A.
10-10--
Notes on installing
L
(
Installation is carried out in the reverse sequence, when doing this

note the following:
- Check clutch release bearing for wear; renew if necessary.

- Lightly grease clutch release bearing and splines on input shaft with
G 000 100 grease (do not grease release bearing guide sleeve).
- Only use nuts approved in parts programme to secure torque con

verter to drive plate.
- Check whether the dowel sleeves for centralising engine/gearbox

are in the cylinder block. install if necessary.
- When installing the assembly. ensure sufficient clearance to drive

shafts.
'
- Align engine mountings stress-free by rocking.
10-11--
;
- Install hydraulic clutch slave cyliilder:

=> 5-Speed manual gearbox 02J; Repairgroup30;Servicing clutch con
trol
- Install selector mechanism:
=> 5-Speed manual gearbox 02J; Repair group 34; Servicing selector
mechanism
- If necessary adjust gearchange cables:
=> 5-Speed manual gearbox 02J; Repair group 34; Servicing selector
mechanism
- Install selector cable on gearbox. adjust if necessary:

=> Automatic gearbox 01 M; Repair group 37; Servicing shift mechan~
ism; Dismantling and assembling shift mechanism
- Installing drive shafts:
=> Running gear; Repair group 40; Removing and installing drive shafts
TE'
pi
th
- Install front exhaust pipe=> Page 26-1. Removing and installing parts
of exhaust system.
- Install intake manifold upper part => Page 15-9. Removing and instal
ling cylinder head cover.
10-12--
- Adjust accelerator cable if necessary => Page 20-2S. Servicing accel

erator mechanism.
- Installing PAS. vane pump:
=> Runni,ng gear; Repair group 4S; Assembly overview: ,vane pump,
reservoir. hydraulic pipes
.
- Install ribbed belt => Page 13-27.
- Electrical connections and routing:
=> Electrical system; Repair group 97
- Install centre, left and right insulation trays:
=> General body repairs exterior; Repair group 50; Body front; Assem
bly overview
- Filling with coolant => Page 19-14
- Install air cleaner.
=> Repair group 24; Servicing injection system; Dismantling and as
sembling air cleaner.
- Carry out a test drive and interrogate fault memory:

=> Repair group 01; Self-diagnosis; Interrogating and erasing fault
memory
- Match engine electronics control unit to throttle valve control part:
=> Repair group 24; Renewing, coding and matching engine control
unit; Matching engine electronics control unit to throttle valve con
trol part
10-13--
lightening torques
lightening
torque
Bolted joint
Bolts. nuts
M6
10Nm
MS
20Nm
M10
45Nm
M 12
60Nm
in variation of this
Assembly mounting to gear
box.carrierll
60 Nm + 900
(1/4 turn)
Assembly mounting to en
gine carrierll
60Nm + 90
(1/4 turn)
Assembly mounting to bodyl)
40Nm + goo
(1/4 turn)
Pendulum support to gear
box1)
40Nm + 900
(1/4 turn)
Pendulum support to sub

frame"
20Nm +90
(1/4 turn)
1)
Renew stretch bolts
1o-14~--
i
'
Additional information and removal instructions

for vehicles with air conditioner
Warningl
The air conditioner refrigerant circuit must not be opened.
Note:
To prevent damage to condenser also to the refrigerant pipeS/hoses,
ensure that the pipes and hoses are not stretched, kinked or bent.
To facilitate removing and installing the engine without opening the re
frigerant circuit:
- Remove retaining clamp(s) from refrigerant pipes.
- Remove ribbed belt ~ Page 13-27.
:i
I
',j
- Removing air conditioner compressor.
~ Heating. Air conditioning; Repair group 87; removing and installing
compressor bracket
- Secure air conditioner compressor to body so that the refrigerant
hoses/pipes are relieved.
I
1015--
1
P
tI
Dismantling and assem

bling engine
Notes:
When stripping and assembling the en

gine it should be secured to the engine
frame with engine and gearbox bracket
VW 540 and supplementary set VW
540/18.
Use assembly tool 3277A only, to pull off
and push on the spark plug connector.
If when repairing an engine, metal shav

ings or large quantities of small metal par
ticles caused, for example, by partial seiz
ure of crankshaft and conrad bearings are
fdund in the engine oil, one must apart
from thoroughly cleaning oil passages,
renewal/ oil spray jets, the oil non-retum
valve, the oil cooler and oil filter element
to prevent consequential damage.
II
I N13-0367 I
13-1--
I => Page 13-3

II => Page 13-22
II
I N13-0367 I
13-2--
f
'
-:
Part I
I'
~
~
5 6
21---/
19----.../
I
18---17---~
16
1514
'I
13 12 11
For roller chain item 9

Removing and installing
=> Page 15-37, removing and instal
ling camshafts
2 -Sender wheel
When installing contact surface on
timing chain and sender wheel must
be dry
For Hall sender (G40)
=> Page 15-37, removing and instal
ling camshafts
3-100Nm
Oil bolt head contact surface when in
stalling
To remove and install counter-hold
with 24 mm open jaw spanner on
camshaft => Page 15-37, removing
and installing camshafts
20---'
I.
1 - Camshaft chain sprocket
10
4 - Pivot pin, 18 Nm
For tensioning plate item 7
I N1:H>280 I
13-3--
5 -Seal
Renew if damaged or leaking
6 Chain tensioner, 40 Nm
For camshaft roller chain item 9
Only rotate engine when chain ten
sioner is installed
7 Tensioning plate
8-Sprocket
Installing => Page 13-11, Adjusting
valve timing
9 Camshaft roller chain

Mark D.O.A. before removing (in
stallation position)
=> Fig. 1
Installing => Page 13-11, Adjusting
valve timing
20--./
19----/
18---
17---../
16
1514
'I
13 12 11
10
J.
( .
I N1:H>280 I
13-4--
10 -100.Nm
Use counter-hold 3406 when loosen
ing and tightening => Page 13-11. Ad
justing valve timing
11 - Sprocket
Installing => Page 13-11. Adjusting
valve timing
12 -10 Nm
13 - Chain tensioner with tensioning

plate
Before installing release locking
spline in chain tensioner with a small
screwdriver and press tensioning
plate against chain tensioner
Only rotate engine with chain ten
sioner installed
21-----"
20-----"
19------/
18---
17---
16
1514
13 12 11
10
I N1:Hl280 I
13-5--
14 -Crankshaft sprocket
Integral. part of crankshaft
Ground down tooth aligned with main
bearing joint =TDC No.1 Cyl.
=> Page 13-11. Adjusting valve timing
15 - Roller chain
Mark D.O.R. before removing (in
sta lIation position)
=> Fig. 1
Installing => Page 13-11. Adjusting
valve timing
. 16 - Guide rail
Remove together with roller chain
=> Page 13-11. Adjusting valve timing
21
20
17 - Locating pin without collar, 10 Nm

For guide rail item 16
19
18
17
16 .
1514
18 - Locating pinwith collar, 10 Nm

For guide rail item 21
13 12 11
10
I N1~280 I
13-6--
19-20Nm
Insert with locking fluid "D6"
20 -20Nm
21 - Guide rail
22-10Nm
Insert with locking fluid "D6"
23 -Thrust washer
23----'~~~~~f-~
.
\
24 -Intermediate shaft
22---"
21---"
20---'"
19------'
,, I
..
18----"
17----'
13
10
'
I N13-0280 I
13-7---
:-1
;
Checking valve timing

Special tools, workshop equipment.. testers, measuring instru
ments and auxiliary items required
3268
....
3268 Camshaft bar
....
3277 A Fitting tool
Tee
pliE:
the
1\"
No
_:
Iwoo-o468l
13-8--
Test sequence
- Removing insulation tray:
::} General body repairs exterior; Repair group 50; Body front: Assem
bly overview
- Remove cylinder head cover::} Page 15-9.
~
- Set crankshaft to TDC No.1 Cyl. marks -arrow- by turning crankshaft

on the vibration damper securing bolt in engine D.D.A.:
If the TDC No.1 Cyl. setting is correct it is possible to see a notch on

the intermediate shaft sprockets -arrow-.
Nate:
This condition is only obtained every 2nd TDC position.
If the notch cannot be seen:
- Tum crankshaft 'one full tum further in engine D.D.R.
IN13-G213 I
13-9--
- The camshaft jig 3268 must locate in the shaft groove of the longer
camshaft and align with the shoulder of the shorter camshaft.
13-10--
Adjusting valve timing
3268
(Install timing chain)

Special tools. workshop equipment, test
required
3268 Camshaft bar

3277 A Fitting tool
,
\.
VAG 1331
3406 Counter-hold
r::
VAG 1332 (40...200 Nm) Torque wrench
VAG 1332
,i
@J"I
I W13-0024 I
111I
!
;, l!
13-11--
;, : f
!
Work sequence
Engine removed
Install roller chain and chain tensioner with tensioning plate:

...
- Set/check position of crankshaft to intermediate shaft.

Ground down tooth on crankshaft sprocket-8
must align with the main bearing joint (TOC No.1 Cyl.)..
- Install pin without collar for guiderail-2- and tighten to
10Nm.
.
ac
ia
I Vl3-1052 I
Ie
fr
) f
ip'f
13-12--
....
- Install guide rail-2-with roller chain -l-and both chain sprockets -3

and -4- (note O.O.A. of roller chain => Page 13-21. Fig. 1)
Marking on roller chain sprocket -4

must align with the notch -C- or -0- on the
thrust washer.
- Release locking spline in chain tensioner with a small screwdriver

-A-.
- Press chain tensioner against tensioner plate and tighten chain ten
sionerto
10Nm.
I V13-10S21
- Lock vibration damper with counter-hold tool 3406.
I N13-0290 I
13-13--
lighten intermet:fl8te shaft sprockets 3 and 4
l00Nm.
- Remove counter-hold 3406.

- Check position of crankshaft to intermediate Shaft.
Ground down tooth on crankshaft sprocket -8
must align with the main bearing joint (TOC No. 1 CyL).
I V13-10S21
Install camshaft roller chain and chain tensionerwith tensioning plate:
- Position both camshafts at TOC No. 1 cylinder.

- Install tensioning plate locating pins and tighten to
18Nm.
13-14--
- Install tensioning plale for chain tensioner (camshaft roller chain).

- Install locating pin with collarfor guide rail and tighten to
10 Nm.
Note:
With cylinder head removed:
- Installing cylinder head => Page 15-17 Removingand installing cylin
derhead.
- Place guide rail on locating pin. Insert short securing bolt with locking
fluid .. 06" and tighten both bolts to
20Nm.
....
- Place camshaft roller chain on intermediate shaft. (Note D.O.A.).

- Fit camshaft chain sprocket and roller chain to camshaft for cylinder
bank 1t 3 and 5 (longer camshaft) and pull tight by hand.
- Install camshaft chain sprocket (with sender wheel for Hall sender)
and camshaft roller chain to camshaft for cylinder bank 2 and 4 and
pull tight by hand.
,~~
;;
'Ii
, I
1'[
,
1:
j.
Ji
(I
III!
I N1:Hl281 I
,}
i~!
13-15--
.I
Note:
~ ~
Oil contact surfaces of bolt heads when installing.

- Remove camshaft jig 3268.
- lighten securing bolts for camshaft sprockets to
looNm.
Note:
Only counter-hoJd with 24 mm open jaw spanner on the camshaft
arrow.. The camshaft jig must not be fitted when tightening/Joosening
the sprockets.
I N15-0157 I
11I
~i
- Coat sealing surface of sealing flange with AMV 188 001 02 and in
stall. lighten securing bolt to
10 Nm.
- Renew sealing flange oil seal

=> Page 13-30, Removing and installing sealing flange and flywheeV
drive plate.
t '
- Prepare cylinder head gasket for assembly
=> Page 15-7, Fig. 2
- Coat sealing surface of cover with AMV 188 001 02.
13-16--
- Lubricate O-Ring for oil channel seal and insert into cover part.
- Install cover, insert all securing bolts and tighten lightly.
-- First tighten M8 securing bolt to
25Nm
then M6 securing bolts to
10 Nm.
- Install chain tensioner for camshaft roller chain and tighten to

40Nm.
Nate:
Only turn engine with chain tensioner installed! Otherwise cam

shaft roller chain will jump!
- Turn crankshaft two full turns in engine D.O.R. and check valve tim
ing ~ Page 13-8.
13-17--
Engine installed, cylinder head removed
....
-'Set crankshaft to TDC No.1 Cyl. marks-arrow- by turning crankshaft

on the vibration damper securing bolt in engine D.O.R.:
....
If the TDC No. 1 Cyl. setting is correct it is possible to see a notch on

the intermediate shaft sprockets -arrow-.
If the notch cannot be seen:
- Tum crankshaft one full tum in engine D.O.R.
Nate:
If the crankshaft is turned with the cylinder head removed, a 2nd
mechanic should guide the camshaft roller chain by hand to prevent it
jamming.
- Position both camshafts at TDC No. 1 cylinder..
13-18--
- Prepare cylinder head gasket for assembly
=* Page 15-7, Fig. 2
- Install cylinder head =* Page 15-17.

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

for cylinder bank 1. 3 and 5 (longer camshaft) and pu II tight by hand.
- Install camshaft chain sprocket (with sender wheel for Hall sender)
and camshaft roller chain on camshaft for cylinder bank 2 and 4 and
pull tight by hand.
Note:
Lubricate bolt head contact surfaces when installing.
- Remove camshaft jig 3268.
13-19--
- lighten securing bolts for camshaft sprockets to

100 Nm.
Note:
Only counter-hold with 24 mm open jaw spanner on the camshaft
arrow-. The camshaft jig must not be fitted when tightening//oosening
the sprockets.
- Coat cover sealing flange with AMV 188 001 02.
I N15-0157I
- Lubricate O-Ring for oil channel seal and insert into cover part.
- Install cover; insert all securing bolts and tighten lightly.
- First tighten M8 securing bolt to
25Nm
then M6 securing bolts to
10Nm.
- Install chain tensionerfor camshaft roller sprocket and tighten to
40Nm.
13-20---
Ul
Note:
Only crank engine with chain tensioner installed otherwise the cam
shaft roller chain will jump.
- Turn crankshaft two full turns in engine D.O.R. and check valve tim
ing ~ Page 13-8.
~
Fig. 1
Marking roller chains
- Mark roller chains before removing (e.g. with paint arrow pointing
in D.O.R.'.
Note:
Do not mark chain with a centre punch or any similar means!
I N13-0281 I
13-21---
29
28J~
30
31
'-----1
..
~1IIiI~---2
'---'----3
Pm II
1-10Nm
4
2 - Oil pump drive cover
3 -O-Ring
Renew
Oil before assembling
4 - Oil pump drive
5 - Cylinder block
Removing and installing sealing

flange and dual mass flywheeVdrive
plate ~ Page 13-30
Removing and installing crankshaft
~ Page 13-40
Dismantling and assembling pistons
and conrods
~ Page 13-45
23 - - - - - - : " ' t f t .
21---...../"'-..-.....
6 -Intermediate shaft
7 - Thrust washer
1~F---16
20---"
18 17
I N13-0146 I
13-22--
,
lWr"1
.,
- . '. .
i
"
29
! 1,
\ r
28J~
30
'....- - - - 1
2 7 - - - -..............",.---....
~
..!""-----2
'-----"'----3
4
810 Nm
Insert with locking fluid "06"
9 - Knock sensor 2 (G66)
Checking:
=> Repair Group 01; Self-diagnosis; Interro
gating and erasing fault memory
1020Nm
lightening torque influences the
function of the knock sensor
11 - Engine speed sender (G28)
Checking:
.
=> Repair Group 01; Seff-diagnosis; Interro
12 - Coolant pipe
=> Page 19-5, parts of cooling system
- engine side
21-~"'/
r---._......
.I
~
"
20---'
18 17
I N13-0146 I
13-23--
30
-----'1
~1IIiiIi!1L----2
'-------:3
1"-,
27--------...
26-----" ~.~\.iii_ .,.~,,~
FF--------,4
13 - Drive .shaft
For oil pump drive
14-0il pump
Dismantling and assembling => Page
17-10
Coat oil pressure pipe on cylinder
block and oil pump housing with AMV
188 001 02
15-25Nm
16-Sump
24
=> Page 17-13
3~~~~~l]rJj
23 - - - - " " ' t f l .
; j
17 - Oil drain plug. 20 Nm
22~'
18-Seal
Renew
!
I
15----~r-7""'T
1915 Nm
21--"""""'"r---._.......
20 - Oil filter bracket

Dismantling and assembling
=> Page 17-8
n~~-16
20---
18 17
I N13-0146 I
13-24--
29
30
28~~
r------1
1Iii!JiIIL-----2
"------:3
4
27------...
26------'"
21 Oil cooler
Coat contact area outside the seal
with AMV 188 100 02
Ensure clearance to adjacent comp(r
nents
See note
~ Page 13-1
22 - Fitted bolt, 25 Nm
25~i,.
(Ii
23 Compact bracket
24--.1>'
For alternator air conditioner com

pressor and P.A.S. vane pump
3
".
23 - - - - - l o t l t .
24 - Vibration damper
Removing and installing ribbed belt
~ Page 13-27
25 120 Nm + '/4 tum (90 0) further
21--..../
Renew
Counter-hold with 3406 to loosen and
tighten ~ Fig. 1
lighten using torque wrench VAG
1601
.....
~-
9=---18
20-----'
18 17
I N13-{)146 I
13-25---
29
28~~
30
26-5Nm
Z1 Guide tube
For dipstick
Secured with bolt on inlet manifold
upper part
27------..
---".-.;;;:
26------'"
2845Nm
29 - Engine bracket
30 - Dipstick
The oil level must not be above the
max. mark!
24
3 ---=~~::::::~~~,~
23 - - - - " t t l ' .
31 Oil non-retum valve, 5 Nm

Note fitting position
Clea n if badly soiled
See note
'
~ Page 13-1
~--16
18 17
I N13-0146 I
13-26--
....
Fig. 1
To loosen and tighten the securing bolt hold vibration

damper with counter-hold tool 3406
Note:
Renew securing bolt for vibration damper.
I N13-02!1O I
Removing and installing ribbed belt

Special tools workshop equipment. testers measuring instru
l
.6mm0 pin
Straight 16 mm ring spanner
Removing ribbed belt

- Removing insulation tray:
blyoverview
- Mark direction of rotation of ribbed belt.
13--27--
- Swing tensioning roller using a straight 6 mm ring spanner in direc

tion of arrow until tensioning roller can be locked.
~'
1
1
....
':
I
"1:
- Lock tensioning roller using an approx. 6 mm 0 pin -arrow-.
Note:
A second mechanic is required for this.
- Remove ribbed belt.
13-28--
Installing ribbed belt
- Install in reverse order.
Notes:
Ensure, before installing ribbed belt, thataI/ancillaries (altemator, air
conditioner compressor, PAS vane pump) are secured tightly.
When fitting the ribbed belt observe belt direction of rotation and
that the belt is seated correctly in the belt pulleys.
.... - Fit ribbed belt.
After completing repairs always:
- Start engine and check belt running.
I N13-03721
13-29--
1 2
3 4
738

sealing flange and dual
mass flywheel/drive plate
Notes:
For repairs to the clutch:
=> 5-Speed manual gearbox 02J; Repair.
group 30; Servicing clutch

.. When stripping and assembling the en
gine it should be secured to the engine
frame with engine and gearbox bracket
VVV 540 and supplementary set VVV
54O!1B.
'1,
1 -100 Nm +
tum (90 )further
Renew
Counter-hold with 3406 to loosen and
tighten => Page 13-33. Renewing
vibration damper end crankshaft oil
seal
11
10
I N13-0373I
13-30--
2 Vibration damper
310Nm
1 2
3 4
738
4 -Oil seal
Renewing ~ Page' 13-33
5 - Sealing flange
Coat sealing surfaces with
AMV18800102
6 Cylinder block
Removing and installing crankshaft
~Page 1340
Dismantling and assembling pistons
and conrods
~ Page 13-45
7 -Sealing flange
Coat sealing surfaces with
AMV18800102
11
10
I N13-0373 r
13-31--
1 2
3 4
8 -Oil seal
Remove with extractor hook 2086
Lightly oil sealing lip
Install over sleeve 2003/2A
Pull in onto stop with installing tool
738
200313
9 -60 Nm + '12 tum (180 0) further

Renewing
10 - Dual mass flywheel/drive plate
Removing and instalIing drive plate ~
Page 13-37
11-25 Nm
"
,
I
Ii
11
.1
J
I' ,
I! .
11
10
I N13-0373 I
13-32--
3266
3203
Renewing crankshaft oil seal

vibration damper endSpecial tools, workshop equipment. Wst
required
3203 Oil seal extractor

.3266 Fitting sleeve
3406 Counter-hold
V.A.G1332
V.A.G 1332 (40...200 Nm) Torque wrench
W-'
f'
V.A.G 1601
I W13-00251
13-33--
Removing

....
- Remove vibration damper. To do this lock vibration damper with

counter-hold tool 3406.
- Unscrew inner part of oil seal extractor 3203 three turns (approx. 4
mm) out of the outer part and lock with knurled screw.
I N13-(129() I
....
- Lubricate threaded head of oil seal extractor3203, place it in position

and exerting firm pressure screw it as far as possible into oil seal.
- Loosen knurled screw and tum inner part against crankshaft until the
oil seal is pulled out.
13-34--
. .,
!f'r
.1
I'
i .
I '
f ~
I.
Installing
- Lightly oil sealing lip of oil seal.
....
- Place guide sleeve from 3266 onto crankshaft journal.

- Slide oil seal over guide sleeve.
....
- Press oil seal in onto stop with press sleeve from 3266. To do this
use an old vibration damper securing bolt.
13-35--
....
- Install vibration damper and lock with counter-hold tool 3406.

- lighten new securing bolt to 100 Nm and then turn
1/4 tum (90)
further.
I N13-0290 I
.i
f.
I;
13-36--
VAG 1331
Removing and installing drive

plate
Special tools, workshop equipment, test
required
.3406 Counter-hold
V.A.G1332
Depth gauge
@!"!
Straight edge
I w13-00281
13-37--
Removing
...
- Lock vibration damper with counter-hold tool 3406.

- Loosen drive plate securing bolts diagonally and remove.
- Remove drive plate.
I N13-Q!90 I
InstaFmg
- Fit drive plate onto crankshaft.
- Insert at least 3 old securing bolts and tighten to
3ONm.
...
- Check dimension 08- to cylinder block through the three holes for se
curing the torque converter using a straight edge and depth gauge
and calculate average.
- Compare average with specification (measured distance + thick
ness of straight edge).
Specification: 15.7 ... 16.5 mm
13-38--
If the specification is not attained:

...
- Remove drive plate again and fit appropriate shim -1-.
Note:
Only one shim of the appropriate thickness may be used.
I V13-1281 I
If the specification is attained:

- Insert new securil}g bolts and tighten by hand.
- Tighten securing bolts to 60 Nm and then turn
1800 (1/2 tum)
further (turning further can be done in several stages).
13-39
1
2
3
4
4
7
3
8
,,<

crankshaft
Notes:
Before removing the crankshaft,
that a suitable surface is prepared to
sure that the sender wheel (item 6) is
damaged or lies against any other item.
When stripping and assembling the
gine it should be secured to the
frame with engine and gearbox
VW 540 and supplementary set
540/1B.
When changing bearing shells ensure
bearing shells of same c%ur code
used.
1 - Bearing cap
Bearing cap 1: Vibration damper end
Bearing cap 4 with recesses
thrust washers
Bearing shell retaining lugs cyr
block/bearing cap must be on
same side
<
I N13-0324 I
13-40--
~-----------1
--2
....-----3
...----4
4-----1
;-----5
,----6
2 - 30 Nm + 1/2 turn (1SOO) further

Renew
2 x 900 further is permitted
3 -Bearing shells 1 ... 6

For bearing cap without oil groove
For cylinder block with oil groove
Do not interchange used bearing

shells (mark)
4 - Thrust washer
For bearing cap 4
Note fixing arrangement
8----..
----7
'----3
~~~---8
I N13-0324 I
13-41--
~----------1
-----3
4----.....,
---4
...-----5
,----6
---7
'-----3
5 Crankshaft
See notes before removing ~
Pagel3-40
Axial clearance new: 0.07 ... 0.23 mm
Wear limit: 0.30 mm
Check radial clearance with Plasti
gage
New: 0.02 ...0.06 mm
Wear limit: 0.10 mm
Do not rotate the crankshaft when
checking the radial clearance
Crankshaft dimensions:
Main journal:
59.958 ... 59.978 mm
Crankshaft journal:
53.958 ... 53.978 mm

reworking is not permitted
6 - Sender wheel
For engine speed sender (G28)
Renew
Installing ~ Fig. 1
:::::5!!;;----8
I N13-0324 I
13-42--
T!I Ii!
'
; I
--------------------1
J-l==--2
-----3
-----4
~--5
4------~
.----6
,!
7 10 Nm + '/4 turn (90 0) further

Renew
8 . Oil spray jet

For crankshaft bearings 2...6
For piston COOling
Opening pressure: 2.0 bar
=> Page 17-6, Fig. 1
See note
=> Page 13-1
;!
, i
,!
------7
8---""""
'-------3
~~----8
I N13-0324 I
13-43--
rig. 1
rltting sender wheel to crankshaft
Ensure crankshafVsender wheel contact surfaces are free of oil and

grease.
- For additional security coat reverse side of sender wheel thinly
with locking compound 0 000 600.
- Ensure when installing that -VR5- (arrow) is positioned over the
individual threaded holes.
- First tighten all securing bolts lightly by hand.
- Then tighten securing bolts to
10 Nm + '/4 tum (goo).
13-44--
I,
i~htl
Dismantling and assem

bling pistons and conrods
Note:
When stripping and assembling the engine

it should be secured to the engine frame
with engine and gearbox bracket VW 540
and supplementary set VW 540/18.
1 - Piston ring
Offset gaps by 120
Remove and install with piston ring
pliers
"TOP" faces towards piston crown
Checking ring gap ~ Fig. 1
Checking ring to groove clearance
~Fig. 2
2 -Piston
Checking => Fig. 3
Mark installation position to conrod
and cylinder number
High point of piston crown faces to
centre of cylinder block
Install with piston fitting tool 3278
=> Fig. 5
I N13-02861
13-45
~--'T'--r-----1
3 -Conrod
Only renew as a set
Mark cylinder number -8
Installation position:
Marks -A- must be above one another
4 Conrod bearing cap

(/,~~ii!------
Note installation position

5-30 Nm + '/4 tum (90 )further
Renew
Oil threads and contact surface
To measure radial clearance tighten
to 30 Nm but not further
&1-------4
rl!------5
I N13->0286 I
13-46--
6 - Bearing shell
'I ;.'
,
'
--V~---"----
,: I,
,l
; i
,,

Do not interchange used
shells
The lugs on the bearing shells must fit

tightly in the recesses
Axial clearance
New: 0.05...0.31 mm
Wear limit: 0.40 mm
Check radial clearance with Plasti

gage:
New: 0.02...0.07 mm
Wear limit: 0.10 mm
Do not rotate crankshaft when
checking radial clearance
7 - CyrlRder block
Checking cylinder bores
=> Fig. 4
Piston and cylinder dimensions
=> Page 13-53
.4....L...-----4
e------5
! N13-02SSI
13-47--
~-~~----
8 - Piston pin
If difficult to remove, heat piston to
6O.()C
Remove and install with drift vw
222a
9 -Circlip
P---V-~----2
;r------4
11------5
! N13-02SS!
13-48--
Fig. 1
Checking piston ring gap
Special tools. workshop equipment. testers. measuring instru

Feeler gauges
Test sequence
- Push ring squa rely from above down to approx. 15 mm from bottom
end of cylinder. To do this use a piston without rings.
Gap
Piston ring
New
Wear
limit
Compression ring
mm 0.20...0.40
1.0
Tapered stepped
ring
mm 0.20...0.40
1.0
Oil scraper ring
mm 0.25...0.50
1.0
13-49--
Fag. 2
Checldng ring to groove clear8nce
Special tools. WOiIcsllop equipment. testers. measuring instru

ments and ....., ..... required
Feeler gauges
Clean groove before check.
Piston ring
Clearance
New
Wear
limit
Compression ring
mm 0.02...0.07
0.15
Tapered stepped
ring
mm 0.03...0.06
0.15
Oil scraper ring
mm 0.02...0.06
0.15
Fig. 3
Checking piston
Special tools, workshop equipment. testers. measuring instru

Micrometer 75...100 mm
I V13-0C1101
Measure pistons approx. 6 mm from the lower edge of skirt. at 90 0 to

the piston pin axis.
Deviation from nominal dimension
max.O.04mm
13-50--
....
F'~.
Checking cylinder bores
Special tools. workshop equipment. testers, measuring instru

ments and aQxiliary items required
Internal dial gauge 50...100 mm
Test sequence
Measure bores at 3 locations in both directions ~A-across the engine
and -8- in line with crankshaft.
Deviation from nominal dimension
max.0.08mm
Note:
Measuring the cylinder bores must not be done when the cylinder
block is mounted on a repair stand with adapter bracket 3269" as in
correct measurements would then be possible,
13-51--
I
....
Fig. 5
Installing pistons with piston fitting tool 3278
Special tools, workshop equipment testers, measuring instru

3278 Funnel
Note:
If a new fitting tool (funnel) is used to install the pistons, first pass pis
ton with oiledpiston rings twice through the tool and then if necessary
remove the resulting metalshavings, Only then install piston with pis
ton rings.
Work sequence
- Oil tool and push piston in by hand. High point of the piston crown
must face to the lug on the fitting tool -arrow-,
- Hold tool (with piston inserted) on upper edge and press piston in
with both thumbs.
- Push piston in until it protrudes approx. 15 mm from the lower edge
of the fitting tool.
- Place piston in appropriate cylinder bore. Lug on fitting tool-arrow
must face to centre of cylinder block.
13-52--
- Hold fitting tool tight against cylinder block and push piston in.
Piston and cylinder dimensions

Honing
dimension
Piston-0
Cylinder
bore-0
Basic dimen.
mm
80.985
81.01
1st oversize
mm
81.485
81.51
2nd oversize
mm
81.985
82.01
13-53--
,PITT
.
,)
[

cylinder head
Checking compression pressures
~ Page 15-24.
Notes:
When installing an exchange cylinder

headwith fitted camshaft the contact sur
faces between bucket tappet and cam
must be oiled after installation.
'f
I!
The plastic protectors fitted to protect the

open valves must only be removed im
mediately before fitting the cylinder head.
When replacing the cylinder head the
complete coolant must be renewed.
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
15-1--
1 -Intake manlold upper part

~ Page 15-9. Removing and instal
ling cylinder head cover
First tighten with intake manifold
lower part to cylinder head, then
tighten the two supportS.
Dismantling and assembling:
~ Repair group 24; Motronic injection and
ignition system; Servicing injection part
2 - Throttle valve control part

Heated by coolant
Removing and installing:
group 24; Motronic injection and
ignition system; Servicing injection part
~ Repair
3-10Nm
4-Cap
Renew seal if damaged
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
152--
6 Cylinder head cover

=> Page 15-9
Renew if damaged or leaking

Before fitting coat cover/cylinder
head transitions and the half-moon
shaped recesses with D 454 300 A3
6-Bracket
--'0
---1
-z.4.~~-13
-~3
--..---=:000--7
22 21 10 20.19 7 18 17 16 6
7-26Nm
8 ~lIIder head bott
Renew
Note installation instructions and se
quence when loosening and tighten
ing
=> Page 15-17
9 - Cylinder head
Check for distortion => Fig. 1
=> Page 15-17
If replaced renew the complete

coolant
15 14 6
I N15-0078 I
16-3--
10 -O-Ring
Renew
11-Cover
Can be removed and installed with
cylinder head fitted
Coat sealing surfaces with AMV 188
00102
If only the cover has been removed,
prepare cylinder head gasket for as
sembly
=> Page 15-7, Fig. 2
. 12 - Chain tensioner, 40 Nm
For camshaft roller chain
Only tum engine with chain tensioner
installed
13 -Seal
Renew
14 -Continued coolant circulation pump

(V61)
Checking => Page 19-22
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
16-4--
15 -Ignition coils N, N128, N158, N163,

N164
~
Checking:
Repair Group 28; Servicing ignition part
16 - Thermostat housing
Dismantling and assembling ~ Page
19-11
17 -Gasket
Renew
18 - Cyflllder head gasket

Renew
If replaced renew the complete
coolant
19 -Intake rill-lower part

20 - Gasket for intake manifold upper
part
Renew if damaged
21-5Nm
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-007SI
15-5--
22 - Combi-valve
Checking ~ Page 26-13
~ Page 26-16
23 - Gasket for
part
i......
manifold lower
Renew if damaged
24 - Tensioning element
For ribbed belt
25-5Nm
26 -Bracket
For secondary air inlet valve (N112)
and intake manifold change-over
valve (Nl56)
27 - Vacuum positioning element
For intake manifold change-over
22 21 10 20 19 7 18 17 16 6
15 14 6
I N15-0078 I
15-6--
.....
~~~~~......I
Fig- 1
Checking cylinder head for alStortion
Special tools. workshop equipment, testers. measuring instru

Feeler gauges
Max. permissible distortion: 0.1 mm
.....
Fig. 2
Preparing cylinder head gasket for assembly
Special tools. workshop equipment, testers, measuring instru

Sealant AMV 188 001 02
- Remove old sealant from 3 mm holes in the cylinder head gasket,
cover and sealing flange -arrows-.
- Fill 3 mm holes in the cylinder head gasket with sealant AMV 188
001 02 and coat sealing surfaces on cover and sealing flange with
sealant.
15-7---
Nate:
With the cylinder head installed the holes are only half v;sible.
15-8--
Removing and installing cylin

der head cover
VAG 1331
:1
-I

required
I
I:
3277 A Fitting tool
V.A.G 1331 Torque wrench (5...50 Nml
V.A.G 1921 Spring-type clip pliers
VAG 1921
I W15-00301
15-9--
Removing
Nate:
Check whether a coded radio is installed as during the forthcoming
work sequences the battery earth strap must be disconnected. Obtain
- With the ignition switched off disconnect battery earth strap.

- All cable ties which are opened or cut open when removing engine,
must be replaced in ~he same position when installing engine.
- Remove spark plug connectors with tool 3277 A and unclip ignition
cables:
=> Repair group 28; Motronic injection and ignition system; Servicing
ignition part
- Remove intake manifold cover.
- Disconnect connector from heater element (N791.
- Remove intake hose between air mass meter (G701 and throttle
valve control part (J338).
=> Repair group 24; Motronic injection and ignition system; Servicing
injection part
15-10--
.....
- Detach connector -1- from throttle valve control part -2-.

- Fit earth connection to throttle valve control unit (J338).
- Open and close the expansion tank sealing cap to release pressure
in cooling system.
.....
- Detach the accelerator cable from the support bracket and the
throttle valve control part -arrow- (do not remove locating clip).
1511--
.....
ft g
- Pull coolant hoses -1- and -2- off throttle valve control part and seal
hose ends.
- Now pull off vacuum hose connections -3-, ..4- and -5- as well as the
connector for intake temperature sender-6-.
a==4>
1 2
- Unclip secondary air pump pipe/hose as well as all other pipes!

hoses/cables from bracket on intake manifold upper part.
- Unscrew dipstick guide tube from intake manifold upper part.
- Now remove the two bolts for the intake manifold support.
- Pull off vacuum hose on intake manifoldchange-overvacuum actua
tor.
.....
- Pull off supply pipe/hose -1- (with white marking) and return pipe/
hose -2- (with blue marking) and collect fuel that leaks out with a
cloth.
Note:
15-12--
Warningl
Fuel srstem is under pressurel Before opening the ,system
place a doth BI'OUnd the connection. Then release pressure by
carefully loosening the connection.
- Seal the pipes so that the fuel system is not contami nated by dirt etc.
- Remove centre, left and right insulation tray:

blyoverview
- Bring lock carrier into service position:
=> General body repairs, exterior; Repair group 50; Body, front; Lock
carrier service position
- Remove ribbed belt => Page 13-27.

- Removing air conditioner compressor:
=> Heating, Air conditioning; Repair group 87; removing and installing
compressor bracket
Warningl
The air conditioner refrigerant circuit _1IOt be opened.
Notes:
15-13--
The opening ofthe refrigerant circuit can only be carried out in work
shops, which have trained personnel and the necessary range of
tools and workshop equipment.
To prevent damage to condenser and the refrigerant pipes/hoses,
ensure that the pipes and hoses are not stretched. kinked or bent.
- Remove combi-valve => Page 26-16.

- Remove bracket for secondary airinletvalve(Nll2)and intake mani
fold change-over valve (N156) => Page 15-6. item 26.
Note:
Connections can remain connected to valves.
- Then unbolt intake manifold upper part from intake manifold lower
part.
- Take off intake manifold upper part and place on a suitable surface
so that the vacuum actuator is not damaged.
15-14--
Nate:
Seal the intake parts in the intake manifold lower part or in cylinder
head with a clean cloth.
- Remove the cylinder head cover.
Installing
Install in reverse order.
Notes:
Replace cylinder head cover if damaged or leaking.
Bolt intake manifold upper part to intake manifold lower part, then
tighten both bolts for the intake manifold supports.
Ensue fuel hoses are tight.
- If necessary top-up coolant => Page 19-14
- Adjusting accelerator cable => Page 20-28, SeNicing accelerator
mechanism.
- Interrogate fault memory:
=> Repair group 01; Self-diagnosis; Interrogating and erasing fault
memory
15-15--
lightening torques
Bolted joint
lightening
torque
Cylinder head cover to cylinder head
10Nm
Intake manifold upper part to intake

manifold lower part
25Nm
Intake manifold upper part to left

and right supports
25Nm
Support for intake manifold upper

part to cylinder head
25Nm
15-16--
3268
Removing and installing cylin

der head
VAG 1306

required
3268 camshaft bar
Y.A.G 1306 Drip tray
VAG 1331
V.A.G 1331 Torque wrench (5...50 Nm)
V.A.Gl332
Y.A.G 1332 (40..200 Nm) Torque wrench
@!-,
V.A.G 1921 Spring-type Clip pliers
V.A.G 1921
I Wl5-0031 I
15-17--
Prerequisites
The engine must be no more than warm to touch.
Removing
Note:
work sequences the batteryearth strap must be disconnected. Obtain

- Remove intake manifold upper part =I> Page 15-9. Removing and in
stalling cylinder head cover.
- Loosen or separate the following components:
High tension cable terminal 4 from ignition coils
The earth strap on ignition coils
- Set crankshaft to TDC No.1 Cyl. marks-arrow- bytuming crankshaft
on the vibration damper securing bolt in engine D.O.A.:
- Drain coolant =I> Page 19-14.
- Remove the cylinder head cover.
15-18--
....
- Pull off fuel return pipe -2- (blue marking) and fuel supply pipe -1
(white marking).
Note:
Warning!
Fuel supply lines are under pressure! Before removing from
hose connection wrap a cloth IIIOfInd the connection. Then re
lease pressure by carefully purmg hose off conn~ion.
- Seal the pipes so that the fuel system is not contami nated by dirt etc.
- Separate connector to injectors and pull vacuum hose off fuel pres
sure regulator.
- Loosen hose clips and pull coolant hoses off coolant thermostat
housing.
- Now remove the thermostat housing.
- Then unclip the electric continued coolant circulation pump (V51)
from its bracket. Coolant hoses can remain connected.
15-19--
- Pull 3 pin connector off hall sender (G40), sender remains installed.
- Now remove the ignition coils.
- Remove the bracket and then the camshaft cover part.
- Remove camshaft chain sprocket, hold camshaft with a 24 mm AF
open jaw spanner.
I Nl~l571
- Separate front exhaust pipe from exhaust manifold ~ Page 26-1,

Removing and installing parts of exhaust system.
....
- Loosen socket head bolts in the sequence given and then remove
completely.
- Carefully lift cylinder head off.
15-20--
Installing
- Place a clean cloth in cylinders so that no dirt or emery cloth particles

can get in between cylinder wall and piston. .
- Also prevent dirt and emerycloth particles from getting into tt:le cool
ant.
- Carefully clean cylinder head and cylinder block sealing surfaces.
Thereby ensuring that no scoring or scratches are formed (when
using abrasive paper the grade must not be less than 100).
- Carefully remove metal particles. emery remains and cloths.

If the piston for No. 1 cylinder is not at TOC:
....
- SetcrankshafttoTOCNo.l CyI.marks-arrow- byturning crankshaft

on the vibration damper securing bolt in engine O.O.R.:
Notes:
Only remove the new cylinder head gasket from its packing im
mediately before installing.
Handle the new gasket with extreme care. Damaging will lead to
leaks.
15-21--
18
....
Fit new cylinder head gasket. Lettering (Part No.) must be readable.
- Ensure dowel sleeves are inserted into cylinder block holes 15 and
16. and the cylinder head gasket is located.
- Position the camshafts in cylinder head to TOC No. 1 cylinder.
15
....
- Now prepare the cylinder head gasket for assembly => Page 15-7
Fig. 2.
- Fit cylinder head, screw cylinder head bolts in and tighten hand tight.
15-22--
- Tighten cylinder head in tightening sequence as follows:

- Pretighten all bolts to 30 Nm.
- Then tighten all bolts to 50 Nm.
- Then tighten all bolts a '/4 tum (90) further using a ridged wrench.
- Then tighten all bolts again a '/4 tum (90 0) further.

The rest of the assembly is baSically a reverse of the dismantling se
quence.
Note:
Ensure the O-ring for sealing the oil channel in the cover part is fitted.
Adjusting valve timing => Page 13-11.

Filling with new coolant => Page 19-14.
Note:
There is no requirement to retighten the cylinder head bolts after re- .
pairs.
15-23--
Checking compression pres
sures
and measuring appnances and aux. items
required
.3122 B Spark plug spanner
1 - - - - - - - - - - - - + - - - - - - - - - - - - 1 .3277 A Fining tool

V.A.G 1331
V.A.G 1763 Compression tester
I W15-0032 I
15-24--
Test conditions
Engine oil tempe~ture at least 30 OC.
Test sequence
- Pull con nector off heater element (N79) and remove intake hose be
tween air cleaner upper pa rt and throttle valve control part (J338) to
gether with the crankcase breather valve:
~ Repair group 24; Motronic injection and ignition system; Servicing
injection part
- Remove spark plug connectors with tool 3277 Aand unclip ignition
cables:
~ Repair group 28; Motronic injection and ignition system; Servicing
ignition part
- Remove intake manifold cover.
- Remove spark plugs with spark plug spanner 3122 B.
- Pull 6 pin connector (brown) -1- off final output stage -2-.
- Fully open throttle valve.
- Check compression pressure with compression tester VAG 1763.
15-25--
Note:
Using the compression tester ~ Operating instructions.
- Operate starter until tester shows no further pressure increase.
Compression pressure:
New: 10...13 bar
Wear limit 7.5 bar
Permissible difference between all cylinders: 3 bar
t
:~
15-26--
,,-------1
Servicing valve gear
r------2
Note:
----3
Cylinder heads which have cracks between

the valve seats orbetween valve seat inserts
and the spark plug thread can be used
further without reducing service life, pro
vided the cracks do not exceed a maximum
of 0.5 mm in width.
1 - Bearing cap
Installation position ~ Fig. 2
Installation sequence
=* Pagel5-37, removing and instal
ling camshafts
11---
2-20Nm
10--~
~----8
~~~--------9
I N15-0161 I
15-27--
.--------1
r------2
----3
3 - Camshafts
Checking axial clearance =* Fig. 1
~ Page 15-37
Checking radial clearance with plasti

gage
Wear limit: 0.10 mm
Run-out: max. 0.01 mm

4 - Camshaft sprocket
=* Page 15-37, removing and instal
ling camshafts
5 - Sender wheel
For Hall sender (G40)
When installing contact surface on
timing chain and sender wheel must
be dry .
=* Page 15-37, removing and instal
ling camshafts
11----
10--~
!~-----8
~~-,--------9
I N15-0161 I
15-28--
;!rn
,
"
-;f
6-100 Nm
To remove and install counter-hold
with 24 mm OJ spanner on camshaft
~ Page 15-37, removing and instal
ling camshafts
Oil bulkhead contact surface when in
stalling
7 Cylinder head height
Minimum height: a =139.5 mm
8 - Cylinder head
See note
~ Page 15-27
Reworking valve seats
~ Page 15-34
. 12
11
10
9-Valves
Do not rework only grinding-in i~ per
mitted
Valve dimensions ~ Fig. 3
>
8
9
I N15-0161 I
15-29
10 - Valve guide
Renewing ~ Page 15-45
Service version with collar
11 Valve stem seal
Renewing ~ Page 15-47
12 . Valve springs
Removing and installing:
Cylinder head
removed: with 2037
installed: ~ Page 15-47, Renewing
valve stem seals
':
13 - Valve spring plate
11
10
14 - Valve cotters
"
'7""'------ 8
~*-~~-----------9
I N15-0161 I
15-30--
....------1
------2
15 - Bucket tappet
.----3
Do not interchange
With hydraulic valve clearance com
pensation
Checking =* Page 15-42
Store with cam contact surface
downwards
Before installing check camshaft
axial clearance =* Fig. 1
Oil contact surface
15-31--
....
Fig. 1
CaInsIIIIIfts. checking axial clearance
Speen.. tools.. . .bhop equipment" testers, measuring instru

ments and ....... 'I items required
VW 387 UnNel'sal dial gauge bracket
Dial gauge
Test sequeIIC8
Wear limit: max. 0.15 mm
Check with bucket tappets removed and with first and last bearing
caps fitted to appropriate camshaft.
....
rig.
Fitting position of camshaft bearing caps
The bearing cap markings (arrows) must face towards vibration

damper side.
I Nl5-()111 I
15-32--
...
rig.
Valve cfnnensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension
Inlet valve
Exhaust valve
39.0
34.20
6.967
6.96
mm
mm
mm
105.95
106.95
L'
45
45
0a
0b
15-33--
Reworking valve seats

Special tools, workshop equipment, testers, measuring instru
Depth gauge
Valve seat refacing tool

Work sequence
Notes:
When repairing engines with leaking valves, it is not always suffi

cient to rework orrenew valve seats and valves. It is also necessary
to check the valve guides for wear. This is particularly important on
high mileage engines.
The valve seats should only be reworked just enough to produce a

perfect seating pattern. The maximum permissible reworking di
mension must be calculated- before reworking commences. If the
reworking dimension is exceeded, the function of the hydraulic
tappets can no longer be guaranteed and the cylinder head should
be renewed.
Calculating max. permissible reworking dimension
- Insert valve and press firmly against seat.
15-34--
Note:
If the valve is to be renewedas part ofa repair. use a new valve for the
calculation.
~
- Measure distance -a- between end of valve stem and upper edge of
cylinder head.
- Calculate max. permissible reworking dimension from measured
distance -a-and minimum dimension.
Minimum dimension:
Inlet valve 33.9 mm
Exhaust va Ive 34.1 mm
Measured distance minus minimum dimension
= max. permissible reworking dimension.
Example:
Measured distance -a
- Minimum dimension
= max. perm. rework dimension 1)
34.8 mm
34.1 mm
0.7 mm
1l=> Page 15-36.
15-35--
Reworking inlet valve seat
a
b
c
Z
X
IS
'Y
= 038.3 mm
= Max. permissible reworking dimension 1)
= 1.4mm ... 2.0mm
if necessary rework valve seat insert with

75 0 correction miller
= Cylinder head lower edge
:: 45 0 valve seat angle'
:: 30 0 upper correction angle
:: 60 0 lower correction angle
Reworking exhaust valve seat
a
b
c
Z
X
IS
'Y
:: 033.5mm
= Max. permissible reworking dimension 1)
= 2.0mm ... 2.5mm
if necessary rework valve seat insert with

75 0 correction miller
= Cylinder head lower edge
= 45 0 valve seat angle
= 30 00 upper correction angle
= 73 lower correction angle
15-36--
Removing and installing camshafts

Special tools, workshop equipment.. testers, measuring
3268
....
3268 Camshaft bar
V.A.G 1331
....
Inmrrll.!
@1'-
Iwoo-o427l
15-37--
Removing
.,
....
!
,{
- Set crankshaft to TDC No.1 Cyl. marks-a~ bvtuming cran

on the vibration damper securing bolt in engine D.O.A.:
- Remove cylinder head cover => Page 15-9.
::... Remove camshaft roller chain tensioner..

- Remove cover part.
- Loosen securing bolts for camshaft sprockets.
Note:
Only counter-hold camshaft with 24 mm OJ spanner -BffOW-.
camshaft jig 3268 must not be in place when tightening O( tan!'UJn.llJi
the chain sprockets.
- Remove camshaft sprockets.
I Nl5-0157 I
15-38--
....
Removing bearing caps of camshaft cylinder bank 1, 3 and 5 as .

well as camshaft cylinder bank 2 and 4.
Longer camshaft:
- First remove bearing cap 1.
- Slacken off bearing caps 3 and 5 alternately and diagonally.
I Nl5-G111 I
Shorter camshaft:
- First remove bearing cap 4.
- Loosen bearing caps 2 and 6 slowly.
.!
Installing
.'!,
- Oil running surfaces of both camshafts.
....
Notes:
When installing the camshafts the recess for the camshaft
sprockets -arrows- must be at top.
When installing bearing caps ensure that the identification mark is
readable from the exhaust side of cylinder head and. that the arrow
points to vibration damper end.
I Nl5-0112I
15-39--
....
Installing camshaft cylinder bank 1, 3 and 5 as well as camshaft

cylinder bank 2 and 4.
.
Longer camshaft:
- Tighten bearing caps 3 and 5. to guide camshaft. alternately and
diagonally to
20Nm.
I N15-G111 I
- Tighten bearing cap 1 also to
20 Nm.
Shorter camshaft:
- "Tighten bearing caps 4 and 6, to guide camshaft, alternately and
diagonally to
20Nm.
- Install bearing cap 2 and also tighten to
20Nm.
- Clean sealing surfaces on cylinder head and cover part.
15-40--
....
- Remove old sealant from 3 mm holes in cylinder head gasket.-ar

rows-.
Nate:
With the cylinder head installed the holes in the cylinder head gasket
are only half visible.
- Install camshaft chain sprockets with camshaft roller chain ~ Page
13-11, Adjusting valve timing.
- Fill 3 mm holes in cylinder head gasket with sealant AMV 188 001
02.
- Coat sealing surface of cover with AMV 188 001 02.
Note:
Ensure the O-ring for sealing the oil channel in the cover part is fitted.
- Install cover, insert all securing bolts and tighten lightly.
- First tighten M8 securing bolts to
25Nm
then tighten M6 securing bolts to
10Nm.
15-41--
- Install chain tensioner for camshaft roller chain and tighten to

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

menta and aUXIliary items required

Feeler gauge
Wood or plastic wedge
Test sequence
Notes:
Irregular valve noises when starting engine are normal

- Start engine and run until the radiator fan has switched on once.
- Increase engine speed to about 2500 rpm for 2 minutes.
15-42--
If the hydraulic tappets are still noisy, locate defective tappets as fol
lows:
-Remove cylinder head cover => Page 15-9.
- Rotate crankshaft clockwise on vibration dampersecuring bolt, until
cam of the tappet to be checked is pointing upwards.
- Determine play between cam and bucket tappet.
- If the play is in excess of 0.2 mm, renew bucket tappet. If the play
is less than 0.1 mm or no play, proceed with check as follows:
- Press bucket tappet down with a wooden or plastic wedge. If free
travel in excess of 0.2 mm is felt before tappet opens valve. renew
tappet.
Note:
After installing new tappets the engine must not be started for approx.
30 minutes. Hydraulic compensation elements must settle (otherwise
valves will strike pistons).
15-43--
Checking valve guides

VW387
Special tools. workshop equipment. testers, measuring instru

ments and auxliary items required
....
VW 387 Universal dial gauge bracket

Dial gauge
Iwoo-l37l
_Test sequence
....
- Insert new valve into guide until end of valve stem is flush with end
of guide. Due to the slight difference in stem dimensions. ensure
that onlyan inlet valve is used in the inlet guideand an exhaust va Ive
in the exhaust guide.
- Determine rock.
- Wear limit:
Inlet valve guide = 1.0 mm
Exhaust valve guide = 1.3 mm
15-44--
Renewing valve guides

Special tools, workshop equipment. testers, measuring instru
....
.3120 Reamer and cutting fluid
....
.3121 Drift
Iwoo-oM>l
15-45--
,J
Removing
3121
- Clean and check cylinder head. Cylinder heads in which the valve
seats can no longer be reworked"or cylinder heads which have al
ready been machined to the minimum dimension (height) =>
Page15-29. Pos. 7. or already have service version valve guides
fitted. are not suitable to have the valve guides replaced.
- Press out wom valve guides with 3121 from the camshaft side.
Installing
- Coat new guides with oil and press in with 3121 from the camshaft
side (cylinder head cold) until shoulder makes contact. When doing
this the cylinder head must be laying flat.
Note:
When the shoulder on guide makes contact. the pressure must not
exceed 1.0 t otherwise shoulder may break off.
- Ream guides out with hand reamer 3120 using plenty of cutting
fluid.
- Rework valve seats => Page 15-34.
15-46--
l~
,
Renewing valve stem seals

(with cylinder head installed)
Special tools. workshop equipment.. test
and measuring appliances and ame. items
required
2036 Assembly appliance
3047A Puller
31228
3122B Plug spanner

3129 Fitting tool
WI! 54111 A Valve lever
WI! 541/5 Thrust piece
VW541I1A
VW541J5
I W15-00331
15-47--
VW65313
.....
WI! 653/3 Pressure hose
Removing
- Remove camshafts => Page 15-37.
- Remove bucket tappets (do not interchange) and store with the con
tact surface downwards.
- Remove gpark plugs with gpark plug spanner 3122 B.
- Set piston of appropriate cylinder to "bottom dead centre".

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

- Screw compressed air hose W.J 653/3 into spark plug thread and
apply a continuous pressure of
min. 6 bar.
- Remove valve springs with lever WI! 54111 A and press piece W.J
54115.
Note:
Tight cotters can be loosened by tapping lightly on the lever.
- Pull off valve stem seals with 3047 A.
15-48--
Installing
- To prevent damage to the new valve stem seals, place plastic sleeve
-A- on valve stem.
- Oil valve stem seal-8-, place it in the tool 3129 and push carefully
onto the valve guide.
15--49--
I~
Removing and installing parts of the lubrica

tion system
Nates:
If when repairing an engine, metal shavings or large quantities of
small metal particles caused, for example, by partial seizure of
crankshaft and conrad bearings are found in the engine oil one
must apart from thoroughly cleaning oil passages, renew all oil
spray jets, the oil non-retum valve, the oil cooler and oil filter el
ement to prevent consequential damage.
The oil level must not be above the max. mark - danger of damage
to catalyst!
I:
l'
Checking oil pressure ~ Page 17-16
Ii
Oil system capacity":
f'
IIJ
with oil filter 4.0 Itrs.

1) Up-to-date figures:
~ Exhaust emissions test binder
Engine oil specifications:
Use engine oil to VW standard 500 00 or 501 01. Only in exceptional

cases: Mu/ti-grade or single-grade oils corresponding to API-SF or SG.
17-1
3
4
21
20
5
6
7
1-10Nm
2 Oil pump drive cover
3 -O-Ring
Renew
Oil before installing
4 Oil pump drive
I,
5 - Cylinder block
8
9
6 . Intermediate shaft
7 Thrust washer
I
f
8-10Nm
10
11
12
13
14
15
19
I
!"
i
Insert with locking fluid "06"
,::,.,1
o
, ';J
IN17-00291
172
~
21
20
1
2
3
4
5
6
7
9 - Oil spray jet

For crankshaft bearings 2...6
For piston cooling
~ Fig. 1

See note
~ Page 17-1
10 - Drive shaft
For oil pump drive
9
o
Ii<
10
11
12
13
14
15
19
11 -Oil pump
Dismantling and assembling ~ Page
17-10
Coat oil pressure pipe at cylinder
block and oil pump housing with AMV
188 00102
12-25Nm
13-8Nm
I N17-0029 ~
17-3
:t
1
2
14 - Baffle plate
3, 15-Sump
21
20
5
6
7
Page 17-13
16 -Oil drain plug. 20 Nm

17 -Seal
18 -15 Nm
19 Oil filter bracIret

~ Page 17-8
2O5Nm
10
11
12
13
14
15
19
r'
,
,i
l:
21 Guide tube
For dipstick
Secured with a bolt on inlet manifold
upper part
I N17-OO29 I
17-4
":''1'1
, ::
'rr
' , 'm , ,
21
20
3
4
22 - Dipstick
The oil level must not be above the
max. markl
Markings ~ Page 17-7. Fig. 2
23 - Oil non-retum valve, 5 Nm

6
Clean if badly soiled

7
See note
~ Page 17-1
I
Il
i
iI
II
10
11
12
13
14
15
19
,J"
I N17-Q029 I
17-5--
rIG. 1
Removing and instalOng oil spray jet
Special toolsr wortcshop equipment, testers, measuring instru
I.'
.4 mm0drift
Note:
"
Oil spray jets are installed in main bearings 2 ... 6.
I,
,r:
Crankshaft removed
Removing
- Press out oil spray jet out towards bearing using a 4 mm 0 punch.
\
Installing
- To install, press in oil spray jet by hand using a 6 mm 0 punch -arrow-.
17-6--
....
rig. 2
Dipstick markings
1 -max. mark
2-min. ma~
a - Area above hatched field up to max. mark: Do not top-up with en
gineoil!
b - Oil level within hatched field: can be topped-up with engine oil
c -Area from min. mark up to hatched field: fill with max. 0.5 Itr. of
engine oil!
I N17-0037 I
17-7---

oil filter bracket
1 -1.4 bar oil pressure switch (F1), .
Nm
Black
Checking => Page 17-16
If sealing ring is leaking nip open
replace.
2 - Oil filter bradtet
With non-retum valve
3 -0 ring
~~------------
I~~~----~----
Renew
Oil before installing
4 Oil cooler
Ensure clearance to adjacent
nents
See note
=> Page 17-1
_J
r-~~----------
~-------------
N17--Q056 I
17-8-..........
1 2
5 - Oil cooler cover, 25 Nm
6-25Nm
7 - Oil filter element
Observe change intervals
See note
=> Page 17-1
8 - 01 filter lower part 30 Nm

Drain before removing
With by-pass valve
9-01 .... ~,10Nm

~--------------
r------7
N~----8
--3
irell----- 9
N17-Q056 I
17-9--
. Dismantling and assembling

oil pump
9---------~
1 - Drive shaft
For oil pump drive
8------------------~
2 - Oil pump housing
3'-25Nm
..-::...-2
:~ ~-.
5 - Oil pump cover with pressure relief
valve
Opening pressure: 5.3...5.7 bar

Clean strainer if soiled
4-Gears
Checking backlash .
=> Fig. 1
Checking axial clearance
=> Fig. 2
I N17-00061
1710-.,--
.,
II
~
6-10Nm
Renew
Install with locking fluid "06"
9~----------------~
7 Oil pressure pipe
8----------------~
Coat cylinder' block and oil pump

housing with AMY 188 001 02
810Nm
"""--- 2
90 ring
Renew if damaged
~+-~-4
I N17-00061
17-11--
-~----I
..
Fig. 1 Checking oil pump backlash

Special tools, workshop equipment. testers, measuring InSltru
Feeler gauge
Wear limit: 0.20 mm
....
rig. 2 Checking oil pump axial clearance

Special tools, workshop equipment. testers, measuring
Feeler gauge
Wear limit: 0.10 mm
li:",
I:
J;
17-12--
Removing and installing oil sump

Special tools. wwbllap equipment,. testers, measuring instru
ments and . ' T , iIems required
Hand drill with plastic brush
Silicone sealant 0176404 A2
Flat scraper
Removing
- Remove centre. left and right insulation tray:
=> General bodv repairs exterior; Repair group 50; Body front; Assembly overview
- Drain engine oi-
I,
- Remove SOO'1P
- Loosen surnpwilh rlQht blows of a rubber headed hammer if necess
ary.
- Remove sealant residue on cylinder block with a flat scraper.
17-13--
....
- Remove sealant residue on the sump with a rotating brush, e.g. a

hand driI willi a plastic brush'(wear protective glasses).
- Clean sealing surface, must be free of oil and grease.
I N17~121
NOIIs
Note the use by date of the sealant.
SurtJJ must be installed wfthin 5 minutes of applying silicone seal
ing COIIJ1OUIId.
....
- Cut-off tube nozzle at forward marking (nozzle approx. 3 mm 0).

- Apply siicone sealing compound, as shown, to clean sump sealing
surface. Sealing compound bead must be:
2...3 mm thick.
I N17~191
and run on inside of bolt holes -arrows-.
17-14--
i"
, ' 'f"IjT
Note:
The sealing compound bead must not be thicker; otherwise excess
sealing compound will enter the sump and may block the oil suction
pipe strainer. ,
....
- Apply silicone sealing bead as shown to the clean sealing surface of

the sump. (The illustration shows the position ofthe sealant bead on
the cylinder block).
- Install sump immediately and tighten all sump bolts lightly.
- lighten sump bolts to
15Nm.
- lighten sump/gearbox bolts to 45 Nm.
I A17-0041 I
Note:
After installing sump the sealant must be allowed to dry for approx. 30
minutes before engine oil is filled
.
The rest of the assembly is basically a reverse of the dismantling se.
Quence.
17-15--
V.A.G 1527 B
V.A.G 1342
~~
Checking oil pressure and oil

pressure switch
/'
__________________________________
______________________

and measuring appfiances and aux.
~requred
V.A.G 1342 Oil pressure tester

V.A.G 1527 B Diode test lamp
V.A.G 1594 A Adapter set
I:
I W17-oD011
17-16--.....
Test sequence
Nate:
Functional check and servicing the optical and acoustic oil pressure
waming:
~ Current flow diagrams, Electrical fault finding and Fitting locations
....
- Remove 1.4 bar oil pressure switch (F1) (black insulation) and screw
into test unit.
- Screw test unit into oil filter in place of the oil pressure switch.
- Connect brown wire of tester to earth
I V17-0540 I
H.
- Connect diode test lamp V.A.G 1527 B using aux. cables from VAG
1594A to battery positive (+) and oil pressure switch. LED must not
light up.
- If the LED lights up, renew 1.4 bar oil pressure switch (F1) .
When the LED does not light up:
- Start engine and run at idling speed
at
1.2... 1.6 bar
17-17--
the LED must light up, otherwise renew 1.4 bar oil pressure switch
(F1 ).
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 C the oil pressure ~hould
be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed
7.0 bar.
- Replace oil pump if necessary ~ Page 17-10, dismantling and as
sembling oil pump.
17-18--
Removing :and installing parts of cooling

system
Nates:
When the engine is warm the cooling system is under pressure. If
necessary release pressure before commencing repair work.
Hoses are secured with spring-type clips. In cases ofrepair only use
spring-type clips.
v.A.G 1921 pliers are recommended when installing spring-type
clips.
When installing coolant hoses route stress-iree. so that they do not
come into contact with other components (observe markings on
coolant connection and hose).
Perform cooling system leakage test with cooling system tester VAG
1274andadaptersV.A.G 1274/B and VAG 127419.
Parts of cooling system body side ==- Page 19-2.
Parts of cooling system engine side ==-19-6.
Dismantling and assembling coolant thennostat housing ==-19-11
18-1--
Parts of cooling system body

side
1 - Radiator
==- Page 19-19
After replacing renew entire coolant
2 -0 ring
Renew if damaged
3 Upper caoImd hose
Secured to radiator by a quick release
coupling
Check securely seated
Coolant hose connection diagram ==
Page 19-9
4 Air ducting
510Nm
6 Radiator fan (V7J

7 Fan retail,.
10
7 8
I N19-0182 I
18-2--
8 Retaining clip
Check seated securely
9 Connector
10 Radiator fan CV35)
15
, I'
-1
11Bracket
For radiator fan connector
:l
"
12 Lower coolant hose

Secured to radiator bya quick release
coupling

Coolant hose,connection diagram :::;>
Page 19-9
15
14
t,
Ii
13 0 ring
Renew
1:'
; ~
13
12
11
10
7 8
I N19-{)182 I
19-3--
14 Thermo switch (F18). 35 Nm

For electric fan
Switching temperatures:
Stage 1 '
on: 92...97 C
off: 84...91 C
Stage 2
on: 99...105 OC
off: 91 ...98 QC
"
15 -Bracket
For radiator
1615Nm
:\
II
10
7 8
I N19-{)182 I
19-4--
1.2 3 4 5
6 7 8
Parts of cooling system engine

side
.
,.
1 - Sealing cover
4 -------'=:::--1"
Check with cooling system tester

VAG 1274 and adapter V.A.G 1274/9
2 -0 ring
Renew if damaged
~--9
3 - Expansion tank
Carry out leak test of cooling system

with cooling system tester \l.A.G
1274 arKfadapter VA G1274/8
Test pressure 1.4... 1.6 bar
4-10Nm
3
4
5 - Upper coaIMt pipe

Clipped to bulkhead
Coolant hose connection diagram =>
Page 19-9
16
N19-0186
I
19-5--
1 2 3 4 5
6 7 8
6 - To top of . .lilt.
Coolant hose comection diagram =>
Page 19-9
7 -0 ring
Renew
8 - To heat.- ~t.Rger
Page 19-9
~--9
9 -10 Nrn
. 10 - Throttle wive control part
Heated by coolant
11 - To top of radiator
Page 19-9
3
12 - Gasket
Renew
13 - To bottom of raal8tor
Page 19-9
17----6]~
16
I N19-0186 I
19-6--
1 2 3 4 5
678
14 -Thermostat housing
Dismantling
Pagel9-11
and
assembling
15 - Continued coolant circulation pump
4---~""""'"""
(V51)
16 - From heat exchanger
Coolant hose connection diagram ~

Page 19-9
17 -2SNm
18 - Oil cooler
~ Page 17-8. item 4
19 - Seali_D9 plug
20 - Coolant pipe
Coolant hose connection diagram ~
Page 19-9
18---!-~~
\
""
17~ ....
- -
16
N19-0186
I
19-7--
1 2 3 4 5
678
21 - Coolant pump
Note installation pOSition
Check arm for ease of movement
If damaged and leaking renew com
plete
~ Page 19-27
4 ---~,,-..I:J1
22-15 Nm
23 -Pulley
For coolant pump
24-25 Nm
- -
16
I N19-0186]
19-8--....
: I
15 16
Coolant hose connection dia
gram
1 - Heater unit heat exchanger .
2 - Non-return valve
3 - Continued coolant circulation pump
(V51)
4 - ATf cooler
Only on vehicles with automatic gear
14
+----+-4
box
5 - Upper coolant hose
13
8 -Cooler
12
7 - Lower coolant hose
9 - Lower coolant pipe
10 - Oil cooler
11-Coolant pump
11
109 8 7
I N19-02021
19-9--
15 16
2 3
12 Cylinder block
13 - Cylinder head
14 - Expansion tank
15 - Upper coolant pipe
18 - Throttle valve control part
14
-I-------+-4
13---tt---t=--..:.-..-l
12--
5
11
109 8 7
I N19-0202 r
19-10--
12
1m

coolant thermostat housing
____- 1
Note:
Connecting the coolant hoses to thermostat
housing
=> Page 19-5, parts ofcooling system engine
side.
2-10Nm
9--+
3 - Coolant thermostat
j..-...::....------3
:-+------- 4
Installation position: Breather slot!
valve uppermost
Checking: heat-up thermostat in
water
Opening commences approx. 80C

Ends approx. 105 OC
Opening lift min. 7 mm
----5
"
I N19-0125 I
19-11--
12
1m
11
4 -Seal
Renew
.!
5 Connection
...---1
.,
"
6-Bush
7-10Nm
8'-O-Ring
Renew
9 - Connection
9--+
10 Coolant temperature sender (G62)
:---:----- 3
-l------4
.---5
With coolant temperature gauge
sender (G2)
For engine control unit

If necessary before removing, re
lease pressure from cooling system
Checking:
.
/
=> Repair Group 01; Fault memory; Interro
,ill
:: i'l
;.,
!II
I N19-012SI
19-12---
I i,l
8
11
12
11 Air concfrtionercut-off
switch (F163)
Jm
thermo
For air conditioning system

If necessary before removing, re
lease pressure from cooling system
~-1
12 Retaining clip
Check seated securely
9-->'
,Ii--:------ 3
-+-------4
.------5
I N19-0125 I
19-13--
Draining and filling cooling system

V.A.G 1306
Special tools, workshop equipment.. test8Is, measuring instru

....
. V.A.G 1306 Drip tray
I woo-o5121
V.A.G 1921
....
VAG 1921 Hose clip pliers

Anti-freeze tester
IWllO-0464I
19-14 --...;-
Draining
- Open cap on coolant expansion tank.
- Remove insulation tray:
. bly overview
....
- To drain coolant from radiator remove drain plug -arrow- in radiator

return.
I
....
- To drain coolant from engine also remove coolant hose from oil
cooler -arrow-.
"~I
Note:
Observe disposal regulations!
!.
1&-15--
Filling
Notes:
Only use coolant additive G 12 in accordance with TL VW 774 D.
Identification: coloured red

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

If the fluid in expansion tank is brown, G 12 has been mixed with
other coolant. In this case the coolant must be changed.
G 12 and coolant additives marked "In accordance with TL VW 774
DN prevent frost and corrosion damage, scaling and also raise boil
ing point of coolant. For this reason the system must be filled al/
year round with frost and corrosion protection additives.
Particularly in countries with tropical climates, the coolant due to
the higher boiling point improves engine reliability when heavily
loaded.
Protected against frost to about -25C (in arctic climatic countries
to about -35 CJ.
The coolant concentration must not be reduced by adding water
even in warmer seasons and in warmer countries. The anti-freeze
ratio must be at least 40 %.
If for climatic reasons a greater frost protection is required, the
amount of G 12 can be increased, but only up to 60 % (frost protec

19-16--
tion to about -40 C). as otherwise frost protection is reduced again

and cooling effectiveness is also reduced.
If radiator, heat exchanger, cylinder head or cylinder head gasket is

replaced, do not reuse old coolant.
Recommended mixture ratios:

Frost
protection
Anti-freeze
G 121)
Water1)
3.61
4.51
5.41
4.51
amouJrt
to
-250(;
-35OC
40%
50%
1) The quantity of coolant
can vary depending upon the vehicle equip
ment.
- Screw drain plug into radiator retum.
- Push coolant hose onto oil cooler connection and tighten.
- Fill with coolant up to max. mark on expansion tank.

- Fit expansion tank cap.
19-17--
- Set heater controls to maximum heat position and switch off air
conditioning system if fitted.
- Start engine and maintain an engine speed of about 2000 rpmforap
prox. 3 minutes.
- Run engine until radiator fan cuts-in.
- Check coolant level and top-up if necessary. When the engine is at
normal operating temperature, the coolant level must be on the
max. mark. when the engine is cold. between the min. and max.
marks.
!
I
19-18--
V.A.G 1306
Removing and installing radi

ator
V.A.G 1331

required
VAG 1306 Drip tray
1------------+-------------1 VAG 1331 Torque wrench (5...50 Nm)

VAG 1921 Spring-type clip pliers
V.A.G1921
Anti-freeze tester
I W19-0001!
1919--
Removing
- Drain coolant ~ Page 19-14.
- Removing from bumper:
~ General body repairs, exterior, Repair group 63; Front bumper, Re
moving and installing front bumper
- Pull coolant hoses quick
relea~e
couplings off radiator.
- Pull connectors off thermo switch and radiator fans.

=> General body repairs, exterior; Repair group 50; Body, front; Lock
- Remove radiator securing bolts and take radiator with fans out
downwards.
Vehicles with air conditioner.
- Observe additional information and removal work => Page 19-21.
InstaDing
Installation is carried out in the reverse order, when doing this note the
following:
- Filling with coolant ~ Page 19-14
1920--
"
I,
"
Additiona. information and removal work on vehicles with air

conditioner
1-"
. : 1lte _ _erre!rigerM1t _
mBIt.not be _ e d
Note:
To prevent damage to condenser a/so to the refrigerant pipeS/hoses,

- Remove condenser from radiator and secure to lock carrier.
19-21--
V.A.G 15278
Checking continued coolant circulation pump

(V51)
Special tools, workshop equipment. testers, measuring instru
~
Y.A.G 1594 A Auxiliary test set

Current flow diagram
I woo-om I
19-22--
"
'.:1'.'.':L'1~.,'."
I
ffl
. oj
:: I
ii'
,"
Check conartions
....
Fuse No. 160K.
Test sequence
;
- Pull 2 pin connector off continued coolant circulation pump (\151).

....
- Connect contacts of continued coolant circulation pump (\151) to bat

tery using aux. cables from VAG 1594.
Continued coolant circulation pump must run.
If the continued coolant circulation pump does not run:
- Replace continued coolant circulation pump (\151).
If the continued coolant circulation pump (V51) runs:
I N19-0175 I
19-23--
....
- Connect diode test lamp VAG 1527 B to disconnected connector

for continued coolant circulation pump (\151) with auxiliary cable
from VAG 1594 A
LED must rlQht up.
"
I
,j
i
Nate:
This check must be performed within 10 minutes of switching ignition
off.
LED does not light up:

- Locate and rectify open circuit using current flow diagram:
=> Current flow diagrams, Electrical fault finding and Fitting locations
Checking radiator fan (V7) and (V35)

V.A.G 1527 B

ments and auxHiary items required
VAG 1527 B mode test lamp
19-24--
--"--
....
V.A.G 1594 A Auxirlary test set

Check conc:fdions
....
Fuse No's. 164 and 180 OK.

Radiator fan thermo switch (fUD OK.
Test sequence
- Pull 3 pin connector oft radiator fan 1Iamoswitch (F18).
19-,25--
1
....
- Bridge contact -1- and contact -2- of conneaor using auxiflary cables
from VAG 1594.
1st speed for radiator fans fII7) and (V35J must run.
- Switch on ignition.
I Ntt-Ot9t I
- Bridge contact -2- and contact -3- of connector with auxiliary cables
from v.A.G 1594.
2nd speed for radiator fans fII7) and (V35) must run.
If fan 1st or 2nd speeds do not run:
- Locate and rectify open circuit using current flow diagram:
If no wiring open circuit is found:
- Renew radiator fan fII7) or (V35).
19-26--
Removing and installing cool

ant pump
VAG 1306
Special tools, workshop equipment test

required
.3387 Pin wrench
1------------+------------1 VAG 1306 Drip tray

VA.G 1331
VAG 1921
v.A.G 1921 Spring~type clip pliers

Anti~freeze tester
I W1!HXJ041
- - _ . 19-27 - -
Removing
- Drain coolant ~ Page 19-14
- Remove ribbed belt ~ Page

....
1~27.
- Remove securing bolts ~, ~ for coolant pump belt pulley ~2~ and
move belt pulley.
r~
Note:
Use pin wrench 3387 when removing and installing coolant pump belt
pulley.
....
- Unscrew coolant pump securing bolts -,- and remove coolant

pump-2-.
Instalrmg
Installation is carried out in the reverse order; when doing th is note the
following:
Note:
The coolant pump plug faces downwards.
- Moisten new a ring with coolant.
19-28--
- Insert coolant pump into cylinder block and tighten securing bolts.
lightening torque: 15 Nm
- Filling with coolant => Page 19-14
.! :
19-29--
Removing and installing parts of fuel supply

system
Notes:
Hose connections are secured with either spring-type or clamp-type
clips.
AllNays replace clamp-type clips .With screw-type clips.
Fuel hoses in engine compartment must only be secured with

spring-type clips. The use of clamp or screw-type clips is not per
missible.
VA.G 1921 pliers are recommended when installing spring-type
clips.
Observe safety precautions

=> Page 20-8 .
Observe rules for cleanliness
=> Page 20-9
Removing and installing fuel tank with its attachments and fuel filter
=> Page 20-2.
Servicing accelerator mechanism => Page 20-28
Adjusting throttle cable => Page 20-30
Servicing parts of the activated charcoal filter system => Page 20-34.
':
20-1--
10
Removing and installing fuel

tank with its attachments and
fuel filter
1 -0 ring
Renew
~---11
~.-----12
2 - Gravity valve
. To remove valve unclip upwards out
of support
Check valve for through-flow
valve vertical: open,
valve tilted 45 0: closed
3 -Yentpipe
Clipped onto top of fuel tank
To activated charcoal filter
=> Page 20-34, item 2
4-Cap
18
14 13 I N20-0108 I
20-2--
5 -Seal
Renew if damaged
6 - Securing screw
7 - Tank flap unit

With rubber cup
8 - Vent valve
f 'd
To remove valve unclip out 0 Sl e
4
support
.
Before installing remove ~ap Item
Checking => Page 20-7. Fig. 2
9 - e.th connection
10 -10 Nm
11-Vent~
.BIacIc
Cf!pped onto side of fuel tan k
Check securely seated .
Secure with spring-type clips
20-3--
I
I
12 - Fuel tank
. k
Supportwithengineandge~rboxJac
VAG 1383 A when removing
=> Page~14
13 - Clamping ___
14 - Heat shield
For fuel tank
15-25Nm
16 -Locknut
17 - Fuel tank caver
18 - Securing SInp
Note <frffering length
. .
.
Installation po~itio~: FIxing pOint
(holes) point in direction of travel
20-4--
19 Supply pipe
Black
To fuel supply pipe on fuel rail:
~ Repair group 24; Servicing injection sys
tem; Dismantling and assembling fuel rail
and injectors
20 - Fuel filter
Fitting position: Arrow points in
through-flow direction
21 Screw-type clip
22 Sealing ring
Renew jf damaged
Coat with fuel when installing
I
i
,. ,
20-5--
23 - Fuel delivery unit

~Page 20-10
Checking fuel pump
=:> Page 20-18
Clean stra.iner if soiled

24 Union nut
Remove and install with spanner

3217
25 -Supply pipe

26 - Return pipe
Blue or blue markings

Clipped onto side of fuel tank
From fuel return pipe on fuel rail
~ Repair group 24; Servicing injection sys
tem; Dismantling and assembling fuel rail
and injectors
l!
i
ii
:, ii
20-6--
;I:
'~
....
Fig. 1
Fitting position of fuel delivery unit flange
Marking on s~nder must align with the marking on fuel tank -arrows-,
Blue or blue marked retum pipe -1- to connection with identification
~
Black supply pipe -2- to connection with identification -V-.

Note:
After installing fuel delivery unit flange, check that the supply, retum
and breather pipes are still clipped onto the fuel tank.
....
Fig. 2
Checking vent valve
Lever in rest position: Closed

Lever pushed in direction of arrow: Open
Note:
Before installing vent valve remove fuel tank sealing cover.
I '120-1040 I
20-7--
Safety precautions when working on the fuel

supply system
Warningl
Fuel supply lines lITe undet' pteSSUl'eI BefOre removing from
hose eonnection wrap II cloth ..ound the t:OIIIIIHII:ion. Then re
lease pressure by carefullypuling hose off connection.
When removing and installing the fuel gauge sender or fuel pump (fuel
delivery unit) from a full or partly full fuel tank the follOwing must be
observed:
Before commencing work, switch on exhaust exctraction system
and place an extraction hose close to the sender opening in the fuel
tank to extract escaping petrol fumes.
If no exhaust extraction system is available, a radial fan (as long as
motor is not in air flow) with a displacement greater than 15 m3/h
can be used.
Prevent skin contact with petrol! Wear fuel-resistant gloves!
20-8--
mas
in..~.:;
'I, ,
,,'
Rules for cleanliness

When working on the fuel supply/injection system, pay careful atten
tion to the following "5 rules":
,i
i
Thoroughly clean all unions and the adjacent areas before discon
necting.
Place parts that have been removed on a clean surface and cover.
Do not use fluffy cloths!
Carefully cover opened components or seal, if the repair cannot be
carried out immediately.
Only install clean mmponents:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
When the system is open:
Do not VtIOrk with mmpressed air if this can be avoided.
Do not move ~icIe unless absolutely necessary.
20-9--
Removing and installing fuel delivery unit

3217
Special tools. _bIIop equipment.. testers. measuring instru

ments and '7. , items required
....
.3217 Ring nut spanner
....
I woo-o2911
V.A.G1332
I W!lO-0428\
I
I
l
. i
20-10---
;I,
II
Removing
- Note safety precautions before starting work ~ Page 20-8
Note:
work sequences the battery earth strap must be disconnected Obtain
- Remove cover under bench seat.
- Pull4-pin connector as well as supply and return pipes off flange.
Note:
Warningl
Fuel supply lines lITe under pressunll ..".. removing from
hose t:OIInection wrap a cloth 1ITOfI1III""" f:OIIItfIf:Iion. Then re
lesse pt'eSSUTe by carefully pulling IJoIe "" COIJIIef:tion.
20-11--
.... - Remove union nut with spanner 3217.

- Pull fuel delivery unit and seal out of the opening in fuel tank.
Note:
If the delivery unit is to be renewed then drain old delivery unit before
disposal.
I A20-01OS I
Installing
- Installing the fuel delivery unit is carried out in the reverse order.
Notes:
Do not bend fuel sender when installing.
Coat flange seal with fuel when fitting.
Ensure fuel hoses are seated securely.
Secure fuel hoses with sprinrrtype clamps.
After installing fuel delivery unit, check that the supply. retum and
vent pipes are still clipped onto fuel tank.
20-12--
....
f.'.!~
I[
Note installation position of fuel delivery unit flange:

The marking on flange must align with marking on fuel tank ~r
:!!;
I Itt
Li'
rows-.
!
I: t:
Removing and installing fuel gauge sender

Removing
- Remove fuel delivery unit
~ Page 20-10.
....
- Release and pull off the terminals for wires -3- and -4-.
- Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge
sender out downwards -arrows-.
Installing
- Insert fuel gauge sender in the guides on the fuel delivery unit and
push up until it engages.
I A2IHl1osi
20-13--
Removing and installing fuel tank

V.A.G 1331

....
....
VAG 1383 A Engine/gearbox jack
Iwoo-o427l
V.A.G 1383 A ~Mi
20-14--
,,
Removing
- Note safety precautions before starting work => Page 2().8
Note:
work sequences the battery earth strap must be disconnected. Obtain
- With the ignition switched off disoonnect battery earth strap.

- Open fuel flap.
- Remove rear right wheel housing liner:
.
=> General body repairs, exterior; Repair group 66; Removing and in
stalling wheel housing liner
- Drain fuel tank, clean fuel filler neck and surrounding area.
- Unscrew securing bolts and remove 1ank flap unit with rubber cup.
- Remove securing bolt on filler necIc..

- Fold rear seat bench forwards.
20-15--
- Remove fuel gauge sender cover plate and detach connector.
- Remove cover from under the fuel1ank.
Remove rear axle:
=> Running gear; Repair group 42; Servicing rear axle; Removing and
installing rear axle.
....
- Disconnect return hose -2- (blue), supply hose -1- (black) and
breather hose -3- (white) at connecting point.
Note:
WlITning!
Fuel supply Hnes lITe under ,."...,,1 Before removing from
hose connection WTIIP B doth around the connettion. Then re
lase pressure by t:llrefully pulling hose off connettion.
- Remove tensioning strap. When doing this support fuel tank with
engine/gearbox jack VAG 1383 A.
-Lower fuel tank.
20-16--
I'
If I
Installing
I:;
Installation is carried out in the reverse order, when doing this note the
following:
Breather and fuel hoses are to be installed kink-free.
Secure fuel hoses with spring-type clamps.
Fuel hoses are to be installed kink-free.
Ensure fuel hoses are seated securely.
Do not interchange supply and return hose (return hose blue or blue
markings, supply hose black).
Note:
After installing fuel gauge sender, check that the supply, return and
breather pipes are still clipped onto the fuel tank.
V.A.G 1318
3217
20-17--
I us_I
I
0_
---==:;l
Checking fuel pump

required
3217 Ring nut spanner
VAG 1318 Pressure tester
V.A.G 1318111
V.A.G 131811
VAG 1318/1 Adapter
. .tI---H--_EJ
VAG 1318/11 Adapter

VAG1318/17 Adapter
VAG 1318/23 Adapter
V.A.G 1318117
VAG 13141/11-1
VAG 1311111....
VAG 131....7...
VAG 1311117-4
~. "iI-~
I W20-0011 I
20-18--
.:i
~:
V.A.G 1332
VAG 1348 Fuel quantity comparison

meter
@f."'
p
V.A.G 1466 Test system
VAG 1594 A Adapter set
VAG 1715 Multimeter
VAG 1527 B
~~
Measuring container
",
VAG 1715
I W20-00121
20-19--
Check conditions
Battery voltage at least 11.5 V

....
Fuse No. 28 OK.

Checking function and voltage supply
- Remove cover from fuel delivery unit.

- Briefly operate starter. Fuel pump must be
heard to run.
- Switch off ignition.
If the fuel pump does not run:
- Remove cover in front of fuse holder.

....
- Pull fuse No. 28 out of fuse holder.

- Connect remote control VAG 1348I3A with adapter cable VAG
1348/3-2 to contact 28a to fuel pump and battery positive (+).
- Operate remote control.
20-20--
Fuel pumps run:

- Check activation of fuel pump relay using current flow diagram and
VAG 1466 A:
Fuel pump does not run:
, I,
- Pull 4 pin connector off flange on fuel delivery unit.

....
- Connect diode test lamp VAG 1527 B with aux. cables from V.A.G
1594 A to the outer contacts of the connector.
' :'
- Operate remote control.
LED must light up
LED does not light up:

- Locate and eliminate open circuit using current flow diagram:
LED lights up (vottage supply OK.):
2021--
....
- Remove union nut with spanner 3217.

- Check that the electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
- Fuel pump defective, renew fuel delivery unit => Page 20-10, Re
moving and installing fuel delivery unit.
Checking delivery rate
Check conadions
Voltage supply OK.

Remote control VAG 1348I3A connected.
Test sequence
- Remove filler cap from fuel tank filler neck.
....
- Pull off supply pipe/hose -1- (with white marking) and collect fuel that
leaks out with a cloth.
Note:
20-22--
! ; I
Warning!
Fuel system is under pt'fISSUI'fI! Before opening the system
plat:B a cloth Mound the connection. Then l'fllease pressUI'fI by
CIIndully loosening the connection.
V.A.G 1318
V.A.G 13181'11
V.A.G 1318f23 ...
- Connect pressure gauge V.A.G 1318 with adapter 1318123 and

V.A.G 1318/17 to the fuel supply pipe.
- Push the hoseV.A.G 1318/1 onto the adapter V.A.G 1318/11 on the
pressure gauge and hold hose in a measuring container.
- Open the pressure gauge cut-off tap. The lever then points in the
throughflow direction -A-.
- Operate remote control V.A.G 134813Aand slowly close cut-off tap.
until pressure gauge shows
1.2 bar.
From this point on do not move position of cut-off tap.
I Na0-01091
- Empty measuring container.

- The quantity of fuel delivered by the fuel pump is dependent upon
battery voltage. Therefore connect the multimeter with adapter
cables from V.A.G 1594 A to the vehicle battery.
20-23--
- Operate remote control for
30 seconds
and measure battery voltage
om~3CIs")
1000
...
- Compare the quantity of fuel delivered with specification.
lIIIO
.-"'"
L.,...--'"
,.....
10
10,2
11
V""
~I
12
-) Minimum delivery cm 3J30 seconds

**)Voltage at fuel pump with engine stationary and pump running (ap
prox. 2 volts less than battery voltage).
lIIIO
2110
Example:
13 Y"')
I NaO-01&91
During the test a voltage of 12.5 volts is measured at the battery. As

the voltage at the pump is approx. 2 volts less than the battery voltage
then this will equate to a minimum delivery of 200 cm3/30 s.
If the minimum delivery rate is not attained:

V.A.G 13181'11
- Check the fuel pipes for possible restrictions (kinks) or blockages.

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

- Connect the pressure gauge V.A.G 1318 with adapter 1318/17 to
hose.
- Repeat delivery rate check.
If the minimum delivery rate is now attained:
20-24--
- Replace the fuel filter.
If the minimum delivery rate is again not attained:
- Remove the fuel delivery unit and check the strainerfifter for soiling.
Only when up to now no fault has been detected:

- Replace the fuel delivery unit.
If the delivery rate has been attained but nevertheless you suspect a
fuel supply system fault (e.g. intermittent failure of fuel supply sys
tem):
- Check the current draw of the fuel pump as follows:
- Reconnect a/l disconnected fuel pipes.
.....
- Connect the multimeterV.A.G 1715 using the current clamp to the

green/yellow wire of wiring harness.
- Start the engine and run at idling speed..
- Measure the current draw of the fuel pump.
Specification: max. 8 amps.
20-25---
Nate:
If the fuel system malfunction is intermittent, you can perform the
check during a test drive, to do this a 2nd person is necessary.
If the current draw is exceeded:

- Fuel pump defective. renew fuel delivery unit => Page 20-10, Re
Checking fuel pump non-retum valve
Test conditions
Remote control VAG 1348fJA is still connected.
Pressure gauge VAG 1318 is still connected.
Test sequence
Note:
With this check the fuelsupplypipe connections from the fuel delivery
unit to the pointat which the pressure gauge VA. G 1318is connected
will be checked for leaks at the same time.
20-26--
....
- Close pressure gauge cut-off tap (lever at right angles to throughflow direction -position B-).
- Operate reroote control at short intervals, until a pressure of
Approx. 3 bar
has built up.
Waming!
Danger of spray when opening the cut-off flip, hold container
over the pressure gauge flee connel:fion.
- If pressure builds up too high, lower excess pressure by carefully

opening the cut-off tap.
I N20-01091
- Watch pressu re drop on gauge. After 10 minutes the pressure must

not drop below
2.5 bar.
If the pressure drops further:
- Check pipe connections for leaks.
If no wiring fault is detected:
- Fuel pump defective, renew fuel delivery unit

Page 20-10, Re
20-27--
~~~--1
Accelerator mechanism
'H--+---2
Servicing accelerator mechan

ism
1 - Accelerator cable
Adjusting ~ Page 20-30
Do not reuse damaged accelerator
cable, replace
\
I
I
I
2 -Cable cam
On throttle valve control part
3 -Retainer
Adjusting throttle cable
20-30
Page
4 - Support bracket
For accelerator cable
5 - KickdoWn switch (FI)
On bulkhead
Checking ~ Page 20-30, Adjusting
throttle cable on vehicles with auto
matic gearbox
10----..
1 3 - - -...""
12----""""
11---~
I N20-0t35 I
20-28--
,;:,
'it
' 1: j ~
II!
~
it
I
I'
6 - Connector
Black. 2-pin
7 - Balance weight
8 - Accelerator pedal
9 - Spacer sleeve
10 -Bush
11-Washer
-'- --- -
.,.-
,
I
12 - Stop bolt
13-20Nm
i'
!'
10------.
13---
12-------11--~
I N2<H>1351
20-29--
Adjusting throttle cable
Work sequence
...
- Adjust throttle cable by moving the retainer -arrow- at the support

bracket. so that the full throttle position is attained at the throttle
valve control part.
20-30--
IJ

V.A.G 1526 A
....
V.A.G 1526 A Hand multimeter
....
V.A.G 1594 A Auxiliary test set
I WOIHI4311
Iwoo-oml
20-31--
Work sequence
....
- Adjustthrottle cable by moving the retainer -arrow- at the support

bracket, so that the full throttle position is attained at the throttle
valve control part.
- Release accelerator pedal.
- Pull 2-pin connector off kick-down switch (FS) in engine compart
ment (on the bulkhead).
....
- Connect hand multimeter V.A.G 1526 with aux. cables from VAG
1594 to kick-down switch.
- Check resistance at switch.
Specification: 00 n
- Slowly move accelerator pedal in direction of full throttle.

Shortly afterthe kick-down pressure point the resistance must'drop to
On.
At this point the accelerator pedal must be just oft the stop_
20-32--
;.
',I
Th'
I;'
Activated charcoal filter system

Notes:
Hose connections are secured with either sprlng-type orclamp-type
clips.
Always replace clamp-type clips with screw-type clips.
1I.A.G 1921 pliers are recommended when installing spring-:type
clips.
Observe safety precautions

=* Page 20-8
Observe rules for cleanliness
=* Page 20-9
! :
,,
!
!,
,
'
ii
20-33--
3
Servicing parts of the activated
charcoal filter system
,l ,i
1-10 Nm
1 - -...
~4
t
2 - Activated charcoal filter

Location: in engine compartment.
right
Secured to body
With solenoid valve 1 for activated
charcoal filter (N80)
When the engine is warm the valve
will be activated from the engine con
trol unit (pulsed)
Checking:
=* Repair group 01; Final control diagnosis;
Performing final control diagnosis
3 - Connector
Black. 2-pin
For solenoid valve 1 ,
I N2D-0170 I
20-34--
4-Ventpipe
Black
From gravity valve on fuel tank
=> Page 20-2. Item 2
5 -Throttle valve control part
1 - ...
6-T-piece
i-4
t
7 - To heater element (N79)
8 - Breather connection
I N20-0170 I
Qaecking fuel tank breather

V.A.G 1368
Special tools, workshop equipment.. testers, measuring instru

ments.and auxiliary items required
.....
VAG 1368 Vacuum tester
.....
VAG 1390 Hand vacuum pump
, I
20-38--
~.
f. ...1;.
Test sequence
1
.A.G.1368
.~
....
- Pull breather pipe/hose -2- from activated charcoal filter -1- off at
throttle valve control part -3- T-piece.
- Connect hand vacuum pump V.A.G 1390 to pipe/hose -2-.
6V.:~~~"~
- Pull breather pipe/hose -5- from fuel tank off activated charcoal filter
and connect to -connection A- of vacuum tester V.A.G 1368.
- Connect vacu um tester V.A.G 1368 -connection 8- to breather pipe!
hose -4-.
- Set vacuum tester to position -8-.
- Introduce final control diagnosis and select activated charcoal filter
solenoid valve (NSO):
=> Repair group 01; Final control diagnosis; Performing final control di
agnOSis
- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
build-up.
If, vacuum builds-up:
- Check breather connection -6- on activated charcoal filter -1- for soil
ing, clean if necessary.
20-37--
If vacuum does not build-up:
, I
I I
- Remove fuel filler cap.

....
! ;
Connect hand vacuum pump VAG 1390 to vacuum tester VAG

1368 -connection 8-.
- Set vacuum tester to -A/8- position.
- Operate V.A.G 1390 several times. Vacuum must
not build-up.
If vacuum builds-up:
- Check gravity valve => Page 20-2, Item 2
- Check pipe/hose -1- from fuel tank for blockage.
If vacuum does not build-up:
- Refit fuel filler cap.
- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
build-up.
20-38--
Nate:
If the fuel level in the tank is low the hand vacuum must be operated
at least 20...30 times. \
If vacuum builds-up:
- Replace fuel tank cap.
20-39--
~,
II"
Removing and installing parts of exhaust

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

....
3337 Ring spanner for Lambda probe
26-1----
4 2
4
, j
Note:
Components marked with an * are
checked by the self-diagnosis:
Repair Group 01; Self diagnosis; Interrogat
ing and erasing fault memory
.---5
16..;.1'.,...;::.....::-__
1
.......
2-25Nm
3 - Heat shield
4 -Bracktrt
~-10
5 - Lambda probe (G39)*, 50 Nm
..---6
1-
Renew
.---7
.---8
~- ---9
1-Seal
.",---.6
17----~
.~t1
I
Xl~~~ ~)
Grease only the threads with "G 052

112 A3"; "G 052 112 A3" must not
get into the slots on the probe body
Remove and install with ring spanner
3337
Checking:
=> Repair group 24; Checking functions;
. Checking Lambda control
I N26-0210 I
26-2--
,!
4 2
6-10 Nm
7 -Clip
8 -Catalyst
.---5
~--6
~--7
~-8
17 -------.;~
16 r-- ......
------10
---6
9 - Double clamp
Note fitting position:::;. Fig. 3
10-40Nm
11 - Mounting
12 -Centre and rear silencer
As standard. central and rear si
lencers are installed as a single com
ponent. In repair cases the central
and rear silencer are supplied individ
uallyand with a double clamp for con
necting.
Separating point:
:::;. Fig. 1
Aligning rear silencer free of stress
:::;. Fig. 2
I N26-0210 I
26-3--
4 2
1 2 3
iii-
13 - Mounting
With retaining ring
.',
14 - Tunnel bridge
,.,:~:~:,.
'",
19
"
...
"""
18
7
8
9
17
16
r--.,
I
10
6
......
.....
15 - Mounting
:::;. Fig. 4
16 Heat shield
For catalyst
17 - Front exhaust pipe with catalyst
18 -Gasket
Renew
19 - Exhaust manifold
......
I N26-0210 I
26-4 ---....;.
~
..
: I: '
..... rig. 1
Sep.sting point on exhaust pipe
- Separate exhaust pipe at right angles at separating point -arrow 2-.

- When installing fit repair type double clamp -4- at side markings -ar
rows 1 and 3-.
lightening torque 40 Nm
..... rig.
Aligning rear silencer free of stress
- The mounting pins on exhaust pipe must run parallel with tunnel
bridge (dimension -x- on left and right the same).
I A2tI-0131 I
26-5--
..... rig.
rltting position of double clamp
- Position double clamp approx. 5 mm away from mark -A-.
AI
Nate:
Mark -A- is valid for vehicles with manual and automatic gearboxes.
I N26-021SI
i,
i
Ii
..... rag.
Installation position of mounting
- Angled side on foot of mounting -arrow- points forwards.

I
I
. ,,
I:
I A26-01281
26-6--
Secondary air system

Function
The secondary air system blows air in behind the exhaust valve for 65
seconds during the cold start (+15 C ... +35 C coolant temperature).
This produces an oxygen rich exhaust gas, causes afterburning and re
duces the heating-up phase of the catalyst. Activation occurs from the
Motronic control unit (J220) via the secondary air pump relay (J229) to
secondary air inlet valve (N112, change-over valve) and combi-valve.
Additionally after each subsequent engine start (up to max. 85C en
gine temperature) the secondary air system will after a 20 second
delay switch in for 5 seconds during idling and will be checked by the
self-diagnosis.
26-7--
Removing and installing parts

of the secondary air system
Notes:
Components marked with an
checked by the self-diagnosis:
7
~--8
9
10
"'"'-----11
'----12
~----,--13
are
=> Repair Group 01; Self diagnosis; Interro

Components marked with ** are checked
by the final control diagnosis:
=> Repair Group 01; Self diagnosis; Final con

trol diagnosis
Secondary air pump relay (J299) '* '* =>
Page 26-12, Fig. 1
1 - Combi-valve
Checking =>Page 26-13
=> Page 26-16
2-5Nm
...."~----14
)-------3
16 15
N26-0199 I
26-8--
3 -O-Ring
Renew
25
4 - Air channel
In cylinder head
5 -Bracket
For secondary air inlet valve (N112)
and intake manifold change-over
valve (N156)
23
22
20
6 - To fuel pressure regulator
7 - To intake manifold upper part
10
8 - Secondary air inlet valve (N1121*1**
20
9 - Connector
Black, 2-pin
11
12
13
14
3
19
18
17
16 15
N26-0199
10 - Non-return valve
White connection faces towards sec
ondary air inlet valve (N112)
I
26-9
6
11 - To vacuum reservoir
12 - To vacuum positioning element for
intake manifold change-over
1'
13 - To air cleaner upper part

14 -Intalar hose
Ensure seated tightly
15 -Second.y air pump motor "'1011**
10
16 - Connector
Black, 2-pin
For secondary air pump motor
17 -Bracket
For secondary air pump motor
11
12
13
14
3
18
17
16 15
,i
I
N26-0199 \
26-10
18 -Rubber bush
3
25
3
19 ~Housing
20~10Nm
21 ~ Intake manifold change-over valve

(N1561
22 - Connection
23
'*---8
22
20
10
23 - Pressure hose
Ensure seated tightly
24Gasket
Renew
25 Connection
For combi-valve
---11
"----12
"""-"----13
...." 'i'-----14 '
N-------3
19
18
17
16 15
N26-01991
26-11--
....
Secondary air pump relay (J299I1 .

If tools are necessary to pull relays or control units out of the relay
plate. first disconnect battery earth strap
Fig. 1
Before disconnecting battery earth strap obtain code for radios with
anti-theft coding.
- - - 26-12--
Checking combi-valve
V.A.G 1331
~:::
Special tools, workshop equipment" testers, measuring instru

ments and auxiliarY items required
I WQO-Oot27I
....
VAG 1390 Hand vacuum pump
I WOO-OS1s1
26-13--
Check conditions
No fault stored in fault memory
=> Repair group 01; Self-diagnosis; Interrogating fault memory
Carry out final control diagnosis

=> Repair group 01; Self-diagnosis; final control diagnosis
Vacuum pipes and hose connections free of leaks.
Vacuum pipes not blocked/kinked.
Test sequence
blyoverview
- Pull vacuum hose from combi-valve off secondary air inlet valve
(N112).
Fitting locations:
=> Repair group 24; Servicing injection system; Fitting locations-over
view
26-14--
.....
- Connect hand vacuum pump VAG 1390 to vacuum hose to combi

valve..
I N:2&-02131
Note:
Do not use compressed air during the following check!
.....
- Detach hose to combi valve at air cleaner upper part -arrow- and
pressurize slightly by blowing into hose.
Combi-valve must be closed.
- Operate hand vacuum pump.
Combi valve must open.
If the combi-valve does not open:
I N:2&-0212 I
- Replace combi-valve => Page 26-16. removing and installing combi

valve.
26-15--
Removing and installing combi-valve

Special tools, workshop equipment" testers, measuring instru
V.A.G 1331
.....

~moving
Note:
work sequences the batteryearth strap must be disconnected. Obtain

blyoverview
=> General body repairs. exterior; Repair group 50; Body. front; Lock
Ii'
1..
11
ti,
26-16--

- Removing air conditioner compressor:
~ Heating, Air conditioning; Repair group 87; removing and installing
compressor bracket
Waming!
The air conditioner refrigerant circuit must not be opened.
Notes:
The opening ofthe refrigerant circuit can only be carriedout in work

shops, which have trained personnel and the necessary range of
tools and workshop equipment.
To prevent damage to condenser and the refrigerant pipes/hoses.
26-17--

- Remove pressure hose between combi-valve and secondary air
pump at combi-valve.
- Pull vacuum hose off combi-valve.
- Unbolt combi-valve from intake manifold lowerpart and pull out with
connections.
Installing
Install in reverse order.
28-1R_-
<D
100-24981
Service.
<tP
Ii~--------------------------------------------------------
Ii
Supplement to Workshop Manual
Golf 1998 ~
With this supplement you will receive the new Assembly group
,,
l'
I:
i'
S..Cyl. injection engine, Mechanics Edition 10.97

(Art. No. KOO.51 07.29.20 + KOO.51 01.13.20 = KOO.51 00.70.201)
..
and revised
Side and spine pocket inserts Edition 03.11.97

(Art. No. K03.5100.01.20)
~.
Technical information is only of use if it is cared for and kept up-to-date. We will
supply you with the latest information please take care to keep it up-to-date
and file this supplement.as follows:
~Exchange side and spine pocket inserts in box 1.
~Complete new assembly group folder and file in box 1.
lIArt. No. of the complete Assembly Group including Assembly Group folder
Service Department. Technical Information
..
---'
'
.......
KOO.5107.29.20

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Service.

Booklet 5-CyI. in~ection engine.,

'" '""'- __ . . .'

5-Cy1. injection engine, Mechanics Edition 10.97

No reproduction without prior agreement from publisher.

Removing and installing engine

Removing and installing engine . ......... ~ ................................................ ,

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

Cylinder head, Valve gear

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

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

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

Fuel supply system

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

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

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

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

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

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

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

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

Activated charcoal filter system ...

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

Removing and installing parts of exhaust system ........

= V-arrangement in compact in-line design

Exhaust gas recirculation system

Secondary air system

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

Removing and installing en

VW 313 Support clamp

VW 540 Engine and gearbox support

V.A.G 1306 Drip tray

VAG 1331 Torque wrench (5... 50 Nm)

VAG 1921 Spring-type clip pliers

G 000 100 grease (vehicles with manual

- With the ignition switched off disconnect battery earth strap_ ,

- Remove battery and battery retainer.

Press buttons on hose couplings to do this.

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

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

carefully loosening the connection.

- Remove centre, left and right insulation tray:

Vehicles with air conditioner

Vehicles with manual gearbox

Vehicles with automatic gearbox

Continued for all vehicles

- Separate connections on following components:

- Remove right-hand drive shaft and disconnect left-hand drive shaft

- Disconnect pendulum support -arrows-.

- Increase size of cut-out on engine bracket 3395 to dimensions as

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

- Unbolt gearbox side of assembly mounting from gearbox carrier at

Engine with gearbox must be guided carefully when lowering to pre

Securing engine to assembly stand

Vehicles with automatic gearbox

Continued for all vehicles

2nd hole in hook at position 1

2nd hole in hook at position 8

The hooksandlocatingpins must be secured with locking pins.

- Rt engine in support clamp VW 313 using workshop crane

Installation is carried out in the reverse sequence, when doing this

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

- Only use nuts approved in parts programme to secure torque con