Awd Aww Awp Engine Mechanical Golf4 Jetta Eng PDF

Service
Repair Manual
Jetta 1999 ➤
Jetta Wagon 1999 ➤
Golf 1998 ➤
Engine Mechanical
Engine ID AWD AWW AWP
Edition 07.2007
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
20 - Fuel Supply
21 - Turbocharger, Supercharger
26 - Exhaust System, Emission Controls
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Jetta 1999 ➤ , Jetta Wagon 1999 ➤ , Golf 1998 ➤
Engine Mechanical - Edition 07.2007
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Engine and Transmission Mounts, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Engine Mount Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Engine, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Engine, Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Cylinder Block Crankshaft Bearing Shells Identification, from approximately 05.00 . . . . . . 18
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Belt Drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Cylinder Block and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Sealing Flange and Flywheel/Drive Plate Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Pistons and Connecting Rod Overview, Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Pistons and Connecting Rod Overview, Engine Codes AWW and AWP . . . . . . . . . . . . . . 28
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Piston and Cylinder Dimensions, Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Piston and Cylinder Dimensions, Engine Codes AWP and AWW . . . . . . . . . . . . . . . . . . . . 31
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 Engine Code AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Engine Codes AWW and AWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Crankshaft Seal, Ribbed Belt Side, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4 Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Contents i
2.1 Cylinder Head Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.2 Valvetrain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Valve Seats, Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.2 Hydraulic Valve Lifters, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.3 Camshaft, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.4 Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1 Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 Camshaft Gear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.4 Camshaft Position Sensor Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.5 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.6 Valve Stem Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Oil Filter Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Cooling System, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.2 Cooling System Components Overview, Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.3 Cooling System Components Overview, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.1 After-Run Coolant Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.1 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3 Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ii Contents

1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.3 Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.4 Crash Fuel Shut-Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.5 Electronic Power Control System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.6 Leak Diagnosis, Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.7 EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Fuel Tank and Attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.2 Electronic Engine Power Control Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.3 Meaning of Electronic Power Control Warning Lamp in Instrument Cluster . . . . . . . . . . . . 116
2.4 EVAP System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.5 EVAP System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.6 EVAP System Routing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.1 Fuel Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Accelerator Pedal Position Sensor and Accelerator Pedal Position Sensor 2, Checking . . 126
4.3 Evaporative Emission Canister Purge Regulator Valve, Checking . . . . . . . . . . . . . . . . . . 129
4.4 EVAP System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.5 Leak Detection Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.6 EVAP System, Checking with Tester KLI 9210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.1 Fuel Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.3 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.3 Charge Air System with Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.1 Turbocharger with Attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.2 Charge Air Cooler Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.3 Exhaust Turbocharger System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.4 Exhaust Turbocharger System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Boost Pressure Regulation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.2 Wastegate Bypass Regulator Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.3 Charge Air Pressure Sensor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.4 Turbocharger Recirculation Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.5 Boost Pressure Regulator Valve Vacuum Diaphragm, Checking . . . . . . . . . . . . . . . . . . . . 166
4.6 Deceleration Shut-Off Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.7 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Contents iii
1.1 Secondary Air Injection System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

2.1 Exhaust System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.2 Secondary Air Injection System Components Assembly Overview . . . . . . . . . . . . . . . . . . 174
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.1 Three Way Catalytic Converter, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.2 Combination Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.3 Secondary Air Injection Pump Motor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.4 Secondary Air Injection Solenoid Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
iv Contents
00 – General, Technical Data

1 General Information
⇒ “1.1 Engine Number“, page 1
1.1 Engine Number

The engine number (“engine code“ and “serial number“) are lo‐
cated at the front of the engine/transmission joint.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 letters) represents the “engine
code“, the second (six digit) is the “serial number“. If more than
999,999 engines with the same engine code are produced, the
first of the six characters is replaced with a letter.
The engine code is also included on the vehicle data plate.
In addition, a sticker with the “engine code“ and “serial number“

is affixed to the timing belt cover -arrow-.
Note
The engine code -arrow- is also stamped on the engine lifting eye.
1. General Information 1
2 Specifications
⇒ “2.1 Engine Data“, page 2
2.1 Engine Data Volkswagen Technical Site: http://vwts.ru http://vwts.info

Engine code AWD AWW AWP
Manufactured from 11.99 from 07.00 from 06.01
Displacement ltr. 1.8 1.8 1.8
Output kW at 1/rpm 110 at 5700 110 at 5700 132 at 5500
Torque Nm at RPM 210 at 1750 to 4600 220 at 1950 to 4500 235 at 1950 to 5000
Bore diameter mm 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4
Compression ratio 9.5 9.3 9.5
RON 95 unleaded 95 unleaded 98 unleaded
System designation Motronic ME7.1 Motronic ME7.1 Motronic ME7.1
Emission values in accordance with TLEV 1 LEV 2 LEV 2
Knock sensor control 2 knock sensors 2 knock sensors 2 knock sensors
On Board Diagnostic (OBD) OBD II OBD II OBD II
Oxygen sensor regulation 2 sensors 2 sensors 2 sensors
Catalytic converter yes yes yes
Exhaust Gas Recirculation (EGR) no no no
Variable intake manifold no no no
Variable valve timing no yes yes
Turbocharger yes yes yes
Electronic Power Control (EPC) yes yes yes
Boost pressure regulation Yes Yes Yes
Secondary Air Injection (AIR) system Yes Yes Yes
♦ 1TLEV = Transitional Low Emission Vehicles (emission val‐
ues Max. 0.125 g/mi HC)
♦ 2 LEV = Low Emission Vehicles (emission values max. 0.075
g/mi HC)
2 Rep. Gr.00 - General, Technical Data

10 – Engine Assembly
⇒ “1.1 Engine and Transmission Mounts, Aligning“, page 3
⇒ “1.2 Air Conditioning“, page 4
1.1 Engine and Transmission Mounts,

Aligning
Caution
Before loosening bolts, secure assembly using the engine sup‐

port bridge -10-222 A- .
Engine Mount
-a- = 14.0 mm
-b- = minimum 10.0 mm
Both bolt heads -1- must be flush with the edge -c-.
Transmission Mount
The edges -a and b- must be parallel to each other.
1.2 Air Conditioning
Caution
The Air Conditioning (A/C) refrigerant circuit must not be

opened.
Note
♦ The refrigerant circuit must only be opened in workshops with

trained personnel and the necessary range of tools and work‐
shop equipment.
♦ To prevent damage to the A/C condenser and also to the re‐
frigerant lines/hoses, ensure that the lines and hoses are not
stretched, kinked or bent.
To facilitate removal and installation of the engine without having

to open the refrigerant circuit:
– Remove the retaining clamp(s) from the refrigerant lines.
– Remove the ribbed belt. Refer to
⇒ “5.1 Ribbed Belt“, page 36 .
– Remove the A/C compressor. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87 ; Description and Operation .
– Secure the A/C compressor to the tow hook so that the refrig‐
erant lines/hoses are not under tension.
Note
Shield the bumper from damage using adhesive tape.
4 Rep. Gr.10 - Engine Assembly

2 Specifications
⇒ “2.1 Engine Mount Tightening Specifications“, page 5
⇒ “2.2 Fastener Tightening Specifications“, page 5
2.1 Engine Mount Tightening Specifications

Engine Mount
1- Mount to body 1 40 Nm + an addition‐
al 90° (1/4) turn
2- Bracket to body 25 Nm
3- Mount to engine mount bracket 100 Nm
Transmission Mount
1- Mount to body 1 40 Nm + an addition‐
al 90° (1/4) turn
2- Mount to body 25 Nm
3- Mount to transmission mount 100 Nm
bracket
Pendulum Support
1- Pendulum support to transmission 40 Nm + an addition‐
1 al 90° (1/4) turn
2- Pendulum support to transmission 40 Nm + an addition‐
1 al 90° (1/4) turn
3- Pendulum support to subframe 1 20 Nm + an addition‐
al 90° (1/4) turn
♦ 1 Always replace
2.2 Fastener Tightening Specifications

Components Bolt Size Nm
Bolts and Nuts
M6 10
M7 15
M8 25
M10 40
M12 60
Deviation from
Engine to transmission bolts M10 45
Engine to transmission bolts M12 80
2. Specifications 5

Converter to drive plate - 60
Drive axle to drive flange/transmission - 40

3 Removal and Installation

⇒ “3.1 Engine, Removal“, page 7
⇒ “3.2 Engine, Securing to Assembly Stand“, page 11
⇒ “3.3 Engine, Installing“, page 12
3.1 Engine, Removal

Special tools and workshop equipment required
♦ Holding Fixture -VW 313-
♦ Engine and Transmission Holder -VW 540-
♦ Lifting Tackle -2024 A-
♦ Retainer -3180-
♦ Shop Crane -V.A.G 1202- or Shop Crane -VAS 6100-
♦ Drip Tray -V.A.G 1306- or Drip Tray for VAS 6100 -VAS 6208-
♦ Torque Wrench -V.A.G 1331-
♦ Torque Wrench -V.A.G 1332-
♦ Engine-/Gearbox Jack -V.A.G 1383 A-
♦ Engine Mount -T10012-
♦ Spring Type Clip Pliers -VAS 5024 A-
♦ Step Ladder -VAS 5085-
♦ Grease -G 000 100- (vehicles with a manual transmission)
(Part numbers are for reference only. Always check with your
Parts Department for the latest part number information).
♦ M10 x 25, 8.8 Bolt
♦ Cable Tie
– First, check whether a coded radio is installed. If necessary,
obtain the anti-theft code.
– The engine is removed downward together with transmission.
– Disconnect the battery Ground (GND) cable with the ignition
turned off.
– All cable ties which are opened or cut off when removing the
engine, must be replaced in the same position when installing
the engine.
– Remove the engine cover.
3. Removal and Installation 7

– Remove the connecting hoses -arrows- between the Secon‐

dary Air Injection (AIR) pump/combination valve and the AIR
pump/air filter.
Note
Squeeze the buttons together on the hose connections to remove

the connecting hoses.
– Disconnect the connector -1- from the AIR pump.

– Remove the air filter. Refer to ⇒ Fuel Injection and Ignition;
Rep. Gr. 24 ; Description and Operation .
– Disconnect the vacuum and vent hoses from the engine.
WARNING
The fuel supply line is under pressure! Wear protective goggles

and protective clothing to prevent injuries and contact with skin.
Before removing from hose connection wrap a cloth around the
connection. Then release pressure by carefully pulling the
hose off the connection.

– Disconnect the supply line -1- (with a white mark) and the re‐
turn line -2- (with a blue mark) and catch any leaking fuel with
a cloth.
– Disconnect the hose from the solenoid valve.
Note
Squeeze the buttons together on the hose connection.
– Seal the lines so that the fuel system is not contaminated by

dirt, etc.
– Remove the intake hose between the mass airflow sensor -
G70- and exhaust turbocharger. Refer to ⇒ Fuel Injection and
Ignition; Rep. Gr. 24 ; Description and Operation .
– Loosen the intake hose (between the charge air cooler and the
throttle valve control module -J338- ) and remove it.
with a Manual Transmission
– Disconnect the selector mechanism from the transmission.
Refer to ⇒ Manual Transmission; Rep. Gr. 34 ; Removal and
Installation .
– Remove the slave cylinder for the hydraulic clutch. Refer to ⇒
Manual Transmission; Rep. Gr. 30 ; Description and Opera‐
tion .
Note
The clutch pedal must not be pressed.
with a Automatic Transmission

– Disconnect the selector lever cable from the transmission. Re‐
fer to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and
Installation .
Continuation for All
– Remove the sound insulation tray. Refer to ⇒ Body Exterior;
– Drain the coolant. Refer to
⇒ “1.2 Cooling System, Draining and Filling“, page 91 .
– Remove the coolant hoses from the engine.
Note
spring type clip pliers -VAS 5024 A- or hose clip pliers -V.A.G
1921- are recommended for installing spring clamps.

– Remove the pendulum support bolts -arrows- and support.

– Disconnect and lay aside all electrical harnesses for the trans‐
mission, generator, and starter.
– Remove the front exhaust pipe. Refer to
⇒ “2.1 Exhaust System Components Overview“, page 171 .
– Remove the securing clamps for the power steering pressure
line.
– Remove the power steering pump from the bracket and place
it to the side, the hoses remain connected. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 48 ; Removal and In‐
stallation
– Disconnect all electrical connections as necessary from the
engine and lay aside.
– Remove the right and left drive axles from the transmission.
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Re‐
moval and Installation .
with Air Conditioning (A/C)
– Remove the A/C compressor:
– Observe the additional information and removal work. Refer
to ⇒ “1.2 Air Conditioning“, page 4 .
– Install the engine/trans. support -T10012- to the cylinder block

with a nut and a M10 x 25/ 8.8 bolt and tighten to approximately
40 Nm.
– Gently lift the engine and transmission using the engine-/gear‐
box jack -V.A.G 1383 A- .
– Remove the engine mount to engine mount bracket bolts

-arrows-.
Note
Use the step ladder -VAS 5085- to remove the bolts.

– Remove the transmission mount to transmission mount brack‐

et bolts -arrows-.
– Carefully lower the engine with transmission.
Note
Carefully guide the engine with transmission, when lowering, to

prevent damage to the bodywork.
3.2 Engine, Securing to Assembly Stand

Secure the engine to the holding fixture -VW 313- using the hold‐
ing fixture -VW 540- when performing repair work.
Procedure
– Remove the transmission.
– After separating the engine from the transmission, secure the
torque converter to prevent it from “falling out“.
– Engage the engine sling -2024 A- with the retainer -3180- as
follows and raise using the shop crane -V.A.G 1202- from the
engine-/gearbox jack -V.A.G 1383 A- .
Belt pulley side: 3rd hole of rail in position 1.
Flywheel side: 2nd hole of rail in position 5.
Caution
Use securing pins at hooks and pins.
Note
♦ The peg positions on the carrying strap marked with 1 to 4 face

the belt pulley.
♦ The bores in the hole rail are counted from the hook.
– Secure the engine using the holding fixture -VW 540- to hold‐
ing fixture -VW 313- .

3.3 Engine, Installing

Installation is in the reverse of removal, note the following:
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to clearance issues:
♦ Route lines of all types (for example, fuel, hydraulic, Evap‐
orative Emission (EVAP), coolant, refrigerant, brake fluid
and vacuum) and electrical wiring so that the original path
is followed.
♦ To prevent damages to the lines, make sure there is suf‐
ficient clearance to all moving or hot components.
– Make sure the alignment sleeves for the engine to transmis‐

sion are installed in the cylinder block. Install if necessary.

– Engage the intermediate plate at the sealing flange and slide

it onto the alignment sleeves -arrows-.
with a Manual Transmission
– If necessary, check the centering of the clutch disc.
– Check the clutch release bearing for wear and replace if nec‐
essary.
– Lightly grease the clutch release bearing, the guide sleeve for
the release bearing and the input shaft splines with grease for
clutch plate splines -G 000 100- . (Part numbers are for refer‐
ence only. Always check with your Parts Department for the
latest part number information).
– Install the hydraulic clutch slave cylinder. Refer to ⇒ Manual
Transmission; Rep. Gr. 30 ; Description and Operation .
– Install the shift mechanism. Refer to ⇒ Manual Transmission;
Rep. Gr. 34 ; Removal and Installation, Servicing .
– If necessary, adjust the selector lever cable. Refer to ⇒ Man‐
ual Transmission; Rep. Gr. 34 ; General Information .
– Secure the torque converter to the drive plate, only use new
nuts.
– Install the selector lever cable to the transmission, adjust if
necessary. Refer to ⇒ Automatic Transmission; Rep. Gr. 37 ;
Removal and Installation .
– Adapt the automatic transmission control module 1.
– When installing, ensure clearance to the drive axles.
– Align the engine and transmission mounts. Refer to
⇒ “1.1 Engine and Transmission Mounts, Aligning“, page 3 .
– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Removal and Installation .
– Install the front exhaust pipe. Refer to
⇒ “2.1 Exhaust System Components Overview“, page 171 .
– Install the intake hose (between the charge air cooler and the
throttle valve control module) and secure it.
– Install the power steering pump. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 48 ; Removal and Installation .
– Electrical connections and routing. Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Component locations.
– Install the ribbed belt. Refer to
– Install the connecting hoses between the Secondary Air In‐
jection (AIR) pump/combination valve and AIR pump/air filter.
– Install the sound insulation tray. Refer to ⇒ Body Exterior;
– Fill with coolant. Refer to
– Perform the “Procedure after Voltage Supply Open Circuit“.
Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis
and Testing .

Tightening Specifications
Bolted connections Tightening
specifications
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M 12 60 Nm
Deviation from
Connecting bolts, engine to transmis‐ M10 45 Nm
sion
Connecting bolts, engine to transmis‐ M12 80 Nm
sion
Converter to drive plate 60 Nm
Drive axle to drive flange/transmis‐ 40 Nm
sion
Note
Tightening torques of the engine/transmission mounts. Refer to

⇒ “2.1 Engine Mount Tightening Specifications“, page 5 .

4 Special Tools

♦ Engine Sling -2024 A-
♦ Retainer -3180-
♦ Shop Crane -V.A.G 1202-
or Shop Crane -VAS 6100-
♦ Drip Tray -V.A.G 1306- or
Drip Tray for VAS 6100 -
VAS 6208-
4. Special Tools 15
♦ Torque Wrench -V.A.G

1331-
♦ Torque Wrench -V.A.G
1332-
♦ Engine-/Gearbox Jack -
V.A.G 1383 A-
♦ Engine/Trans. Support -
T10012-
♦ Spring Type Clip Pliers -
VAS 5024 A-
♦ Step Ladder -VAS 5085-

13 – Crankshaft, Cylinder Block

⇒ “1.1 Engine“, page 17
⇒ “1.2 Crankshaft“, page 17
⇒ “1.3 Cylinder Block Crankshaft Bearing Shells Identification,
from approximately 05.00“, page 18
1.1 Engine
Note
♦ Secure the engine to the assembly stand using the holding

fixture -VW 540- and spacers -VW 540/1B- when performing
repair work.
♦ If large quantities of metal particles or abraded material are
detected during engine repairs, it may be an indication for a
damaged crankshaft or rod bearings. To prevent further dam‐
age, perform the following steps after the repair:
♦ Carefully clean the oil passages
♦ Replace the oil injection jets
♦ Replace the oil cooler
♦ Replace the oil filter
1.2 Crankshaft
Note
♦ Before removing the crankshaft, prepare for appropriate stor‐

age, so that sensor wheel does not make contact or become
damaged.
♦ Secure engine to assembly stand using the holding fixture -
VW 540- and spacers -VW 540/1B- when performing repair
work.
1.3 Cylinder Block Crankshaft Bearing

Shells Identification, from approximately
05.00
Cylinder Block Crankshaft Bearing Shells Identification
From the factory, the upper bearing shells are allocated to the
cylinder block with the correct thickness. Colored dots serve to
identify the bearing thicknesses.
Note
The arrow points in the direction of travel.
The letters marked on the lower sealing surface of the cylinder

block identify which bearing thickness must be installed in which
location.
Color identification
Letter on cylinder Color of bearing
block
S = Black
R = Red
G = Yellow
– The crankshaft bearing shells in the bearing caps are only
available as a replacement part with a “yellow“ colored dot.
18 Rep. Gr.13 - Crankshaft, Cylinder Block

2 Description and Operation

⇒ “2.1 Belt Drive Overview“, page 19
⇒ “2.2 Cylinder Block and Components“, page 21
⇒ “2.3 Crankshaft Overview“, page 23
⇒ “2.4 Sealing Flange and Flywheel/Drive Plate Overview“, page
24
⇒ “2.5 Pistons and Connecting Rod Overview, Engine Code
AWD“, page 26
⇒ “2.6 Pistons and Connecting Rod Overview, Engine Codes
AWW and AWP“, page 28
2.1 Belt Drive Overview
1 - Bolt
❑ 25 Nm
2 - Ribbed Belt Tensioner
❑ To release tension on
the ribbed belt, pivot us‐
ing a open-end wrench.
Refer to
⇒ “5.1 Ribbed Belt“,
page 36
3 - Upper Toothed Belt Cover
4 - Center Toothed Belt Cover
5 - Bolt
❑ 27 Nm
6 - Idler Roller
7 - Tensioning Roller
❑ Toothed belt, removing,
installing and tension‐
ing. Refer to
⇒ “5.1 Toothed Belt“,
page 60 .
8 - Toothed Belt
❑ Mark the rotation direc‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning. Refer to
page 60 .
9 - Coolant Pump
❑ Check for ease of move‐
ment.
❑ If damaged or leaking replace completely.
❑ Removing and installing, refer to ⇒ “5.2 Coolant Pump“, page 104 .
10 - O-ring
❑ Always replace.
11 - Bolt
❑ 15 Nm
Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Description and Operation 19

12 - Toothed Belt Tensioner

❑ Toothed belt, removing, installing and tensioning. Refer to ⇒ “5.1 Toothed Belt“, page 60 .
13 - Crankshaft Toothed Belt Gear
14 - Bolt
❑ 15 Nm
15 - Bolt
❑ 20 Nm
16 - Bolt
❑ 90 Nm + an additional 90° (1/4) turn.
❑ Always replace.
❑ Use the counter support -3415- to loosen and tighten.
❑ Threads and shoulder must be free of oil and grease.
17 - Lower Toothed Belt Cover
18 - Bolt
❑ 10 Nm
❑ Install using liquid locking fluid -D 000 600 A2- .
19 - Pulley
❑ For the power steering pump.
20 - Bolt
❑ 25 Nm
21 - Ribbed Belt
❑ Mark the rotation direction before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing, refer to ⇒ “5.1 Ribbed Belt“, page 36 .
22 - Bolt
❑ 25 Nm
23 - Vibration Damper
❑ Only possible to install in one position - Bores are offset.
❑ Note the position when installing the toothed belt. Refer to ⇒ “5.1 Toothed Belt“, page 60 .

2.2 Cylinder Block and Components
1 - Knock Sensor 1 -G61-

2 - Bolt
❑ 20 Nm
❑ The tightening specifi‐
cation affects the func‐
tion of the knock sensor.
3 - Knock Sensor 2 -G66-
4 - Oil Dipstick
❑ The oil level must not be
above the MAX. mark!
❑ Marks, refer to
⇒ Fig. ““Marks on the Oil
Dipstick““ , page 82 .
5 - Inlet Spout
❑ For the oil dipstick.
6 - O-ring
❑ Always replace.
7 - Coolant Line
8 - Bolt
❑ 20 Nm
9 - Oil Filter Bracket
❑ Overview, refer to
⇒ “2.2 Oil Filter Housing
Overview“, page 82 .
10 - Bolt
❑ 15 Nm + an additional
90° (1/4) turn.
❑ Always replace.
11 - Oil Cooler
❑ Coat the contact area to
the oil filter bracket, outside the seal, with sealing paste -AMV 188 100 02- . (Part numbers are for
reference only. Always check with your Parts Department for the latest part number information).
❑ Ensure sufficient clearance to surrounding components
❑ See the note in ⇒ “1.1 Engine“, page 17 .
12 - Nut
❑ 25 Nm
13 - Oil Filter Element
❑ Remove using a tension strap.
❑ Tighten by hand.
❑ Observe the installation instructions for the oil filter.
14 - Gasket
❑ Always replace.
15 - Bolt
❑ 10 Nm
2. Description and Operation 21

16 - Engine Speed Sensor -G28-

17 - Connecting Piece
18 - Bolt
❑ 15 Nm
19 - O-ring
❑ Always replace.
20 - Coolant Thermostat
❑ Removing and installing, refer to ⇒ “5.3 Coolant Thermostat“, page 105 .
❑ Note the installed position, refer to ⇒ “5.3 Coolant Thermostat“, page 105 .
❑ Checking: Heat up the thermostat in water.
❑ Opening begins approximately 86 °C (187 °F).
❑ Opening lift, a MIN. of 7 mm.
21 - Bolt
❑ 45 Nm
22 - Accessory Bracket
❑ For the generator, Air Conditioning (A/C) compressor, and power steering pump.
23 - Engine Mount Bracket

2.3 Crankshaft Overview
1 - Oil Pump with Chain

Sprocket
❑ With a pressure relief
valve, 12 bar.
❑ Before installing, check
to be sure both align‐
ment sleeves are
present (for centering oil
pump/cylinder block).
❑ Removing and instal‐
ling, refer to
⇒ “1.2 Lubrication Sys‐
tem“, page 79 .
2 - Bolt
❑ 15 Nm
3 - Chain Sprocket
❑ For the oil pump drive.
❑ Check for wear.
4 - Bearing Shells 1, 2, 3, 4 and
5
❑ For the bearing caps
without oil grooves.
❑ For the cylinder block
with a oil groove.
❑ Do not interchange
used bearings (mark
them).
❑ Vehicles from approxi‐
mately 05.00: Classifi‐
cation for replacement
part ordering, refer to
⇒ Fig. ““Cylinder Block
Crankshaft Bearing
Shells Identification““ ,
page 18 .
5 - Bolt
❑ Always replace.
❑ Fully threaded.
❑ When measuring crankshaft radial play, tighten to 65 Nm.
6 - Bearing Cap
❑ Bearing cap 1: Belt pulley side
❑ Retaining tabs on the bearing shells and cylinder block/bearing caps must align above one another.
7 - Bearing Shell 3
❑ See -item 4-
❑ Do not interchange used bearings (mark them).
8 - Sensor Wheel
❑ Always replace.
❑ For the engine speed sensor.
❑ Only possible to install in one position - Bores are offset.
9 - Screw

❑ Always replace.
10 - Thrust Washer
❑ For bearing 3.
❑ Observe the locating point.
11 - Crankshaft
❑ Axial play:
New: 0.07 to 0.23 mm
Wear limit: 0.30 mm

❑ Check the radial clearance using Plastigage®:
0.01 to 0.04 mm
Wear limit: 0.15 mm

❑ Do not rotate the crankshaft when measuring the radial play.
❑ Crankshaft dimensions, refer to ⇒ “3.2 Crankshaft Dimensions“, page 30 .
2.4 Sealing Flange and Flywheel/Drive

Plate Overview
Note
Servicing the clutch. Refer to ⇒ Manual Transmission; Rep. Gr.

30 ; Description and Operation .

1 - Bolt
❑ 90 Nm + an additional
90° (1/4) turn.
❑ Always replace.
❑ Use the counter support
-3415- to loosen and
tighten.
❑ Threads and shoulder
must be free of oil and
grease.
2 - Crankshaft Toothed Belt
Sprocket
3 - Bolt
❑ 15 Nm
4 - Seal
❑ Replacing, refer to
⇒ “5.2 Crankshaft Seal,
Ribbed Belt Side, Re‐
placing“, page 37 .
5 - Sealing Flange
❑ Must be located on the
alignment sleeves.
❑ Clean the sealing sur‐
face before installing.
❑ Install using silicone
sealant -D 176 404
A2- .
ling, refer to
⇒ “5.3 Sealing Flange,
Belt Pulley Side“,
page 39 .
❑ To remove and install,
remove the oil pan.
6 - Cylinder Block
❑ Crankshaft overview, refer to ⇒ “2.3 Crankshaft Overview“, page 23 .
❑ Piston and connecting rod overview, refer to one of the following:
⇒ “2.5 Pistons and Connecting Rod Overview, Engine Code AWD“, page 26 .
⇒ “2.6 Pistons and Connecting Rod Overview, Engine Codes AWW and AWP“, page 28 .
7 - Bolt
❑ Always replace.
8 - Flywheel/Drive Plate
❑ To remove and install the flywheel, secure using the flywheel retainer -3067- .
❑ Drive plate, removing and installing, refer to ⇒ “5.4 Drive Plate“, page 41 .
9 - Intermediate Plate
❑ Must be located on the alignment sleeves.
❑ Do not damage or bend when doing assembly work.
10 - Sealing Flange with Seal
❑ Only replaced as a complete unit.
❑ To remove and install, remove the oil pan. Refer to ⇒ “5.1 Oil Pan“, page 87 .
❑ Before installing, remove any remaining oil from the crankshaft journal with a clean cloth.

❑ Do not additionally oil or grease the sealing lip of the seal.
❑ To install, use the provided support sleeve.
❑ The support sleeve may only be removed after the sealing flange has been slid onto the crankshaft
journal.
2.5 Pistons and Connecting Rod Overview, Engine Code AWD
1 - Piston Rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers for
removal and installa‐
tion.
❑ “TOP“ faces toward the
piston crown.
❑ Checking the ring gap,
refer to
⇒ “4.1.1 Piston Ring
Gap, Checking“,
page 32 .
❑ Checking the piston ring
groove clearance, refer
to
⇒ “4.1.2 Ring to Groove
Clearance, Checking“,
page 32 .
❑ Oil scraping ring, 2 or 3
piece, mixed installation
is permitted.
2 - Piston
❑ Checking, refer to
⇒ “4.1.3 Piston, Check‐
ing“, page 33 .
❑ Mark the installed posi‐
tion and cylinder alloca‐
tion.
❑ The arrow on the piston
face points toward the
belt pulley side.
❑ Install using a piston
ring compressor.
3 - Connecting Rod
❑ Only replace as a set,
❑ Affiliation to the cylinder mark -B-.
❑ Installed location: Marks -A- point to the belt pulley side.
4 - Connecting Rod Bearing Cap
❑ Installed location: Marks -A- point to the belt pulley side.
5 - Nut
❑ Always replace.
❑ Lubricate the threads and contact surface.
❑ Tighten to 30 Nm to measure the radial play, do not tighten the additional torque angle.
6 - Pressure Relief Valve
❑ 27 Nm

❑ Opening pressure: 1.3 to 1.6 bar positive pressure.
7 - Oil Spray Jet
For piston cooling.
8 - Bearing Shell
❑ Note the installed position.
❑ Do not interchange used bearing shells (mark them).
❑ Check for a secure fit in the retaining tabs.
❑ Axial play:
New: 0.10 to 0.31 mm
Wear limit: 0.40 mm

❑ Measure radial clearance using Plastigage®:
New: 0.01 to 0.05 mm
Wear limit: 0.09 mm

❑ Do not rotate the crankshaft when checking the radial clearance.
9 - Cylinder Block
❑ Cylinder bore, checking. Refer to ⇒ “4.1.4 Cylinder Bore, Checking“, page 33 .
❑ Piston and cylinder dimensions, refer to
⇒ “3.3 Piston and Cylinder Dimensions, Engine Code AWD“, page 31 .
10 - Connecting Rod Bolt
❑ Always replace.
11 - Circlip
12 - Piston Pin
❑ If difficult to move, heat the piston to 60 °C (140 °F).
❑ Removing and installing using a pilot drift -VW 222 A- .

2.6 Pistons and Connecting Rod Overview, Engine Codes AWW and AWP
1 - Piston Rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers for
removal and installa‐
tion.
❑ “TOP“ faces toward the
piston crown.
❑ Checking ring gap, refer
to
⇒ “4.1.1 Piston Ring
Gap, Checking“,
page 32 .
❑ Check piston ring
groove clearance, refer
to
⇒ “4.1.2 Ring to Groove
Clearance, Checking“,
page 32 .
2 - Piston
⇒ “4.2.3 Piston, Check‐
ing“, page 34 .
❑ Mark the installed posi‐
tion and cylinder alloca‐
tion.
❑ The arrow on the piston
face points toward the
belt pulley side.
❑ Install using a piston
ring compressor.
3 - Piston Pin
❑ If difficult to move, heat
the piston to 60 °C (140
°F).
❑ Removing and installing
using a pilot drift -VW
222 A- .
4 - Circlip
5 - Connecting Rod
❑ Only replace as a set.
❑ Installed location: Marks -A- points to the belt pulley side.
6 - Bearing Shell
❑ Note the installed position, refer to ⇒ Fig. ““Bearing Shells - Installed Positions““ , page 29 .
❑ Do not interchange used bearing shells (mark them).
❑ Axial play:
New: 0.05 to 0.31 mm
wear limit: 0.37 mm

❑ Measure radial clearance using Plastigage®:
New: 0.01 to 0.06 mm
Wear limit: 0.09 mm

❑ Do not rotate the crankshaft when checking the radial clearance.
7 - Cylinder Block
❑ Cylinder bore, checking, refer to ⇒ “4.2.4 Cylinder Bore, Checking“, page 35 .
❑ Piston and cylinder dimensions, refer to
⇒ “3.4 Piston and Cylinder Dimensions, Engine Codes AWP and AWW“, page 31 .
8 - Connecting Rod Bearing Cap
9 - Oil Spray Jet
❑ For piston cooling.
❑ 27 Nm
11 - Connecting Rod Bolt
❑ Always replace.
❑ Lubricate the threads and contact surface.
❑ Use a old bolt to measure radial play.
❑ Tighten to 30 Nm to measure the radial play, do not tighten the additional torque angle.
Bearing Shells - Installed Positions

Bearing shell -1- with a oil bore -arrow- for the connecting rod.
Bearing shell -2- without a oil bore for the connecting rod cap.
– Place the bearing shells centered into the connecting rod and
connecting rod cap.
Dimension -a- must be the same on the left and right. Max. devi‐
ation: 0.2 mm

3 Specifications
⇒ “3.2 Crankshaft Dimensions“, page 30
Engine Code AWD
⇒ “3.3 Piston and Cylinder Dimensions, Engine Code AWD“, page
31
Engine Codes AWP and AWW
⇒ “3.4 Piston and Cylinder Dimensions, Engine Codes AWP and
AWW“, page 31

Tensioning device for ribbed belt - 25
Center toothed belt cover - 10
Tensioning device for toothed belt 1
- 15
- 20
Coolant pump - 15
Tensioning roller - 27
Lower toothed belt cover - 10
Pulley for power steering pump - 25
Belt pulley/vibration damper - 25
Knock sensor - 20
Coolant line - 20
Oil filter bracket - 15 + 90°
Oil cooler - 25
Engine speed sensor - 10
Connecting piece - 15
Compact bracket for generator, air condi‐ - 45
tioning compressor, and power steering
pump
Right engine bracket - 45
Oil pump with chain sprocket - 15
Bearing cap - 65 + 90°
Sensor wheel - 10 + 90°
Crankshaft toothed belt sprocket - 90 + 90°
Sealing flange - 15
Flywheel/drive plate - 60 + 90°
Sealing flange with seal - 15
-Engine Code AWD-
Connecting rod - 30 + 90°
Pressure relief valve - 27
♦ 1 For bolt tightening clarification, refer to
⇒ “2.1 Belt Drive Overview“, page 19 and see items
-14 and 15-
3.2 Crankshaft Dimensions

(Dimensions in mm)
Volkswagen Technical Site: http://vwts.ru http://vwts.info

Honing dimen‐ Crankshaft bearing Connecting rod bear‐

sion pin-diameter ing
pin-diameter
Basic dimension 54.00 -0.017 47.80 -0.022
-0.037 -0.042
1st oversize 53.75 -0.017 47.55 -0.022
-0.037 -0.042
2nd oversize 53.50 -0.017 47.30 -0.022
-0.037 -0.042
Stage III 53.25 -0.017 47.05 -0.022
-0.037 -0.042
3.3 Piston and Cylinder Dimensions, Engine

Code AWD
Honing dimen‐ Piston diameter Cylinder bore di‐
sion ameter
Basic dimension mm 80.965 1 81.01
1st oversize mm 81.465 1 81.51
♦ 1Measurement without graphite coating (0.02 mm thick). The

graphite coating wears off.
3.4 Piston and Cylinder Dimensions, Engine

Codes AWP and AWW
Honing dimen‐ Piston diameter Cylinder bore di‐
sion ameter
Basic dimension mm 80.965 1 81.01
1st oversize mm 81.465 1 81.51
♦ 1Measurement without graphite coating (0.02 mm thick). The

graphite coating wears off.
3. Specifications 31
4 Diagnosis and Testing

⇒ “4.1 Engine Code AWD“, page 32
⇒ “4.2 Engine Codes AWW and AWP“, page 34
4.1 Engine Code AWD

⇒ “4.1.1 Piston Ring Gap, Checking“, page 32
⇒ “4.1.2 Ring to Groove Clearance, Checking“, page 32
⇒ “4.1.3 Piston, Checking“, page 33
⇒ “4.1.4 Cylinder Bore, Checking“, page 33
4.1.1 Piston Ring Gap, Checking

♦ Feeler Gauge
– Insert the ring into the lower end of the cylinder bore at a right
angle from above, approximately 15 mm from the cylinder
edge.
Piston ring Gap
New Wear limit
Compression rings mm 0.15 to 0.40 0.8
Oil scraping ring mm 0.25 to 0.50 1.00
4.1.2 Ring to Groove Clearance, Checking

♦ Feeler Gauge
Clean the ring groove before checking.
Piston ring Ring to groove clearance
New Wear limit
compression rings mm 0.02 to 0.07 0.12

4.1.3 Piston, Checking

♦ External Micrometer 75 to 100 mm
Take the measurement approximately 10 mm from the lower edge
of the piston skirt and offset 90° to the piston axis.
Deviation from nominal size: max. 0.04 mm.
4.1.4 Cylinder Bore, Checking

♦ Internal Dial Gauge 50 to 100 mm
– Measure diagonally at 3 positions transversely -A- and longi‐
tudinally -B-.
Deviation from nominal size: Max. 0.10 mm.
Note
The cylinder bore measurement must not be performed if the cyl‐

inder block is secured to the assembly stand using the holding
fixture -VW 540- , since inaccurate measurements are possible.
4. Diagnosis and Testing 33

4.2 Engine Codes AWW and AWP

⇒ “4.2.1 Piston Ring Gap, Checking“, page 34
⇒ “4.2.2 Ring to Groove Clearance, Checking“, page 34
⇒ “4.2.3 Piston, Checking“, page 34
⇒ “4.2.4 Cylinder Bore, Checking“, page 35
4.2.1 Piston Ring Gap, Checking

♦ Feeler Gauge
– Insert the ring into the lower end of the cylinder bore at a right
angle from above, approximately 15 mm from the cylinder
edge.
Piston ring Gap
New Wear limit
4.2.2 Ring to Groove Clearance, Checking

♦ Feeler Gauge
Clean the ring groove before checking.
Piston ring Ring to groove clearance
New Wear limit
4.2.3 Piston, Checking

♦ External Micrometer 75 to 100 mm

Take the measurement approximately 10 mm from the lower edge

of the piston skirt and offset 90° to the piston axis.
Deviation from nominal dimension: Max. 0.04 mm
4.2.4 Cylinder Bore, Checking

♦ Internal Dial Gauge 50 to 100 mm
– Measure diagonally at 3 positions transversely -A- and longi‐
tudinally -B-.
Deviation from nominal size: Max. 0.08 mm.
Note
The cylinder bore measurement must not be performed if the cyl‐

inder block is secured to the assembly stand using the holding
fixture -VW 540- , since inaccurate measurements are possible.


⇒ “5.1 Ribbed Belt“, page 36
⇒ “5.2 Crankshaft Seal, Ribbed Belt Side, Replacing“,
page 37
⇒ “5.3 Sealing Flange, Belt Pulley Side“, page 39
⇒ “5.4 Drive Plate“, page 41
5.1 Ribbed Belt

♦ Locking Pin -T10060 A-
Removing
– Mark the rotation direction of the ribbed belt.
– Rotate the tensioner in the direction of the -arrow- using an
open end wrench until it can be locked.
– Secure the tensioner using the locking pin -T10060 A- .

– Remove the ribbed belt.
Installing
– Installation is in the reverse order of removal.
Note
♦ Ensure, before installing the ribbed belt, that all ancillaries

(generator, Air Conditioning (A/C) compressor, power steering
pump) are secured tightly.
♦ Note the previously marked belt rotation direction and be sure
that it is seated correctly on the pulleys.
♦ In vehicles without A/C, lay the ribbed belt last on the generator
last.
♦ In vehicles with A/C, lay the ribbed belt last on the A/C com‐
pressor last.
After completing the repairs always:

– Start the engine and check the belt running.
Ribbed Belt Routing

without A/C
with A/C
Note
Engines with A/C are equipped with a double ribbed belt.
5.2 Crankshaft Seal, Ribbed Belt Side, Re‐

placing
♦ Seal Remover -3203-
♦ Counter Support -3415-
♦ Assembly Tool -T10053-
♦ Torque Wrench (5-50 Nm) -V.A.G 1331-
Removing
– Remove the ribbed belt and tensioner. Refer to
– Remove the toothed belt. Refer to
⇒ “5.1 Toothed Belt“, page 60 .
– Remove the toothed belt crankshaft sprocket. To do this, se‐
cure the toothed belt gear using the counter support -3415- .

– To guide the seal remover -3203- , thread the bolt into the
crankshaft by hand until seated.
– Remove the inner portion of the seal remover -3203- nine ro‐
tations (approximately 20 mm) from the outer portion and
secure it with the knurled thumb screw.
– Lubricate the threaded head of the seal remover -3203- , po‐

sition it and screw it into the oil seal as far as possible with
forced pressure.
– Loosen the knurled thumb screw and turn the inner portion
against the crankshaft until the oil seal is pulled out.
Installing
Note
Phased in introduction of PTFE seals (Distinguishing features:

without a ring spring, seal lip designed wider). The seal lip of this
seal may not be oiled or greased. An oil seal of the old version
(with ring spring) can be replaced by a PTFE seal - but not the
other way around.
– Before installing, remove any remaining oil from the end of the
crankshaft with a clean cloth.
– Position the guide sleeve -T10053/1- on the crankshaft.

– Slide the seal over the guide sleeve onto the crankshaft.
– Press in the oil seal using the pressure sleeve -T10053- and
bolt -T10053/2- (M16 x 1.5 x 60) until seated.

– Install the toothed belt crankshaft sprocket and secure it using

the counter support -3415- .
– Tighten the new center bolt to 90 Nm + an additional 90° (1/4)
turn, the additional turn may occur in several stages).
Note
The threads and shoulder must be free of oil and grease.
Install the toothed belt and adjust the valve timing. Refer to
– Install the ribbed belt and tensioner. Refer to
5.3 Sealing Flange, Belt Pulley Side

♦ Hand Drill with Plastic Brush Attachment
♦ Silicone Sealant -D 176 404 A2- (Part numbers are for refer‐
♦ Protective Glasses
♦ Flat Scraper
Removing
– Remove the ribbed belt and tensioner. Refer to
– Remove the toothed belt. Refer to
– Remove the toothed belt crankshaft gear. To do this, secure
the toothed belt gear using the counter support -3415- .
– Drain the engine oil.
– Remove the oil pan. Refer to ⇒ “5.1 Oil Pan“, page 87 .
– Remove the front sealing flange.
– Remove the sealing flange, and if necessary loosen it by ap‐
plying light strikes with a rubber hammer.
– Remove the sealant residue from the cylinder block with a flat
scraper.
– Cover the seal with a clean cloth.

– Remove any sealant residue from the sealing flange using a

rotating plastic brush (wear safety glasses).
– Clean the sealing surfaces. They must be free of oil and
grease.
Installing
Note
♦ Note the expiration date of the sealant.

♦ The sealing flange must be installed within 5 minutes after ap‐
plication of the sealant.
– Cut off the nozzle on the tube of sealant at the front mark (di‐
ameter of nozzle approximately 3 mm).
– Apply the sealant, as shown, to the clean sealing surface of
the sealing flange. The sealant bead must be:
♦ 2 to 3 mm thick
♦ and run on the inside of bolt holes -arrows-
Note
♦ The sealant bead must not be thicker, otherwise the excess

sealant could enter the oil pan and may block the oil suction
pipe strainer. Likewise, it could drip onto the sealing surface
of the crankshaft seal.
♦ Before applying the bead of sealant, cover the sealing surface
of the seal with a clean cloth.
– Set the sealing flange in place immediately and lightly tighten

the bolts.
Note
To position the sealing flange with the seal installed, use the guide
sleeve -T10053/1- .
– Tighten the sealing flange bolts in a diagonal sequence. Tight‐

ening specification: 15 Nm
– Remove any excess sealant.
– Install the oil pan. Refer to ⇒ “5.1 Oil Pan“, page 87 .
Note
After installing, allow the sealant to dry for approximately 30 mi‐

nutes. Only after then may the engine oil be added.

– Install the toothed belt crankshaft sprocket and secure it using

the counter support -3415- .
– Tighten the new center bolt to 90 Nm + an additional 90° (1/4)
turn, the additional turn may occur in several stages.
Note
The threads and shoulder must be free of oil and grease.
– Install the toothed belt and adjust the valve timing. Refer to
– Install the ribbed belt and tensioner. Refer to
5.4 Drive Plate

♦ Flywheel Lock Adapter -VW 558-
♦ M8 x 45 Bolt and two M10 Nuts
♦ Depth Gauge
Loosening and Tightening
– Install the flywheel lock adapter -VW 558- suing the M8 x 45
bolt to the drive plate. Insert two M10 nuts -1- between the
flywheel lock adapter and drive plate.
Installed location of the flywheel retainer:
-A- to loosen
-B- to tighten
– Loosen the drive plate bolts.
Installing
– Set the drive plate in place, using the washer with notches
-1-.
– Insert new bolts -3- and tighten them to 30 Nm.

– Check the dimension -a- at three points and calculate the

mean value. Specified value: 19.5 to 21.1 mm
Note
This is measured through the hole in the drive plate to the ma‐
chined surface of the cylinder block.
If the specification is not obtained:
– Remove the drive plate again and use shim -2-. Tighten the
bolts again to 30 Nm.
– Tighten the bolt to 60 Nm + an additional 90° (1/4) turn, the
additional turn may occur in several stages.

6 Special Tools
♦ Locking Pin -T10060A-
♦ Flywheel Lock Adapter -VW 558-
6. Special Tools 43
♦ Seal Remover -3203-

♦ Torque Wrench (5-50 Nm) -
V.A.G 1331-
♦ Torque Wrench (40-200
Nm) -V.A.G 1332-

15 – Cylinder Head, Valvetrain

⇒ “1.1 Cylinder Head“, page 45
⇒ “1.2 Valvetrain“, page 45
1.1 Cylinder Head
Note
♦ When using an exchanged cylinder head with the camshaft

installed, the contact surfaces between the lifters and cam
lobes must be lubricated before installing the cylinder head
cover.
♦ The plastic protectors installed to protect the open valves must
only be removed immediately before installing the cylinder
head.
♦ When the cylinder head is replaced, all coolant must also be
replaced.
♦ Intake manifold removing and installing. Refer to ⇒ Fuel In‐
jection and Ignition; Rep. Gr. 24 ; Description and Operation .
1.2 Valvetrain
Note
♦ Cylinder heads with cracks between the valve seats, or be‐

tween the valve seat and the spark plug threads, can continue
to be used without reducing the service life, as long as the
cracks have a MAX. width of 0.3 mm, or only the first 4 threads
of the spark plug threads are cracked.
♦ After installing new valve lifters, the engine may not be started
for approximately 30 minutes. (otherwise valves will strike pis‐
tons), then turn crankshaft two revolutions.

⇒ “2.1 Cylinder Head Overview“, page 46
⇒ “2.2 Valvetrain Overview“, page 48
⇒ “2.3 Valve Seats, Refacing“, page 51
2.1 Cylinder Head Overview
1 - Cap
2 - Nut
❑ 10 Nm
3 - Cylinder Head Cover
4 - Cylinder Head Cover Gas‐
ket
❑ Replace if damaged.
❑ Before installing, coat
the contact surfaces of
the bearing cap or cam‐
shaft adjuster/chain ten‐
sioner to cylinder head
with sealant -AMV 174
004 01- , refer to
⇒ Fig. ““Double Bearing
Cap Contact Surfaces,
Sealing““ , page 51
and
⇒ Fig. ““Chain Tension‐
er or Camshaft Adjuster/
Cylinder Head Contact
Surfaces, Sealing““ ,
page 51 (Part num‐
bers are for reference
only. Always check with
your Parts Department
for the latest part num‐
ber information).
5 - Oil Deflector
❑ Note the installed posi‐
tion: Above the intake
camshaft.
6 - Cylinder Head
❑ Check for distortion, re‐
fer to
⇒ Fig. ““Checking the
Cylinder Head for Distortion““ , page 47 .
❑ Resurfacing the sealing surfaces, refer to
⇒ Fig. ““Refacing the Cylinder Head Sealing Surface““ , page 50 .
❑ Removing and installing, refer to ⇒ “5.2 Cylinder Head“, page 64 .
❑ After replacing, replace the entire amount of coolant.
7 - Intake Manifold Gasket
❑ Always replace.
8 - Cylinder Head Gasket
❑ Always replace.
❑ Made of metal
❑ After replacing, replace the entire amount of coolant.
46 Rep. Gr.15 - Cylinder Head, Valvetrain

❑ Note the installed position: Identification: Part number must be visible from the intake side.
9 - Toothed Belt
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing and tensioning, refer to ⇒ “5.1 Toothed Belt“, page 60 .
10 - Exhaust Manifold Gasket
❑ Always replace.
11 - Cylinder Head Bolt
❑ Always replace.
❑ Remove and install the polydrive cylinder head bolts using the polydrive bit socket and drive key -3452-
or -T10070- .
❑ Sequence for loosening and tightening, refer to ⇒ “5.2 Cylinder Head“, page 64 .
12 - Gasket
Checking the Cylinder Head for Distortion

♦ Straight Edge
♦ Feeler Gauge
Max. permissible distortion: 0.1 mm

2.2 Valvetrain Overview
1 - Bolt
❑ 10 Nm
2 - Intake Camshaft
❑ Checking axial play, re‐
fer to
⇒ Fig. ““Camshaft,
Checking Axial Play““ ,
page 50 .
ling, refer to
⇒ “5.5 Camshaft“,
page 71 .
❑ Check the radial clear‐
ance using Plasti‐
gage®:
Wear limit: 0.1 mm
❑ Run out:
Max. 0.01 mm
3 - Drive Chain
tion before removing (in‐
stalled position), refer to
⇒ “5.5 Camshaft“,
page 71 .
4 - Bolt
❑ 10 Nm
5 - O-ring
❑ Always replace.
❑ Only on vehicles with
engine codes AWP and
AWW.
6 - Camshaft Adjustment Valve
1 -N205- Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Only on vehicles with engine codes AWP and AWW.
❑ Camshaft adjustment, checking. Refer to ⇒ “4.3 Camshaft, Checking Adjustment“, page 57 .
7 - Bolt
❑ 3 Nm
8 - Camshaft Adjuster
❑ For vehicles with engine code AWD: Chain tensioner.
❑ Before removing, secure using the bracket for chain adjustment -3366- , refer to
⇒ “5.5 Camshaft“, page 71 .
❑ Camshaft adjustment, checking. Refer to ⇒ “4.3 Camshaft, Checking Adjustment“, page 57 .
9 - Gasket
❑ Always replace.
❑ Made of rubber/metal.
10 - Cylinder Head
❑ Removing and installing, refer to ⇒ “5.2 Cylinder Head“, page 64 .

❑ Refacing the valve seat, refer to ⇒ “2.3 Valve Seats, Refacing“, page 51 .
❑ Resurfacing the sealing surfaces, refer to
⇒ Fig. ““Refacing the Cylinder Head Sealing Surface““ , page 50 .
❑ Sealing contact surfaces, refer to ⇒ Fig. ““Double Bearing Cap Contact Surfaces, Sealing““ , page 51
and
⇒ Fig. ““Chain Tensioner or Camshaft Adjuster/Cylinder Head Contact Surfaces, Sealing““ , page 51 .
11 - Valves
❑ Do not grind, Only hand lapping is permitted.
❑ Valve dimensions, refer to ⇒ Fig. ““Valve Dimensions““ , page 51 .
❑ Exhaust valves with sodium filling: Observe the note for disposal, refer to
⇒ Fig. ““Double Bearing Cap Contact Surfaces, Sealing““ , page 51 .
12 - Seal
❑ Replacing, refer to ⇒ “5.3 Camshaft Gear Oil Seal“, page 67 .
13 - Hood
❑ For the camshaft position sensor.
❑ Observe the installed location.
14 - Washer
❑ Conical
15 - Bolt
❑ 25 Nm
16 - Camshaft Position Sensor -G40-
❑ Refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 28 ; Description and Operation .
17 - Bolt
❑ 10 Nm
18 - Bolt
❑ 65 Nm
❑ Use the retainer -3036- to loosen and tighten.
19 - Camshaft Sprocket
❑ Note the installed position: Thin rib of the camshaft gear points outward and cylinder 1 Top Dead Center
(TDC) mark is visible.
❑ Note the position when installing the toothed belt, refer to ⇒ “5.1 Toothed Belt“, page 60 .
20 - Seal
❑ Replacing, refer to ⇒ “5.3 Camshaft Gear Oil Seal“, page 67 .
21 - Valve Guide
❑ Checking, refer to ⇒ “4.4 Valve Guide, Checking“, page 59 .
22 - Valve Stem Seal
❑ Replacing, refer to ⇒ “5.6 Valve Stem Seal, Replacing“, page 75 .
23 - Valve Spring
❑ Cylinder head removed: remove and install using the valve spring compressor -3362- .
❑ Cylinder head installed, refer to ⇒ “5.6 Valve Stem Seal, Replacing“, page 75 .
24 - Valve Spring Plate
25 - Valve Retainers
26 - Valve Lifter
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
❑ Checking, refer to ⇒ “4.2 Hydraulic Valve Lifters, Checking“, page 56 .
❑ Place on the running surface when setting down.

❑ Before installing, check the axial play of camshafts, refer to
⇒ Fig. ““Camshaft, Checking Axial Play““ , page 50 .
❑ Lubricate the contact surface.
27 - Intake Camshaft Bearing Cap
❑ Installation position and installation sequence, refer to ⇒ “5.5 Camshaft“, page 71 .
28 - Double Bearing Cap
❑ Must be located on the alignment sleeves.
❑ Lightly coat contact the surface with sealant -AMV 174 004 01- and follow the installation position and
sequence, refer to ⇒ “5.5 Camshaft“, page 71 .
❑ Seal the contact surfaces of the double bearing cap/cylinder head, refer to
⇒ Fig. ““Double Bearing Cap Contact Surfaces, Sealing““ , page 51 .
29 - Exhaust Camshaft Bearing Cap
❑ Installation position and installation sequence, refer to ⇒ “5.5 Camshaft“, page 71 .
30 - Exhaust Camshaft
❑ Checking axial play, refer to ⇒ Fig. ““Camshaft, Checking Axial Play““ , page 50 .
❑ Removing and installing, refer to ⇒ “5.5 Camshaft“, page 71 .
❑ Checking the radial clearance using Plastigage®:
Wear limit: 0.1 mm
❑ Run out:
Max. 0.01 mm
Refacing the Cylinder Head Sealing Surface

The refacing measurement is made via holes for cylinder head
bolts.
-a- = at least 139.2 mm
Camshaft, Checking Axial Play

♦ Dial Gauge Holder -VW 387-
♦ Dial Gauge
Measure with the valve lifters removed, chain removed and bear‐
ing caps 2 and 4 installed.

Wear limit: Max. 0.2 mm

Valve Dimensions
Note
Valves must not be ground. Only hand lapping is permitted.
Dimension Intake valve Exhaust valve

Dia. a mm 26.9 29.9
Dia. b mm 5.963 5.943
c mm 104.84 to 105.34 103.64 to 104.14
α ∠° 45 45
Note
Worn sodium-filled exhaust valves must not be scrapped without

first being properly treated. The valves must be cut in the middle
of the shaft using a metal saw. While doing this, do not come into
contact with water. At the very most, throw 10 of the prepared
valves into a bucket filled with water. Then, move quickly away,
because a sudden chemical reaction will occur during which the
sodium is burnt away. The treated parts may then be discarded
through conventional disposal channels.
Double Bearing Cap Contact Surfaces, Sealing

– Apply a small amount of sealant -AMV 174 004 01- to the con‐
tact surfaces -arrows- on the double bearing cap. (Part num‐
bers are for reference only. Always check with your Parts
Department for the latest part number information).
Chain Tensioner or Camshaft Adjuster/Cylinder Head Contact

Surfaces, Sealing
– Apply a small amount of sealant -AMV 174 004 01- to the chain
tensioner/cylinder head or camshaft adjuster/cylinder head
sealing surfaces -arrows-. (Part numbers are for reference on‐
ly. Always check with your Parts Department for the latest part
number information).
2.3 Valve Seats, Refacing

⇒ “2.3.1 Intake Valve Seat, Refacing“, page 52
⇒ “2.3.2 Exhaust Valve Seat, Refacing“, page 53
♦ Depth Gauge

♦ Valve Seat Refacing Tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to reface or replace valve seats and valves. It is also necessary
to check the valve guides for wear. This is particularly impor‐
tant on high mileage engines. Refer to
⇒ “4.4 Valve Guide, Checking“, page 59 .
♦ Only reface valve seats enough until a perfect contact pattern
is obtained. The maximum permissible refacing dimension
must be calculated before work is carried out. If the reworking
dimension is exceeded, the function of the hydraulic lifters can
no longer be guaranteed and therefore the cylinder head
should be replaced.
The maximum permissible refacing dimension is calculated as

follows:
– Insert the valve and press it firmly against the seat.
Note
If the valve is to be replaced as part of a repair, use a new valve

for the calculation.
– Measure the gap -a- vertically between the valve stem tip and
upper edge of the cylinder head -1-.
– Calculate the Max. permissible refacing dimension from the
measured distance and minimum dimension.
Minimum dimensions: Outer intake valve 34.0 mm, center intake
valve 33.7 mm, exhaust valve 34.4 mm
Measured distance minus minimum dimension = Max. permissi‐
ble refacing dimension.
Example:
Measured distance 34.4 mm
- Minimum dimension 34.0 mm
= Max. perm. rework dimension 0.4 mm
♦ 1 Maximum allowable refacing dimension is represented in il‐
lustrations for refacing valve seats as dimension “b“.
2.3.1 Intake Valve Seat, Refacing

Di‐ Intake valve seat
men‐
sion
Dia. a mm 26.2
Dia. b mm Max. permissible rework dimension 1
c mm 1.5 to 1.8
Z Cylinder head lower edge
α 45° valve seat angle
β 30° upper correction angle
γ 60° lower correction angle

2.3.2 Exhaust Valve Seat, Refacing

Di‐ Intake valve seat
men‐
sion
Dia. a mm 29.0
b mm Max. perm. refacing dimension 1
c mm approximately 1.8
Z Cylinder head lower edge
α 45° valve seat angle
β 30° upper correction angle
γ 60° lower correction angle
♦ 1 Calculating maximum permissible refacing dimension, refer
to ⇒ page 52 .

3 Specifications

Cylinder head cover 10
Bearing cap for intake camshaft 10
Camshaft adjustment valve 1 1
3
10
Camshaft Position Sensor Hood 25
Camshaft sprocket 65
⇒ “2.2 Valvetrain Overview“, page 48 and see items
-4 and 7-


⇒ “4.1 Compression, Checking“, page 55
⇒ “4.2 Hydraulic Valve Lifters, Checking“, page 56
Engine Codes AWP and AWW Only
⇒ “4.3 Camshaft, Checking Adjustment“, page 57
⇒ “4.4 Valve Guide, Checking“, page 59
4.1 Compression, Checking

♦ Spark Plug Removal Tool -3122 B-
♦ Compression Tester -V.A.G 1763-

– Remove fuse No. 32
Note
Removing fuse No. 32 interrupts the voltage supply to the injec‐

tors.
Test Conditions
• Engine oil temperature must be at least 30 °C (86 °F).
Procedure
– Disconnect the ignition coil connectors.
– Remove the ignition coils.
– Remove the spark plugs using the spark plug removal tool
-3122 B- .
– With help from a 2nd technician, have the accelerator pedal
completely pressed.
– Check the compression pressure using the compression test‐
er -V.A.G 1763- .
Note
Using the tester, refer to the operating instructions.
– Operate the starter until the ester shows no further pressure

increase.
Compression Pressure
New Wear limit Difference between
bar positive pres‐ bar positive pres‐ cylinders
sure sure bar positive pres‐
sure
10.0 to 14.0 7.0 Max. 3.0
– Install the spark plugs using the spark plug removal tool -3122
B- and tighten them to 30 Nm.
with Engine Code AWD
– Install the ignition coils and tighten them to 10 Nm.
with Engine Codes AWP and AWW
– Install the ignition coils. Ensure the ignition coils are seated
securely.
– Check the Diagnostic Trouble Code (DTC) memory.
– Read the readiness code
– If the DTC memory was cleared or the Engine Control Module
(ECM) disconnected from the voltage supply, the readiness
code must be regenerated.
4.2 Hydraulic Valve Lifters, Checking

♦ Feeler Gauge

♦ Wooden or Plastic Wedge
Note
♦ Replace the complete valve lifter only (cannot be adjusted or

serviced).
♦ Irregular valve noises are normal while starting the engine.
Test Sequence
– Start the engine and let it run until the coolant fan has turned
on once.
– Increase the engine speed to approximately 2500 RPM for 2
minutes.
If the hydraulic valve lifters are still noisy, determine which lifter
or lifters are faulty as follows:
– Remove the cylinder head cover.
– Rotate the crankshaft clockwise until the camshaft lobe for the
valve lifter to be tested is pointing upward.
– Measure the play between the camshaft lobe and valve lifter.
– If the play is greater than 0.2 mm, replace the valve lifter. If
minimal play of 0.1 mm or no play is measured, continue the
procedure as follows:
– Lightly the press valve lifter downward with a wooded or plastic
wedge. If a 0.20 mm thick feeler gauge can be inserted be‐
tween the camshaft and valve lifter, replace the valve lifter.
Note
After installing new valve lifters, the engine may not be started for
approximately 30 minutes. The hydraulic equalization elements
must seat themselves (otherwise the valves will crash into the
pistons).
4.3 Camshaft, Checking Adjustment

Only on vehicles with engine codes AWP and AWW
The camshaft adjustment is load and speed dependent. The elec‐
trical valve for camshaft adjustment switches oil pressure onto
camshaft adjuster (mechanical adjustment mechanisms), which
adjusts the camshaft.
♦ Fault Read Out Device -V.A.G 1551- or Vehicle Diagnosis,
Testing and Information System -VAS 5051-
♦ Portable Multi-meter -V.A.G 1526 C-
♦ Connector Test Set -V.A.G 1594 C-
♦ Speed Adjuster Tool -V.A.G 1788/10-
Activation, Checking
– First check the camshaft adjuster solenoid valve activation via
the Diagnostic Test Mode (DTM).
If the control is OK:

Solenoid Valves, Checking

– Measure the resistance between the terminals of the solenoid
valve. Specification: 10 to 18 Ω (at room temperature)
If no malfunctions are found on the valve:
– Check the camshaft adjuster function.
Camshaft Adjuster, Checking Function
Test Conditions
• Coolant temperature must be at least 85 °C (185 °F) ⇒ Display
group 04, display field 3
Test Sequence
– Connect the fault read out device -V.A.G 1551- and select the
engine electronics control module with “Address word 01“.
Engine must run at idle for this. Connect the fault read out
device -V.A.G 1551- and select the Engine Control Module
(ECM).
Scan tool display:
Quick data transfer HELP
Select function XX
– Press buttons 0 and 4 for function “Initiate basic setting“ and

press Q button to confirm input.
Scan tool display:
Initiate basic setting HELP
Enter display group number XXX
– Press buttons 0 9 and 4 for “Display group number 94“ and

confirm entry with Q button.
Scan tool display: (1 to 4 = display fields)
System in basic setting 94 ->
1 2 3 4
Engine code AWW

– Adjust the engine speed using the speed adjuster tool -V.A.G
1788/10- to 1800 to 2200 RPM.
– Hold the speed at 1800 to 2200 RPM until the display in display
field 3 goes from “Test OFF“ to “Test ON“.
– Continue to hold the speed at 1800 to 2200 RPM until the
specified value “Syst. OK“ is shown in display field 3.
Reading results as described:
– Remove the speed adjuster tool -V.A.G 1788/10- from the gas
pedal.
Engine code AWP
– Press the brake pedal and hold firmly.
– Press the gas pedal to Wide Open Throttle (WOT) position.
The engine speed is raised to approximately 2300 RPM by the
ECM.
– Hold the brake and gas pedal down until the display in display
field 3 goes from “Test OFF“ to “Test ON“.
– Continue to hold the brake and gas pedal until the specified
value “Syst. OK“ is shown in display field 3.
Reading results as described:

– Release the brake and gas pedals.

– Press → key.
Scan tool display:
Select function XX
– Press buttons 0 and 6 for function “End output“ and press

Q button to confirm input.
– Turn the ignition off.

If “Syst. not OK“ is shown in display field 3, read out DTC memory.
The following malfunctions can take place with malfunction code
17927:
The camshaft adjuster solenoid valve switches oil pressure cor‐
rectly on mechanical camshaft adjuster but it cannot reach its end
position (e.g. due to difficulty in moving).
– Replace the camshaft adjuster.
– Check the DTC memory.
– Read the readiness code.
– If the DTC memory was cleared or the ECM disconnected from
the voltage supply, the readiness code must be regenerated.
– Repeat function test.
If the specified value is not obtained again:
– Replace the ECM. Refer to ⇒ Fuel Injection and Ignition; Rep.
Gr. 24 ; Removal and Installation .
4.4 Valve Guide, Checking

♦ Dial Gauge
Test Sequence
– Insert a new valve into the guide. The valve stem tip must be
flush with the guide. Due to the slight difference in stem di‐
mensions, ensure that only an intake valve is used in the intake
guide and an exhaust valve in the exhaust guide.
– Determine the tilt clearance. Wear limit: 0.8 mm
If the tilt clearance is exceeded:
– Replace the cylinder head.


⇒ “5.1 Toothed Belt“, page 60
⇒ “5.2 Cylinder Head“, page 64
⇒ “5.3 Camshaft Gear Oil Seal“, page 67
⇒ “5.4 Camshaft Position Sensor Seal“, page 69
⇒ “5.5 Camshaft“, page 71
⇒ “5.6 Valve Stem Seal, Replacing“, page 75
5.1 Toothed Belt

♦ Engine Support Bridge -10-222 A-
♦ Bracket for Engine -10-222 A/1-
♦ Retainer -3180-
♦ Tensioning Bolt -T10092-
♦ Locking Pin -T40011-
♦ Liquid Locking Fluid -D 000 600 A2-

Toothed Belt, Tensioning

– Tension the toothed belt. To do this, remove the locking pin -
T40011- and remove the tensioning bolt -T10092- .
– Rotate the crankshaft twice and check if the marks on the
camshaft and crankshaft still align with their reference points.
– Install the vibration damper bolt. Tightening specification: 25
Nm
– Install the center part of the toothed belt cover (install the bolts
using liquid locking fluid -D 000 600 A2- .) (Part numbers are
for reference only. Always check with your Parts Department
for the latest part number information). Tightening specifica‐
tion: 10 Nm
– Install the toothed belt cover - upper part.
– Install the engine mount. Tightening specifications, refer to
⇒ “2.1 Engine Mount Tightening Specifications“, page 5 .
– Install the tensioner for the ribbed belt. Tightening specifica‐
tion: 25 Nm
– Install the ribbed belt. Refer to ⇒ “5.1 Ribbed Belt“, page 36 .
Removing
– Read the safety precautions before beginning work. Refer to
⇒ “1.1 Safety Precautions“, page 109 .
– Observe the rules for cleanliness. Refer to
⇒ “1.2 Clean Working Conditions“, page 110 .
– Remove the right headlamp. Refer to ⇒ Electrical Equipment;
Rep. Gr. 94 ; Removal and Installation .
– Remove the air guide pipe between the turbocharger and
charge air cooler.
– Remove the ribbed belt tensioning element.
Engine Installed
– Position the crankshaft at Top Dead Center (TDC) cylinder 1

(with a manual transmission).

– Position the crankshaft at TDC cylinder 1 (with a automatic

transmission).
Engine Removed
– Position the vibration damper to TDC cylinder 1 -arrows-.

– Remove the coolant expansion tank and set aside.
– Remove the power steering fluid reservoir and set aside.
– Remove the vacuum line to the throttle valve connection.
– Remove the upper toothed belt guard.
– Install the engine support bridge -10-222 A- with the bracket

for engine -10-222 A/1- .
– Engage the retainer -3180- to the right lifting eye and tighten
on cylinder head and lightly pre-tension the engine.
– Remove the engine mount bolts -arrows- and completely re‐

move the mount.
– Remove the engine mount bracket from the cylinder block.

– Remove the vibration damper.

– Remove the lower and middle toothed belt cover.
– Mark the rotation direction of the toothed belt.
– Install the tensioning bolt -T10092- into the tensioning device

for the toothed belt.
– If necessary, align the pressure piston before tensioning, us‐
ing needle nose pliers or a thin wire (hole in pressure piston
and hole in housing must line up).
– The tension pressure the piston is just enough that the pres‐
sure piston can be secured using the locking pin -T40011- .
– Remove the toothed belt.
– Turn the crankshaft back slightly.
Installing
Note
When turning the camshaft, the crankshaft must not be at TDC.

Valves and/or pistons may be damaged.
A - Toothed Belt Completely Removed

If the toothed belt was only removed from the camshaft gear, refer
to ⇒ page 64 .
Conditions
• The pistons must not be positioned at TDC.
Procedure

– Align the mark on the camshaft gear with the mark on the cyl‐
inder head cover.
– Place the toothed belt onto the crankshaft sprocket (observe
the rotation direction).
– Install the engine mount bracket to the cylinder block. Tight‐
ening specification: 45 Nm
Note
Before installing the engine mount bracket, insert the bolts in the
bracket.
– Install the toothed belt cover - lower part. (Insert the bolts using
liquid locking fluid -D 000 600 A2- .) (Part numbers are for
reference only. Always check with your Parts Department for
the latest part number information). Torque specification: 10
Nm
– Using a bolt, secure the vibration damper (watch locating
point).
– Turn the crankshaft to set cylinder 1 at TDC.

– Position the toothed belt on the coolant pump, tensioning roller
and camshaft gear.
– Tension the toothed belt. Refer to ⇒ page 61 .
B - Toothed Belt only Removed from the Camshaft Gear
– Align the mark on the camshaft sprocket with the mark on the
cylinder head cover.
– Place the toothed belt on the camshaft gear.
– Tension the toothed belt. Refer to ⇒ page 61
5.2 Cylinder Head

♦ Guide Pins & Handle 1112 mm -3070-


♦ Polydrive Bit and Drive Socket -3452- or -T10070- (engines
with polydrive cylinder head bolts)
Requirements
• The engine must be no more than warm to the touch.
Removing
– Observe the rules for cleanliness. Refer to
– First, check whether a coded radio is installed. If so, obtain the
anti-theft code.
– With the ignition turned off disconnect the battery Ground
(GND) cable.
– Drain coolant. Refer to
WARNING

– Disconnect the fuel supply and return lines at the connecting

points of the fuel rail.
– Seal the lines so that the fuel system is not contaminated by
dirt, etc.
– Remove the front exhaust pipe from the exhaust manifold or
turbocharger.
– Disconnect all required connections:
♦ Cooling system
♦ Crankcase ventilation
♦ Secondary Air Injection (AIR) system
♦ Turbocharger/regulation
♦ Fuel injection and ignition system
– Remove the ribbed belt tensioning element.

– Bring the camshaft gear to the mark for Top Dead Center
(TDC) cylinder 1 by turning the crankshaft. The mark on the
camshaft gear must align with the arrow -arrow- on the toothed
belt guard.
– Remove the toothed belt from the camshaft gear. Refer to
– Loosen and remove the cylinder head bolts in the specified

sequence.
Note
For polydrive cylinder head bolts, use the Polydrive bit and drive
socket -3452- or -T10070- .
– Carefully lift the cylinder head off.

Installing
Note
♦ There must be no oil or coolant in the blind holes for the cyl‐
inder head bolts in the cylinder block.
♦ Only remove the new cylinder head gasket from its packaging
immediately before installing.
♦ Handle the new gasket with extreme care. Damaging will lead
to leaks.
– Insert clean cloths into the cylinder bores so that no dirt or

abrasive powder can get between the cylinder wall and piston.
– Do not allow dirt or abrasive powder to get into the coolant
either.
– Carefully clean the cylinder head and cylinder block sealing
surfaces. Avoid introducing scratches or scoring (do not use
sandpaper with grit below 100).
– Carefully remove any metal particles, emery remains and the
cloths.


– To center, install the guide pins -3070- in the cylinder head bolt
holes 8 and 10.
– Install the new cylinder head gasket. Text (replacement part
number) must be visible.
Note
Always install new cylinder head bolts.
– Install the cylinder head with new bolts, insert the remaining 8
cylinder head bolts and hand tighten.
– Remove the guide pins -3070- through the bolt holes using the
guide pin handle. Do this by turning the handle toward the left
until the pins are free.
– Insert both remaining cylinder head bolts and then tighten
them hand tight.
– Tighten the cylinder head bolts in sequence as follows:

– Tighten all the bolts to 40 Nm.
– Then, tighten all the bolts an additional 90° (1/4) turn using a
wrench.
– Then, tighten all the bolts again an additional 90° (1/4) turn.
The rest of the installation is basically a reverse of the removal
sequence.
Fill with new coolant. Refer to
and Testing .
5.3 Camshaft Gear Oil Seal

Camshaft position sensor gasket removing and installing. Refer
to ⇒ “5.4 Camshaft Position Sensor Seal“, page 69 .
♦ Seal Puller - General Usage -2085-
♦ Retainer -3036-


Removing
camshaft gear must be flush with the mark on the cylinder
head cover.
– Remove the camshaft sprocket. To loosen the bolt, counter
hold the camshaft gear using the retainer -3036- .
– Insert the camshaft gear bolt -arrow- into the camshaft by hand
to the stop to guide the seal puller.
– Remove the inner portion of the seal puller - general usage
-2085- two rotations (approximately 3 mm) from the outer por‐
tion and secure it with the knurled thumb screw.
– Lubricate the threaded head of the seal puller - general usage

-2085- , position and screw it into the oil seal as far as possible
with forced pressure.
– Loosen the knurled thumb screw and turn the inner part
against the camshaft until the seal is removed.
Installing
Note

without a ring spring, the seal lip is designed wider). The seal lip
of this seal may not be oiled or greased. An oil seal of the old
version (with a ring spring) can be replaced by a PTFE seal - but
not the other way around.
– Before installing, remove any remaining oil from the camshaft

journal with a clean cloth.

– Install the guide sleeve -T10071/1- on the camshaft.

– Slide the oil seal over the guide sleeve onto the camshaft.
– Press in the seal until seated using the thrust sleeve -

T10071/3- . To do so, use the bolt -T10071/4- .
The rest of installation is in the reverse order of removal.
5.4 Camshaft Position Sensor Seal

♦ Seal Remover - General Usage -2085-
♦ Seal Installer -3241- (for standard version seal with ring
spring)
♦ Assembly Tool -T10071- (for PTFE version of seal)
♦ M8 x 60 Bolt
Removing
– Disconnect the connector from the Camshaft Position (CMP)
sensor -arrow-.
– Remove the housing for the sensor.
– Remove the washer and cover for the sensor.

– To guide the seal puller - general usage -2085- , thread the

adapter -2085/1- in the camshaft by hand until seated.
– Remove the inner portion of the seal puller - general usage
-2085- two rotations (approximately 3 mm) from the outer por‐
tion and secure it with the knurled thumb screw.
– Lubricate the threaded head of the seal pullet, position it and

with forced pressure screw it into the oil seal as far as possible.
– Loosen the knurled thumb screw and turn the inner part
against the camshaft until the seal is removed.
Installing
Note

without a ring spring, seal lip is designed wider). The seal lip of
this seal may not be oiled or greased. An oil seal of the old version
(with a ring spring) can be replaced by a PTFE seal - but not the
other way around.
PTFE Seal, Installing

– Before installing, remove any remaining oil from the camshaft
journal with a clean cloth.
– Place the guide sleeve -T10071/5- on the camshaft.

– Slide the seal over the guide sleeve -T10071/5- .
– Press in the seal until seated using the thrust sleeve -

T10071/3- . Use a M8 x 60 bolt -1- for this.
Seal (with a ring spring), Installing
– Lightly oil the sealing lip of the seal.

– Place the guide sleeve -3241/2- on the camshaft.

– Slide the seal over the sleeve -3241/2- .
– Press in the seal until seated using the thrust sleeve -3241/1- .
To do so, use the bolt -3241/3- .
– Insert the CMP sensor trim with notch in the intake camshaft.
– Install the washer (with cone outward) and tighten the bolt to
25 Nm.
– Install the CMP sensor housing and tighten it to 10 Nm.
– Install the toothed belt cover - upper section.
– Connect the connector to the CMP sensor -arrow-.
5.5 Camshaft
(with the cylinder head installed)
♦ Retainer -3036-
♦ Bracket for Chain Adjustment -3366-
♦ Sealant -AMV 174 004 01- (Part numbers are for reference
only. Always check with your Parts Department for the latest
part number information).
♦ Sealant -D 454 300 A2- (Part numbers are for reference only.
Always check with your Parts Department for the latest part
number information).
Removing

camshaft gear must be flush with the mark on the cylinder
head cover.
– Remove the camshaft sprocket. To loosen the bolt, counter
hold the camshaft gear using the retainer -3036- .
– Remove the sensor housing.
– Remove the washer and cover for the sensor.
– Clean the drive chain and camshaft chain sprockets -arrows-

across both bearing caps and mark the installed position with
a colored mark.
Note
♦ Do not mark the chain using a center punch or similar means!

♦ The distance between both -arrows- of the colored marks con‐
sists of 16 rollers of the drive chain.
– Secure the camshaft adjuster or chain tensioner using the

bracket for chain adjustment -3366- .
Note
Hydraulic chain tensioner can be damaged if the bracket for chain

adjustment -3366- is tightened too hard.

– First, remove bearing caps 3 and 5 from the intake and ex‐
haust camshafts.
– Remove the double bearing cap.
– Remove both bearing caps from the chain sprocket on the in‐
take and exhaust camshafts.
– Remove the bolts for the camshaft adjuster/chain tensioner.
– Alternating in a diagonal sequence, loosen the bearing caps
2 and 4 of the intake and exhaust camshafts and remove.
– Remove the intake and exhaust camshafts with a camshaft
adjuster or chain tensioner and bracket for chain adjustment
-3366- .
Installing
Note
♦ When installing the camshafts, the cam lobes for cylinder 1

must point upward.
♦ When installing the bearing caps, verify the mark on the cap
is readable from the intake side of the cylinder head.
– Place the drive chain onto both camshaft sprockets according

to the colored marks.
Note
♦ When using a new drive chain, the distance between notches

-A and B- must be 16 rollers of the chain.
♦ Illustration shows where the first and sixteenth drive chain roll‐
ers must be installed on the chain gears.
♦ Notch -A- is slightly offset inward toward the chain roller -1-
– Replace the rubber/metal seal for the camshaft adjuster or

chain tensioner and coat the hatched surface with a thin coat‐
ing of sealant -D 454 300 A2- . (Part numbers are for reference
– Insert the camshaft adjuster/chain tensioner between the drive
chain.
– Oil the running surfaces of both camshafts.
– Insert the camshafts with drive chain and camshaft adjuster/
chain tensioner into the cylinder head.
– Tighten the camshaft adjuster/chain tensioner to 10 Nm (pay
attention to the bushing).

– Alternating in a diagonal sequence, tighten the bearing caps

2 and 4 of the intake and exhaust camshafts and tighten to 10
Nm (pay attention to the bushing).
– Install both bearing caps on the chain gears of the intake and
exhaust camshafts. Check the camshaft for proper adjustment
and tighten the bearing cap to 10 Nm (pay attention to align‐
ment bushing).
– Remove the bracket for chain adjustment -3366- .
– Coat the hatched surface of the double bearing cap lightly us‐
ing sealant -AMV 174 004 01- , install and tighten to 10 Nm
(pay attention to the bushing). (Part numbers are for reference
– Install the remaining bearing cap and tighten to 10 Nm (pay
attention to the alignment bushing).
– Install the camshaft gear (thin rib toward the outside and TDC
mark visible) and tighten the bolt to 65 Nm (use the retainer
-3036- ).

– Check the position of the camshafts -arrows- to each other

again.
The rest of the installation is basically a reverse of the removal.
Note
After installing new valve lifters, the engine may not be started for
approximately 30 minutes. The hydraulic equalization elements
must seat themselves (otherwise the valves will crash into the
pistons).
5.6 Valve Stem Seal, Replacing

(with the cylinder head installed)
♦ Valve Spring Compressor -3362- and Thrust Piece -3362/1-
♦ Valve Seal Removal Tool -3364-
♦ Pressure Hose -VW 653/3-
♦ Valve Stem Seal Driver -3365-
Removing
– Remove the camshafts. Refer to ⇒ “5.5 Camshaft“, page 71 .
– Remove the valve lifters and place them on the contact surface
when setting them down. Be careful not to switch the valve
lifters.
– Remove the spark plugs using the spark plug removal tool
-3122 B- .
– Move the piston for the respective cylinder to the Bottom Dead
Center (BDC) position.

– Install the pressure hose -VW 653/3- into the spark plug
threads.
– Place the thrust piece -3362/1- into the valve spring compres‐
sor -3362- .
– Using the bolts bolted in the tool, secure the valve spring com‐
pressor -3362- to the cylinder head.
– Bring the valve spring compressor -3362- into the following
position to press the valve springs together
Outer intake valves: Lower position
Center intake valve: Upper position
Exhaust valve: Lower position
– Connect the compressed air hose to a pressure of at least 6
bar and then remove the valve springs.
– Remove the valve stem seals using the valve stem removal
tool -3364- .
Installing
– Place the plastic sleeve -A- on the valve stem to prevent dam‐
age to new the valve stem oil seal.
– Oil the sealing lip of the valve stem oil seal -B-, insert it into
the valve stem seal driver -3365- and carefully slide it onto the
valve guide.

6 Special Tools
♦ Bracket for Engine -10-222 A/1-
♦ Valve Spring Compressor -3362-
♦ Valve Seal Removal Tool -3364-
♦ Pressure Hose -VW 653/3-
♦ Engine Support Bridge -10-222 A-
♦ Retainer -3180-
♦ Tensioning Bolt -T10092-
♦ Locking Pin -T40011-
♦ Guide Pins & Handle 1112 mm -3070-
♦ Drip Tray -V.A.G 1306-
♦ Polydrive Bit and Drive Socket -3452-
♦ Seal Puller - General Usage -2085-
♦ Seal Installer -3241-
♦ Compression Tester -V.A.G 1763-
♦ Valve Stem Seal Driver -3365-
6. Special Tools 77
♦ Retainer -3036-
♦ Bracket for Chain Adjust‐
ment -3366-
V.A.G 1331-
Nm) -V.A.G 1332-

17 – Lubrication
⇒ “1.1 Engine Oil“, page 79
⇒ “1.2 Lubrication System“, page 79
1.1 Engine Oil

Oil System Capacity
For the oil capacity, refer to Fluid Capacity Tables, Rep. Gr. 03.
Engine Oil Specifications
Use engine oil conforming to VW standard 502 00. Only in ex‐
ceptional circumstances: Multi-grade oils corresponding to API-
SF or SG.
1.2 Lubrication System
Note
♦ If large quantities of metal particles or abraded material are

detected during engine repairs, it may be an indication for a
damaged crankshaft or rod bearings. To prevent further dam‐
age, perform the following steps after the repair:
♦ Carefully clean the oil passages
♦ Replace the oil injection jets
♦ Replace the oil cooler
♦ Replace the oil filter
♦ The oil level must not be above the Max. mark - danger of
damage to catalytic converter! Marks, refer to
⇒ Fig. ““Marks on the Oil Dipstick““ , page 82 .

⇒ “2.1 Lubrication System Components“, page 80
⇒ “2.2 Oil Filter Housing Overview“, page 82
2.1 Lubrication System Components
1 - Bolt
❑ 15 Nm
2 - Sealing Flange
❑ Must be located on the
alignment sleeves.
❑ Clean the sealing sur‐
face before installing.
❑ Install using silicone
sealant -D 176 404 A2-
(Part numbers are for
reference only. Always
check with your Parts
Department for the lat‐
est part number infor‐
mation).
ling, refer to
⇒ “5.3 Sealing Flange,
Belt Pulley Side“,
page 39 .
3 - Chain Tensioner with Ten‐
sioning Rail
❑ 15 Nm
❑ Check for wear.
❑ When installing, preten‐
sion the spring and in‐
stall.
4 - Chain Sprocket
❑ For the oil pump drive.
❑ Check for wear.
5 - Cylinder Block
❑ Crankshaft overview,
refer to
⇒ “2.3 Crankshaft Over‐
view“, page 23 .
❑ Piston and connecting rod overview, refer to one of the following:
⇒ “2.5 Pistons and Connecting Rod Overview, Engine Code AWD“, page 26 .
⇒ “2.6 Pistons and Connecting Rod Overview, Engine Codes AWW and AWP“, page 28 .
6 - Oil Dipstick
❑ The oil level must not be above the Max. mark!
❑ Marks, refer to ⇒ Fig. ““Marks on the Oil Dipstick““ , page 82 .
7 - Inlet Spout
❑ For the oil dipstick.
❑ For extracting oil.
80 Rep. Gr.17 - Lubrication

8 - Guide Tube
9 - Oil Spray Jet
❑ For the piston cooling.
❑ 27 Nm
11 - Bolt
❑ 15 Nm
12 - Suction Pipe
❑ Clean the strainer if dirty.
13 - O-ring
❑ Always replace.
14 - Splash Wall
15 - Bolt
❑ 15 Nm
❑ Loosen and tighten using the T-bar and socket 10 mm -3185- .
❑ Remove using socket -3249- .
16 - Oil Pan
❑ Clean the sealing surface before installing.
❑ Install using silicone sealant -D 176 404 A2- (Part numbers are for reference only. Always check with
your Parts Department for the latest part number information).
❑ Removing and installing, refer to ⇒ “5.1 Oil Pan“, page 87 .
17 - Oil Drain Plug
❑ 30 Nm
❑ If the sealing ring is leaking cut if off and replace it.
18 - Gasket
❑ Always replace.
19 - Oil Return Pipe
❑ From the turbocharger.
20 - Bolt
❑ 10 Nm
21 - Oil Pump
❑ With the pressure relief valve, 12 bar.
❑ Before installing, check to be sure both alignment bushings are present (for centering oil pump/cylinder
block).
❑ Replace if the contact surfaces and gears are scored.
22 - Chain Sprocket
❑ For oil pump.
❑ Check for wear.
23 - Bolt
❑ 25 Nm
24 - Roller Chain
❑ Check for wear.
25 - Alignment Sleeves
❑ Check for secure seating.

Marks on the Oil Dipstick

1 - MAX. mark
2 - MIN. mark
a - Area above the hatched field up to the MAX. mark: Do not add
engine oil!
b - Oil level within the hatched field: Engine oil can be added.
c - Area from the MIN. mark up to the hatched field: Add a Max.
0.5 liter of engine oil!
2.2 Oil Filter Housing Overview
1 - Locking Bolt
❑ 40 Nm
2 - Seal
❑ If the seal is leaking cut
it off and replace it.
3 - Spring
❑ For the pressure relief
valve, approximately
4 bar.
4 - Piston
❑ For the pressure relief
valve, approximately
4 bar.
5 - Gasket
❑ Always replace.
6 - Return Flow Check Valve
❑ 8 Nm
7 - Seal
❑ Slide up to the collar of
the tube.
8 - Connecting Pipe
❑ For the crankcase ven‐
tilation.
9 - Retaining Clip
❑ Check for secure seat‐
ing.
10 - Locking Bolt
❑ 15 Nm
11 - Seal
❑ If the seal is leaking cut it off and replace it.
12 - Bolt
❑ 20 Nm
13 - Oil Supply Pipe
❑ To the turbocharger.

14 - Banjo Bolt
❑ 30 Nm
15 - Gasket
❑ Always replace.
16 - Oil Pressure Switch -F1-
❑ 25 Nm
❑ Black, 1.4 bar
❑ Checking, refer to ⇒ “4.1 Oil Pressure and Oil Pressure Switch, Checking“, page 85 .
17 - Seal
❑ If the seal is leaking cut it off and replace it.
18 - Bolt
❑ Always replace.
19 - Gasket
❑ Always replace.
❑ Snaps into the tabs of the oil cooler.
20 - Oil Filter Element
❑ Remove using a tension strap.
❑ Tighten by hand.
❑ Observe the installation instructions for the oil filter.
21 - Nut
❑ 25 Nm
22 - Oil Cooler
❑ Ensure sufficient clearance to surrounding components.
❑ See the note in the ⇒ “1.2 Lubrication System“, page 79 .
❑ Coat the contact surfaces to the oil filter bracket outside seal with sealant -AMV 188 100 02- . (Part
numbers are for reference only. Always check with your Parts Department for the latest part number
information).
23 - Oil Filter Bracket
❑ With the pressure relief valve, approximately 4 bar.

3 Specifications

Sealing flange - 15
Pressure relief valve - 27
Oil pan - 15
Oil drain plug - 30
Oil return pipe - 10
Chain sprocket - 25
Chain tensioner with tensioning rail - 15
Oil filter bracket 1
- 40
- 15
- 25
- 15 + 90°
Return flow check valve - 8
Oil supply pipe - 30
Oil cooler - 25
⇒ “2.2 Oil Filter Housing Overview“, page 82 and see items
-1, 10, 16 and 18-


⇒ “4.1 Oil Pressure and Oil Pressure Switch, Checking“,
page 85
4.1 Oil Pressure and Oil Pressure Switch,

Checking
♦ Oil Pressure Gauge -V.A.G 1342-
♦ Voltage Tester -V.A.G 1527 B-
Test Conditions
• Engine oil level OK, checking. Refer to
⇒ Fig. ““Marks on the Oil Dipstick““ , page 82 .
• Engine oil temperature at least 80 °C (176 °F) (coolant fan
must start up once)
Note
Function test and servicing the optical and acoustic oil pressure
indicator: Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.

Test Sequence
– Remove the oil pressure switch and install it into the oil pres‐
sure gauge.
– Install the oil pressure gauge -V.A.G 1342- into the oil filter
bracket in place of the oil pressure switch.
– Connect the brown wire from the tester to Ground (GND).
– Connect the voltage tester -V.A.G 1527 B- using an adapter
cable from the connector test set -V.A.G 1594 C- to B+ and
the oil pressure switch. The Light Emitting Diode (LED) must
not light up.
– If the LED lights up, replace the oil pressure switch.
If the LED does not light up:
– Start the engine and let run at idle: The LED must light up at
1.2 to 1.6 bar positive pressure, otherwise replace the oil pres‐
sure switch.
– Check the oil pressure at different speeds:
2000 RPM: 2.7 to 4.5 bar
Above 2000 RPM: maximum 7.0 bar
If the specifications are not obtained:
– Correct the mechanical damage, for example, bearing dam‐
age.
– Replace the oil filter bracket with pressure relief valve or oil
pump.
At higher engine speeds the oil pressure must not exceed 7.0 bar
If the specification is exceeded:
– Check the oil passages.
– If necessary, replace the oil filter bracket with pressure relief
valve.


⇒ “5.1 Oil Pan“, page 87
5.1 Oil Pan

♦ T Bar and Socket 10 mm -3185-
♦ Socket -3249-
♦ Silicone Sealant -D 176 404 A2- (Part numbers are for refer‐
♦ Hand Drill with Plastic Brush Attachment
♦ Protective Glasses
♦ Flat Scraper
Removing
– Drain the engine oil.
Note
Observe disposal regulations!
– Remove the turbocharger oil return pipe from the oil pan.
– Loosen the oil pan bolts using the T-bar and socket 10 mm
-3185- . (Remove using the socket -3249- .)
– Remove the oil pan. Loosen the oil pan with light blows using
a rubber mallet, if necessary.
– Remove any sealant residue from the cylinder block with a flat
scraper.
– Remove any remaining sealant from the oil pan using a rotat‐
ing brush, for example, a drill with a plastic brush attachment
(wear protective glasses).
– Clean the sealing surfaces. They must be free of oil and
grease.
Installing
Note
♦ Note the expiration date of the sealant.

♦ The oil pan must be installed within 5 minutes after application
of the sealant.

– Cut off the nozzle on the tube of sealant at the front mark (dia.
of the nozzle approximately 3 mm).
– Apply the sealant to the clean sealing surfaces of the oil pan
as shown. The sealant bead must be:
♦ 2 to 3 mm thick
♦ and run on the inside of bolt holes -arrows-
Note
The sealant bead must not be thicker than specified. Otherwise,

the excess sealant could get into the oil pan and clog the strainer
in the intake line of oil pump.
– Apply the silicone sealant -D 176 404 A2- to the clean sealing
surface as indicated in the illustration. (The fig. shows the lo‐
cation of the sealant bead on the cylinder block). (Part num‐
bers are for reference only. Always check with your Parts
Department for the latest part number information).
– Install the oil pan immediately and tighten all the oil pan bolts
lightly.
Note
After installing the oil pan, allow the sealant to dry for approxi‐
mately 30 minutes. Only after then may the engine oil be added.
– Tighten the oil pan bolts to 15 Nm.

– Tighten the oil pan to transmission bolts to 45 Nm.
– Tighten the oil pan to oil return line bolts to 10 Nm.

6 Special Tools
♦ T-Bar and Socket 10 mm -3185-
♦ Socket -3249-
6. Special Tools 89
♦ Oil Pressure Gauge -V.A.G

1342-
♦ Voltage Tester -V.A.G 1527
B-
♦ Connector Test Set -V.A.G
1594 C-

19 – Cooling System
⇒ “1.1 Cooling System Components“, page 91
⇒ “1.2 Cooling System, Draining and Filling“, page 91
1.1 Cooling System Components
Caution

is followed.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.
WARNING
Hot steam may escape when opening the expansion tank.

Wear protective goggles and protective clothing to prevent
damage to eyes and scalding. Cover the cap with a cloth and
open very carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary release pressure before beginning repair
work.
♦ Hoses are secured with spring type clamps. In cases of repair
only use spring type clamps.
♦ Hose clip pliers -V.A.G 1921- or spring type clip pliers -VAS
5024 A- are recommended for installing spring clamps.
♦ When installing coolant hoses, make sure they are free of
stress and do not come into contact with other components
(observe the marks on the coolant connections and hoses).
Perform a cooling system leakage test using the cooling system

tester -V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G
1274/9- .
1.2 Cooling System, Draining and Filling

♦ Refractometer -T10007-
♦ Cooling System Charge Unit -VAS 6096-
Draining
WARNING

– Open the cap for coolant expansion tank.

– Open the drain plug -arrow- to drain the coolant from the ra‐
diator.
92 Rep. Gr.19 - Cooling System

– In addition, to drain the coolant from the engine, disconnect

the coolant hose at the oil cooler -arrow-.
Note
Observe disposal regulations!
Filling
Note
♦ Only use coolant additive G 12 (according to TL VW 774 D).

Distinguishing feature: red color
♦ G 12 must not be mixed with any other coolant additives under
any circumstances!
♦ The fluid in the reservoir is brown, G12 was mixed with another
coolant. In this case, the coolant must be replaced.
♦ G 12 and coolant additives marked in accordance with “TL
VW 774 D“ prevent frost and corrosion damage, scaling and
also raise the boiling point of the coolant. For this reason the
system must be filled all year round with frost and corrosion
protection additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Protection against frost must be assured to about -25 °C (-13
°F) (in arctic climatic countries to about -35 °C (-31 °F)).
♦ The coolant concentration must not be reduced by adding
clean water even in warmer seasons and in warmer countries.
The coolant additive portion 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
protection to about -40 °C (-40 °F), as otherwise frost protec‐
tion is reduced again and cooling effectiveness is also re‐
duced.
♦ The refractometer -T10007- is recommended for determining
anti-freeze density.
♦ If the radiator, heater core, cylinder head or cylinder head
gasket is replaced, do not reuse the old coolant.
Recommended Mixture Ratios

Frost protection Anti-freeze por‐ G 12 1 Clean water
to tion 1
-25 °C (-13 °F) 40% 2.0 l 3.0 l

-35 °C (-31 °F) 50% 2.5 l 2.5 l
♦ 1The quantity of coolant can vary depending upon vehicle
equipment.
– Tighten the drain plug in the radiator.
– Push the coolant hose onto the oil cooler connection and fas‐
ten with the spring type clamp -arrow-.
Using the Cooling System Charge Unit -VAS 6096-
– Install the adapter from the cooling system tester -V.A.G 1274-
that is appropriate for the vehicle on the expansion tank.
– Fill the coolant circuit using the cooling system charge unit -
VAS 6096- . Refer to the Operating instructions fro the cooling
system charge unit.
Without Using the Cooling System Charge Unit -VAS 6096-
Through Model Year 2001 Vehicles
– Fill the coolant to the MAX. mark on the expansion tank.

From Model Year 2002 Vehicles

– Slowly fill the coolant up to the top mark of the hatched area
on the expansion tank.
– Seal the expansion tank.
– Turn off the heater and Air Conditioning (A/C).
– Start the engine and maintain an engine speed of about 2000
RPM for approximately 3 minutes.
– Allow the engine to run until the fan turns on.
WARNING

Through Model Year 2001 Vehicles

– Check the coolant level and top off if necessary. With the en‐
gine at operating temperature, the coolant level must be at the
MAX. mark, with the engine cold, it must be between the MIN.
and MAX. marks.
From Model Year 2002 Vehicles
With the engine at operating temperature, the coolant level must
lie at the top mark of the hatched area.
When the engine is cold, the coolant level should be somewhere
in the middle of the hatched area.

⇒ “2.1 Coolant Hose Connection Diagram“, page 96
⇒ “2.2 Cooling System Components Overview, Body Side“, page
99
⇒ “2.3 Cooling System Components Overview, Engine Side“,
page 100
2.1 Coolant Hose Connection Diagram

⇒ “2.1.1 Engine Code AWD“, page 96
⇒ “2.1.2 Engine Code AWP with a Manual Transmission and
AWW with a Manual and Automatic Transmission“, page 97
⇒ “2.1.3 Engine Code AWP with a Automatic Transmission“, page
98
2.1.1 Engine Code AWD
1 - Radiator
2 - Oil Cooler
3 - Coolant Thermostat Hous‐
ing
4 - Cylinder Head/Cylinder
Block
5 - Expansion Tank
6 - Turbocharger
7 - Heater Core
9 - Transmission Oil Cooler
❑ Only with a automatic
transmission.
10 - Lower Coolant Pipe
11 - Intake Manifold
12 - Drain Plug

2.1.2 Engine Code AWP with a Manual Transmission and AWW with a Manual
and Automatic Transmission
1 - Expansion Tank
2 - Turbocharger
3 - Intake Manifold
Block
6 - Heater Core
❑ Only with engine code
AWW with a automatic
transmission.
9 - Upper Coolant Hose
10 - Drain Plug
11 - Radiator
12 - Lower Coolant Hose
13 - Oil Cooler
ing
15 - Coolant Pump
16 - Coolant Pipe

2.1.3 Engine Code AWP with a Automatic Transmission
1 - Expansion Tank
2 - Turbocharger
3 - Intake Manifold
Block
5 - Coolant Pipe
7 - Heater Core
❑ Only with a automatic
transmission.
10 - Oil Cooler
12 - Radiator
14 - After-Run Coolant Pump -
V51-
ing
16 - Coolant Pump

2.2 Cooling System Components Overview, Body Side
1 - Radiator
ling, refer to
⇒ “5.1 Radiator“,
page 104 .
❑ After replacing, replace
the entire amount of
coolant.
2 - O-ring
❑ Secured to the radiator
with a retaining clip.
❑ Ensure it is seated se‐
curely.
❑ Coolant hose connec‐
tion diagram, refer to
⇒ “2.1 Coolant Hose
Connection Diagram“,
page 96 .
4 - Fan Shroud
5 - Bolt/Nut
❑ 10 Nm
6 - Auxiliary Fan
optional equipment.
7 - Bracket
8 - Retaining Clip
❑ Check for secure seat‐
ing.
9 - Connector
10 - Fan
11 - Bracket
❑ For the fan connector.
❑ Secured to the radiator with a retaining clip.
❑ Ensure it is seated securely.
❑ Coolant hose connection diagram, refer to ⇒ “2.1 Coolant Hose Connection Diagram“, page 96 .
13 - O-ring
❑ Always replace.
14 - Coolant Fan Control Thermal Switch -F18-
❑ 35 Nm
❑ For the electric fan.
❑ Switch temperatures:
❑ 1st stage on: 92 to 97 °C (198 to 206 °F), off: 84 to 91 °C (183 to 196 °F).
❑ 2nd stage on: 99 to 105 °C (210 to 221 °F), off: 91 to 98 °C (196 to 208 °F).
15 - Bracket
❑ For the radiator.

16 - Bolt
❑ 15 Nm
2.3 Cooling System Components Overview, Engine Side
1 - Bolt
❑ 15 Nm
2 - Toothed Belt
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning, refer to
page 60 .
3 - Coolant Pump
❑ Check for ease of move‐
ment.
❑ If damaged or leaking
replace completely.
ling, refer to
⇒ “5.2 Coolant Pump“,
page 104 .
4 - O-ring
❑ Always replace.
5 - Coolant Thermostat
❑ Checking: Heat up the
thermostat in water.
❑ Opening begins approx‐
imately 87 °C (188 °F).
❑ Ends approximately 102
°C (216 °F).
❑ Opening lift a MIN. of 7
mm.
6 - O-ring
❑ Always replace. Volkswagen Technical Site: http://vwts.ru http://vwts.info
8 - to the Heater Core
9 - O-ring
❑ Always replace.
10 - Connector
❑ 4 pin
11 - Engine Coolant Temperature Sensor -G62-
❑ With the engine coolant temperature gauge sensor -G2- .
❑ For the Engine Control Module (ECM).
❑ If necessary, release the pressure in the cooling system before removing.

❑ Checking, refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis and Testing .
12 - Retaining Clip
15 - Oil Cooler
16 - from the Heater Core
18 - Bolt
❑ 10 Nm
19 - Cap
❑ Check using the cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- .
❑ Test pressure: 1.4 to 1.6 bar positive pressure.
20 - Seal
21 - Bolt
❑ 10 Nm
22 - Expansion Tank
❑ Perform the cooling system leakage test using the cooling system tester -V.A.G 1274- and adapter -
V.A.G 1274/8- .
23 - to the Turbocharger
24 - Bolt
❑ 15 Nm
25 - to the Top Coolant Hose
❑ Only on engine code AWP with a automatic transmission.
26 - After-Run Coolant Pump -V51-
❑ Checking, refer to ⇒ “4.1 After-Run Coolant Pump, Checking“, page 103 .
27 - from the Turbocharger

3 Specifications

Fan shroud - 10
Coolant Fan Control Thermal Switch -F18- - 35
Bracket for radiator - 15
Toothed belt - 15
Lower coolant line - 10
Expansion tank - 10
Connecting piece - 15


⇒ “4.1 After-Run Coolant Pump, Checking“, page 103
4.1 After-Run Coolant Pump, Checking

♦ Wiring Diagram
Test Conditions
• All fuses must be OK.
Test Sequence
– Disconnect the 2-pin connector from the after-run coolant
pump -V51- .
– Connect the contacts from the after-run coolant pump to the

battery, using adapter cables from the connector test set -
V.A.G 1594 C- . The after-run coolant pump must start run‐
ning.
If the after-run coolant pump does not start running:
– Replace the after-run coolant pump.
If the after-run coolant pump does starts running:
– Turn the ignition off and then on again.
– Connect the voltage tester -V.A.G 1527 B- to the disconnected

connector of the after-run coolant pump, using adapter cables
from the connector test set -V.A.G 1594 C- . The Light Emitting
Diode (LED) must light up.
Note
This test must be performed inside of 5 min. after the ignition has
been turned off.

– Determine and eliminate the open circuit according to the wir‐
ing diagrams. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations.


⇒ “5.1 Radiator“, page 104
⇒ “5.2 Coolant Pump“, page 104
⇒ “5.3 Coolant Thermostat“, page 105
5.1 Radiator
Removing
– Remove the front bumper. Refer to ⇒ Body Exterior; Rep. Gr.
63 ; Removal and Installation .
– Disconnect the coolant hoses from the radiator.
– Disconnect the harness connector from the thermal switch.
– Bring the lock carrier into the service position. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Description and Operation .
– Remove the bolts from the radiator and remove the radiator
with fans downward.
with Air Conditioning (A/C)
– Observe the additional information and removal work. Refer
to ⇒ page 104 .
Installing
Installation is in the reverse order of removal, note the following:
Additional information and assembly work on vehicles with A/C
Caution
The A/C refrigerant circuit must not be opened.
Note
To prevent damage to the A/C condenser and also to the refrig‐

erant lines/hoses, ensure that the lines and hoses are not stretch‐
ed, kinked or bent.
– Remove the retaining clamp(s) from the refrigerant lines.

– Remove the A/C condenser from the radiator and secure it to
the lock carrier.
5.2 Coolant Pump


Note
♦ Always replace gaskets and seals.

♦ The lower part of the toothed belt cover can remain installed.
♦ The toothed belt remains in position on the crankshaft sprock‐
et.
♦ Cover the toothed belt with a cloth to protect it from coolant
before removing the coolant pump.
Removing
– Remove the upper and lower sections of the toothed belt
guard. Refer to ⇒ “5.1 Toothed Belt“, page 60 .
– Remove the toothed belt from the coolant pump toothed belt
gear. Refer to ⇒ “5.1 Toothed Belt“, page 60 .
– Remove the coolant pump bolts -1- and remove the coolant
pump -2-.
Installing
– Moisten the new O-ring with coolant.
– Insert the coolant pump into the cylinder block and tighten the
bolts. Tightening specification: 15 Nm
Note
The coolant pump sealing plug faces downward.
– Install the ribbed belt. Refer to ⇒ “5.1 Ribbed Belt“, page 36 .
5.3 Coolant Thermostat


Removing
Note
Always replace gaskets and seals.

– Disconnect the coolant hose from the connecting piece -3-.
– Remove the bolts -4- from the connecting piece -3- and re‐
move the connecting piece -3- with the thermostat -1-.
Installing
– Moisten the new O-ring -2- with coolant.
– Insert the thermostat -1- in the connecting piece -3- and turn
it 90° (1/4) to the right.
– Insert the connecting piece -3- with thermostat -1- into the en‐
gine block.
Note
The clip of the thermostat must be positioned at approximately a

right angle.
– Tighten the bolts -4-. Tightening specification: 15 Nm


6 Special Tools
♦ Drip Tray for VAS 6100 -VAS 6208-
♦ Cooling System Charge Unit -VAS 6096-
6. Special Tools 107

♦ Drip Tray -V.A.G 1306-
V.A.G 1331-
♦ Spring-Type Clip Pliers -
VAS 5024 A-

20 – Fuel Supply
⇒ “1.1 Safety Precautions“, page 109
⇒ “1.2 Clean Working Conditions“, page 110
⇒ “1.3 Fuel Supply System“, page 110
⇒ “1.4 Crash Fuel Shut-Off Function“, page 110
⇒ “1.5 Electronic Power Control System Function“, page 111
⇒ “1.6 Leak Diagnosis, Function“, page 111
⇒ “1.7 EVAP System“, page 112
1.1 Safety Precautions
Caution

is followed.
Always observe the following when removing and installing the

fuel level sensor or the fuel pump (fuel delivery unit) from a full or
partially filled fuel tank:
WARNING

♦ Before starting work, turn on the exhaust extraction system

and place an extraction hose close to the opening in the fuel
tank to extract escaping fuel 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 fuel from contacting skin! Wear fuel resistant gloves!

– For safety reasons, fuse No. 28 must be removed from the

fuse holder before opening the fuel system as the fuel pump
can be activated by the door contact switch in the driver's door.
1.2 Clean Working Conditions

When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules“ of cleanliness:
♦ Thoroughly clean all connections and the surrounding area
before disconnecting.
♦ Place parts that have been removed on a clean surface and
cover them using lint free cloths!
♦ Carefully cover or seal opened components, if repairs are not
performed immediately.
♦ Only install clean components: Only unpack replacement
parts immediately prior to installation. Do not use parts that
have been stored loose (for example, in a tool box, etc.).
♦ When the system is open: Avoid working with compressed air
if possible. Do not move the vehicle unless absolutely neces‐
sary.
1.3 Fuel Supply System
Note
♦ Hose connections are secured with either spring type or clamp

type clamps.
♦ Always replace clamp type clamps with spring type clamps.
♦ Fuel hoses at the engine must only be secured with spring type
clamps. The use of clamp or screw type clamps is not permis‐
sible.
♦ Sporing type clip pliers -VAS 5024 A- or hose clip pliers -V.A.G
1.4 Crash Fuel Shut-Off Function

Vehicles with an airbag are equipped with a crash fuel shut-off
system. It reduces the danger of a fire in a crash as the fuel pump
is switched off via the fuel pump relay. At the same time, with this
set-up, an improvement in the comfort of engine startability is also
attained. When opening the door, the fuel pump is activated for 2
seconds to build pressure in the fuel system.
When opening fuel system:
Observe the safety precautions. Refer to
– Check the fuel pump relay according to the wiring diagram
using the test system -V.A.G 1466 A- ⇒ Wiring diagrams,
Troubleshooting & Component locations.
110 Rep. Gr.20 - Fuel Supply

1.5 Electronic Power Control System Func‐

tion
For Electronic Power Control (EPC), the throttle valve is not op‐
erated by a cable from the accelerator pedal. There is no me‐
chanical connection between the gas pedal and the throttle valve.
The position of the accelerator pedal is transmitted to the Engine
Control Module (ECM) via two accelerator pedal position sensors
(adjustable resistances, accommodated in one housing), that are
connected to the accelerator pedal.
The position of the accelerator pedal (driver controlled) is a main
input for the ECM.
Operation of the throttle valve occurs via an electric motor (throttle
valve actuator) in the throttle valve control module. This applies
across the entire engine speed and engine load spectrum.
The throttle valve is operated by the throttle drive according to the
instructions of the ECM.
With the engine at a standstill and the ignition turned on, the ECM
activates the throttle valve actuator precisely according to the
specifications of the Throttle Position (TP) sensor. This means, if
the accelerator pedal is pressed half way, the throttle drive opens
the throttle valve to the same degree; for example throttle valve
is then opened approximately half way.
With the engine running (under load) the ECM can open and close
the throttle valve independently of the accelerator pedal position
sensor.
This means, for example, that the throttle valve could be fully
opened even though the accelerator pedal has only been pressed
half way. This has the advantage of preventing torque losses at
the throttle valve.
Aside from that, it results in clearly better pollutant output and
consumption values under certain load conditions.
The necessary engine torque can be produced by the ECM via
the optimal combination of throttle valve profile and charge pres‐
sure.
It would be incorrect to think that “EPC“ consists of only one or
two components. EPC is much more of a system containing all
components that contribute to recognizing, controlling and moni‐
toring the position of the throttle valve, for example, sensor for
accelerator pedal position, throttle valve control module, EPC
warning lamp, ECM.
Observe safety precautions. Refer to
Observe rules for cleanliness. Refer to
1.6 Leak Diagnosis, Function

The Evaporative Emission (EVAP) system (including fuel tank) is
equipped with leak diagnosis. The leak diagnosis will detect
whether the system is leaking.
The diagnosis operates by pressurizing the system and should
detect leaks where the damage exceeds 1 mm in diameter.
During the diagnostic, the leak detection pump -V144- generates
a positive pressure of approximately 30 mbar in the EVAP system.
The pump will switch off when the pressure is attained. When the
pressure falls to below a certain figure, the pump will switch on
again. On Board Diagnostic (OBD) monitors the switch intervals

and stores a Diagnostic Trouble Code (DTC) in the DTC memory

if the intervals are too short.
1.7 EVAP System
Note
♦ Hose connections are secured with either spring type or clamp

type clamps.
♦ Always replace clamp type clamps with spring type clamps.
♦ Hose clip pliers -V.A.G 1921- or spring type clip pliers -VAS
5024 A- are recommended for installing spring clamps.


⇒ “2.1 Fuel Tank and Attachments Overview“, page 113 .
⇒ “2.2 Electronic Engine Power Control Components Overview“,
page 116
⇒ “2.3 Meaning of Electronic Power Control Warning Lamp in In‐
strument Cluster“, page 116
⇒ “2.4 EVAP System Function“, page 117
⇒ “2.5 EVAP System Overview“, page 118
⇒ “2.6 EVAP System Routing Diagram“, page 119
2.1 Fuel Tank and Attachments Overview
1 - Cap
2 - Seal
3 - Bolt
4 - Tank Flap Unit
❑ With a rubber gasket.
5 - Vent Line
❑ Black
curely.
❑ Clipped in at the top of
the fuel tank.
6 - Ground (GND) Connection
curely.
7 - Vent Line
❑ White
curely.
8 - Gravity Valve
❑ To remove the valve,
unclip upward out of the
support.
❑ Check the valve for
through flow:
❑ Valve vertical: open,
valve angled at 45°:
Closed.
9 - Seal
10 - Switch-Over Valve
❑ To remove the valve, unclip sideways out of the support.
❑ Before installing, remove the cap -item 1-.
❑ Checking, refer to ⇒ Fig. ““Checking the Switch-Over Valve““ , page 115 .
11 - Vent Line
❑ Black

12 - Pressure Retention Valve

❑ Checking, refer to ⇒ Fig. ““Checking the Pressure Retaining Valve““ , page 116 .
13 - Vent Line
❑ Black
14 - Fuel tank
❑ Support using the engine-/gearbox jack -V.A.G 1383 A- when removing.
❑ Removing and installing, refer to ⇒ “5.3 Fuel Tank“, page 144 .
15 - Lock Washer
16 - Heat Shield
❑ For the fuel tank.
17 - Bolt
❑ 25 Nm
18 - Nut
❑ 2 Nm
19 - Fuel Tank Cover
20 - Securing Strap
❑ Observe the varying lengths.
❑ Installed location: Locating point (hole) points in the driving direction.
21 - Supply Line
❑ Black
❑ To remove from the fuel filter, press the release buttons on the connecting piece.
❑ To the fuel supply line at fuel rail, refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Description and
Operation .
22 - Fuel Filter
❑ Installed location: The arrow points in the direction of flow.
23 - Screw Clamp
24 - Vent Line
❑ White
❑ Clipped to the side of the fuel tank.
25 - Seal
❑ To install, place into the opening of the fuel tank dry.
❑ Only coat with fuel when installing the fuel delivery unit flange.
26 - Fuel Delivery Unit
❑ Installation location on the fuel tank, refer to
⇒ Fig. ““Installed Position of the Fuel Delivery Unit Flange““ , page 115 .
❑ Removing and installing, refer to ⇒ “5.1 Fuel Delivery Unit“, page 143 .
❑ Fuel level sensor removing and installing, refer to ⇒ “5.2 Fuel Level Sensor“, page 144 .
❑ Checking the fuel pump, refer to ⇒ “4.1 Fuel Pump, Checking“, page 121 .
❑ Clean the strainer if dirty.
27 - Lock Nut
❑ 75 Nm
❑ Use the ring nut spanner -3217- for removal and installation.

28 - Supply Line
❑ Black
❑ To remove from the flange and fuel filter, press the release buttons on the connecting piece.
29 - Return Line
❑ Blue or with a blue mark.
❑ To remove from the flange, press the release buttons on the connecting piece.
❑ From the fuel return line at fuel rail, refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Description and
Operation .
30 - Connector
❑ Black, 4-pin
❑ For the fuel level sensor -G- and transfer fuel pump -G6- .
31 - Bolt
❑ 10 Nm
Installed Position of the Fuel Delivery Unit Flange

The mark on the sensor must align with the mark on the fuel tank
-arrows-.
Blue or blue marked return line -1- to the connection with identi‐
fication -R-.
Black supply line -2- to connection with designation -V-.
Note
After installing the fuel pump flange, check whether the supply,
return and ventilation lines are still clipped in at the fuel tank.
Checking the Switch-Over Valve

Lever in rest position: Closed
Lever pushed in the direction of the - arrow-: Open
Note
Before installing the switch-over valve, remove the cover from the
fuel tank.

Checking the Pressure Retaining Valve

The pressure retention valve is opened for flow in both directions
-arrow 1- by the Evaporative Emission (EVAP) canister and EVAP
canister purge regulator valve 1 -N80- .
It is only opened in one flow direction -arrow 2- on the side of
gravity valve.
2.2 Electronic Engine Power Control Components Overview
1 - Bracket
ling, refer to ⇒ Brake
System; Rep. Gr. 46 ;
Removal and Installa‐
tion .
2 - Connector
❑ Black, 6-pin.
3 - Bolt
❑ 10 Nm
4 - Accelerator Pedal Position
Sensor -G79- and Accelerator
Pedal Position Sensor 2 -
G185-
❑ Not adjustable.
❑ The sensor transmits
driver control to the En‐
gine Control Module
(ECM).
❑ To remove, remove the
instrument panel and
pedal assembly cover.
⇒ “4.2 Accelerator Ped‐
al Position Sensor and
Accelerator Pedal Posi‐
tion Sensor 2, Check‐
ing“, page 126 .
❑ If replaced, adapt the
automatic transmission
control module.
5 - Bracket
❑ For the foot well cover.
❑ Version through model
year 2001 is illustrated.
❑ Clipped onto the sensor.
2.3 Meaning of Electronic Power Control

Warning Lamp in Instrument Cluster
“EPC“ is an abbreviation and stands for Electronic Power Control,
also known as electronic performance regulation.

After turning on the ignition, the Engine Control Module (ECM)

checks the function of all components used by the EPC system.
If malfunctions are detected in the EPC system during engine op‐
eration, the ECM switches on the EPC warning lamp. (These
Diagnostic Trouble Codes (DTCs) are identified in the DTC ta‐
bles). The malfunction is stored in the DTC memory of the ECM
at the same time.
EPC warning lamp location
2.4 EVAP System Function

Depending upon air pressure and ambient temperature - more or
less fuel vapors will form in the fuel tank.
The Evaporative Emission (EVAP) system prevents these Hy‐
drocarbon (HC) emissions from entering the atmosphere.
With quantity restrictions, fuel vapors travel from the highest point
of the tank via the gravity valve (closed at a tilt of 45°) and the
pressure retention valve to the EVAP canister.
The activated charcoal in the canister stores these gases like a
sponge.
While driving, with oxygen sensor control active (engine is warm),
the EVAP canister purge regulator valve 1 -N80- , is activated by
the Engine Control Module (ECM) in pulses dependent on load
and engine speed. The opening time is dependent on input sig‐
nals.
When purging (recovery of the activated charcoal), the suction
tube vacuum sucks fresh air in through the ventilation opening on
the underside of the EVAP canister. The fuel vapors stored
amongst the activated charcoal and fresh air are proportionately
supplied to be burned.
The pressure retention valve prevents fuel vapors from being
sucked out of the tank when the EVAP canister purge regulator
valve 1 is opened and an intake manifold vacuum is present. It
therefore ensures that the evacuation of the EVAP canister has
priority.
When no voltage is applied (for example, an open circuit), the
solenoid valve is closed. The EVAP canister is not purged.
The vacuum line from throttle valve control module to EVAP can‐
ister is also connected with crankcase ventilation valve via a
bypass. The check-valve integrated there prevents intake air from
entering the crankcase in certain partial throttle ranges. Thereby
the crankcase ventilation is altogether improved. The bypass en‐
sures crankcase ventilation.

2.5 EVAP System Overview
Note
♦ Components marked with a * are checked via On Board Di‐

agnostic (OBD).
♦ Components marked with a ** are checked via output Diag‐
nostic Test Mode (DTM).
1 - from the EVAP Canister

Purge Regulator Valve 1 -N80-
*/**
2 - Seal
3 - Vent Line
5 - Connector
❑ 3-pin
6 - Vacuum Line
❑ To the throttle valve
control module.
7 - Leak Detection Pump -
V144- */**
❑ Under the right rear
wheel housing liner.
⇒ “4.5 Leak Detection
Pump, Checking“,
page 134 .
8 - Connecting Hose
❑ Pressure side.
9 - Screw
❑ 3 Nm
10 - Air Filter for the Leak De‐
tection Pump
11 - Connecting Hose
❑ Suction side.
12 - Bracket
13 - Bolt
❑ 10 Nm
14 - EVAP Canister
❑ Under the right rear wheel housing liner

2.6 EVAP System Routing Diagram
1 - Tank Flap Unit

2 - Fuel Tank
3 - Fuel Delivery Unit
4 - Intake Tube
5 - Throttle Valve Control Mod‐
ule -J338-
6 - Intake Manifold
7 - Fuel Rail with Injectors
8 - Fuel Pressure Regulator
9 - Fuel Filter
❑ Installed location: The
arrow points in the direc‐
tion of flow.
10 - EVAP Canister Purge
Regulator Valve 1 -N80-
❑ Check the activation.
❑ Function, checking, re‐
fer to
⇒ “4.3 Evaporative
Emission Canister
Purge Regulator Valve,
Checking“, page 129 .
11 - Test Connection
12 - Gravity/Expansion Valve
13 - Pressure Retention Valve
14 - Switch-Over Valve
15 - EVAP Canister
❑ Under the right rear
16 - Leak Detection Pump -V144-
❑ Check the activation.
17 - Air Filter for the Leak Detection Pump

3 Specifications

Heat shield for fuel tank - 25
Securing strap - 25
Cover to securing strap nut - 2
Fuel delivery unit lock ring - 75
Fuel tank - 10
Air filter for Leak detection pump -V144- - 3


⇒ “4.1 Fuel Pump, Checking“, page 121
⇒ “4.2 Accelerator Pedal Position Sensor and Accelerator Pedal
Position Sensor 2, Checking“, page 126
⇒ “4.3 Evaporative Emission Canister Purge Regulator Valve,
Checking“, page 129
⇒ “4.4 EVAP System, Checking for Leaks“, page 131
⇒ “4.5 Leak Detection Pump, Checking“, page 134
⇒ “4.6 EVAP System, Checking with Tester KLI 9210“,
page 136
4.1 Fuel Pump, Checking

⇒ “4.1.1 Function and Voltage Supply, Checking“, page 122
⇒ “4.1.2 Delivery Rate, Checking“, page 123
⇒ “4.1.3 Fuel Pump Check Valve, Checking“, page 125
♦ Ring Nut Spanner -3217-
♦ Fuel Inj. Pressure Gauge-CIS -V.A.G 1318-
♦ Pressure Gauge Adapter -V.A.G 1318/1-
♦ Adapter -V.A.G 1318/11-
♦ Pressure Gauge Adapter -V.A.G 1318/17-
♦ Fuel Line Feed Adapter -V.A.G 1318/23-
♦ Injection Rate Comparison Meter -V.A.G 1348-
♦ Test System -V.A.G 1466 A-
♦ Connector Test Set -V.A.G 1594 A- or -V.A.G 1594 C-
♦ Multi-meter -V.A.G 1715-
♦ Measuring Container
♦ Wiring Diagram
Test Conditions
• Fuse No. 28 is OK
• Battery voltage must be at least 11.5 volts.
• All electrical consumers such as, for example, lights and rear
window defogger, must be turned off.
• If the vehicle is equipped with Air Conditioning (A/C), it must
be turned off.
Note
Observe the description of the crash fuel shut-off function. Refer

to ⇒ “1.4 Crash Fuel Shut-Off Function“, page 110 .

4.1.1 Function and Voltage Supply, Checking
Note
In the continuing work procedure, it is possibly necessary to dis‐

connect the battery Ground (GND) cable. Check whether a coded
radio is installed. If so, obtain the anti-theft code beforehand.
– Remove the cover from fuel delivery unit.

– Briefly operate the starter. The fuel pump must run audibly.
– Turn off the ignition.
If fuel pump does not activate:
– Remove the cover from the front fuse holder.
– Pull fuse No. 28 from the fuse holder.
– Connect the remote control -V.A.G 1348/3A- with the adapter
cable -V.A.G 1348/3-2- to the contact 28a to fuel pump and
battery positive (+).
– Operate the remote control -V.A.G 1348/3A- .
If the fuel pump is activated:
– Check the fuel pump relay according to the wiring diagram
using the test system -V.A.G 1466 A- . Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Component locations.
If the fuel pump is not activated:
– Disconnect the 4-pin connector from the flange at the fuel de‐
livery unit.
– Connect the voltage tester -V.A.G 1527 B- using adapter ca‐

bles from the connector test set -V.A.G 1594C- to the outer
terminals of the connector.
– Operate the remote control. The Light Emitting Diode (LED)
must light up.
– Locate and repair the open circuit in the wiring using the wiring
diagram. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.
If the LED lights up (the voltage supply is OK):
– Use the ring nut spanner -3217- to remove the lock nut.
– Check if the electrical wiring between the flange and fuel pump
is connected.
If no open circuits are found:
– The fuel pump is faulty, replace the fuel delivery unit. Refer to
⇒ “5.1 Fuel Delivery Unit“, page 143 .

4.1.2 Delivery Rate, Checking

Test Conditions
• The voltage supply is OK.
• The remote control -V.A.G 1348/3A- is connected.
Test Sequence
– Remove the fuel filler cap from the fuel filler tube.
WARNING

– Disconnect the fuel supply line -1- and catch any leaking fuel
using a cloth.
– Connect the fuel inj. pressure gauge-CIS -V.A.G 1318- with

the fuel line feed adapter -V.A.G 1318/23- and the pressure
gauge adapter -V.A.G 1318/17- to the fuel supply line.
– Connect the pressure gauge adapter -V.A.G 1318/1- to the
adapter -V.A.G 1318/11- on the fuel inj. pressure gauge-CIS
-V.A.G 1318- and hold it in a measuring container.
– Open the shut-off lever on the fuel inj. pressure gauge-CIS -
V.A.G 1318- . The lever will point in the direction of flow -A-.
– Operate the remote control -V.A.G 1348/3A- . Slowly close the
shut-off lever, until the pressure gauge shows 3 bar. From this
point on do not move the position of the shut-off lever.
– Empty the measuring container.
– The delivery rate of the fuel pump is dependent on battery
voltage. Therefore, connect a multi-meter to the vehicles bat‐
tery using adapter cables from the connector test set -V.A.G
1594 C- .
– Operate the remote control for 30 seconds and measure the
battery voltage.

– Compare the quantity of fuel delivered with the specification.

*) Minimum delivery rate cm3/30 s
**) Voltage at fuel pump with engine off and pump running (ap‐
proximately 2 volts less than battery voltage).
Example
During the test, a voltage of 12.5 volts is measured at the battery.
Since voltage at the pump is approximately 2 volts less than bat‐
tery voltage, there is a minimum delivery rate of 200 cm3/30 s.
If the minimum delivery rate is not attained
– Check the fuel lines for possible restrictions (kinks) or block‐
ages.
WARNING

– Disconnect the supply line -1- from the inlet on the fuel filter.
– Connect the fuel inj. pressure gauge-CIS -V.A.G 1318- with
the adapter -V.A.G 1318/17- to the fuel supply line.
– Repeat the delivery rate check.
If the minimum delivery rate is now obtained
– Replace the fuel filter:
If the minimum delivery rate is again not obtained
– Remove the fuel delivery unit and check the filter strainer for
dirt.
Only when up to now no malfunction has been detected:
– The fuel pump is faulty, replace fuel delivery unit. Refer to
(ECM) was disconnected from the voltage supply, the readi‐
ness code must be regenerated.
If the delivery rate has been obtained, but malfunctions are still
suspected in the fuel supply, for example sporadic loss of fuel
supply:
– Check the current draw of the fuel pump as follows:
– Reconnect all disconnected fuel lines.

– Connect the multi-meter -V.A.G 1715- with a current clamp to

wire for the 4-pin connector terminal 1 -arrow- on the wiring
harness.
– Start the engine and run at idle speed.
– Measure the current draw of the fuel pump. Specified value:
Max. 8 amps.
Note
If the malfunction in the fuel system is sporadic, the test can also
be performed during a road test, but a second person is required.
If the current draw is exceeded:

– If the DTC memory was cleared or the ECM was disconnected
from the voltage supply, the readiness code must be regen‐
erated.
4.1.3 Fuel Pump Check Valve, Checking

Test Conditions
• The remote control -V.A.G 1348/3A- is connected.
• The fuel inj. pressure gauge-CIS -V.A.G 1318- is still connec‐
ted.
Test Sequence
Note
This test also checks the connections of the fuel supply line from
fuel delivery unit to the connection point of the fuel inj. pressure
gauge-CIS -V.A.G 1318- for proper sealing.

– Close the fuel inj. pressure gauge-CIS -V.A.G 1318- shut-off

lever (lever is at right angle to the direction of flow position
-B-).
– Operate the remote control at short intervals, until a pressure
of approximately 3 bar has built up.
WARNING
Danger of spraying when opening the shut-off lever; wear pro‐

tective goggles and protective clothing to prevent injuries and
contact with skin. Hold the container in front of the free con‐
nection from the fuel inj. pressure gauge-CIS -V.A.G 1318- .
– If pressure builds up too high, lower the excess pressure by

carefully opening the shut-off lever.
– Watch the pressure drop on the gauge. After 10 minutes the
pressure must not drop below a 2.5 bar decrease.
If the pressure drops further:
– Check the line connections for leaks.
If no fault is detected in the wiring:
4.2 Accelerator Pedal Position Sensor and

Accelerator Pedal Position Sensor 2,
Checking
♦ Multi-meter -V.A.G 1526 A- or -V.A.G 1526 C-
♦ Adapter Cable (121-pin) -V.A.G 1598/31-
♦ Wiring Diagram
Function
The accelerator pedal position sensor -G79- and accelerator ped‐
al position sensor 2 -G185- are located on the accelerator pedal
and transmit the driver's intentions to the Engine Control Module
(ECM) completely independent of one another. Both sensors are
integrated into one housing.

Test Conditions
• The fuses must be OK.
Test Sequence
engine electronics control module with “Address word 01“. For
this, the ignition is turned on. Connect the fault read out device
and select ECM.
Scan tool display:
Select function XX
– Press buttons 0 and 8 for function “Reading measuring value

blocks“ and press Q button to confirm input.
Scan tool display:
Read measuring value block

Scan tool display: (1…4 = display fields)
Read measured value block 62 ->
1 2 3 4
– Check the specified value of the accelerator pedal position

sensor at idle stop in display field 3.
Specified value: 6 to 96%
– Check the specified value of the accelerator pedal position
sensor 2 at idle stop in display field 4.
Specified value: 3 to 48%
Note
The ECM converts the angle sensor voltage values based on 5

volts and shows these in percentage values. (5 volt voltage supply
corresponds to 100%).
– Slowly press the accelerator pedal to the Wide Open Throttle

(WOT) position, when doing so, observe the percentage dis‐
play in display fields 3 and 4:
The percentage displays in display field 3 must increase evenly.
Specified range 6 to 96% is not completely utilized during this.
The percentage displays in display field 4 must increase evenly.
Specified range 3 to 48% is not completely utilized during this.
Note
Displayed value in display field 3 must always be approximately

twice as large as value in display field 4.
– Press → key.

If the readings do not result as described:

– Check the voltage supply and sensor wiring connections:
Voltage supply and wiring to control module, checking
– Remove the drivers side storage compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Description and Operation .
– Disconnect the 6-pin connector from accelerator pedal posi‐
tion sensor and accelerator pedal position sensor 2.
– Turn the ignition on.
– Connect the multi-meter for voltage measurement to the fol‐

lowing connector terminals with adapter cables from the con‐
nector test set -V.A.G 1594 C- .
Terminal 1 + Ground
Terminal 1 + 5
Terminal 2 + Ground
Terminal 2 + 3
Specified value: at least 4.5 V
– Turn the ignition off .
If no voltage is present:
– Connect the adapter cable, (121-pin) -V.A.G 1598/31- to the

ECM wiring harness. The ECM remains disconnected.

– Check the wires between the adapter cable, (121-pin) -V.A.G

1598/31- and connector for open circuit according to the wiring
diagram.
Terminal 1 + socket 72
Wiring resistance: Max. 1.5 Ω
– Also check the wires for short circuit to B+ or Ground.
– Also check the wires for short circuit to each other.
If no malfunction is detected in the wiring:
– Replace the accelerator pedal position sensor.
– Adapt the automatic transmission control module.
erated.
4.3 Evaporative Emission Canister Purge

Regulator Valve, Checking
The solenoid valve is closed when no voltage is present.
Check activation.

Test Conditions
• The coolant temperature must be at least 80 °C (176 °F) ⇒
Display group 04, display field 3
• Fuse no. 43 must be OK.
Functional Test
– Connect the fault read out device -V.A.G 1551- and select en‐
gine electronics control module with “Address word 01“. The
engine must run at idle for this. Connect the fault read out de‐
vice and select Engine Control Module (ECM).
Scan tool display:
Select function XX

Scan tool display:

1 2 3 4
– Press button 4 for “Basic Setting“ function (“Tank ventilation

valve diagnosis“ is initiated)
Note
During this diagnosis, engine load must not be generated or di‐

agnosis will be terminated and can only be re-initiated after press‐
ing the accelerator pedal.

1 2 3 4
If the diagnosis is initiated by the ECM, the display in display field

4 goes from “Test OFF“ to “Test ON“.
– Allow the engine to continue running at idle until specified val‐
ue “TEV OK“ is shown in display field 4.
Note
TEV means (tank ventilation valve) (solenoid valve 1 for EVAP

canister)
If “TEV not OK“ is shown in display field 4:

– Initiate the diagnostic test mode (DTM) and activate the EVAP
canister purge regulator valve 1 -N80- .


erated.
If the specified value “TEV OK“ is reached:
– Press the → key.
Scan tool display:
Select function XX

4.4 EVAP System, Checking for Leaks


Test Conditions
• No Diagnostic Trouble Codes (DTCs) in the DTC memory.
• All electrical consumers such as, for example, lights and rear
window defogger, must be turned off.
• If the vehicle is equipped with Air Conditioning (A/C), it must
be turned off.
• Throttle valve angle less than 10° ⇒ Display group 03, display
field 3.
• Coolant temperature less than 99 °C (210 °F) ⇒ Display group
04, display field 3.
• Intake air temperature less than 95 °C (203 °F) ⇒ Display
group 04, display field 4
Functional Test
– Connect the fault read out device -V.A.G 1551- and select en‐
gine electronics control module with “Address word 01“. The
Scan tool display:
Select function XX

Scan tool display:

Scan tool display
Reed open Test OFF
– Press button 4 for “Initiate basic setting“ function

Scan tool display
Reed open Test ON
Scan tool display

Reed closed Test ON
The Evaporative Emission (EVAP) system test is initiated. First,

function of the reed contact (in the leak detection pump -V144- )
is checked by the control module.
Scan tool display
Reed closed Syst. Test Test ON
After approximately 10 seconds, the leak detection pump is acti‐

vated and generates pressure in the fuel system.

Scan tool display

Reed open Syst. Test Test ON
After approximately 50 seconds, the test is initiated (this can take

up to 120 seconds if there is insufficient pressure in the fuel sys‐
tem).
Scan tool display
Reed open Measurement Test ON
The leak detection pump switches off and the time until the reed
contact closes is measured by the control module.
Scan tool display
Reed closed END of measurement Syst. OK
– Check the display in display fields 3 and 4:

Display field 3 specified value: END of measurement
Display field 4 specified value: Syst. OK
– Check for leaks. Refer to ⇒ page 133 .
If the specified values are achieved:
– Press → key.

Checking for Leaks
If a small or large leak was recognized during the EVAP system
functional test, proceed as follows.
– Check whether the fuel filler cap is completely closed or wheth‐
er the seal leaks, replace as necessary.
– Repeat the functional test.
If the malfunction persists:
– Fold the rear seat bench forward.
– Remove the cover under the bench seat.
– Check whether the fuel delivery unit lock nut is tight or the seal
is faulty, replace as necessary. Tighten the lock nut using the
ring nut spanner -3217- . Check the supply and return lines to
fuel delivery unit for leaks.
– Remove the right rear wheel housing liner. Refer to ⇒ Body
– Check the pressure hose between the leak detection pump
and EVAP canister for leaks, replace as necessary.
– Check the lines and line connections between the EVAP can‐
ister and tank flap unit or tank ventilation valve for leaks. Refer
to ⇒ “2.6 EVAP System Routing Diagram“, page 119 .


– Remove the EVAP canister and check for tears and leaks, re‐
place if necessary.
4.5 Leak Detection Pump, Checking

⇒ “4.5.1 Diagnostic Pump, Checking Electrically“, page 134
⇒ “4.5.2 Voltage Supply, Checking“, page 134
4.5.1 Diagnostic Pump, Checking Electrically

♦ Adapter Cable, (121-Pin) -V.A.G 1598/31-
♦ Wiring diagram
– Disconnect the 3-pin connector from the leak detection pump
-V144- .
– Connect the multi-meter for resistance measurement between
terminals 1 and 3 of the leak detection pump. Specified value:
640 to 720 Ω.
– Connect the multi-meter for resistance measurement between
terminals 2 and 3 of the leak detection pump. Specified value:
12.5 to 19.5Ω.
If specifications are not obtained:
– Replace the leak detection pump.
4.5.2 Voltage Supply, Checking

♦ Adapter Cable, (121-Pin) -V.A.G 1598/31-
♦ Wiring Diagram

Test Conditions
Test Sequence
– Disconnect the 3-pin connector from the leak detection pump

-V144- .
– Connect the voltage tester -V.A.G 1527 B- between terminal
3 (positive) on the connector and Ground (GND).
– Start the engine and run at idle speed: The Light Emitting Di‐
ode (LED) must light up.
– Check the wire between terminal 3 on the connector and the
central electronics for a open circuit according to the wiring
diagram. Wiring resistance: Max. 1.5 Ω
If the LED lights up (the voltage supply is OK):

Engine Control Module (ECM) wiring harness. The ECM re‐
mains disconnected.

– Check the wiring between the adapter cable, (121-pin) -V.A.G

1598/31- and 3-pin connector for a open circuit according to
the wiring diagram.
– Also check the wires for short circuits to each other. Specified
value: ∞ Ω
If no malfunction is found in the wires and there was voltage be‐
tween terminal 3 and Ground (GND):
– Replace the leak detection pump.
erated.
4.6 EVAP System, Checking with Tester

KLI 9210
⇒ “4.6.1 Introduction“, page 136
⇒ “4.6.2 KLI 90210 Tester, Calibrating“, page 136
⇒ “4.6.3 Fuel Cap, Testing“, page 137
⇒ “4.6.4 Leak Detection Pump V144, Checking for Internal
Leaks“, page 137
⇒ “4.6.5 Conditions“, page 138
⇒ “4.6.6 EVAP System, Checking for Leaks“, page 141
4.6.1 Introduction
The -KLI 90210- Evaporative Emission (EVAP) tester allows test‐
ing using nitrogen to pressurize the EVAP system and a smoke
generator or ultrasonic tester to locate the source of EVAP system
concerns.
This procedure is intended as a general guide for the use of the
EVAP tester. EVAP systems vary between models.
♦ -VAS 5051- or -VAS 5052- diagnostic tester
♦ -KLI 90210- EVAP system tester (set to 14 in. H2O)
♦ Light source (for viewing smoke)
♦ Hose Clamps up to 25 mm dia. -3094- or equivalent
Using the -KLI 90210- EVAP system tester ⇒ Tester operating
instructions
4.6.2 KLI 90210 Tester, Calibrating

Determine the vehicle leak threshold:
♦ Up to and including Model Year (MY) 1999 leak threshold =
0.040 in.
♦ From MY 2000 leak threshold = 0.020 in.

– Attach test hose to the appropriate preset port

-black arrows-.
– Turn the control valve from “Hold“ to “Test“.
– Set the flow meter flag -white arrow- at the indicated value on
the flow meter.
– Turn the control valve to “Hold“; remove the test hose.
4.6.3 Fuel Cap, Testing

– Remove the fuel cap.
– Connect the fuel cap receiver -arrow- to the hose.
– Screw the fuel cap tightly to the cap receiver.
– Turn the control valve to “Test“ pressurizing the cap.
– Turn the valve to “Hold“.
– Watch the pressure gauge for a drop in pressure from 14 in‐
ches H2O.
If no pressure drop is indicated:
– Proceed to checking the leak detection pump -V144- for inter‐
nal leaks.
If a pressure drop is indicated:
– Replace the fuel cap and retest.
– Proceed to checking the leak detection pump for internal
leaks.
4.6.4 Leak Detection Pump V144, Checking

for Internal Leaks
Basically, in the following procedure the EVAP system will be fil‐
led with smoke, the engine started and the leak detection pump
activated using the -VAS 5051- or -VAS 5052- . With the leak
detection pump activated, and after clearing the initial smoke
away from the leak detection pump area using compressed air,
the system is then filled with smoke again and rechecked for
smoke at the leak detection pump filter.

4.6.5 Conditions
• The ignition is turned off
• Leak detection pump is visible ⇒ Component Locations
• Tester hose connected to the fuel filler neck
• -VAS 5051- or -VAS 5052- Diagnostic tool connected to the
vehicle
• Smoke generator connected to the battery
– Turn the -KLI 90210- valve to “Test“ and use the smoke gen‐
erator trigger to fill the system with smoke (wait until smoke is
coming out of the leak detection pump filter).
– Start the engine.
– From the -VAS 5051- Start-up screen, select “Vehicle self di‐
agnosis“.
– Select the vehicle system “01 - Engine electronics“.
– Select the diagnosis function “04 - Basic settings“.
– Input the appropriate display group from the table below on

keypad.
Engine code Display group

AEB, AEG, AFP, AHA, APH, ATQ, ATW, AUG, AWD, 071
AWM, AWP, AWV, AWW, BDC, BDF, BEV, BGD, BGJ

Engine code Display group

AVH, AZG, BAP, BBW, BDP 202
– Press “Q“ on keypad to confirm.

The leak detection pump should activate
If the leak detection pump does not activate:
For some vehicles using Display group 202 a similar screen ap‐
pears indicating “Test Off“.
– Select “Activating“ button.
If the leak detection pump does not activate:
– Check the electrical connections to the leak detection pump.
– Check the vacuum source to the leak detection pump.
If the leak detection pump activates:
A similar screen appears, Test is “ON“(indicated by a “1“ in posi‐

tion 5, -arrow-).
Position 1 -arrow- alternates between “0“ and “1“ during pump

operation.

If the test is OK:

Indicated by “1“ in position 6 and a “0“ in position 8 as shown.
The leak detection pump has activated and the system is pres‐
surized.
– Using a compressed air blow gun, clear the area near the leak
detection pump and leak detection pump filter of any residual
smoke.
If the test aborts and Diagnostic Trouble Codes (DTCs) other than
for small or large leaks are stored:
– Check and repair according to the DTC listed in the DTC table
for the appropriate engine code.
When “Check end“ is indicated on the -VAS 5051- or -VAS 5052- :
Note
Only check the leak detection pump during “Check end“ phase
when “Test OK“ was indicated.
– Use the smoke generator trigger to fill the system with smoke
again.
– Check for smoke coming from the leak detection pump filter
and leak detection pump hose connections.
♦ Smoke coming from the filter indicates a faulty leak detection
pump
♦ Smoke coming from the leak detection pump outlet or hose
indicates a faulty hose or clamp
– Make repairs as necessary and check with smoke again.
♦ No smoke coming from the filter indicates the leak detection
pump is OK and the leak is somewhere else in the EVAP sys‐
tem
Note
If the -KLI 90210- EVAP system tester is connected in “Test“

mode and Basic settings (using Self Diagnosis) and Fault finding
are activated, a false “System OK“ message may be generated.
If the leak detection pump is OK and a DTC was stored for the
EVAP system:
– Turn the ignition off.
– Continue checking the EVAP system as follows:

4.6.6 EVAP System, Checking for Leaks

– Clamp off the leak detection pump outlet (EVAP side) -1- using
a hose clamp up to 25 mm dia. -3094- or equivalent.
WARNING
Clamp only the soft rubber hoses when isolating a leak. To

avoid risk of damage, never clamp hard plastic lines!
– Turn the control valve from “Hold“ to “Test“.

– Allow the fuel system to pressurize.
Note
The fuel system pressurization depends on the volume of the fuel

system and amount of fuel in tank.
If the fuel system pressurization does not stabilize:

– Verify that all fuel system outlets have been sealed before
continuing.
Note
Any flow shown on the flow meter indicates a leak. Flow below
the flow meter flag set at vehicle leak standard may indicate a
sporadic Diagnostic Trouble Code (DTC).
If the flow meter on the tester registers flow near or above the
preset pressure:
– Clamp off the hose leading from the EVAP canister purge reg‐
ulator valve 1 -N80- to the intake manifold.
If the flow stops:
– Replace the EVAP canister purge regulator valve 1 and repeat
the test before continuing.
If the meter indicates no flow after the test:
– Perform a quality check and return the vehicle to the customer.
If the flow continues:
– Use the smoke generator trigger to charge the fuel system with
smoke again.
– Inspect the complete EVAP system for escaping smoke.
Note
It may be necessary to move, twist, or wiggle EVAP components

around to reproduce the leak.
If the leak cannot be found using smoke:

– Locate the leak using an ultrasonic tester.

♦ General the search: tester only
♦ Localized search: tester with extension wand (left)
If the leak cannot be located:
– Disconnect and plug or clamp the shut EVAP lines to isolate
the fuel tank using a hose clamp up to 25 mm dia. -3094- or
equivalent before continuing.
WARNING
Clamp only the soft rubber hoses when isolating a leak. To

avoid risk of damage, never clamp hard plastic lines!
If the flow stops:

– Reconnect the EVAP lines and search area that was isolated.
When the leak has been located:
– Repair the leak and repeat EVAP system test.
Note
♦ Because the leak may be at the top of the fuel tank, it may not
be possible to locate through fuel pump/sending unit access
plate.
♦ Lower the fuel tank if necessary to locate the leak.
WARNING
Do not return the vehicle to the customer without having per‐

formed a proper diagnosis and repair.


⇒ “5.1 Fuel Delivery Unit“, page 143
⇒ “5.2 Fuel Level Sensor“, page 144
⇒ “5.3 Fuel Tank“, page 144
5.1 Fuel Delivery Unit

Removing
anti-theft code.
(GND) cable.
– Remove the cover under the rear bench seat.
– Disconnect the 4-pin connector and the supply and return lines
from the flange.
Note
Squeeze the buttons together on the line connections to do this.
WARNING
The fuel supply lines are under pressure! Wear protective gog‐
gles and protective clothing to prevent injuries and contact with
skin. Before removing from hose connection wrap a cloth
around the connection. Then release pressure by carefully
pulling the hose off the connection.
– Use the ring nut spanner -3217- to remove the lock nut.
– Pull the fuel delivery unit and seal out of the fuel tank opening.
Note
If the delivery unit is to be replaced then drain the old delivery unit
before disposal.
Installing
– Installation of the fuel delivery unit is in the reverse order of
removal.

Note
♦ When inserting the fuel delivery unit, be sure not to bend the
fuel level sensor.
♦ Insert the dry flange seal into the opening of the fuel tank.
♦ Only coat the seal with fuel when installing the fuel delivery
unit.
♦ Ensure the fuel hoses are seated securely.
♦ Note the installed position of the fuel delivery unit flange: The
mark on the flange must align with the mark on the fuel tank
-arrows-.
♦ After installing the fuel delivery unit, check that the supply, re‐
turn and ventilation lines are still clipped onto the fuel tank.

and Testing .
5.2 Fuel Level Sensor

Removing
– Remove the fuel delivery unit. Refer to
– Disengage the connector prongs for the wires -3 and 4- and
disconnect.
– Pry up the retaining tabs -1 and 2- using a screwdriver and
remove the fuel level sensor towards the bottom -arrows-.
Installing
– Insert the fuel level sensor into the guides on the fuel delivery
unit and push it up until it engages.
– Install the fuel delivery unit. Refer to
5.3 Fuel Tank

Removing
anti-theft code.
(GND) cable.
– Open the fuel tank flap.
– Remove the rear subframe. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 42 ; Removal and Installation .

– Drain the fuel tank and clean the fuel filler tube and surround‐
ing area.
– Remove the bolt and remove the fuel flap unit with rubber
gasket.
– Remove the bolt for the filler neck.
– Fold the rear seat bench forward.
– Remove the cover plate from the fuel level sensor and dis‐
connect the connector.
– Remove the covers under the fuel tank.
WARNING
The fuel supply lines are under pressure! Wear protective gog‐
gles and protective clothing to prevent injuries and contact with
skin. Before removing from hose connection wrap a cloth
around the connection. Then release pressure by carefully
pulling the hose off the connection.
– Disconnect the return line -2- (blue), supply line -1- (black) and
ventilation line -3- (white) from their connection points.
Note
Squeeze the buttons together on the line connections to do this.
– Remove the tensioning strap. While doing so, support the fuel
tank using the engine-/gearbox jack -V.A.G 1383 A-
– Lower the fuel tank.
Installing
♦ Make sure the ventilation and fuel lines are not kinked when
installed.
♦ Route the fuel lines free of kinks.
♦ Ensure the fuel lines are seated securely.
♦ Secure the fuel hoses with spring type clamps.
♦ Do not interchange the supply and return lines (the return line
is blue or has blue marks, the supply line is black).
Note
After installing the fuel tank, check that the supply, return and
ventilation lines are still clipped onto the fuel tank.

and Testing .

6 Special Tools
♦ Adapter Cable, (121-pin) -V.A.G 1598/31-


♦ Fuel Inj. Pressure Gauge-
CIS -V.A.G 1318-
♦ Pressure Gauge Adapter -
V.A.G 1318/1-
♦ Adapter -V.A.G 1318/11-
♦ Pressure Gauge Adapter -
V.A.G 1318/17-
♦ Fuel Line Feed Adapter -
V.A.G 1318/23-


Nm) -V.A.G 1332-
♦ Injection Rate Comparison
Meter -V.A.G 1348-
♦ Test System -V.A.G 1466
A-
♦ Voltage Tester -V.A.G 1527
B-
♦ Connector Test Set -V.A.G
1594 A- or -V.A.G 1594 C-
♦ Multi-meter -V.A.G 1715- or
-V.A.G 1526 C-

21 – Turbocharger, Supercharger
⇒ “1.1 Safety Precautions“, page 149
⇒ “1.2 Clean Working Conditions“, page 149
⇒ “1.3 Charge Air System with Turbocharger“, page 150
1.1 Safety Precautions
Caution

orative Emission (EVAP) system, coolant, refrigerant,
brake fluid and vacuum) and electrical wiring so that the
original path is followed.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.
WARNING
Observe the following if test and measuring instruments are

required during a test drive:
♦ Test and measuring instruments must be secured to rear
seat and operated by a 2nd person from this location.
If test and measuring instruments are operated from the front
passenger’s seat and the vehicle is involved in an accident,
there is a possibility that the person sitting in this seat may
receive serious injuries when the airbag is triggered.
1.2 Clean Working Conditions

When working on the turbocharger, carefully observe the follow‐
ing “5 rules“ of cleanliness:
♦ Thoroughly clean all connections and surrounding area before
disconnecting.
♦ Place parts that have been removed on a clean surface and
cover them using lint free cloths!
♦ Carefully cover or seal, opened components if repairs are not
performed immediately.
♦ Only install clean components: Only unpack replacement
parts immediately prior to installation. Do not use parts that
have been stored loose (for example in a tool box, etc.).
♦ When the system is open: Avoid working with compressed air
if possible. Do not move the vehicle unless absolutely neces‐
sary.

1.3 Charge Air System with Turbocharger
Note
♦ Various hose connections are secured with clamps.

♦ The charge air system must be properly sealed.
♦ Replace self-locking nuts.
♦ Vacuum hoses and connectors must be free of grease when
reinstalling.
♦ Spring type clip pliers -VAS 5024 A- or hose clip pliers -V.A.G
150 Rep. Gr.21 - Turbocharger, Supercharger


⇒ “2.1 Turbocharger with Attachments Overview“, page 151
⇒ “2.2 Charge Air Cooler Components Overview“, page 155
Engine Code AWD
⇒ “2.3 Exhaust Turbocharger System Overview“, page 157
Engine Codes AWP and AWW
⇒ “2.4 Exhaust Turbocharger System Overview“, page 158
2.1 Turbocharger with Attachments Over‐

view
⇒ “2.1.1 Part I“, page 151
⇒ “2.1.2 Part II“, page 153
2.1.1 Part I
1 - Nut
❑ 40 Nm
❑ Coat the threads with
hot bolt paste -G 052
112 A3- .
2 - Seal
❑ Always replace.
3 - Bolt
❑ 10 Nm
❑ Must not be loosened.
4 - Vacuum Diaphragm
❑ For the boost pressure
regulator valve.
❑ Can only be replaced to‐
gether with the turbo‐
charger.
❑ Charge pressure regu‐
lation, checking. Refer
to
⇒ “4.1 Boost Pressure
Regulation, Checking“,
page 161 .
5 - Clip
6 - Turbocharger
❑ Charge pressure regu‐
lation, checking. Refer
to
⇒ “4.1 Boost Pressure
Regulation, Checking“,
page 161 .
❑ The boost pressure reg‐
ulator valve and vacuum
diaphragm for boost
pressure regulator valve
are part of the exhaust turbocharger and cannot be replaced individually.
❑ Before connecting the oil supply line, fill the turbocharger with oil at the line connection.
❑ After installing the turbocharger, let the engine idle for approximately 1 minute without increasing the
engine speed. This ensures adequate oil supply to the turbocharger.
Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Description and Operation 151

7 - O-ring
❑ Always replace.
8 - Bolt
❑ 10 Nm
9 - Intake Manifold
10 - Gasket
❑ Always replace.
11 - Bolt
❑ 20 Nm
12 - Heat Shield
13 - Bolt
❑ 10 Nm
14 - Banjo Bolt
❑ 30 Nm
15 - Oil Supply Line
16 - Bolt
❑ 30 Nm
❑ Always replace.
❑ Coat the threads and bolt head contact surfaces with hot bolt paste -G 052 112 A3- (Part numbers are
for reference only. Always check with your Parts Department for the latest part number information).
17 - Exhaust Manifold
18 - Gasket
❑ Always replace.
19 - Bolt
❑ 20 Nm
20 - Banjo Bolt
❑ 30 Nm
21 - Nut
❑ 25 Nm
❑ Always replace.
❑ Coat the threads with hot bolt paste -G 052 112 A3- (Part numbers are for reference only. Always check
with your Parts Department for the latest part number information).
22 - Banjo Bolt
❑ 35 Nm
23 - Coolant Return Line
24 - Bolt
❑ 25 Nm
25 - Spacer Sleeve
26 - Banjo Bolt
❑ 35 Nm
27 - Bolt
❑ 10 Nm

28 - Coolant Supply Line

29 - Banjo Bolt
❑ 35 Nm
30 - Bolt
❑ 30 Nm
❑ Only use the original bolt from the Parts Catalog.
31 - Bracket
❑ Between the turbocharger and cylinder block.
32 - Bolt
❑ 25 Nm
33 - Gasket
❑ Always replace.
34 - Gasket
❑ Always replace.
35 - Bolt
❑ 10 Nm
36 - Oil Return Line
❑ To the oil pan.
37 - Bolt
❑ 10 Nm
38 - Nut
❑ 10 Nm
❑ Do not change the adjustment.
❑ Must not be loosened.
2.1.2 Part II
Note

agnostic (OBD).
♦ Components marked with a ** are checked via output Diag‐
nostic Test Mode (DTM).
♦ Note the installed position of the heat shield mats

1 - Deceleration Shut-Off
Valve
⇒ “4.6 Deceleration
Shut-Off Valve, Check‐
ing“, page 166 .
2 - Connecting Hose
❑ To the turbocharger re‐
circulation valve -N249-
*/**
3 - Pressure Regulator Valve

❑ For crankcase ventila‐
tion.
4 - Connecting Hose
❑ From the deceleration
shut-off valve to the up‐
per charge air pipe.
5 - to the Crankcase Housing
Ventilation
6 - from the Air Filter
7 - Upper Charge Air Pipe
tion of the heat shield
mat.
❑ With engine codes
AWP, AWW with a
quick-release connec‐
tion (with O-ring and re‐
taining clip).
❑ With engine code AWD
with screw-type clamps.
8 - Bracket
9 - Bolt
❑ 40 Nm
10 - Bolt
❑ 25 Nm
11 - to the Connection Hose for the Lower Connection Sleeve/Charge Air Cooler
12 - O-ring
❑ Always replace.
13 - Retaining Clip
14 - Bolt
❑ 10 Nm
15 - from the Turbocharger Exhaust Connection
❑ To the vacuum diaphragm for boost pressure regulator valve.
18 - Retaining Clip

19 - O-ring
❑ Always replace.
20 - Intake Tube
❑ To the intake tube of the turbocharger.
21 - Wastegate Bypass Regulator Valve -N75- */**
❑ Valve is activated (pulsed) by the Engine Control Module (ECM).
❑ Check activation.
2.2 Charge Air Cooler Components Over‐

view
Note
♦ Various hose connections are secured with clamps.

♦ The charge air system must be properly sealed.
♦ When installing, follow the installation marks on the hoses and
components.
♦ Note the installed position of the heat shield mats

1 - Air Duct
2 - Bolt
❑ 10 Nm
3 - Charge Air Pressure Sen‐
sor -G31-
⇒ “4.3 Charge Air Pres‐
sure Sensor, Checking“,
page 163 .
4 - O-ring
❑ Always replace.
5 - Rubber Grommet
❑ With a sleeve.
6 - Bolt
❑ 10 Nm
7 - Intake Tube
❑ Between the intake
manifold and charge air
cooler.
8 - Heat Shield Mats
tion.
9 - Screw Clamp
engine code AWD.
❑ Vehicles with engine co‐
des AWP and AWW
with a quick-release
connection (with O-ring
and retaining clip).
11 - Air Guide Pipe
12 - Bracket
14 - Charge Air Cooler

2.3 Exhaust Turbocharger System Overview
1 - Connecting Hose
❑ From the leak detection
pump -V144- .
2 - to the Vacuum Reservoir
❑ Under the right front
3 - Non-Return Valve
4 - Turbocharger
regulator valve.
Valve
8 - Wastegate Bypass Regula‐
tor Valve -N75-
❑ Valve is activated
(pulsed) by the Engine
Control Module (ECM).
9 - Brake Booster
❑ For the brake booster.
11 - Air filter with Mass Airflow
Sensor -G70- .
12 - Crankcase Housing Ven‐
tilation Pressure Regulator
Valve
13 - Combination Valve
❑ For the Secondary Air
Injection (AIR) system.
❑ Checking, refer to ⇒ “4.2 Combination Valve, Checking“, page 179 .
16 - Turbocharger Recirculation Valve -N249-
17 - Secondary Air injection Solenoid Valve -N112-
❑ Checking, refer to ⇒ “4.4 Secondary Air Injection Solenoid Valve, Checking“, page 180 .
18 - Crankcase Ventilation
20 - Charge Air Pressure Sensor -G31-
❑ Replace the O-ring if damaged.
21 - Secondary Air Injection Pump Motor -V101-
❑ Function, checking, refer to ⇒ “4.3 Secondary Air Injection Pump Motor, Checking“, page 179 .


24 - EVAP Canister Purge Regulator Valve 1 -N80-
❑ Function, checking, refer to
⇒ “4.3 Evaporative Emission Canister Purge Regulator Valve, Checking“, page 129 .
❑ To the EVAP canister.
2.4 Exhaust Turbocharger System Overview
1 - Connecting Hose
❑ From the leak detection
pump -V144- .
❑ Under the right front
4 - Turbocharger
regulator valve.
Valve
7 - Brake Booster
❑ For the brake booster.
9 - Wastegate Bypass Regula‐
tor Valve -N75-
❑ Valve is activated
(pulsed) by the Engine
Control Module (ECM).
10 - Air Filter with Mass Airflow
Sensor -G70-
11 - Crankcase Housing Ven‐
tilation Pressure Regulator
Valve
❑ For the Secondary Air
Injection (AIR) system.
❑ Checking, refer to ⇒ “4.2 Combination Valve, Checking“, page 179 .


15 - Crankcase Ventilation
17 - Turbocharger Recirculation Valve -N249-
18 - Secondary Air Injection Solenoid Valve -N112-
❑ Checking, refer to ⇒ “4.4 Secondary Air Injection Solenoid Valve, Checking“, page 180 .
19 - Suction Jet Pump
21 - Intake Manifold
22 - Charge Air Pressure Sensor -G31-
25 - EVAP Canister Purge Regulator Valve 1 -N80-
❑ Function, checking, refer to
⇒ “4.3 Evaporative Emission Canister Purge Regulator Valve, Checking“, page 129 .
❑ To the EVAP canister.

3 Specifications

Exhaust pipe nut - 40
Vacuum diaphragm - 10
Intake manifold - 10
Heat shield - 20
Oil supply line
- 101
- 301
- 201
Exhaust manifold
- 25
Nut - 30
Coolant supply line
- 102
- 352
Bracket between turbocharger and cylinder block
- 253
- 303
Oil return line - 10
Bracket
- 104
- 254
- 404
Charge Air Pressure Sensor -G31- - 10
Air charge cooler - 10
• 1For bolt tightening clarification, refer to
⇒ “2.1.1 Part I“, page 151 and see items -13, 14 and 19 -
⇒ “2.1.1 Part I“, page 151 and see items -26, 27 and 29-
⇒ “2.1.1 Part I“, page 151 and see items -30 and 32-
⇒ “2.1.2 Part II“, page 153 and see items -9, 10 and 14-


⇒ “4.1 Boost Pressure Regulation, Checking“, page 161
⇒ “4.2 Wastegate Bypass Regulator Valve, Checking“,
page 163
⇒ “4.3 Charge Air Pressure Sensor, Checking“, page 163
⇒ “4.4 Turbocharger Recirculation Valve, Checking“, page 165
⇒ “4.5 Boost Pressure Regulator Valve Vacuum Diaphragm,
Checking“, page 166
⇒ “4.6 Deceleration Shut-Off Valve, Checking“, page 166
⇒ “4.7 Charge Air System, Checking for Leaks“, page 167
4.1 Boost Pressure Regulation, Checking

Test Conditions
• There must be no malfunctions stored in the Diagnostic Trou‐
ble Code (DTC) memory.
• No leaks on the intake or exhaust sides.
• The engine oil temperature is at least 80 °C (176 °F).
Test Sequence
– Charge pressure is measured under Wide Open Throttle
(WOT) while driving or on a roller type test stand.
Observe the safety precautions that apply to road tests. Refer to
engine electronics control module with “Address word 01“. The
Scan tool display: Quick data transfer HELP
Select function XX

Scan tool display: Read measuring value block
– Press buttons 1 1 and 4 for the “Display group number 114“

and press Q button to confirm input.
Scan tool display: (1 to 4 = display fields) Read measured value block 114 ->
1 2 3 4
– During a road test or on a test stand, check (at full throttle

between 1800 and 2300 RPM) the duty cycle of the wastegate
bypass regulator valve -N75- in display field 4. Specified value:
5.0 to 95.0%
If the specified value is not achieved:
– Switch to display group 15 as follows: Press 3 button.
Scan tool display: (1 to 4 = display fields) Read measured value block 115 ->
1 2 3 4

– Check the charge air pressure actual value at WOT in display

field 4:
While Driving
with a manual transmission
– Accelerate the vehicle at WOT in 2nd gear.
with a automatic transmission
– Manually shift the vehicle into 4th gear and accelerate the ve‐
hicle from low speed at WOT (without kick down, transmission
does not downshift any more).
Engine Codes AWD and AWW
– Press print button between 1800 and 2300 RPM and read out
charge air pressure actual value in display field 4. Specified
value: 1350 to 1750 mbar
Engine code AWP
– Press print button between 1800 and 2300 RPM and read out
charge air press actual value in display field 4. Specified value:
1700 to 2000 mbar
– Compare charge air pressure actual value with specified value
in display field 3. Difference: Max. 100 mbar
Note
Repeat measurement if full charge air pressure had not been

reached yet or difference between specified and actual value is
too large.
– Press → key.

If the boost pressure is exceeded:
– Test the charge air pressure sensor -G31- . Refer to
⇒ “4.3 Charge Air Pressure Sensor, Checking“, page 163 .
– Check the wastegate bypass regulator valve. (Throughput in
hose from turbocharger via valve to vacuum diaphragm with
connector disconnected)
– Check that vacuum diaphragm for charge pressure regulator
valve is securely seated on turbocharger.
– Check the vacuum diaphragm. Refer to
⇒ “4.5 Boost Pressure Regulator Valve Vacuum Diaphragm,
– Check the mounting of the boost pressure regulator valve
shaft in the turbocharger for ease of movement. If rusted in
place, replace the turbocharger.
If the boost pressure is exceeded:
– Test the charge air pressure sensor. Refer to
⇒ “4.3 Charge Air Pressure Sensor, Checking“, page 163 .
– Check the wastegate bypass regulator valve.

– Check the mounting of the boost pressure regulator valve

shaft in the turbocharger for ease of movement. If rusted in
place, replace the turbocharger.
– The turbocharger is faulty, replace it. Refer to
⇒ “2.1 Turbocharger with Attachments Overview“, page 151 .
erated.
4.2 Wastegate Bypass Regulator Valve,

Checking
Testing and Information System -VAS 5051 B-
♦ Multi-meter -V.A.G 1526 C-
Test Conditions
• Output diagnostic test performed:
• The ignition is turned off.
Test Sequence
– Disconnect the connector -2- from the wastegate bypass reg‐
ulator valve -N75- -1-.
– Measure the resistance between the terminals of the valve.

Specified value: 25 to 35 Ω
– Replace the wastegate bypass regulator valve.
If the specified value is not achieved:
– Check the specified values in measured value blocks for
charge pressure regulation: Display groups 110 to 119.
4.3 Charge Air Pressure Sensor, Checking



♦ Wiring Diagram
Test Conditions
• A malfunction in the charge air pressure sensor was detected
by On Board Diagnostic (OBD).
• The ignition is turned off.
Voltage Supply and Wiring to Control Module, Checking
– Disconnect the 4-pin connector -2- from the charge air pres‐
sure sensor -G31- (-1-).
– Connect the multi-meter for voltage measurement with adapt‐

er cables from the connector test set -V.A.G 1594 C- to ter‐
minals 1 (Ground) and 3 (positive) of the charge air pressure
sensor connector.
– Turn the ignition on. Specified value: at least 4.5 V
– Turn the ignition off .
If no voltage is present:

Engine Control Module (ECM) wiring harness. The ECM re‐
mains disconnected.
– Check the wires between the adapter cable, (121-pin) -V.A.G
1598/31- and connector for open circuits according to the wir‐
ing diagram.


– Check wires for short circuits to each other.
If no malfunction is found in the wires and there was voltage be‐
tween terminals 1 and 3:
– Check the function. Refer to ⇒ page 165 .
If no malfunction is found in the wires and there was no voltage
between terminals 1 and 3:
– Replace the ECM. Refer to ⇒ Fuel Injection and Ignition; Rep.
Gr. 24 ; Removal and Installation .
Checking Function
ECM wiring harness and ECM.
– Reconnect the connector to the charge air pressure sensor.
– Use adapter cables from the connector test set -V.A.G 1594
C- to connect the multi-meter to sockets 101 (B+) + 108
(Ground (GND)) for voltage measurement.
– Start the engine and measure the voltage. Specified value:
1.80 to 2.00 V
– Increase the engine speed by pressing the gas pedal sudden‐
ly. Specified value: 2.00 to 3.00 V
– Replace the charge air pressure sensor.
erated.
4.4 Turbocharger Recirculation Valve,

Checking
♦ Multi-meter -V.A.G 1526 C-
♦ Wiring Diagram
Test Conditions
• Output diagnostic test performed.
Test Sequence
– Disconnect the connector from the turbocharger recirculation
valve -N249- .
– Measure the resistance between terminals of the valve. Speci‐
fied value: 27 to 30 Ω
– Replace the turbocharger recirculation valve.


(ECM) disconnected from the voltage supply, the readiness
code must be regenerated.
4.5 Boost Pressure Regulator Valve Vac‐

uum Diaphragm, Checking
Test Conditions
• The engine oil temperature is at least 60 °C (140 °F).
• No leaks on the intake or exhaust sides.
Test Sequence
– Disconnect the connector -2- from the wastegate bypass reg‐
ulator valve -N75- (-1-).
– Start the engine and increase the engine speed to maximum

RPM by pressing the accelerator pedal suddenly. The actuator
rod -2- for the boost pressure regulator valve must move.
If the actuator rod does not move:
– Check the lever -1- for the boost pressure regulator valve for
ease of movement. If rusted in place, replace the turbocharg‐
er.
If the actuator rod does not move through light prying:
– The turbocharger is faulty, replace it. Refer to
⇒ “2.1 Turbocharger with Attachments Overview“, page 151 .
4.6 Deceleration Shut-Off Valve, Checking

♦ Hand Vacuum Pump -V.A.G 1390-
Test Conditions
• Performance deficiency or load change shocks

Test Sequence
Note
The deceleration shut-off valve is located in front of the turbo‐

charger. It is opened by vacuum during deceleration and at idle.
– Connect the hand vacuum pump -V.A.G 1390- to the vacuum

connection of the deceleration shut-off valve.
– Operate the hand vacuum pump -V.A.G 1390- . The deceler‐
ation shut-off valve must open in the direction of the -arrow-.
– Operate the ventilation valve at the hand vacuum pump -V.A.G
1390- . The deceleration shut-off valve must close
If the deceleration shut-off valve does not open or does not close,
replace the valve.
Note
Connections of the deceleration shut-off valve are to be fastened

with screw type clamps.
4.7 Charge Air System, Checking for Leaks

♦ Testing Unit for Turbocharger -V.A.G 1687-
♦ Accessory Adapter -V.A.G 1687/1-
– Remove the intake hose from the air filter.
– Remove the crankcase ventilation pressure regulator valve
from the intake hose.
– Insert the accessory adapter -1687/1- into the intake hose and
seal the connection for the pressure regulator valve using the
adapter -V.A.G 1687/4- . Tighten the hose clamps.
Prepare the testing unit for turbocharger -V.A.G 1687- as follows:
– Remove the pressure regulator valve -2- completely and close

valves -3 and 4-.
Note
In order to be able to turn the pressure regulator valve -2-, the

rotary knob must be pulled upward.

– Connect the testing unit for turbocharger -V.A.G 1687- as

shown.
– Connect the pressurized air hose -1- (pressurized air supply)

to the testing unit for turbocharger -V.A.G 1687- .
Note
If water is located in the viewing glass, drain it via the water drain
plug -6-.
– Open the valve -3-.

– Set the pressure to 0.5 bar using the pressure regulator valve
-2-.
Caution
Pressure must not exceed 0.5 bar! A pressure set too high may
damage the engine.
– Open the valve -4- and wait until the testing circuit has filled.
If necessary, continue to regulate pressure to 0.5 bar.
– Check the charge air system for leaking areas by listening,
touch, using leak detection spray or using the ultrasonic meas‐
uring device -V.A.G 1842- .
Note
♦ A minimal amount of air will escape through the turbocharger

into the oil pan. A retaining pressure test is not possible for this
reason.
♦ Handling instructions of the ultrasonic measuring device -
V.A.G 1842- . Refer to the operating instructions.
♦ If a poorly sealed area is discovered, observe the notes for
charge air system when repairing. Refer to
⇒ “1.3 Charge Air System with Turbocharger“, page 150 .
♦ Before removing the adapter, release pressure from the test
circuit by separating the connection from the accessory adapt‐
er -1687/1- .

5 Special Tools
♦ Accessory Adapter -V.A.G 1687/1-
♦ Multi-meter -V.A.G 1526 C- or -V.A.G 1526 A-
♦ Connector Test Set -V.A.G 1594 C- or -V.A.G 1594 A-
♦ Testing Unit for Turbocharger -V.A.G 1687-

26 – Exhaust System, Emission Controls

⇒ “1.1 Secondary Air Injection System Function“, page 170
1.1 Secondary Air Injection System Func‐

tion
Caution

orative Emission (EVAP) system, coolant, refrigerant,
brake fluid and vacuum) and electrical wiring so that the
original path is followed.
Air is blown behind the exhaust valves by the Secondary Air In‐
jection (AIR) system for a maximum of 100 seconds following a
cold start (coolant temperature of +5 °C to +33 °C (+41 °F to +91
°F)). This produces an oxygen rich exhaust gas, causes after
burning and reduces the heating-up phase of the catalytic con‐
verter. Activation is triggered by the Motronic engine control mod‐
ule -J220- via the secondary air injection pump relay -J299- to the
secondary air injection solenoid valve -N112- , (change-over
valve) and combination valve.
170 Rep. Gr.26 - Exhaust System, Emission Controls


⇒ “2.1 Exhaust System Components Overview“, page 171
⇒ “2.2 Secondary Air Injection System Components Assembly
Overview“, page 174
2.1 Exhaust System Components Overview
Note
♦ After exhaust system repairs, make sure the exhaust system

is not under stress and that it has sufficient clearance from the
bodywork. If necessary, loosen the double clamps and clamp
and align the exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and support rings carry uniform loads.
♦ Replace self-locking nuts.
agnostic (OBD).
1 - Tunnel Bridge
2 - Center Muffler
❑ As a standard, the cen‐
ter and rear mufflers are
installed as a single
component. In cases of
repair, the center and
rear muffler are supplied
individually and with a
double clamp for con‐
necting.
❑ Separating point, refer
to
⇒ Fig. ““Separation
Point on the Exhaust
Pipe““ , page 173 .
3 - Suspended Mount
tion, refer to
⇒ Fig. ““Installed Loca‐
tion of the Mount““ ,
page 173 .
4 - Bolt
❑ 25 Nm
5 - Nut
❑ 40 Nm
❑ Always replace.
6 - Washer
7 - Gasket
❑ Always replace.
8 - Turbocharger
9 - Front Exhaust Pipe with

Catalytic Converter
10 - Heated Oxygen Sensor -G39- *
❑ 50 Nm
❑ Grease only the threads with hot bolt paste -G 052 112 A3- (anti-seize compound). The hot bolt paste -
G 052 112 A3- must not get into the slots on the sensor body. (Part numbers are for reference only.
Always check with your Parts Department for the latest part number information).
❑ Use the ring spanner 7-piece set -3337- for removal and installation.
❑ If the sealing ring is leaking cut it off and replace it.
❑ Checking, refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis and Testing .
❑ Connect with engine code AWD: 4-pin, contact gold-plated.
❑ Connect with engine codes AWP and AWW: 6-pin, contact gold-plated.
11 - Oxygen Sensor after Three Way Catalytic Converter -G130- *
❑ 50 Nm
❑ Grease only threads with hot bolt paste -G 052 112 A3- (anti-seize compound). The hot bolt paste -G
052 112 A3- must not get into the slots on the sensor body. (Part numbers are for reference only. Always
check with your Parts Department for the latest part number information).
❑ Use the ring spanner 7-piece set -3337- for removal and installation.
❑ If the sealing ring is leaking cut it off and replace it.
❑ Checking, refer to ⇒ Fuel Injection and Ignition; Rep. Gr. 24 ; Diagnosis and Testing
❑ Connector: 4-pin, terminals 3 and 4 gold-plated.
12 - Double Clamp
❑ Note the installed position, refer to ⇒ Fig. ““Installed Position of the Double Clamp““ , page 173 .
13 - Nut
❑ 40 Nm
14 - Suspended Mount
15 - Bolt
❑ 25 Nm
16 - Rear Muffler
❑ As a standard, the center and rear mufflers are installed as a single component. In cases of repair, the
center and rear muffler are supplied individually and with a double clamp for connecting.
❑ Separating point, refer to ⇒ Fig. ““Separation Point on the Exhaust Pipe““ , page 173 .
❑ Installing the muffler free of tension, refer to
⇒ Fig. ““Installing the Muffler Free of Tension““ , page 173 .
17 - Suspended Mount
18 - Bolt
❑ 25 Nm
19 - Double Clamp
20 - Nut
❑ 40 Nm
21 - Bolt
❑ 25 Nm

Separation Point on the Exhaust Pipe

– Cut through the exhaust pipe at a right angle at the separating
point -2-.
– Position the repair double clamp -4- between the
-arrows 1 and 3- during installation. Tightening specification
40 Nm
Installing the Muffler Free of Tension

– The bolt at the exhaust pipe must be parallel to the tunnel
bridge (dimension -x- same at left and right).
Installed Position of the Double Clamp

– Position the double clamp approximately 5 mm from the mark
A -arrow 1-.
Note
Mark -A- applies to vehicles with a manual or automatic trans‐

mission.
Installed Location of the Mount

– Angled side at the foot of the suspended mount -arrow- faces
the front of the vehicle.

2.2 Secondary Air Injection System Compo‐

nents Assembly Overview
Note
♦ Components marked with * are checked via On Board Diag‐

nostic (OBD).
♦ Components marked with ** are checked via output Diagnostic
Test Mode (DTM).
♦ Secondary air injection pump relay -J299- **. Refer to
⇒ Fig. ““AIR Pump Relay -1- ““ , page 175 .
⇒ “4.2 Combination
Valve, Checking“,
page 179 .
2 - Gasket
❑ Always replace.
❑ Secured to the cylinder
head.
4 - Bracket
5 - Bolt
❑ 10 Nm
6 - Bracket
❑ Secured to the intake
manifold.
8 - Vacuum Hose
9 - Connector
❑ 2-pin
10 - Secondary Air Injection
Solenoid Valve -N112- */**
❑ Tightened to 6 Nm on
the bracket.
❑ Resistance: 21 to 24 Ω
⇒ “4.4 Secondary Air In‐
jection Solenoid Valve,
11 - Intake Tube
❑ For the Secondary Air Injection (AIR) pump.
❑ Ensure it is seated tightly.
❑ Squeeze together at the front to release.
12 - to the Air Filter
13 - O-ring
❑ Always replace.

14 - Connector
❑ 2-pin
❑ For the AIR pump motor.
15 - Nut
❑ 10 Nm
17 - Bolt
❑ 10 Nm
18 - Pressure Hose
❑ Ensure it is seated tightly.
❑ Squeeze together at the front to release.
19 - Nut
❑ 10 Nm
❑ Secured to the bracket -item 6-.
20 - Bolt
❑ 10 Nm
21 - Gasket
❑ Always replace.
AIR Pump Relay -1-

♦ If tools are necessary to pull the relay or control module out of
the relay plate, first disconnect the battery Ground (GND) ca‐
ble.
♦ Obtain the radio code for radios with a anti-theft code before
disconnecting the battery.

3 Specifications

Suspended mount - 25
Front exhaust pipe with catalytic converter - 40
Oxygen Sensor - 50
Double clamp - 40
Suspended mount - 25
Tunnel bridge - 25
Bracket for connecting piece secured to - 10
cylinder head
Secondary Air Injection Solenoid Valve - - 6
N112- on bracket
Secondary Air Injection Pump Motor - - 10
V101-
Pressure hose - 10


⇒ “4.1 Three Way Catalytic Converter, Checking“, page 177
⇒ “4.2 Combination Valve, Checking“, page 179
⇒ “4.3 Secondary Air Injection Pump Motor, Checking“,
page 179
⇒ “4.4 Secondary Air Injection Solenoid Valve, Checking“,
page 180
4.1 Three Way Catalytic Converter, Check‐

ing
♦ Speed Adjuster Tool -V.A.G 1788/10- (only on engine codes
AWD and AWW)
Test Sequence
engine electronics control module with “Address word 01“. The
vice and select the Engine Control Module (ECM).
Select function XX
– Press buttons 0 and 4 for function “Initiate basic setting“ and

Scan tool display: Initiate basic setting HELP
– Press buttons 0 3 and 4 for the “Display group number 34“

and press Q button to confirm input.
Scan tool display: (1 to 4 = display fields) System in basic setting 34 ->
1 2 3 4

– Adjust the engine speed using the speed adjuster tool -V.A.G
1788/10- to 1800 to 2200 RPM:
field 4 goes from “Test OFF“ to “Test ON“. Catalytic converter
temperature in display field 2 must be between 350 and 500 °
C (662 and 932 °F).
– Continue to hold the speed at 1800 to 2200 RPM until the
specified value “B1S1 OK“ is shown in display field 4.
Engine Code AWP
– Press the gas pedal to the Wide Open Throttle (WOT) position.
The engine speed is raised to approximately 2300 RPM by the
ECM.
– Hold the brake and gas pedal down until the display in display
temperature in display field 2 must be between 350 and 500 °
C (662 and 932 °F).
– Continue to hold the brake and gas pedal until the specified
value “B1S1 OK“ is shown in display field 4.


If the reading does not result as described:
erated.
Read the results as described:
– Press C key.
Scan tool display: (1 to 4 = display fields) Basic setting 46 ->
1 2 3 4

temperature in display field 2 must be at least 440 °C (824 °
F).
– Continue to hold the speed at 1800 to 2200 RPM until specified
value “Catalytic convert B1 OK“ is shown in display field 4.
– Remove the speed adjuster tool -V.A.G 1788/10- from the gas
pedal.
Engine Code AWP
– Press the gas pedal to the WOT position. The engine speed
is raised to approximately 2300 RPM by the ECM.
– Hold the brake and gas pedals down until the display in display
temperature in display field 2 must be at least 440°C (824 °F).
– Continue to hold the brake and gas pedals until the specified
value “Catalytic converter B1 OK“ is shown in display field 4.
“Catalytic converter B1 not OKB“ shown in display field 4:
erated.
If the specified value “Catalytic converter B1 OK“:
– Press → key.
Select function XX


4.2 Combination Valve, Checking

Test Conditions
ble Code (DTC) memory
• Output diagnostic test performed
• Vacuum lines and hose connections are free of leaks
• Vacuum lines are not blocked or kinked
Test Sequence
– Disconnect the vacuum hose -1- from the secondary air injec‐
tion solenoid valve -N112- -2-.
– Connect the hand vacuum pump -V.A.G 1390- to the vacuum
hose -1-.
Note
Do not use compressed air during the following check!
– Disconnect the pressure hose -3- from the secondary air in‐
jection pump motor -V101- and blow air in with light pressure
-arrow-. The combination valve must be closed.
Note
To disengage, squeeze the buttons at the hose coupling.
– Operate the hand vacuum pump -V.A.G 1390- . The valve

must open.
If the combination valve does not open:
– Replace the combination valve.
4.3 Secondary Air Injection Pump Motor,

Checking

Test Conditions
• The secondary air injection pump relay -J299- fuse -arrow- in
the main fuse box is OK.
• The Secondary Air Injection (AIR) intake hose is not sealed or
kinked.
Test Sequence
– Install the pressure hose to the secondary air injection pump
motor -V101- .
Note
To disengage, squeeze the buttons at the hose coupling.
– Activate the AIR pump relay via the output Diagnostic Test
Mode (DTM).
– The AIR pump motor must start in intervals and air must es‐
cape at the exhaust connection.
If the motor starts, but no air escapes:
– Continue with the output DTM to the end.

– Replace the AIR pump motor.
If the AIR pump motor does not start up in intervals:
– Check the AIR pump motor activation.
4.4 Secondary Air Injection Solenoid Valve,

Checking
Test Conditions
• Coolant temperature is 5 to 33 °C (41 to 91 °F).
• The Secondary Air Injection (AIR) pump motor is OK.

Test Sequence
– Disconnect the vacuum hose -arrow- from the at combination
valve.
– Start the engine and let run at idle. Vacuum must be present
at the vacuum hose (sense by touch) when the secondary air
injection pump motor -V101- is running.
If no vacuum can be felt:
– Turn off the engine.
– Check the valve activation. Refer to ⇒ Fuel Injection and Ig‐
nition; Rep. Gr. 01 ; Diagnosis and Testing .

5 Special Tools
♦ Speed Adjuster Tool -V.A.G 1788/10-
Edition 06.28.2012 FB

Awd Aww Awp Engine Mechanical Golf4 Jetta Eng PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Awd Aww Awp Engine Mechanical Golf4 Jetta Eng PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Service

Service Department. Technical Information

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.1 Cylinder Head Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.1 Secondary Air Injection System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

00 – General, Technical Data

1.1 Engine Number

In addition, a sticker with the “engine code“ and “serial number“

2.1 Engine Data Volkswagen Technical Site: http://vwts.ru http://vwts.info

2 Rep. Gr.00 - General, Technical Data

1.1 Engine and Transmission Mounts,

Before loosening bolts, secure assembly using the engine sup‐

1.2 Air Conditioning

The Air Conditioning (A/C) refrigerant circuit must not be

♦ The refrigerant circuit must only be opened in workshops with

To facilitate removal and installation of the engine without having

Shield the bumper from damage using adhesive tape.

4 Rep. Gr.10 - Engine Assembly

2.1 Engine Mount Tightening Specifications

2.2 Fastener Tightening Specifications

Components Bolt Size Nm

6 Rep. Gr.10 - Engine Assembly

3 Removal and Installation

3.1 Engine, Removal

3. Removal and Installation 7

– Remove the connecting hoses -arrows- between the Secon‐

Squeeze the buttons together on the hose connections to remove

– Disconnect the connector -1- from the AIR pump.

The fuel supply line is under pressure! Wear protective goggles

8 Rep. Gr.10 - Engine Assembly

Squeeze the buttons together on the hose connection.

– Seal the lines so that the fuel system is not contaminated by

The clutch pedal must not be pressed.

with a Automatic Transmission

3. Removal and Installation 9

– Remove the pendulum support bolts -arrows- and support.

– Install the engine/trans. support -T10012- to the cylinder block

– Remove the engine mount to engine mount bracket bolts

Use the step ladder -VAS 5085- to remove the bolts.

10 Rep. Gr.10 - Engine Assembly

– Remove the transmission mount to transmission mount brack‐

Carefully guide the engine with transmission, when lowering, to

3.2 Engine, Securing to Assembly Stand

Use securing pins at hooks and pins.

♦ The peg positions on the carrying strap marked with 1 to 4 face

3. Removal and Installation 11

3.3 Engine, Installing

When doing any repair work, especially in the engine compart‐

– Make sure the alignment sleeves for the engine to transmis‐

12 Rep. Gr.10 - Engine Assembly

– Engage the intermediate plate at the sealing flange and slide

3. Removal and Installation 13

Tightening torques of the engine/transmission mounts. Refer to

14 Rep. Gr.10 - Engine Assembly

♦ Holding Fixture -VW 313-

♦ Torque Wrench -V.A.G

16 Rep. Gr.10 - Engine Assembly