set'vlce

SEF- T

I I ' WorkshopManual 1Toledo1999), Le6n Booklet

Edition 06.02
4-cyl. injection egine, (5-valve).

Customer Service. Technical lnformation

s er v i G e

Toledo1999 Le6n ),
]AMK
It

List of WorkshopManual RepairGroups

lBOOklet

4-cyl. injection (S-vatve), engine, edition06.02

when fiInga Technicai Bufletrn enter Bu etinNo.in the adjacent the corumn.when. using j Nlan u a lyo u nthens eeat a gl anc e h e t h eT e c h n a g u t t e in s h a v e:en puorsned thework.lo ca bi w r c n respect Tle' c panicutar Cepiir-ci".ip *r-'iZn arerookrng. i. v", Re p a i Gr o u r p 00 l0 13 15 17 Technical Data R e m o v g a ndi ns tal l i ng n enqrne group Crankshaft Cylinder gear head, Valve L u b r i ca tion T e c h ic a lBu l l e ti n s n
j l

1
I

19 Coo ng

Injection

26 Exh a u st s tem sy

e L htCd ' r l or Tal o'' sl o-lo al,voys Oe o / d a b - ro d o t e n e . ' )o -o T e L n o r' S h o r: . ^ " 5 o -15.,..1.o'rrgver 5es>o , . d ro e olid^ e . o J a rL e o d o , ^ o , . o t r. " . r . ljj, , ) i . ' . ] ^ n ' , ^ a " t he n o fn .r sa l ety pfec autons tobeo b s e r v e d wh e n wo r k in g o n m o t c r v e h ic le sa r *i i a "' j ""i

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All riqhtsresefved on r' p. No reproduct withoLrt of aqfeementfrom p ublishe

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Contents 00 Technical data

Techn;caldata

Page 00-1 00 1 00,2

10

|-temovtno anct tnstallrno enotne Engine: removing and installing .... . . . .. . . .. Rerrova notes .. Engne securng engrne assembly 10 stand lfslat,ng nltes T ghlening tofques Enginebrackets
- Fn..a h r :.1 !1 < A ^ n .^

Page
10-l 103 1A-23 1A-24 1A21 10-28 1030

13

C.ankshaft group
Engine: dismantling and assembling Ribbed bett...........
P f h o , r h 6 lr .^ ,i ^^

Page
t3-1 13-10 13-11

R bbedbe t: removng and nstaI ng . . . . . . - BeI puleylvibrat dampert on removng andinstaI ng . . . - Add t ona sLrbjrarne b|acket:rernovng and nstaling . . . Toothedbelt......... - Toothed t: removtng instaltng be and Sealingtlanges and engine tlywheel: removing and installing C|ankshafl seal-bet puley end:replace oil

73-25 13 29 13-37 1341

' Front sealing flange: removing ard nslaIng Fywheerremovrng instaIng and Crankshaft removing and installing :

- Cranlshaft d mens ons

Pistonand conrod:dismantling and assemb|ing.................. P stonandcylnderdlanens ons

13-44 t3 49 13,51 13,58 13-67 Page 15-r

15

Cylinder head,Valvegear
Cylinder head: removing and installing ' nlakernanifoldt removng andinsta ng . . . . . . Cy nderheadcover: removing rnstalting and - Cy nderhead: removng andinstalling - Compression ratio: check . . . . Valve gear: repairing

15-22

- Camshait sea repace or s: Exhausl camsha{tI sea replace o

Inet camshaJt seal:replace oil Hydraul cam fol owers check c ng Canrshafts: removing r.staling anci Vave guides: check ng \,'a slem sea iep ace ve Variablevalve timing: checking . . . va - Soenoid v of ihe cafishafl adl!stment syslem check nll

15-41 1 54 8 15,51 15-54 1 55 7 15-68 15-12

17

Lubrication
Lubrication systemcomponents: removingand installing. .. .. . . . . . .. Parl O er'e ci eck

17-1 11-3 1 79

: 1, r'r :: ' ::l : ra l ! f - r , , : r:,. .:::r,1 .: : .t,) .i ) F : : : ! i! J r,l : . ; ,:::r!i . .i ,ti -:rtt1 rI rr

''a - t l 2: 't i l'/

Page
19,1 t9 3 19 6 1.2-12 l!,15 19 22 13 21 r9-29 1933 t9 40

19

Coolingsystem
Cooling systemcomponents: removingand insra ing .............. - coa rg system aompoi3nis, boaty srce Coc ng sysleil compcnents, ne s.le eng Ccafa"i hoseconnecl d agram oil ' C.o art drirnrg andf lfg A:o.1or reanoving nslalng anil Cooarl pump:remlvrng anC |sial rng - coo antthefffostat:femovtng instaIng and
'oo o . . .r ^de. 05n6. Cor1nuedcooant c fculal pump,V51I check on ng Fadelorlans V7-and V35 checklng 'g

20

Fuelsupply system
Fuelsupply systemcomponentsi removingand instatling pafisandfi]elftter removrng i fstal i nq - Fuel lankw th accessory and precautrons Safely whenworkng on the fLresupply system
E.6 Ot . oo, .e c

Page
..

y Genera assenrb diagram th-a of fue detveryLrnrt fuelgaugesendel and FLre rvery de unilrernov and nstal ng Ng FLreeveisenderremov and nstaing ng Fuei tankr rernovrng instalng and

20-1 243 2 D1 2 20-13 20-15 2A-1e 2 A2 2 2A-23 2A-28

Crash shutoff tuel

- Fue pumpard fuelsyslem: checking power control{EPC} .. . . . .. . . .. . Electronic .. peda posilon senderscheck Acce;eralor rrg Activated charcoalfilter system . . . .. . .. .. . .. - Servicng pafts of the act vatedcharcoaii ter systern repairing . .
- F ra 1:.1 h' a ) il_ io r .h a .t n^

2A-29 20-30 20-43 20 44 20'41 20-54 20-55 20-58 Page 21-1 21-1 2 12

21

Charging Supercharging system with exhaust turbocompressor gas

es - FLr forc eanrness
- Tufbocompressor refaov and nstaling ng parts rgmovngandnsialing systear - lnleraocier
q:1!r, r'6.. i ^ ".

Connection diagram for the regulation of the supercharging pressure and vacuumcontrol - Tesi ng condrtcns fof exhauslgas supercharg syslern ng Effects pcssb e eaks n the superch:rg sysrem oi no ' SirDeraharg pfess!recontro check ng ng - llecha:r ca al: fec .culaton va ve checkng A r recrcLJ aton salenc va ve for tu.bocompressor i : ng -N2:19cireck ,N75- checlNg Soieno va ve 10jrmt s:percharg press!re d ng
D.1 -l_ a: r i. . D- . . , o . 06. . no . g . g p . | ... J

, ... . . 21-2,1 . . . . . .21-32 Zt 33

2i- 41,

2 1a A Page 24-1
2! - 1 : r 'l. l

Mixturepreparation, Iniection
Injection system: repairing F tt n! ocatonsoverv ew
A'l ief C s | Ia r:;n g a i a l E s s e n b n g

F L, ! r fi t ie
. q ;1:n , .' . . -

rJ e a l rr5 .j ,.i r:i a | rg ;

i ^^-

ai a;s:mbi ng

nali: an .l--a!ar - Gelarirl

Fiu forcieanlness es
Technicaldala.... Checkingcomponents Componenls fLrnct and ons.addpt ng

..

24 ia 24,20 24-21 24-24 24-26 24-27 2428 24-36 24-39 24-40 24-44 2444 24 52 24-59

ne - Eng control fault unrt rnemory: consu andclear trng ng Check cables cor.ponents testboxVA.G1598/31 ng and with Procedure interr!ption voltage aiter in supply Controlunit voltagesupply:checking intake r system leaks Check a for a r) lunmetered ... ' Eng speed ne sender checking . . . . -G28't nleclors chec(rng ... .. Iniectors: checking injectors leaksand amountinjected the {or C he ck pressurethefuelsupp s y s t e m n dt h eh o ld inp re s s u re . . . . . . . . . the n y a g

Exhaustsystem

page

Exh a u st system components: remov in a n din s t a llin . . . . . . . . . . . . . . . . . . . . . . . _ .. . . . . . . , . . . . . . . 2 6 - 1 g g ' Exh a ust manifoldr removing inst a llin g and . . . . . . . . . . .. . 2 6 t O pipe: exhaust removngand - Front nstaihng .... .. . . . . . . . . . . . 26-11 gas Exhaust temperature sender removing inst6| ng -G235-: and . . 26 ZA Exh a lst system:checking forLeaks . . . . . . . . . ... .......... .... 26-28 system: lnstaLl adlust h o us lb t e c t intg s t re s s - Exh a ust and wlt t o . .. ............... 26-26 lgnition system lg n iti on system: repahing ........... . . . . . . . information: ignition - Genera system l gn tonsystem ponents: com remov a n d n s t a lin g . . . . . . . . . . . ng page .......................... 28-1 . . . 2B-1 . . . . . . . . . . .. 2A3

q a f a n , n r a .r ,r)r

r ^ .. u o o , Jp d . Piu q )

relay controunit-J2 7 J chocti ng - Voltage supply to sender'G40-: - Hall checking ... gnition withoutput coils stages -N128 Nl58- -N]63-N-, and checklng ... , kno't qelso's -C6 -and G66 . "Ltrq

28$ 28-8 28,9 28-14

..

28)5 2834

Technicaldata En g in e u m b e r n
Theengfe nul]rber.ofslsts LJ;j r ne cfrar6ciers pnan!nieflct. o1 to (a Ine trrstpart(ntaximurn chatacters) 3 fraliesupthe,enginecode,,, ro"r. ,6 ro... , e co.c .qt 6. r , ro e rLa. 19 ll"^ -"
y"9,q-9e10 o ^ Ine sr' cnaracter: repacedwitl a lette. s t' -!6,d. 6a)gto.od.-.poouLoo,,tef . .o J

Theengrnenrmber("Codelefters and,'Seria nunrber,,lcanbefound on ine lo nt between engine/gearbox.

Theengi necode i s ona l abe pl acedontherool neci oettcov er or on t he cy Inoer neao -arTows . -heongi ,l ecooe . d,oonl hauel { e oai a p ot. l oul d i , t.ec_sr o r eT ve1r. a serl tce sa' l ed-l ed1d a ,o dr the .Faror rhe ,/eh .. .. . L r . sp. t e w heel housi ngor the fl oor ofthe boot_

Fo0-1_

Engine data
Enginecode ExhaLrst ssonlimitsaccord to em ng Disp acement Torque Diameter Stroke Compressiono rat OCT nlect on lgnitron Knock contfo
Variable striblton d Varrab ntakenanifod e rl Exceptionally, mtnim!m

AMK EU3Standard 178 1 154/5800 cm3 kWmin Omm mm 86,4

Nm/min210/2140 ...5A0A

{. -..l.

3u[ t

Motronrc ME75 Motronic ME75

octane95 OCl,butwth somepoweross

AMI( SelfiAcdiagnpsis

iF6rratioo taqldea
convener Catalytic gaa Exhaust fitcirculstlon Super.flarging 6ir Secondary syslgJn r

yes no no

\14

L . a T\a'!l

Engine: removing and installing

Special tools.workshop systems, testers, measuringinstrumentsand auxiliary items required I Engine brackel 22044 AF a Bracket T10012 I S!pport toolT20082 a HodingtoolT20127 1 Workshop crane VA.G12024 a VA.G1306 p tray Dr

10-1-

sAT801o q0m!E-{8"_* (Gdn{+- "*. @0!!:}

r Hydrau co umnjackSAT ic 1040 a Torque spanners 8010 SAT p t T20029 iers a Guid centrahser ng T20070 a Compression U-30042 tool a Step ladder

f2@29

120070

I Cabeclamps a G 000100grease I Boltlvll0X 25/ 8.8

u-30042

Ti;-;1

Removal: notes
a The engineis renoved d.y,nrrds iogeiher r,,itl th_.Ee:rbc!. ) All cableties wh ichare openedar cut opertwtten renjovng engne must be replecedin Lhesame position wheD re tnstallitlg. a AII thermal prctectian sleeves rcmoved must be re ffted in the same place on teassembly. a Theremavedcoalentshauldbe put nIo a cleanreceptacle be rc to used ar dtspased()f. Femoving ribbedbelt page13 11

- "t'i- a;
\, -

{v
ae=

Drain coolant page19 15 - With ignition switched disconnect off, battery earthstrapandthen tfrepostrveterminal. - Removesecur ng bolts -arrows-and removecoveT -1

_ 10-3

Unc|p fuseholder the suppcrl framearrows-. Openandremove proteclive the battery cover , . 1 Remove -2-,supoort plate-3 Endremove lrattery. bolt tie

Remove batteryhodernrrowsthe

Locserc anr! .i- rer-|!!e n;err .,se-5.6rdconi eal t I ir ol- t h Fernove ls -l anC3 :nd rerrovethe arr bo

pressure D sconnect reguatorvalvel of the engne breather from the arrinlethose4-. Fernove a r recirculatLonve ,2-from the air rnlethose,6,. the va Removeconnector-3 of the sLrpercharglng press!fe soJenold valve

Femove hoses and 5 fromthe supercharglng pressure enod -4 so valve'N75FeLease tube-arrow-and the remove a r in ethoseS reeasrng the the fange that secures to the exhaust turbocompressor gas it

Reease cooantpipef ange 1-andremove t irom the meta the tube. D sconnect vacLrum -a(ow-. the hose

<

' Uernove airoari ltose5 iir lreaixchaoger thr ioi -erfou"rs-

<

' Remove earthcable-1-lfom the engne/gearbox the - Fernovecab es -3 and -4-from the braner moror Sepatethe connector andremove from the bracket. -2 it Remove cabes from the clipon the starter the motorand piace on one s de; unbot the clip.

_ 10_7

-1r=-==1,i

a screwdriver a(ows and loosen hexagon th nuts a few turns. - Loosen w ndscreen per aTmsl- from the shalt. the w - UnscTewand Temove hexagon andremove windscreen the nuts the w per arms. Remove rubber the gasket 2 from the p enumchamber cover. Remove p enlm chamber the cover andplace thed rectonof -3 in Ine wrnoscleen.

<

- Se@ratethe e{t-ha con nd nector romthe con Lrntbymovtngthe f tro catchrrow-

Open e11 d ., de .:abie iar cfarrrl e n i i e er qtre tr:y : rc\ a- sD sc n rectihe a.r n,.cror ' i tfre cei l l e channel .

Femove conneclor the from the bracket reeaserl ,arrowand Uncover w nngharness thecontroLtnil engne. the of to

_ 10-9

Femove gearbox the contro cabes on gearbox iolows: as - Removethecrrcip-4-secur ngthe connection cable t he connec to tron rod l the - Remove c rclip-3-securing selection the cable the selector to le\/et 2. - Remove select cableandthe connection e from the plthe on cab vots -aTTows-.

fows and p ace t on one s de.

C l amp tn hose f. i i r: . .ri .l _P !rnp,.^.' ri 13ol ! 3l !!2. P l l the cai ch u pi .!: fcs -arrow , remove tne pressur e pt pe - 'l-

Waming! Do not prcss the clutch pedal altet refiovingthe ctutch pump.

Removetheconneclorforthesupercharg ngpressuresender G7lano re easethe a r hose arrowsRemove the alr hose frornthe throtte va ve contro un t.

_ 10-11

an1crculaiton p!mp -v51-. - Unboltthe contLnued coolantcrcuattonpump -V51 fromthear condurt -left-hand arrows-; cooant hosesremainconnected the

,l o- 12 _

Removethe connectof-arTowof the exhaustg:s lemperature sender -G235.

-_

f e@$t

_ 10_13

the - Remove vacuumhose-2-from the ntakemanifold Remove coolant the hose-1-lrom the expansion tank Release coolant the expans tank and lay10srde. on - Reeasethe vacLrum tLtbe the charcoal lter system for f powersteerng tank and lay10 s de. Remove

so, pressthe unlock keys ng Aftention! The fuel system is under prcssurc.Before opening the system place a cloth arcund the connection, Then release Drcssurebv carefully Ioos ening the connection.

'10-14 .-

_2_ tlrbeconnectrno two ntercoolers the

_ 10_15

- Brino ockcarrer into servicepositonl + Gefera BodyRepairs, installation work,exterior; Repar group50; Generabodyreparrs, iront;Lockcarrier pos! LeonCLtpra service R: tion Bemoverighthand drve shaftand dlsconnect handdriveshajl left at gearbox: + Runninggear,axles,steering,frontwhee andfourwheeldrve; Repa r group40; Drve shaft:removing and instal|ng Remove pipe+ page26t1 front exhaust

It ts not necessaryto remove the sub-f?me, just push the front exhaust pipe to one side so tt does not tnterfereduring disassembly - Be ease the ower rad ator hose pendulum - Dlsconnect suppon affows-.

f EnTqol

_ 1 0- 1 6

<

FenloveI ghl nand nsu aticn arrows-

Loosenthe bolts-aTTows- removethe puley,l- from power and sreefing vanepump.

_ 10-17

Removethe bolts ,arrows and remove the vane pump. - Secufethevanepumplolhebodyworkinsuchwaythatthehoses are not in tension.

ReLease powersteering the pressure pipe-j- from the flanges ar

IOWS-.

r\:?

.' I

-_ _ o 'r al Fo.or3-1.

.-_ 10_18

_ 10_19

Vehicles with air conditioning

Attention! The ah conditioning cooling circuit must not be opened.

Drsconnect connectorf- in the air conditicning compTessor. Remove bo ts -arrows-secur the aircondtion ng compressoc the ng

Move the air condtionercompressor downwdrus ano securelro the ockcarrrer thatthe refrgerant sc hoses/pipes not underten are

_ 10_20

continued for all vehicles Secure T 10012 the bracket cy inderblock th Ml0 X 25l8 I nut to w and bolt

-ll-_j

itr{ i
---/ '-T10012
SAT 1O4O TEii-ofi;l

- Liftthe eng ns andgearbox ght y w th the SAT1040 sl hydrau co, ic

en9ne bracket -arrows-_the Toremovesecuing bolts use a ladder

assembly moLrnting gearbox - Unbolt support fromabove, side,ffom Ine gearoox aTTows-. lowerthe engineandgearbox. - Carefully Note: Engine and gearbox must be guided carefully when lowering ta prevent damageto the bodywork.

10-22_

Engine: securing engineto assembty stand

Forassemb the engrne y, must be secured the AR2204A to assembly standwith the T20082enginebracket. Work sequence - Freethe gearbox. - F t the holdlng tool T20127 engineandwith the aid of the work to shopcraneVA.G 1202remove the engine from bracket Tl00l2. Note: Checkthat the hooksare closed with their safety nuts

- Securethe enginewith tool T20082 to bracketAR2204A.

10-23_

Installing: notes
g

l^cialatro- _a- ed o ti t- tre er'e.leceoLrenc6.whe-dongths-ote ts tne ro owtnq - Checkwhethef the dowel sleevesfor centring engine/gearbox are rnthe cy nderblock, instaI f necessary.

' Fit intermediate plate onto seaing lange and slde onto dowel sreeves-EfiowsCheckcentr ng of clutch drive plate, f necessary.

Checkclutchreleasebearng for wear, renew i,fnecessary. grease - Lrghtly clutchrelease bearng, re easebearng guides eeve and inputshaftsplLnes wtth G 000 jOO - When rnsta ng the engineassembly, I ensLlre there s soffrc ent ciearance wlh relaton to drive shafts

-m;a

.to-24 _

- Fftthe enginebrackets - A ign the enginebrackets page 10-30 + Note: Engine bracket tightening torques+ page 1G2B rbox - Fit.gea contfoand,i{necessary, adjustgearboxact oningmech-

+02M 6.speed qepair 1r4lrr.gearbo\; gearoo\. ^ran-at g.oLp 34; tleaf onvemecnanrsm: adjL'lst nq - Fitright-hand driveshaftandfit left-hand driveshaft the gearbox: to + Running axles, gear, steering, wheeland wheel front four d-rive; Repairgroup40; Drrve shaft:removing lnstalling and pipe+ page26-11 - Fitf rontexhaust . Continue assembly reverse in order the dismantling of procedure

anrsm:

10-25_

Notes: a lf the battery is reconnectedcheckthe vehicleequipmentlradio/ radioand navigatioh system, clock,power windowsLlolowihg the indicdtionsin the Operatinglnstructions. a Other measures after reconnectingthe voltage supply + page 24-39. - Carry a test driveand interrogate memory: oui fault + VAS5051;Vehicle sell-diagnosis

_ 10-26

Tighteningtorques
Elements Bots, nuts N4 6
M7 MS

Tightening
10 Nffl

1 5Nm 25Nrn
4A N,TI 60 Nm

I t

lr4 lO M12 Different itghtening torques

i I
I I

Engine gearbox to connecting ts bo Engne to gearbox connecting bolts

M10 l\A12

45 Nm 80 Nm

i I
_ _ 10-27

Enginebrackets
I

Tighteningtorques

I - Mounting bodyr) to 2 - S e c un gb oI t o mo u n n g r t 3 Mounting engne rr to

-Nost

40 Nm + 90 . (1/a turn) iurther 2 5 Nm 60 Nm+ 90 " { /4 turn)fufther

t
I

r) Fepacebolis

i
ifl-1Mo u n n gt o b o d yr) t 4 0 Nm* 9 0 . (r/4turn) fufther 2b Nm 60 Nrn+ 90. (r/4turn)ruftner 2 - Mountrng body to rr 3 - Mounting gearbox to
I N-dMl

1 )F e p c eb o h s a

_ 10_28

/-3 1 2 3 10 gearbcx l to gearbox r to the engine bracketrr 40Nm+90' 1r/atufn)iLrther 40Nm+90' {r/a lurn)fLrrther 20 Nm + 90' (r/a turn)fufiher

-. 1 0 -2 9 -

Engine brackets: Aligning

u-30025E
Special tools,workshopsystems, testers,measuring instruments and auxiliaryitems required a Cross member U-30025E

tw26il

Note: Beforcloosening engine bracket bolts,securethe enginewith cross memberU-30025E. gearbox Engine brackets, Theedges and b mustbe paralle -awithoneanother

_ 10-30

a = 14.0 mm b = At leasilo.Omm Eolh bolt hads-1- must be in flus* Wid!6dalec

r
I

: I F

10-31_

I
I

tI

I
I I

tI I I
I

iI

I I

I
I

r
i_

Engine: dismantling and assembling

lf when tepatringan engtne,metalshavings ar latge quantties of sma1metal pafttcles caused, fat e\anple, by patdal seizure af crankshalt and conrod bea|)ngs- are faund in engtne on, to prevent consequentialdam, age,apartf rom tlrcraughlycleanng ailpesseges,tt ts necessaryto renewthe ajlcaoler I + page 13-2 + 11 pagel3 6

lll- page13 25 V+ page13,37

G(

"Kl\"s
f-T-oi ?6I
Part I

6-s

\u

$I

1]

ii

\-6

1 - Knock sensors 1 -G61- and 2 -G66a Checkng Page 28-34 2 "20 Nm a T ghtening torque Inf uences the f!nctionof the knock sensor 3 - Dipstick a The oll levelmust not go abovethe

7
f,e-8

4 - Coolantpipe a Secured cy nderb ock to a Cooa.r ho)e o ,e.r o. o.ago- > page19-12

10 11 12 14

20 19

'I a 1 7

tEi3-oor5l 13-2_

if

qiJ
)))..

5 -20 Nm 6-15Nm 7 - Oil filter bracket a D smanting andassemblng Page 11 11 8 - 15 Nm + l/a turn (90 ") 9 - Oil cooler a Lubrcatecontactsudaceswth the olfiter bracketbeyondthe O-ring with AMV 18800102 a Ensure clearance adlacent to compo, nents

/r

I g

'6

7
l_1, @ 8

12 13 14 16

20 '19
13-3-

rz

l\tl

.t

t\F

\\ \\,r I
\\ rlP

10'25 Nm 11- Oillilter ,f Loosen th turnng loo U40078or w a unversaftlterextracior a Tighten hand by a Noteinstructions f lterwhen rn on sraI ng 12- Gasket

cJ

\\ \tll

Y 1/

| A

ds -4"*u
7 I

1 3 -1 0 Nm 14- Enginespeedsender-G28a Checking page + 24-48 15- Connection sleeve 1 6 -1 5 Nm

12
l't

14
l5 lo

18 1 7

t F,

^oq

13-4 -

12

il

dJ-

I
/

tr

17 - O{ing a Flen-.w danralted rf 18 - Coolant thermostat l| ChecLrng: leat iiE iirirn osi;t

+6

Openng comrnences approx87 'a Endsapprox. 102'C OpenLng min 7 mm iit D smantling fitt ng page19 29 and 19 -45 Nm 20 -Additional sub-frame brackets a Dismantlng fit ng page13 17 and 21 -45 Nm

t a t a

11 12 _-13

22 - Right-hand engine bracket

.$J[t

to

2 0 19

1A 17

l=-r3 oorsl
13-5 -

89

Ribbedbelt
Part ll 1 - Ribbedbelt
a Err rg -he b6\ ro r'6ri.l6r ,.-\o.r a. + conditioning page1310 t F tting the be t 10 vehcLes with a r page13 10 conditonng a Engines wth -an a r condtioner com
nr e<<^r :,o {l da/l ,! r l r ! /l ^ h a . h Fa . l

bet i Checkfor wear a Do not kink a Dismantng andfttng + page13-l1 2-23Nm

't7

16

'15

TA13-0380-l 13-6-

89

10

d.

3 -Tensioning device for ribbed belt 1To reeasethe lens or ofthe toothed relt Lrs.r flarspanrer page13 12 a 4 - Belt pulley/vibration damper r w th I bbed beft a Drsmant andfrtttng pagel3 l5 ing > 5 '45 Nm 6-23Nm 7 - Alternator a Removirg and nstalingl = Electricalsystem; Fepai. group 27; Staft motol current er supply; ternator: A reraovtng instai and ing a To faciliatethe instalat of the a on ternator, movethe threaded bushes tor tne alternator bolts a tte back_ watos.

14

fAr-3 o3sdl 13-7_

8 9

10

8 - Air conditioner compressor IAfter rernovng, secure the compressorto the srl, e.g. wth some w re. Do notlet thangfromthecoo ng agentprpes a Do not unbovremovethe coolng agenrp pes a Tofacltate thefrtting the aircond of tron ng compressor, move the threaded bushes the compTessor for boltsa rtte backwards. I -Spacer 10 -Additional sub"frame bracket a Disman ng andfitilng paqel3-17 11-45 Nm 12-23Nm

16

15

f;i3 b3so] _ 13-8

'13- 23 Nm a Forpowersteerng a Removing an,:]nsiaLing gear, {rolrtwhee steering, + Funning axles, foLrr whee dnve; RePargroup 48; End Dox:re Powerass stedsteenng Steerlng, movingand nslallng a To faciltate the ftting of the vane bLrshestor PunP,movethe ihteaded the bo ts of the bracketa itt e back' 15 - Belt pulley i Forvanepump 16 -23 Nm 17 - Special bolt Q For 8.8 reStstan..bo t: ono.^ the ool..! g-ior ro l0 N' a_d errohran to 90' a For 10.9 resistancebots, the bo' shouldbe tghtened to 40 Nm

,,to

14

tAi3 o38o-l 13_9 -

Ribbedbelt routing
onercompTessol withoutarrcondLt Bet routing

wLiharrcondttoner Beltrouting Note: Engineswllh an air condn oner fitted with a daubie

13-10 -

Ribbed belt: removing and installing

Special tools. workshop systems.testers. measuring'instruments and auxiliary items required a Ho dingtoolT10060 Notes: a Beforercmoving the ibbed bel{ matk thedrcct@nof rotatian wih chalkor a felt tip marker ../ a 1fthe belt has been useiJand is made to vr'otk the opposie djrecn tian tt may be destraied

rwoet

Dismantlirr'g L}sas<an 'g ITp e g -6 cor'er 0 .row.

eg 1:

-' tu,i( |
_ _ 13_11

./

,;

tension the ribbed t, turntherensionrng ce inthe on be dev ., To re ieve drrectron tfre-arrow, oT

13-12_

arrow Locktension e ement !srngtoo T'10060 ng

centra insulation -4ffowsFemove

,! r eP

t 'u'-\'
13-13 --

insuiaton rrow's. rght-hand - Remove ribbedbelt. - Remove Installation (alternatot, ai ribbedbelt, that a ancillaries Ensure,befare instalting comptessar,PASvanepump) arc secured tightly. conditianer Fit the ribbedbelt to the crankshait and vane pump pulleys

pulley last - Firthe ribbedbeltto the alternator _arlow'and the release ten_ irom its position toolT10060 ' Remove elemenl. slonrng CheckcorrectJtt ng o{ the Rlbbedbelt. ng in orderof the dLsmant procedure Continue assembly reverse and checkhow be 1 is runnrng. Sta.tenglne

13-14--.

Belt pulley/vibrationdamper: removing and installing

t
I

Dismantling

Ta loosen and ttghten the beit pulley/vibratian dampea immobitise h, holdingthe centralbalt whh a ring spanner page13 TT. - Removethe bolts and the beit pulley/vrbration damper. - Femoveribbed bell

Installation I lt can only be fitted in one posit on, ihe dfilled hole -arrow' of the vibration dampershould on the highllghted ofthetoothed be part pu ey.

_ 13_15

- Tightenthe vrbraton damper/beltpulleybolts as indicated: a For8.8 resstancebo ts, renewthe bolt,t ghtento l0 Nm andre ttghten 90' to a For 10.9resistance bolts,the bot shouldbe tightenedto 40 Nm Install rlbbedbelt + page13 11. Contnueassembly reverse tn procedure orderof the dismanting

13-16 -

Additional sub-framebracket:removingand installing

Removing , "o'5'1 .o..r'' t p t Bet6,s6,,s n-. qao., in the radtonanual ':,ust be absetved cluded a When the bettery is recannected check the 'lelticle equtpment iLl fallawingtheindicatrcns the WorL tadrc, clock,powet wtr)daws), .o. M I L"lar1o. t.' ODca a 11" u\ia' battefy eadh srrap Wth igndonswiched off d sconnect ribbed belt + Page13-11 Removing the nnuts-l-and remove removethe the -arrows-, - Loosen flanges ng connecl tube -2 tefcooler

_.:.--:--::

r1

13-17-

pul and bolts-arrows- remove ey 1 fromthepowefsteerlng Lcosen

the and remove vanepump the bolts _arrows- Femove ' Securethevanepurnptothebodyworkinsuchawnythatthehoses are not n te nsion

13-18 -

Femove th bo ts -arfows and removethe coverl-

t t
I I
Remove the connector -arrow of the exnaust lemperatuae gas sender -G235.

t
I i
i
_ 1 3_ 1_ 9

I
Feleasecoolant hose 1 from bracket-4-. Removethe bo ts -2, and -3- and remove bracket 4-

_ 13_20

Sp:iaiethe conneclorarrow. Remove .i -1 ard removethe :1-rndtor eeatr c cai r! r

2

Remove ts -1-and rernove alternator. bo ihe

13-21-

the rlbbedbelttensroner. Removebo ts -arrows-and remove

Vehicles with air conditioning:

Attention! Theafuconditioningcoolingcircuit must not be opened.

compressor conoectof lor the alrcondtlonrng -1- Disconnect arrowssecunngthea rcondrtoningcompressor. - Femovethebolts

13-22_

Y o,

. e-

.or,d.ro.r < orha-r

,:::..." ,-

oo{ .,y.ro. a.o . ( o. t o no.e> ,proo a. a or - noel -roorroooo-r

010,6,u

I
I
D

Removebolts fforn the addttional sub{rame bracket n the estab_ lished order-E....A-.

I
f
-Net

_ 13_23

Installation

E B

- Tighlen the bolrsof the additona subjramebracket the estab_ in lished order -,A .....F- 45 Nm. to Continue assemblyn reverse orderof the drslram ng proceoure Nots: a lf the battery is reconnected ctreck the vehrcle equipment lradjo / tadta and navgahon sistem Toct. pov\e! Andowst. totta^,ng the tndicat@ns the Operatng lnstuctians. in a Other measures after rcconnecting the voltage supply + page

T@;6I

t'
i

13,24_

Toothedbelt
Part lll 1 '25 Nm 2 -Tensioning device {or ribbed belt a To re easethe lension of the toothecl + be t usea flat spannef Page13'12 3 -Toothed belt guard - upper Part 4 - Toothed belt guard - centre section 5 - Toothed belt a Mark D.O.R. beloreremovng a Check wear for a Do not kink and a D snrantling ftting + page13 29

23 22 21 20

19 18

17
Erruqrl

13-?5 -

6 - ldler roller 7-27Nm 8 -65 Nm I Use tool T20018Ato loosen and t ghten 9 - Camshaft sprocket thin I Notefitt ng posltion:The coreof the carnshaft sptocket Ponts oLrt wardsandTDC markof the cylrndel canbe seen.1 roller 10 - Tensioning 11 -Tensioning device for toothed belt a iesting the hydraulicelernent for / 12 - O-ring

rry
23 22 21 20

t\

19 18

17
13-26-

45

6 7

10

13 Coolantpump t Lhecllfor elsaiof rovenreni andro g.p: a T dan ;!te.l or lsakrng: fenew ccri a Drsmanl andlinjnq+ pale jgtj ing 14-15Nm 15 - Crankshaft toothed belt sprocket a Thefemusl be no oil on the contact sur%ce between toothed the belland the cranksheft 16 - 90 Nm + 1/aturn (90 .)

13 14 24

a use tool T20018Ato loosen and trghten a Threads shoLr m!st befreeof and der o anogTease 17-15Nm 18 -20 Nm 19 - Toothed belt guard - lower part

23 22

2"1

18

17
fEJr oi l
_ 13_27_

4567I

9 j

2 0 -1 0 Nm 21 - Pulley a Forpower sledsteering ass pump 22 -25 Nn

@
11
T I

23 - Ribbedbelt a N/ark dlrecton of rolationbeioreremoving a Dismant andlttjng> page 1l ing l3 24 -25 Nm 25 - Beltpulley/vibration damper t Can onlybeinsta in oneposit ted on. Hoes afe of{set t D smant|ng fitl nq page and 1315 -

14

21 20

lo

18

17
I c,r-u 4)

_ 13_28

6nng!-:-r
OdB!]:F

,."-

*s\.

Toothedbelt: removingand installing

Special tools, workshop sYstems,testers, measuring instruments and auxiliary items required SAf 8010 a Torque spanners a Holding tooLT20046 a U-30025Ebracket

t L130056l 13-29-

Dismantling Femoveribbedbelt+ page13-11 RemoveboLts-arrows-and removethe ribbedbeJttensloner

= w7

FN;]

installed: Englne to ' T\rrn crankshaft TDC No.1cylnder

13-30 -

Ern rarrenrlvgal: < ' Trr r vibrat Canrper TDC l.,loI cylinder on ,arrows ro Reiease coolant th exfrans tank ano ay ro s de on - Reeesethe vac!L_]ff tubefor the charcoalftller system pov,,er - Remove steerng tankand ay to side. Bemove upperpaft of toothedbelt guard.

- F t the hookof the spindleA- n the righthandsuspenston and eye pre,tension slghtly.

Ji.i*
_ _ 13_31

Femove the bolts-arrows- remove and the enginebracket Rernove braton dampe/beltpuley + page13 j 5 v

Remove bolts the securing support theengneblock the to rrowsRemove toothed t guard be centre and owerpans MarkD.O.F. ioorhed oi beft.

_ 13-32

Lr" to ' T ghient.,olT2004e th-' toolhecl l l:ns ofrng cevce p pressLrreslon Lrsing iens on devce orry r ntllpressure Tighten 'rg e p sinn cai be sec!fed r'"ltl_ ockln! bol -fiio""/ Fenrovetoothed beh lnstallation a When camshaftis tutred, ensurec?nkshaft ts nat al fDC Danger crawn damage. of valve/piston

a Marl<D.O.R.af toothed belt, dangeraf breakage head with the mark on cylinder sprocket Algn mark on camshait

/f"(tt
lz^...
\ \\J,/

Lfl16x-''
I /-

l-'.
{

lt

r,,----.,\-,2

13"33 -

removed: Engrne damperto TDC No. 1cyInder_arfows - Turnvibration

N '\
Ergn. r-s-aed 'alrow_. cyLinder to crankshafl TDCNo.1 - Turn o ro - o , a a e o t h e o 6 ho n . ra rrs ^ o lp u 6 \ o o s e . . e t' e . r i o o ' ' o l a t on) rol tensoning erandcamshl be toothed I oncooantpump, - Place

f= @ 5 1

13-34 -

r
l
I
Unscrewthelensroning bolloitoo T20046and removethe rmmob a Jhe pressure slon relufnsto its work ng postion p Turn crankshaft tufnsandcheck camshafl cfankshaft the two il and marksalgn with refetence marks. ' Fit toothed beh guard centre and ower pafts. Note: Befate fitting the engine bracket attach its balts.

t I I
I

I
I

- Fttheenginebracketon thecyltnderb andtighten bo ts -ar, ock the rows- to 45 Nm. - Fitthe vibraion darnper/bepulley page13 15. + t

_ 13-35

Frtthe engne brackel remove engrne and the support tool + - A ignthe engrne brackets page 10-30 Note: Engine bracket tightening torques page 1G28 Continue assembly reverse in procedure order the disfftantling of

t
!

i
_ 13_36

and engine Sealing flanges and inf lywheel: removing stalling

Part lV

For repairc to the clutch: +02M 6speed manual gearbox,4x4lm. gearbox; Repa group30; ClLrtch: r repairng 1 - 90 Nm + l/a turn 190') further a llse tooi T20018Ato oosen and tighten a Threads shoLrlder and mustbef reeof
o r d 'd g e d ! .

2 - Crankshaft toothed belt sprocket a There must be no o on the contact grfa belweentheroorhed I d.d be -e the crankshaft

7
13-37 -

12 3

3 -' t 5 Nm 4 - Oil seal I Fenew page 13-41 a Do noloil 5 - Sealing flange 13'4, a D smantling fttlng+ page and 6 - cylinder block I Cfankshaft: removing and nstalrnc + page T3-51 anu a P stonand conrod: smantlng d + 13-58 assembllng page 7 -60 Nm + r/atum (90')further t Use tool T20075A loosenand to t ghten

llIL l

ttt
,Se

10 3 9
13-38 -

8 - F,ywheel I Flemovrng arid p3get 3-49

insta ng

I - Intermediate plate a Do not damage/bend when assem blrng I Installation position Fig. i 10 -Sealingflangewith oil seal a On y renew complete aDonotol a Makesurethe oi seallipis not damagedor benton fitttnq a To ft, insertthe guide sleeve(suo pliedwith the seal)on the cranksh;ft a To removeandfit it is necessarytore, movelfre sump paoe 17_15 -

10 3 9
_ _ 13_39

Fig. 1

Insta ing intermediate plate

plate onto sealng flangeand slrdeonto oowel - Fit intermediate s eeves arrows-.

=-_

13.40_

{01((::-.: fi!1ft:_ tni0]]+la ];

. ,," -,",,., .,

Crankshaftoil seal -belt pulley end: replace

testers, tools,workshopsystems, Special measuring instruments and auxiliary items required a Torque spanners 8010 SAT a Hod ngtoolT20018A T200818 a Gulde sleeve I Extractor T20143

t Litno54l
1341-

Dismantling Removetoothed belt + page 13-29. - Removecrankshafttoothed belt sprocketby lockrngwlth counler_ holdT20018A.

nsert exlfactorT20'143 and removethe oil seal 1

13-42-

Installation

T200818/4
Do not ail the seahng lip cr the e.lge of the ott seat

i-

- Sl de o I sealoverg! de steeve T200g1B/4 - P ace set ontocrankshaft stub U'e g- de < ee.. T-005 8 t o p e"s o. le q.66ve-o l seot cFa. d. " lllvd,1., a r.,\tl oou-- lhe5eolt-llu.h. lodoths,u.e..6otd securing boltfor vibration damper . Femove gurd6 eeveT20081B/4 s

' Ft crankshaft toothed bet spfocket immobilse and wth counter hold T20018A. - Tighten newcentraboltto: 90 Nm + 1/4 the turn{90'). Note: Thread shoulder and must be freeof ail andgrease. Fittlng toorhed the belt + pagej3,29.

13__

T20018A

Frontsealing flange:removing and installing

SpeciaI tools.worftshop systems, testers. measuring instruments and auxiliary items required a Torque spanners 8010 SAT a HodingtoolT20018A

sAT8010

a Gude sleeve T200818 a D116404 Silcone A2 sealanr

fmml+ @Ir:_E

E -__

a Hand with p astic drll brush insen i) Flatscraper

tLi3-oo35 l _ 13_44

Dismantling Femove tooihedbe t 3 pagel3 29. Femove crankshall toothedbe 1 sprocket ocking by wth counter ho d T20018A Remove slmp page 1715.

bo - Fernove ts 1...6 securrng front sealLng the flange lf releasebygenilytappngwth -Removeseaingflange.necessary, a rubber malet.

13-45

Femove seaant residue cy inderblock th a ilat scraper. on w pastic - Remove sealant remains sealing on fLange with a rotating bruslr (wear protectivegoggles). .. -'r-st be r ee o- or a-d g ea.6 -leo_sea rg s ida lnstallation

a Note the use by date of the sealant_ a The sealing flangemust be installedwithin 5 minutes of applying the siliconesealant.

(nozz d ameter: Cutoff tubeno2zle lorward at marking e appfox. : Appy si cone ingcompound, shown, c eansumpseal sea as to n! o Thckness seaLant -arrows-:.. 3 mm of bead 2

13-46-

I
i

t
I I I

The,sealing compoundbeed r,ust not be thicker,otl)erwisee\cesstve sealtngcompaund wjll enter the surnp and may block the oit suctjon - Appiy-silicone seaIngcoJnpound, shown,to cleansump sealing as Fit seahng flangeirnmediate and lightly y tightenall bolts. Use.guidesleeve T20OB1B/4 fit sealingftangewhh the oil seal to al ready installed. - Tighlen the boltssecuring searngflangein d agonal the seqLrence to 15 Nm ' Installsump page17J5. + qtler FsGth,ng sumphe sealahl must DFa|otuedb d,V foroppr|\.30 mtFLtes. Anet rfts ttme has passad, tha sumDma, be litled.

T
i I
I t

I
t

1347 --

I
I

- F t^crankshaft toothed be t sprocket by ocking with counter ho d T20018A - Tightenthe new central bo t to 90 Nni + 1/4turn. {90 .) .

Note: Threadand shoutdermust be frce of oil anogrease. - Fitting toothedbett pagej3 29. the -

_ 13_48

Flywheel:removing and installing

1200754
Specialtools. workshop systems.testers. measuring instruments and auxiliary items required a Holdrng toolT20075A

sAT 8010 t Torqle spanners 8010 SAT

fi0m]l*:ln ll]]mt]H=tri.,.". mCIl':

t!!@;E

1349 _

Dismantling on - N/larklnstalat postionoif ywheeltocrankshaftwithpermanent a ' Se.u.ecoLnre-hold_200754_ocy heaohoea-o m-loolse 'loe the flWvheel. fywhee securng bo ts and remove flywhee. - Loosen the lnstallation ' Pace fywheelon crankshaft the previously position. in marked T ghlen the new fl\..wheel secur ng bo ts to 60Nm + r/a lurn (90")

_ 13_50

Crankshaft: removingand installing

a The cylinderblock will be assgned with the carrect thicknessbearingshellsat the factory. The thicknessts tdentifiedby ce I Farassembly, engtnemust besecured the to the AB2204A assembly standwnh the 720A82enginebracket. 1 - Bearingshell I Forcylinder ockwth oitgroove b a Do not mix !p used bearng shells (mark them) I New bearngshells ofthe correct coour shouldbe used Flq 2. oaoe I3-56

aa'a;,
f A l3 o t g l _ _ 13_51
2 - Chain sprocket a Foroi pLrmp drve 3 - Bearingshell a Forbearngcapwthout oitgroove rl Do not m x up used bearng shels (mark rhem) o Lowercrankshaft bearing shels are always suppied as a sparepartwth the colourmarking "yellow" 4 -Thrust washers a Forcylinder ock,bearng3 b a Notefixingaffangemenl

A\

r.\h

_ 13,52

5 -6s Nm + 90" (r/a turn) I Tghten to 65 l..lrn nr.asorng radrelcleaiance ^'hen 6 - Bearing caps 1 Bearng cap 1:Puley end I Bearngcap3 w th recsses forlhrLrst I Shellbearng retanrngluqs (cyirder block/beafng cap) must be on the 7 - 10 Nm + g0' (1/aturn) l} Wheneverthe ts are oosened, bo the senderwheelshouldbe replaced Fq. l, paqe13-55

tAi3 oo?r l _ _ 13_53

8 ' Sender wheel

a F ^. a^d na <naor l c o.dar

q Canonlybeftted n one posrt (the on holes afe ofisetl a Wheneverthe boltsareloosened, the
<an.]ar M ,h6a <h^ d l !a r6 ^ l ! . o n

-C t c -

o Dls ma n t ln g d f ln g -f i g 1 , p a g e an n 13-55 S - Crankshaft a Axralclearance, 0 07 .0.23 new: rnm. Wear t: 0.30 lim mm a Checkradial cearance with Plastigage.New: 0.02.0.04 mm. Wear irn lt0 1 5 mm : a Do not rotate the crankshall when checklng radial the clearance a Crankshafl d mensions-page13 57

fFtm?r-l
_ _ 13_54

Fig. 1

Removingand installingsenderwheel

Whenever bolts 1 are oosened, sender the wheel sho! d be re placed -2-

tM;$

a After a secand assenbly, the countersutlkbalts holes arc sa de tarmed thatthe headsaf the balts make cantactwtth the cankshaft -3- and the sender wheel rcmainsloase a Thesendet wheel can only be fifted in ane pasitian;the halesare

I I
_ _ 13_55

Fig. 2

Assigning the crankshaft shell bearings tor the cylinder block

n the factorythe correct thickness I beafngs are selected. she The th ckness is ident fred by co oured spots. Note: Thearrow indicatesdirectianof mavement. The p aceto f t the shellbearings indicated letters the lower is by on sealngsudaceof the cylinder block.

Letters on the cylindrb!ock S

Colourof shell bearing

black

F;A;l

R
G

Note: Replacement kshaft cran bearing shells always are suppliedasa spare parl wtth the colourmarking"ye aw".

_ 13_56

Crankshaft dimensions
(Drnrens r rnm) ons

Honing Main jou.nal I dimensions Basrc

Conrod journal

4,411 54,00 {,037

-0,017 53,75 ,0,037 {,017

-0,422 47,44 ,a,o42 4.A22 41,55 -0,442

Phase

PhaseI

o,022 47,34 4,442

4,A22 41,45 -a,442

Phase lll

-a,017 53,25 {,037

13-57

Pistonand conrod:dismantlingand assembling

1 - Pistonrings a Offsetgapsby 120' o Femove and nsta with piston I ring p le rs I "TOP"faces towafdsptstoncrown a Checking gap+ fig. t, page rng 1 36 3 t Checking 10groove = nng clearance trg. 2, page 134 1)2 or 3 piece scraper oi ring,canb-

1 1,)-

\
'!-

-bM,

-F

t v lJ - io rt l _ _ 13_58

* -2 11 -3

2 - Piston a Checking Fig. 3, page 13S5 positon and prsion/ a Mark nstall:tion cyltnoer cofiesponoence a Arrow on plston crov/n ponts to crankshaftpu ey end a InslaI Lrsing ston r ng s eeve p a Pston and cylnder dimensions + page13S7 3 - Conrod a Onlyrenewas a set a Mark cylinder number-Ba MarkingA facestowards pulley end t With a dr led holefor lubficating the prston prn

c\
10
R-1

7 ---. 6 .---w13- 1o1il

_ _ 13-59

4 - Conrodbearingcaps a Mark cylnder numberI pulleyend t Marking -A-faces towards

12 11

(9 5 -3 0 Nm+ 1 / 4 t u rn 0 ' ) O Renew conrod the bolt'item 8a Oilthreads contact and surface a To measure radial clearance t ghten to 30 Nm 6 - Pressure reliefvalve a 2 7 Nm pressure: ...3.2bar a Opening 2.5 7 - Oil iniector a Forpiston cooling

10 8 9 I

_-

..?
\

5 ---

3 l,/-r - lorrl
13-60 -

.11

..3

10

_.\,, ___? 'H

o.;2

8 - Bearing shell a Upperbeanng wrtha dr i :d holr shell for ubrcatngihe plsionp r posrtion. I Notethe {rtting a Do not nterchanqe used lreafing sne ts a Observe ght positoning I ontoailaal ment f anges a Axal clearance.New: 010..0.35 mm. Wear ir.]it: 0.40mm I Check radialclearance with Past gage. New: 0 01...0.05 mm. \l/ear lim i: 0.12mm a Do not rotatethe crankshaft wher checklng radal clearance the

9 8 7 6

tvL - 101;l f961 -

9 - Cylinderblock o Checking cyinderbores+ Fg. 4, page13'66 a Piston and cy inderd mens ons = page137

11 ..

10- Conrodbolt I Benew

10

-o

11- Safetywasher a Renew 12- Pistonpin piston 60 a lf difficultlo move, heat to a Remove lnsta withtoo T2001 I and

'c

/,'p(Tvt>-;
)12 .'-

-i;/:;t'/I v-r3 1or - al

13-62 -

Fig. 1

Pistonring gapsrcheckgap

Special tools, workshop systems, testers, measu.ing instruments and auxiliary items required a Feeler gauge Checking procedure l1)e r r1e r-g om.he-oot op-c. -g.ora.6y'-.oraoo\eoo\ to aooro,. tb m-r I.o .lhe edoeof Inc t-oe. -/ Piston ring

Gap Ne w lwe a rt mt
mm 0 2 0 . . . 0 , 4 0

Compression fings

Oi scraper ring

mm 0,25...0,50 1 , 0 0

_ 13,63

Fig. 2

Checkingring to grooveclearance

Specialtools, workshop equipment,testers.measuringinstru_ ments and auxiliaryitems required a Feeler gauge procedure Checking groove Clean before checking. Pistonring Clearance Ne w lWe a rt mt

1s1 compression mm 0,06...0,09 0,24 ring 2ndcompress on ring O rls c ra p e r g nn mm 0,05...0,08 a,24 mm 0 , 0 3 . . 0 , 0 6

.13-64 _

Fig. 3

Checking pistons

Specialtools, workshop systems, testers, m easuring instru m entl and auxiliaryitems required a N/licrometer 75...100 rr]rn Checking procedure It1:4il Measure approx. mm from loweredge,at right anges to pistor to I0 MaximLrm deviation from nominal dimenson 0.04mm

13_65

Special tools,workshopsystems, testers.measurin instruments g and auxiliaryitems requi@d I Interna a gauge ..100 d 50 mm procedure Checking 1 \ e . n e a s ue . n e 1 rc a l3 p o s lo -s t .o t t a re ra l-A - a o ' r g t , d n d a o ol -BMaximum deviat Jromnom nal dimension on O.O8 mm. Measuring the cylinder bores must not be done when the cylinde,_ blockis maunted on a tepairstand with adapterbtacketAR 2204A,as tncarrectmeasurementswauld then be posstble

.13-66 _

Pistonand cylinder dimensions

Itoning dimooglons Basic dmrcion PistonO 80.950 Cylindel boro g 81,01

lst ovetsize mm 81,4501r 81,51 1)Dimensions withootgraphite (thj;knoss: mating O.02 mm) Nota: Thegrapute caating wea9 away.

_ 13_67

and installing head:removing Cylinder

a Feptacecylitder head balt!; as a rule repiaceseri /otlirrg ,'luij, bo/ij s-ir/ecl l' gtllr'neL a On assembhng, gasket's .?nd as ic ttqhtening, we// as o 'ngs and hasesfar the supercharyirgsYstemshould a The hose sleeves be ftee ftom ailand grcasebefore asse/'b//tg an a When installtng exchangecylnde( head wih camshaftfitted' ail between the ptungersand the cams must be contactsurfaces the oled befare installtngthe cylndet head covel be a The ptasticpackingpiecesfor protecting apen valvesmus.tnat bet'orefilling the cylinderhead r-.mave(l untl imt;ediately allthe I After the cyltnder headot cytifier head gasketts replacecl' caolantmust also De reneweo ,' Cvlinderheads whictt have cncks between lhe valveseats or De tieei uatve seat insertsand the spark plug thread can be used fufthet without reducingservicelife pravidedthe ctacksdo nat ex' ' ie)ia naxinum ot o.i-m in wtdth,ar when na mare than the fist four sparkplug threadsarc cracked

t5-1 ---

1- cap

a Fe . . q: .eL:' dd-ndgod o- r eo r - o

2 -1 0 Nm

_ e ^u1> a,l'gI.'(h sethe I Tlqhten outernuls n dlagona

3 - Cylinderhead cover a Removlnoand nstallng +

Page

11 10
4 - Cylinder head cover gaskets or a Fenewif damaqed leaKng t ApplyD 454300A2 to doLrblebearing IO ' .dp Lan<r1or cea 1Apply D 454 300 A2 on the adJuster ten' e for lhe variab dlsttibutLon/charn ''o e' Io y| de' lead L an Lo 2qns5 Fig. 4 Page15 -

5 ' Oil deflector t Noleflttng pos1on on in etcainslaf.t 6 -Cylinder head a D efirant aid f]t1rng pag: i5:2 ing a fhecl fo drstort = - F q I o:oe on t Rewofk sealng surface F g 2, the page15'5 I ll rep aced,renewal the coolant 7 - Intake manifold gasket

10 -_
6

eTo replace,retnoveand {t page15 7 manio d a Note the fitting pos tion.

ntake

l- Nr 5- 01?6-l

15"3 -

8 - Cylinder headgasket a To rernove rernove and frt cylnder head page + 15,22 a li repaced, renew the cooant al a Note fittng postion:Pa.t number mustbevisible frorn the ntake srde I -25 Nm a Fortensoning roller 10- Exhaustmanitoldgasket

4
'11 '10

i To feplace, remove and ftt exhaLtst manifold page 26-10 a Note - tt nq posit thef on. 11- Cylinderheadbolt o 40Nni+ 90'+ 90" a Sequence oosening tighten for and ing+ page 15-30

fNi5 oi?61

154_

Fig. 1

Checkingcylinderheadfor distortion

Che.k cyl rder headior cislortof will, straghidgd ard e feel. gaLrqe. 1 Max.lo efaledd stofton: 0.1 mm

Fig.2

Reworkingthe cylinderhead

The cylnderheadcan ony be rewo*ed (fat grnd ng)to the min. mum dLmenston a-. I Minimumd menson: a = 139.20 mm

_ 15-5

Fig. 3

Seal transition areas between double bearing cap anr cylinderhead

jontngareas errows-of - Applyalttiegasketsealanton thecyind c rr heao 'ealng "-es. a Silconesealant 454 300 42 D

Fig. 4 Sealthe iointing areasbetweenthe hydraulic chaintensioner and the cylinder head and between the camshaft adiuster and the cylinder head. - Aoo,a i-pgosl'e-reaa-ro-.onL'ga.ee(.d o.j.o-r'o.! headse: ing sLtrfaces. I Silconesaant D 454 300 A2 te

_ 15-6

Intake manifold: removing and installing

Removal

, All cable ties v/hichare apenedot cut apen when remavng engine, must be teplacedtn the same positton when re nstelling. I ln vehicles v\1thcoded radp/ coded radta and navigationsystem lRl\S), take note af the cade, if necessary,find tt. W th gnilion swrichedolf dLSconnect batteryea|th strap. D sassembl the enginecoveTaTTowsng

15-7_

Remove aLr the ccnduit+rrows-

Rernove Hal sender the connector -G40 ,arrow,.

iF-..."i-l
I,"

15,8 -

I
o mo.e

the securing ft el drsifblt on pipe_2

o 'r e . t o '

'o r

'L - L e

'

el 1dremove lhe bolt s

Attention! The fuet system is under pressurc' Befote opening tlrc system olace a ctoth aroundthe connection, Then rcleaseprcssure lJy carelully loosening the connection

tube 1- andthe fle returntube -2-.Tc do the Remove luel suPPlY keYS. pfess tfre Lrnlocklng so,

15_9 -

I maniiold the Remove vacuumhose arrow from the rntake

and-4-ior -G42connectors3 for inlakeair temperaiure Remove the throtie valvecontrolunit J338' un air Remove hose-2-from the throtte valvecontrol t filterot the charcoal Femovethe vacuumpipe 1 to the aciivaled thrott e valve control un t.

15-10 -

a o^/<-and remo"/e ro\ e: -lth.

Remove the connector rrow of the exhaustgas lemperature sender G235-.

1 5, 1 1 _

Reeasecooant hose-1, from bracket . -4 Removethe bo ts -2 and ,3- and remove biackel 4-.

Remove bolts-arrows-ofthe manfold-l -exnausl remperainlet gas rufe sen0eI-(l2J5-

_ 15-12

Lirecket L Remove bolt aff.vr' fronrthe n et nranifold Release \,-.cu hoses romihe lowerpartof the rlet manfo d f rhe !m

manifo d.

15-13 -

ruotes.
a Sealthe cylinderhead inlet ducts with clean cloths. a Replacethe gaskets. a The hose sleevesand hoses fot the supercharying system shoulo be free from ailand greasebefore assembling. Installation boltsto 10 - Ftthe nletmanfoldwtha new gasketandtightenthe ( o,rt asse^roly_ re/ese o oe' o t e dr:-ani ng procedL e -e a lf the battery E reconnectedcheckthe vehicieequipment tadjor radio and navigation sistem, clock, powet windaws), folowing the indicationsin the Operatinglnsttucttons. a Other measures after reconnectingthe voltage supply + pag; 24-39.

15-14 -

Cylinderhead cover: removingand installing

I At eL.e.. t.t t a a D a F a o l . t a o e ^ '. h a n , a n a \ .)ustDa-aDd F c J 1 '\ a . n a a a - a . A \ - n . e . . . . t a . , n q.

to \.g

-.

a ]n vehicles vith caded radto/ caded radia and nevigatian system lake note of the code, if necessarv fin(l it /FA/S/, With igniton sw ichedoff disconnect battery eafthstrap. Drsassemb the eng ne cover affows. rng

_ 15_.15

Remove a r aondu rrowsthe t Remove uppefpafi of toothedbet guard.

Remove turbocompressor recrculation the aI valve-N24g- and -4the vacLJum TeseTVe tank,2-in the cy nderheadcovea

1 5 _ 1_ 6

liracket -1Releasethef ange 2, removetheaclvatedcharcoaicondui 1 ancl move to one stde

head.

_ 15-17

Remove bolts arrows-from aiacondutr the the Drac(erano rernoL. the bracket.

1 5 _ 1_ 8

<

- Fienlovgrd trcts arrlws irurnii e vacuLrm rk braclet i la

Remove earthcable-2,,connectors the -l,ano re easetne caO es Femoveignition corls 3 .

_ 15_19

-l

-4ll

SeqUence, endtng th the nner. and w - Remove nuts -arrows the and remove ihe cylrnder headcover

Installation

a Beplacethe cylnder head gasketif tt is damaged. t Beplacethe ignition coil seals,f damaged Applya ttle gaskelsealant Joint areas-arrows_ the upper on n9 of seaing sudaces the cy rnderhead of

.-

_ 15_20

ga5'!i sealsrl cn iornlng areas atro!/s of th9 Ltpper Applya ltLe seallng surls.esoi the c! inder

the lnnernuts andthen the olter nuts of the cylinde- Firsttighteir headcover,n diagonal sequence 10 Nm. to Conr,r.6.s.rno, ,n o.erseo de of ile dsma.t ng p,oceoure

a lf the baftery is reconnectedcheck the vehicleequipment (radia / radio and navigation sstem, clock, power windows), fallawing the tndicatians n the Aperating lnstructions. a Other measuresafter reconnecting the voltage supply + page 24iS.

15-21-

saT 8oso
|nlnrl::.5_*," nm4o:= |Ill']Ir:r E b d6

Cylinder head:removing and installing

Special tools.workshopsystems.testers measuring instruments and auxiliart items requi.ed a Torque spanners 8010 SAT a SAT 8050socket spanner

T20029

T20046

pliers a T20029 a Holding T20046 too a T20079 Wrench a VA.G1306 Dnptray

T200?9

15-22_

Hemoval

a All cableties which are openedor cut open wt)en rcmovingengine, must De replacedln the sarrtepasttbn when re installing I All ihermal p@tectiorl sleeves renoved rnust be re1tted in the sane place on reassembly. With ignt on swtched c)1{ sconnect d battery earthstrap pagel9-15. intake + - Remove maniiold page15 7 - Feeaseclamp4, removenlethose-5-andconnector-j-fromthe Remove boits 2 and 3- and remove the airfiltercasing. Drain cooant

_ 15-23

pressure Disconnect regulator ve -1 of the engine va breather.from the air rnet hose-6Femove the air recircua|on valve-2- from the air nlet hose 4-. ,3Removeconnector of the supercharg pressure enoide ng so valve-N75-. Bemovehoses-4- and 5, from the supercharging pressure sole noidevalve-N75'. Releasethetuberrow-and remove airinel hose releasing the lhe 'ld ge1'ar<a(Le, l-oihaey aLs'gas .J oocorp essor.

j!stment system N205-.

15-24_

o{ sLde ihe cylnderhead.and p ace Lior one srde hesdcr]v'cr page15-15 Ferrovecylinder -

tube. outletalr conduit the - Remove turbocompressor and the Release thermalinsulation remove. the the - Removethebotsarrows-securing turbocompressorto exhaust man fold wLth socket spannerSAT8050.

,15-25 -

Engne Lnstalled: to ' Turncronkshaft TDC No.1cy inder.

removed: Enqine ' Turnvibrai on damper to TDC No. 1 cy inder -arrows

15-26 -

Tlghten tensiofrng devc-.T200.16 unti the tcolhedbeltc! I be re movedlrolTi tie camshafl sprocket Loosen tens on ng dev ce T20046 ancJ remove

Loosen cylinder the headbolts n the gtven orderandthen remove them lrom the cyrnderhead.

l;'furl

_ 15_27

Installation

a Beplacethe cyinder head balts. a OFdssemDltngGpla( e sctLla.,t!.g httts.Dat$ subiec. gon,anctro r.c ltgalcltng as as o-.ing. ano gaste$ ^ell a Secure lhep 1rsDe'weenhajes O\ usfig thc samactam1s ong as a lf repaired, carefullyremave gasketrernains from cylinderbtack and cyhnderhead.Avoid making scntches or gooves. a Carefullyremove all tracesol abrasive paftrcles. a Onlyremovethe new cylinderheadgasketfram itspackingimmedi ately before instalhng. a Handlethe new gasketwith extremecarc.tfthe tayer silicone of and the gtooved arca are damagedthere is a possibiity af leakage. a The,e muSIoe 10 or ot caoDnr tneC\ttndet t. haaa tn bo| por],era tne crltndet tatocK

--

_ 15_28

systefi shoufu I Thehase sleer'esand hosesfar the sLtpercharglng he free fron oiland greasebefa.e assenbltng.
a Bcto F t- a .1t 6 - 1 1 - '3 6 o . d 'l t a r l '\ . d fDa \t:'d " l

to - Tlrn cranksheft TDC No.1cy inde. T! rn crankshe'it slghtly. back

f'racket, approx. Loosen bo t -arrow- on the turbocompressor head. when fitting cylinder the turns,to avod tension

15-29 -

Fit cylrnder headgasket. (Thepartnumber Note nstallal postionof cy inderheadgasket: on rro- L\p'ral. s,de. be r''s,be -Lsr Note the centr ng pins n cy|nder b ock -arrows-. lnstallcyLinder head.

I( r(J; a
e(>vJ

9z-1159
u

Fil r' e cy|| oernoaobo-_a-d d'drgrter.

- Tightenthe cylinderheadin the sequenceind cated below: Firsttghten to 40 Nm. turn Thenre tightenol bo ts 1/.1 190'l ly - Fina re t ghtenall boltsr/4turn(90') 9

rscn

Thereis na requtrementta retghten the cylinderhead balts altet rc-

15-30 -

Trghten bo ts affows,securirgthe tufoocompressor the erthe io nauslman10d to 30 Nm a The bolts securing the tubocampressor to fie exhaustmanifald a Apply lockingfluid to threadanctcantactsurfaceof cytindet head.

15_31_

Contine assembly reverse in order the dismantling of procedu.e a lf the bafteryis recannected checkthe vehicte (radia equipment / rad@ and naveationsistem, clock,power windaws),foltowng the indicationsin the Operatinglnstructions. a Other measures after reconnecting voltagesupply+ page the 24-39.

_ 15_32

r20024

SAT O sOI rl'irro:-*-

Compressionratio: check
-E ",.".
Specialtools, workshop systems, testers, measuring iestruments and auxiliary items required I T20028spafkp !g spanner I Torque spanners SAT8010 a VA.G 1763 Compression teslef

(f '

-.ra.::t;')

@ +..-, "

mm:

va.G 1763

tr5-ooo6-.l
_ 15-33 -

'//t d. T, - - f :a Tiid r f ,

,t;

Femove fuse 32

Bemovingfuse Na 32 nterrupts the valtagesupply ta the tnle.tars Test conditions . Engine I tempercture, mln.30'C o . Mn battery volage 12.7V

coveTaTfo\{s-. the - Remove engrne lrom gnrllor - Wth gniton switchedoif, feleasethe connectors cois the rgnt on co ls. - Femove T20C28 soarkplugswiih sparkp ug spanner - Remove

15-34 -

tfe - Open throtite valve competety.

+ Equ pment Instruci manual. on - Check compression pressure compression with testerVA.G 1763. - Operate starter until tester showsnofurther pressure increase. Compression values New:10...13 pressure bar Wear lmit: 75 barpressure Permissiblefference d betweenall cylinders: bar max 3 plugs - Tigthen spark withtoolT20028 30 Nm. to Contine assembly reverse n order the disn|amlng of proceoure interrogate faultmemory+ page24-28_

_ 15-35

Valvegear: repairing
Notes: a Cyhnder heads which have cracksbetween the valve seatsor between valveseat nserts and the sparkplug threadcan be used furtherwithout reducingservicelife, providedthe cracksdo not exceedamaximum of0,3 fim in width,orwhennomarethanthefist four sparkplug thrcads are cracked. a Aftet f,lng the camshans not stadup theengne fot appro\ 30 da . mtn the htotaulccor,pensaton pans ha\eta seftte lothetwsefie valves wouldhh the pistons). a After working on the valvegear, turn the engine carefullyat least two turns to ensute that no valvewill be stuckwhen the engineis a Alwaysrenewsealsandgaskets.

_ 15_36

I -65 Nm a Use tiol T20013A1o oosen and r !hien 2 ' Canrshaft sprocket .l Fof exhausl carnsheft a Notei tting post on: the thin coie oi the camshait sproc!..et ponts oLrt \",,ards TDC mark of the cylndel and cnn oe seen 1 3 ' Exhaustcamshaftoil seal I Do nol oi sealng p ol o seal t Renew+ page 15118 4 - Cylinderhead t Dismant andf tting+ page15 22 ing a Rework valveseats Page15B t Checkvalveguides+ page 15,72 a Sealthe tfanstionafeas Fig. 3 and + 4, page 15 6 a The bearing cap dowel pegs shoud be fittedto the cy rnderhead

12 =L-\\>
11'. -Lr' -

\-tX
?,

7 -'
4

6-_,-''-,-.'

,,-"'

d Yss gz et

de)

TE:=:ni.tr

5 -Valve guide l Checknq + page15-72

16
tc

14 't3 12 '11 10 I 7
.NN-'1

N-*
1!

6 - Valve stem seal I Renew page 15,73 7 - Valve spring I Removrngand Insta ing: Cy nder head removedwth too T20034/1, cyhnder headitted page15 73 I - Valve spring plate I - Valve cofters

2
I

\.!arTE:=:N:E]

_ 15_38

-1 7

10 - Hydrauliccam follower t Do not rfterchange I With hydra!ia va ve c earsfce conl t ClLecking page15 54 =. a Pace wth contact surface down_ t Oi s ding slrface

14 13 12 '11 '10 9 8 20

1'l - Inlet camshaft I Checking axa clearance Ftg. 1, page15 45 t Dismdnt and f tling paqe tE 57 rng a Checl rada c e. ance \rrth ptastrgage,wear I mit: 0.1 mm (c6m fo rowers Temovedl a Eccentr city:max C.035 mm 12 - lnlet camshaftbearingcap a Notethe Jtting positon. I Fittng post on + page15-66 a Must be properly ocated on the dowelpegs

b--26

fEl s:dr3, I
_ _ 15-39

16---

14 -\5S
13

13 - Double bearingcap I Coatthe contactsurface wth a itte "D 454300 42" sealant before{trinq o Sea the transticnareas Fio. 3and + 4, page 15-6 I Must be ocatedonlhedowelsleeves '14- Exhaust camshaft a Checking al clearance F g. 1, ax : page 1545 I D smantlngandfrttng+ pagel5 57 a Check radialclearance with plasti gage,wear lm t: 0.1 mrn (cam folowefs Temovedl a Eccentr chy: max. O 035 mm l5 - Exhaust camshaft bearing cap a Notethe fitt ng postion a F tt ng postron+ page15 66 a Must be properlv ocated on the dowe pegs

12 11 '10 I 7 4 1

b-26
_ _ 15-40

16-10Nm

1 6j 1 5-.:
14 13

17-10Nm 18 ' Drag chain t MarkD O.R.beioreremovng page t5$l I Checkfor wear a To removeand irt, tisnecessaryto remove tfe camshalls pagelS 57 19-10Nm 20 - O-ring 21 "Camshaft adjustment system solenoid valve -N205a Checking page15 78 + 22-3Nm

12 11 10 9 8 -j',.o
J ?

!r < :-.\

r: ^

tl

-zZ

i\\r'-'\\>.
'' ' . ' 4
--,'-)

23

fE15:aLtl
_ _ 15-41

14

12 11 10
o

23 - Camshaft adiuster a Before remova secure with too T20044+ paqe 15 61 a Wth solenodvalvefor camshaft regu ation -N205 a To removeand fit, rt s necessary to remove the camshafts- pagel5-57 a Checkng camshaft reguatton page 15 76 I Coat the contact surtacewith a ttie "D 45430042' seaant beforeI tt ng 24 - Metal"rubber gasket I Applyseaer + paget5 63 25 - Gasket

I 7
b

2
1

'.

\\-

a5-"r

I Err-u

Jz I

15-42_

16
'1 5

14 '13

26 - Exhaustvalve a Scdrlm frled ,f Pay afteniionto d sposalstandards fcr sodiun J led vslves paget5-,16 + a ,c not rewofk,only grtndng s pef rnrtted i Vave dimensions Frg t5 46 I Checkva ve guides+ page 15-12 a Reworkvaiveseals + Page1 56 8 27 - Inlet valve a Do not fework,only gr nd ng s perm tted a valve drmensrons Frg 2, page 1546 a Checkvalvegurdes page 15-72 + a Feworkva ve seats Page15 68 -

12 11 10
q

a-

6 5

'1

trE-iii -tl

_ 15_43

--e 16

la -..\B
t5

28 - lnlet camshaft oil seal I Do not oil sealng ip of o 1sea a Fenew pagel5-51 29 - Frame for Hall sender I For l-ia sender t Makesureit is ftted to the camshaft when assembing 30 - Washer o cone shape t Notethe Jltling postion. 31 -25 Nm 32-Hallsender -G40t To remove, itwil be necessaryto remove tfre upper toothed be t cover. 33-10Nm

12 11 10 8 7 6 4

fE1s-o-n
15-44_

Fig. 1

Camshaftr checkingaxial clearance

r20020

Special tools, workshop systems.testers, measuring instruments and auxiliary items required a T20020bracker a D algauge Test conditions . Drag cha n rernoved

rwsel

. Hydraulic cam folLoweTs Temoved Checking process Measure with the bearrng capson the charns 1'andthe doube cap de 2 litled Wear im t: max.0.2 mm

The checkingpracessis the same for both camshafts.

_ 15_45

Fig. 2

Valvedimensions

Valvesmust nat be rcwarked. anly lappingiinis permitted.

Dim. Aa
gb

Inlet valve

Exhaustvalve 29,80...30,00

mm 26 80 2700
mm

1 0 4 , 8 41 0 5 4 1 0 3 , 6 41 0 4 , 1 4 3

Note: Sadiun ftlledexhaustvalvesmust not be discarded atdinary scrap es without being properlyprepared. Thestem rnust be cut with a metal saw at the centre. Avatd contect whh water. The valveswill then be placedina bucketofwater lten at e time). Move awayfrornthe bucket as there wll be a chemicalreactrcnthat burns the sodium After this they may be dispasedaf as normal scrap

1546 _

r
Camshaft oil seals:replace
df in+ : ! . . . , . i1il101l+-A 6t0t:+, -,*

Special tools, workshop systems,testers, measuring- instruments and auxiliary t Torque spanners SAT8010 t Ho d ng tool T20018A a Ho dingtoolT20046 a GLride sleeve T200818 t Extractor T20143

fi;;;;;;r _ 15-47_

Exhaustcamshaft oil seal: replace

Dismantling - D cacse .b I g -np a q'ae ( 0/6- .a ro^c .

the - Remove c ips from the upperpalt of toothedbe I guardandre move lne covet.

_ 15-48

Y
I

shait I Thcaffrshafl sprockel nrarfsholrdco ncrde,"^.,ith mark the on the cy nde.headcover T! rn cranlishafl backslghtly.

Y d . -. in z:-qll
fArJ--@t

irom tire camshaftsprocket. - Bemovecamshaftsprocket To loosenthe bo t secLtre sprocket the with ocking tool T2001gA

_ 15_49

F,
Installation ' Do not oil sealng ip of ortseat.

ffi
t'r 9' ,

'6i:,ry
.i T200818/1

Frtlhesealjnto de sleeveT200Bi andftihe unrton the cam_ gu B/3 shaft.

tr:.y

U'eou ge 700818/ ano o-essr-e 9- 09 sreer'e s6a ..tU.Ll Lneo 9ea cr- o.ce. U,e-h^."-n.ha'tso.o-.91 .o irri.gDol Lo oorns Femoveguldesleeve T2OOBi B/3.

*t\

Conirnue assemby n reverse orderof the d smanling procedure

_ 15-50

lnlet camshaft oil seal: replace

Dismantling Ing - Drsassemb the e|g ne coveTarrows,

15-51_

Remove connector the Hal s,^nder,alow-. the of Remove clps from the upperparlof toothedbe t gLtard rethe and Bernove Hallsender housng. Remove washerandthe ffrotcrr ng ol the Hal sender. the

_ 15,52

lnstallation - Do nct o sealng |p o{ o I seal. T200818/3. ' Place o I sea on the guidesleeve the _ .no,P/1 l-.r . .r_de sleeveseai ^.' unitunril ' the oil sealis in place.To do so use a M 8x45 boltw th a washet guidesleeve T200B1B/3. Remove

ffi,

PIace Hallsenderrotorring with the grooveon the lnletcamthe and lnstallthe washer(withtheconefac ng outward) t ghtenthe securing bolt to 25 Nm. procedufe in orderof the dlsmantling Continue assernbly reverse

15-53 -

Hydrauliccam followers: checking

testers.measuring instruments specialtools.workshopsystems, and auxiliaryitems required t Fee gauge er a Wooden plastlc wedge or Notes; be n a Thehydraulic followers cam shouldalways replaced thei enindividualy). be ar tiety (theycannot adjusted repaired duringstarting normal. are a Unusual noisesfrcm the valves Checkingprocess on fan ' Slartup the motorandrununti the radiator hasswitched 2,500 rpmfor 2 mlnutes. speed approx. to - Increase

15-54 -

I I t1e d usLot I et\e o.sl, a s.DpaatDr r d.e -t.I raa-o or -. o- t.tt < _neoJr,Fl-.r,o. rdr.c I b- .ne\ed. t,ft.ne.a. e.ao o be ^,ll\.,e ott retentton valve:oil filtet bracket+ nem 6, pege 17-1i lf the hydraul cam iollowerscontinue makea noisecheck see c to to wh ch one/s is/arefaLrty as folLows: - Remove nderheadcover+ page lS 15. cy - TLrrn crankshaft the clockwrse untllthecamsof the fo lowersto be checkedare facing upwards. - Checkthe clearance betweencams and folowers. - lf it is greater than0.2 mm, replace followe.l{ it slessthanO.l the mm or f there s no clearanceproceed fo lows wth the check: as ,

_ 15-55

' Press camfollower the slightly downwards th a wooden plast w or c wedge.f it ispossbleto inseft 0.2rnmthickfee gauge a er between the camshaft the follower,the attershouldbtrep]aced. and Note: At'terfitting new cam followersdo not startthe engne for approx.30 mtnutes. Th hydrauIic campens ati pa rtsmust sattte (other wise the e on valves would hit the pistans).

_ 15_56

dowj:Ir"..," mrlllF::E cEti.+ 5 ---

Camshafts:removing and installing

Special tools. workshop systems, testers

;i;;il;

l."t*;.nis'

and auxiriary

items required SAT8010 spannefs a TorqLre a Holding T20018A too a Hod ngtoolT20044 a Holdlng T20046 too a Sealant 454300 42 D

t Ll5 oom-l
15-57-

Dismantling . Cy inderheadfitled . D sd,.e_rb||_g ''rq ne r ove -alrow5 1'e

15-58 -

Fenove the conreclofoi r r H.,,1 senaler i1!ow Fernove ci ps Jrorn ihe ihe !pper partof toolhedbettguardandre Remove Hal senderl.rous nlt Femovethe washerand the rfDtor r ng of the Ha sender

SetcamshaftsprockettoTDCcylnder markingbyturn ngthecrank_ shaft. Thecamshaft 1. sprocket mark shou coincide themark d wiih on the cylinder head cover. Turn crankshaft slghtly. back

/ , - d .-.^ '

n7ffi'

t;s@l _ _ 15_59

trom the caanshaft sprocket. Removecamshaftsprocket To loosenthe boh securethe sprocket w rh locking toolT20018A

necl0r -aTTow- Remove cylinder headcoverpage 1Sj5

_ 15_60

op_ 3t sp - Clean chan a rd tlle canLShail ockets the po nis localgo the pos1ethetwo afiowson the beafngcapsandmark nstalat onpositior by nreans a co o!r maftlng .,1 j Do nat merk chatnwith a centre punch ar aDysimilar rneans beiween the two araws ar colau narks is 16 rallers a The distarrce an the dtag chain.

|;""6.]

caps3 and 5. camshatt bearing removein et and exhaust Frrst cap. the Remove doube beafing netandexhaustcamshaft Removebothdoublebeafingcapsonthe securlng ts. bo the tensioner UnboLt chain caps2 and4alternatively camshaft bearing in Loosen etandexhausl thern and in diagonalseqLrence remove cha camshafts, n tens onerandretalnlng Remove et andexhaust in toolT20044

15-62-

Inslallation

a When tnstallingthe camstafts, the cams of cytinder 1 should be potnttng upwards. a When installingthe bearingcaps checkthat the mark on the caver is legible fron the cylinder head inlet side. a lf reusing the old drive chain, place the clrive chain according to the colour Klentificatian bath camshafts. on - Replace the chaintensionerrubber-metal gasketand thiny coat sealng surJaces catedwrth hatchedines with "AMV .lBB ind 001 42".

_ 15_63

Fitthe charn ontothe camshaft sprockets Jollows: as a lf usinganewchain,lhe distance betweengrooves-A-and B-on the camshafts shoLl be 16 rolers on the chan The Jig.shows d wherethe 1stand 16throllers should placed the sprockets. be on a Groove-A- hBsa slight dev ation inwardswrth regardto the roller n9e ( rhe _-a - .e s one- oet(e6n the .hdtn. Oll slid ng surfacesof both camshafts. PLacethe carnshaftswiththe chain andthechaintenstonerinthe cylTighlenthe chain tensioner lO Nm. (notethe dowejpegs). to

_ 15-64

vely nshafibearifgcaps2 3n.j4 altetnal Tighlennletandexhaust.a pegs) sequence 10 Nm lnole the do\^re to n d agonal

finedandt ghten are Check that the camshafts properly sprockets. capsto 10 Nm. (notethe dowe pegs). the bearing retaining toolT20044. - Remove

15-65 -

cap lineson the double bearing with wrth hatched Coatthe surface " D 454 300 A2 ,fitandtlghtento10Nm.(becafelul a thin ayerof with the dowel Pegs). the to bearing capsandtighten 10Nm. (note dowel FittheremainLng pegs).

r*dt

15-66 -

' InstaI the can-ish3ft spiockri pornts outwards -affowsandTDCrnark cyjtnder canbe seen of I rrom tne tTont.
C ontnue asseraby i n reverseorder oi the o srnanr!ng pr oceclur e

.:

GEe,t

4f1 l ' a,ng ,he (at.shdtts do t oL sta r ua L\e eng;ne' a, app, o\ . JA mtn tne n\d' d-tt' rompancaton pctl - 111 t sFt110 har \ ir e t he t> tot valves would hh the pistans).

.15-67 _

Valveseats:reworking
Special tools,workshopsystems. testers,measuring instruments and auxiliaryitems requited gauge a Depth a Valve seatrefac tool ng ,Votes. I Whenrepatring engineswhh leakingvalves, notsufficient ttis torc, placear renewvalve seats valves. ispanicularly and tt impotlanton high mileageenginesta checkthe valveguides for wear
i ) rhc' 64 e sedt, sro,td ar t I oe .ew o,. eo,L sr enaLgn r c pr cour c d pe,fect .eal,ag DaFa,n The rr,a\,r'urt Dcrmissbte rcwo4thg dr nenston rnust be catculared belore tewott..g LotFehces t1e teworktng dtmension is exceeded, the functjon af the hydraulic tappets can na longer be guaranteed and the cylindet head shauld

_ 15_68

I
reworkingdimension the max permissible Calculate
'a4va.-onopr_ 'l n , doail 1 ea

fotthe lfthe valveis tabe renewedas part al a repa[ use a Dew valve edgeot cyl stemandupper end tretween ofvelve distance lVeasure dmension from measLlred ble max permiss reworklng - Calculate dlmensron and minrmum d stance

Minimumdimensions valves Exhaust lnet vave

central

mm 31 . 0

3 2 2 mm

31.9mm

15-69 --

= acceprminusminlmumdimenslon maxrmum measured Dlstance ablefeworkng diTnenslon Example fo. inlet valve outside: drstance Measured - Minimumdimension = max.perm.reworkdimenslon isshownon llustratlons dimenslon ')Themax.permiss e reworking b "b". as drmension Notei tf .|,ema\ |ewattt q dtncnsionb 0 mr o' !'ss IhanA nn raDeaIr'e af tho medsu'enent\^tth ; 'e vaae /rlne i"it"i".""L ^,r, a mm ar less than "s.r/I the cylindethead shautd o mm, a iii vilve is sttlt

mm 31.4 mm 31.0

15-70 -

lnlet valve seat: reworking a = A 26.2nn = lv-a e re,/ _p_ermrssrb o I nlt d mansonl = Cylinder head ower edge = 45 q va ve seat ange = 30 ' uppercoffecton angle = 60 'lower correction angle

z
It

Exhaustvalveseat: reworking = O 29.0mm = Max.permssible reworktng dimens on* 'l = approx. I mm z = Cylinder loweredge head = 45 " Vave seatange correction angle F = 30' Upper = 60 ' Lowercorrectton Y angle -rCalcLrlating permissible max. rework dimension page ng l59 a b

_ 15_71

Valve guides:checking
Special tools,workshopsystems, testers.measuring instruments and auxiliaryitems required a T20020 bracket t Dialgauge

tr@2-@t Checking process - F t a new valvein the guide.The end of the valvestem shoud be flush with the guide.Due to the slightdifference stem dimen, in srons, ensurethat oniy an inLet valve s usedin the nlet guideand an exhaust valve n the exhaust de. gLt

-) WJ =^,-a',2

Determne rock,wear lim t: 0.9 mm

za,)
_ 15-72

I l
r20024 mi rt- - 5" - " . GI]BE : + - . " |]ern+E

Valve stem seal:replace

testers. tools.workshopsystems. Special instruments and auxiliaty measuring items required SAT spanners 8010 a TorqLre sPanner spark a T20028 Plug tLrbe a T20033

:H.%k tt. qlu:-

tool a Cornpressron T200348 T20039 a Plunger T20058 a Extfactor

15-73-

Dismantling . Cylinder headfLtled + carnshafts Page 15_57 - Remove surface and the Remove cam{ollowers p acethemonthe contact lnem youdo notlntercnange facedown,makng sule plugs wth spannerT20028 the - Remove spark cy - Setp stonof appropriate indefto "bonomdeadcentre plugthread. into T20033 the spark hose - Screw head lo toolT20034B the cyllnder - Fitcompresslon 6 oi air pressure to a compressed system at least bar hose Connect valve spnngs alr of compressed andremove withexrectorT20058 slemseals vaLve Remove

15-74 -

lnstallation

Toavotddamegingvatvese;/:-,p/3.e thepiastc sleeveovervet,.te stem (thtssleeve is inctudedwtth the spatel - Oil valveste.. seal sealinglp anclpjess carefully onto the valve gurde.

- Remove plastc blsh the , F t the cam fol owers as removed Contnue assemblyn reverse orderof the dismantlng procedure
Ahcr I'Rng ,hp cdmshdhs da nat sblt up th- engn- tot dppta, 30 nl n. tne nydtaot. canD ensatton p.l ts must setl c pth ct At se t he valves would hit the pistons).

_ 15-75

Variable valve timing: checking

a Thecamshaft adjustment dependant is upontoadand speed.By meansof the electricvalvefor the camshaft adjustment system (mechanical device whjchrcgulates camshaft. the ) a Thecamshaft adjustment systemwill not start to operate until2E seconds alterthe engineis started. Special tools,workshopsystems, testers.measuring instruments and auxiliaryitems required
vA.G 1551

--.ffiffi
t*G*A

a Fau reader G 1551 vehicle t VA or syslem tester G 1bS2 VA wlth c a b le A . Gl5 5 T / 3 8 V Checking conditions . VA.G155T (VA.G 1552) connected. Selectenginecontrol unitwith the Address code 01.

_ 15-76

Checking Process a|ldconl ftrl setting" baslc keysOand4 forthefunct on " Begin Press wrth the o key entry gand4for "DispaygroLrpnurnber094 andconlan ' Presskeys0, vvithO key e rvy
Sys:e- ,. basc set ig 09,1c1r An on Tesl OFF !*:/min

nd catedon d splaYi - Takeeng ne speedto above1800rpm In - Allowthe eng ne to run at high speedunti the message display from "TESTOFF to "TESTON' field 3 changes "Sys OK' shouldlhen be drsplaYedl - The followngmessage memory tne Intelrogate Tallll - lf "Syst No Ok' is displayed,

15-77 -

."2/q
\,' ,t/

Solenoidvalveof the camshaft adiustment system:checking

tools,workshopsystems,testers, Special measuring instruments and auxiliary items required VA.G15264 a Manuamutimeter VA.G15278 testlamp a Diode o' a A- r'o y n'eo,, ng reL\ a C 15944 VA.GT594C a TestboxVA.G1598/31

15"78-

Check solenoid valve - Drsconnect canrshaft tfe acllusi'Ient !stenr so enordvd /e ion s

- Measurethe resistance the solenoid of vave with manualnrulti_ meterVA.G 1526A and adapter cabtes from VA.G 15944or VA G 1594C, specilications: 10... tg O. lf the specifrcation not obta ned: is - Renewsoleno valve. d 1fthe specification oblEined: rs fMml Checkvoltage suppy + page 15,80

--

_ 15_75

Voltage supply of the camshaft adjustment system solenoid valve:checking Checking conditions . Winngofthe solenoid valve the camshaftadjustment of systemOK . Fue pump re ay must be OK. Note: The valtagesupply of the solenoidvalveaf the camshaitadjustment system ts carnedaut through the rclay of the fuel pump. - Disconnecl camsha{t the adiustmenl systemsc enotdva ve conConnect diodetest lampVA.G 1527to contactI of the connector d sconnected to earth!sing adapter es from VA.G 1594C. and cab The LEDmust ight up

_ 15"80

TfreLEDdoesnot lightup: the installation: the - Check continuittlof electrical Connoctor, contact
1

Measurg no
FuelpumPn lay. ground Engine

check wiresfbr shortto one anoiher. - Additionally ll no laultcanbe loundin the wiring: + Curent flow diagrams, Electricalfault findingand Fitting locations LEDlights up: + VAS 5051;Vehicle selfdiagnosrs

15t -

Lubrication systemcomponents: removing and installing

lvotesi a If when repairingan engine, metal shavingsor large quantitiesof small metal pafticles - caused, for example,by paftial seizure of crankshaft conrodbearings-are foundin engineoil, to prevent and consequentialdamage, apaft from thotoughty cleaningoil passages, ft ts necessaryto renew the oil cooler. a Theoil levelmust not be abovethe max.ma* - dangerof damaging catalr,ttc convefter! level:checking page17-9. + Oil Oil injectorjet and pressure reliefvalve+ F g_ 1, page17. Pressure oil pressure and switch:checking paget7-22 +

17_1_

Oil capacity wirh oilfltrer L. 4.5 Engineoil specifications Useengine oilto\ y'y' standard 00,50101or 502OO. 500 Ontyin exceptionalcasest multirade corresponding oils toAplSFor SGspecifica-

17-2-

Part I
1-15Nm 2 - Sealingflange I D snra t|lngandfilling page13-44 t Assemhle \",,lth si cone sealant page 1344 D 176 4A4A2 end ollsea- pLrlley I Renewcrankshaft + page l3-44 3 - Chain tensioner with tensioning plate a 15 Nnl replace cornpLete a Do not dlsmantle, a Note the f tt ng posltion thaOn a5.-'_rbl g. peenr on springand hook t L 4 - Dipstick a Tne ot l^.- -r.(- -ot go cbo.e lh6 max. maTKl level- page 17-9 a Checking

2521 22 16 20 18 19 17 14
?\ -.--\ !_!Fr1

/^1 L1o
11 12
q

lf,

i;
17-3-

5 - Dipsticktube a Remove extract lby abrasron to o tube 6 - Guide relief 7-Oil iniectoriet and pressure + a For pistoncooling Frg 1, page 114

25 21 22 23 16 20 18 19 17
t5

relief valve 8 - Pressure 4 2 7 Nm pressure: ..3.2 bat + 2,5 a Opening 1 F lg 1 , p a g e 78 9 -1 5 Nm 10- Suctionpipe I C eanf lteflf soiled

10
11

11- O-ring 12 - Baffleplate 1 3 -1 0 Nm

14

12

felz-oortl
17-4-

4 -f)

\ -.-L

,i
ii+l l',.-+a
\i.]i'fl

14 ' Oil level/temperature senCer t Onlyveh c es wth o'tg te servrce 15 - O-ring 16 - Sump a Dsmant ng andi tt ng > pagej7 t5 a F t with siiconesealanlD1764A4 A2 17 - Oil drain screw a30Nm a Wrlh attached seal l8 - Gasket

24 21
22

23 20 18
la

17 15 14

\LI$r: \ w L lo

li/
Bo

t -;;;tr
_ 17_5

19 - Oil return pipe il Ffornturbocompressof 2 0 -1 0 Nm 2 1 -O ilp u mp a Whh 12barreiefvalve a D smantngandf tting page 21 + 17 a Before assemb!y, check thetwo that centr bushes o I pump/cylndef ng of block- tem 25-arefitted a F e pa c eiis c o rn gs f o Lr n d o n t h e s i d ng sudaces gears and a Pump cover to casrnglghlenng torqLre: Nm 10

'.-7

10 11 12
q

ri I

e_o
aEl nin

17-6 -

22 - Oil pump sprocket a t can on y be Inseftednto one pos tion on the oi pump shaft

,) r
'E

23-25Nm 24-chain for oil pump a V.'t D.O R befo'" e' o/ng a Checkfor wear 25 - Centring bushes

24 2'l 22 23 16 20 18 19 '17 15 14

c..1j-" cJ
7) .7 L10

11 12
q

coolng) 1 O I injector (forpiston iet reliei valve 27 Nm 2 - Boltwithpressure 2 b a O p e n inp re s s u re i, 5 . . . 3 . 2 a r g

19 .f1-',-2
IAfo .7 |

Oil level:check
Checking conditions . Theoillevel should onlybe (oiltemperature checked onahotengrne above 'C ) 60 o Thevehrcle should on levelground. be Onceengine swttched is off, warta lew mrnutes that the oil can return the sump so to process Checking - Remove oil dipstick, the cleanwith a cleanragandreplace fully. - Thenremove drpstick check oil level. the and the

17-9-

Markings the dipsrick on I -Max.mark 2 -Min.mark a -Areaabovehalched field up to max.mark:do not add oil b -Oil levelwthin hatched fieldi canbe toppedup with engine oil c -Areafrom min. markup to hatched tield:fill with max.0.5 ltr of engine oil Theoil levelmust not go abovethe max.mark

_ 17_10

'll

12

Partll
1 'Plug 4 40 llm 2 - O" ring opr a Ii the sea nq lng rs leekng, -r1p afd repacelhe o rlng 3 -Spring I Fof relef va ve approx4 lar
l0

--

4 - Piston a Forreliefvalvapprox4 bar 5 - Gasket

L)-'-18

- ---'----.s
2

6 -Anti-return valve agNm n I Integrated the o I flter bracket

fl*
23 21
fAr;0018 I
1l11/ - u-nng a F t as far as the shouder ol the 1!5e pos I blockbreather I Cylinder I - Securing cliP 10 - Plug a15Nm 11 - O- ring a ll sealng ring s leakng n P openano seal. replace 12 -23 Nm

6-

@
l<

16

n'-ur
32

17

---------s -6d-

4/7;;^--ts

13 - Oil suPP|Y PiPe a To turbocomPressor 14 - Hollow bolt t30Nm

22

21
17-12 -

78

10

11 12

15 - O- ring 16 - Oil pressureswitch -Fl,, 1.4bar | 25 llnl a Black nsulat on t Checking pagej7,22 +

@
,,- - 16

17 -O- ring a I sealngr ng is eakng nip openand replace. 18 - 15 Nm + 90 . {1/aturn) 19 - O-ring a Hold wilh tabs provded on the oil

^6,''
- 19

20 - Oil filter a Loosenwtth turning tool U 4OO7B or a universa filterextractor t Tighten hand by I Note instrucl ons on f lter when In_ sral[ng

22

[;i?

ool8l _ 1 7 _1_ 3

10 1 1 1 2

-25 Nm - Oil cooler a See note+ page17-1 a Ensure eafance adlacent c to compoa Lubricatecontact surfaces of the oflng wth the o I filier bracketwth AMV 18800] 02 I Cooiant hoseconnection djagrara +

/,/-0^\

2 X$rl \r'-'adr

page19,12

:tu
i
I

23 - Oil filter bracket a Wth relef valve approx.4 ber

22

21

n/-uuol

-1 7 -1 4 _

Sump: removing and installing

sAT 8010
instruments workshopsystems testers'measuring Specialtools, and auxiliaryitems requlreo SAT8010 spanners a Torque
I

r*M6"1

u-400s1A

U40051A a Tool insert brush drll a Hand with plastic goggles a Protective sealant 404 t D176 A2 Sillcone

r!@;;1

17-15 -

Removal insulation -arrows centra Remove

il r l r ,
L,r ._ _ ]\'-

oil. engine - Drain

-2-' necess_ tubefromthesump Lt the and - llnbolt rernove oilfeturn b tubeto the cvlLnder ock' the u'ivlrunllu" ir,u rt"t"t securrng

17-16 -

Fiemoveiie bolts l.rir ,!Jsu|iplgearbox -arrows. - Loosert_ebolts-l 20 diagonally.

tt necessaiy,r-Ernave bolis from the sunlp wiih taal u 1j00S1A. the

a ^ '- l ^ : - d herd . gntryw - a rLrbber if hainm-"r o 06 n6\a dr o etad.. 1 ,. p o . r :D p .!

20 19 18 17 16 15

Femoveseaant fesrdue cylinder ockw th a flat scraper. on b

handdrrl wth a p asticbrush.

I
C ean sealing surface, must be free of oil arrugrease.

_ 17-17

Installation

a Nate the use by date ol lhe seajant a Replacethe gaskets. a The sump must be fifted wtthin 5 minutesof applyingthe silicane seahngcampaund. - Cut off tr.rbe nozzleat fofward mark ng (nozzlediarneterapprox.3 o eSeal g.o'1 oo,nd a,q-o/,7. loc.a-.u^o ^opi, 'il su.a.e.\6o. g o po. doeao .-<-o.. -.dl.q

a233mmthck I RLrn beadon the insideof bolt ho es -arrows_ the Thesealingcompaundbead must nai be rnorc thart3 nm thick,athet wse.excessseafingcompoundcould enterthe sump and blockthe oil sucuan ptpe stralner.

_ 17_18

o g o-rlo. Apo'., as shownin the Lllstiat on.

"

J.Lrla

ln the areaaf tta rear sealng flange, take spectalcarc applyingtLle bead of sealer-aftows-

in and allsumpbots theindicated immediateJy tighten Fitthesump in sequence 5 Nm io tighten d agonal 1... BoLts 20-:firstly to bolts T ghten sump/gearbox arrows- 45 Nm to sequence 15Nm. J bolts ...20' n diagona Tighten 20 19 18 17 16 1s
'14

f{-;;l -

17-19-

a On fitting the sump on a dismantledenginesee that it is flush with the cylinder blockat the flYwheelend a Sealantmust be left to dry for approx.3A minutes after fitting the sump. Only then can the engine be ftlled vtith oil. a Whenengineailis dftinedand is natextractedwiththe usedoilvac uurn device, the gasket ring of the oil drainplug has to be replaced a Observe disposalregulations! hasto be takenIntoac with oil,the following the engine afterfilling the countwhen first staTling engrne: a While the oil pressurevlarninglamp on dash displayremains lit the enqine must anly idle. Do nat press accelerator!lf not the turb> could sufler damage at brcak down completely co-mpressot a Only when the warnng lamp goes aut, has the max- oil pressure been reachedand yau can accelerate orderof the d smanting procedure assemblyn reverse Contine

17-20 -

-.,'?

Oil pump removing and installing

Removal Remove sump + page1715. - Remove t 2 onpurrpshaft bo - Femovegearfrom the oi pLrffrp shaft. - Unscrewbolts-1, and 3 and removeo I pump with baff p ate. le Installation - Fit the centrngbushesitem 25, + page j7-7,to the Lrpper partof the o I purnp a Assemblypos tronoftheorlpumpshaft/sprocket: tcanon ybef tted Contine assenrbly reverse in orderof the disrnantling procedure

'::.)',4
.' l"',

11 .r
ERS

:'t f

l:

#\ l )/
yr
ii

L -' - r

i'l

ti

17-21_

Pressure oil pressure and switch:check

Special tools,workshopsystems. testers, measuringinstnrmentsand auxiliary items required a VA.G1342 pressure Otl tester a D odetest ampVA.G15278 a Auxrlary measufing VA.G 15944 set or vA.G 1594C

f wl? -o o o 1 l _ _ 17-22

Buzzer function warning low oil pressure tcloses scpenwhenlhereisnopress!lTeand TheolpressLrreswitch pressLlle ihe on reaching switchng atef 10 in comesintoactlon approx' seconds Low oilpressurewarnrng on switching the ignltron with a delayof approx3 warnlngcomes nto action Low oil pressure Warning ends with a delay of approx 5 seconds Note: pressule Functianatcheckand setvtcing the optical and acausttcotl ""n''o" d aq ams. F'-.r'ca' au,l I nd ng dno lrfling localor s -?ui Checkthe warning lamP e ,vl Afier>wrlchr_gon.^'lgn:lro,land ntheenglreo{ l' eol o'essu seco ds a'd Lhe"go out ! h'rr shorlal ghLup fo' app or' J wa-^rng ls if ing is interrupted the engrne on

17-23-

Warnings lamp in lamp (warning warnrng oil of Activation the optlcal pressure locc- rr 1nelolow,'qc r_ t,ashtaqmode)dnorn.oewar.t^gbuzles\^ swilchclosed . "lgnltion on", englneoff, oil pressure

swltcn greater than1500R PM ' oil pressure . Engine revolutions Notes: |afip stays greatetthan5,000R PM , watntng revolutions a Enqine ' switchis ctasedAt lessthan5'000tpn wnenoitprZssure on\rin lampgoesaut agatn warntng at switchis apenat only0 3 3 0 seconds anen' a lf theoitpressure

i.5i1s 'p1 1t''ss65" 62ne!pracesso' wi" .,;;;;;;;;';;;',;;. \ \)e enEle ts tr oael n ths happensIn-ee t ;;;r;;" 'i 'les diately activated and wi1l atton.-tni oii pressure rn rning wilI be im me not tun off even at less than 1 5AA rpm

17-24-

a Eliminalionaf the ail pressurewaffing wll happen when the oil pressure sr1r1'ch been closed for nlore therj 5 secandsebave has 1,544rpm. ar tgnittanis n!rned aff. Checking conditions . O I evel:check + page 17 9 ng . Theo i pressure warningamp K3,must ght up Jorapprox3 sec_ ondswrth gn tion on . Engne otl ternpereture leastg0.C kadatof fan mLrst at havetun Checking process D ,o)se-iol g l-. er g '6 .a. .ng -arrov\S-

17-25 _

Remove securing the bolts arrows-and removethe cover -] -

Remove the oI pressure swtch,F]-+ tnread( ontothe tester.

page 1713, tem. j6 and

Screwtesler\1A.G 1342intothe o fiherbracket, placeof the orl in pressureswrtch. Connectbrown wire of tester to earlh ( )

F ;@ 5 l

17-26j _

va.G 1342
1527Brisirgaux.cablesfrornVA.G - Connectdrodetesl anlp \r.A.G 15914o. lA6 po(ir'6 rl rndt.oloes,_,e 594r.'be-o. LEDmust not lght up. lf t.irDl,ohr tenl. 16.
0 fN ].M I

up E e!^o'oes,-rer,^,rLch-T - 'pdge

/.13

lf the LEDdoes not light up: Startengineand run at idl ng speed,at 1.2-1.6barthe LEDshoud lght up,if not renewoilpressure switch-F1-+ page1713,iiem.16. Note: Observer the tester and the LED durlng the stafting cycle, because the responsepaint af the oil pressure switch can now be surpassed on statting.

17-27 -

Check pressure di{ferent oil at speedsi I dLing: mrnimum bar 2.0 o 2 0 0 0RP M.3 . 0 4 . 5b a r : a above 2,000RPM:maximum bar 70 lf the specifications notattained: are mechan damage, damage the oilp pes,oilfiter, ca e.g. in - Rectify etc. w the - O I fi ter bracket th reliefvalveor o I pumpfaulty:Replace oll + + filter bracket page 17-l4, item. or replace oi pump page 23, the 11-21 . At higher engine speeds, oilpressure the mLrst exceed ba. not 70
lf rh. <nc.i fi .,r ^n '< D ,.aa,{a.l

oil - Check pipes. relief or replace pump+ page oiL - PressLrre valve oil pump faulty, 11-21.

17-28 -

Cooling system components:removingand installing

I Whenthe engineis hot the cooling systemis under pressure. lf necessaryreleasepressurc before commencingrepairwork, a Hoseconnections secured arc withspring-type clips. cases rc_ ln of parr onty use spnngitwe clips. I Tofh spring type ctips use ptiers T20O2g. a Coolanthosesshouldbe stress,freewheninstalling,so thatthey do nol come into contactwth ohet components bbservemarkings on coolant connection hosd. and Perform cooling systemleakage with cooling test systemtesterSAT T274andadaptors VA.G 127418 V.A.G and 12j4lg. Cooling systern components. bodyside+ pagel9-3

19-1-

Coolrng system components, engine + page19 side Coolant hose connection + dragram page l9-12 Coolant: draining filling pagetgt5 and + Noteson coolant mixtureratios paget9-17 +

19-2-

Cooling system comPonents, body side

1 ' Radiator endf ttlng+paqe19-2) I Dlsmantlng renewa lcoolaft a After replacrng, 2 - O-ring

Ji
f lJ

13 9 12

3 - Upper coolant hos rad a Securedto alorwtlrreta nlngclp ng a Checkfor securesea'l > a oo'o I o,e o '.lond"gd'l page19-12 4- 10 Nm 5 -Air duct

'I 1 8

10
19_3 -

6 - Continuedcoolant circulationpump a Checklng Page19 36 fan -V357 - Additional + a Checking Page19-40 8 - securing cliP a Checklor secureseatlng 9 - Connector 10 - Fadiator fan -V7a Checkng + Page19-40 11 - Bracket a For the connectorsof the tan tec 12 - Lower coolant hose clip with retaining to a Secured radrator a Checktor secureseal ng on hose connect d agram 1 Coolant page1912

-v51-

/,,

8 11 8

1j

10

f-r-oo6tl
19-4 -

'13- Termoswitch-F18-and -F54. 35 l..Irr a Forrhe rrdiator f:r I Swriching iemperaru es: '|st gear Connected 92...97'C .C Disconnecte 84...9,]

14 13
q

2nd gear 99...105.C Dtsconnecte 9i. 9g .C d 14 - Bracket t Note the fit ng positon 15-15Nm Connected

't2 4

t Err-006-l
19,5-

1 2 3 4 s 6 5 7 I 9 5 10 11 . t 2

Cooling system components, engine side

1'15Nm 2 -To expansiontank a Cooant hoseconnectondiagram + pagel9l2 3 - Toothed belt a Mark D-O.F. betoreremoving a Checkfor wear a Do not kink a Femoving, inslalingand tensoning + page 13-29 4 - Coolaflt pump a Check easeof movement for a lf damagedor eaktng: renew comp ete a Drsmant andf nrng+ page19-27 rng

17 18 19

14 20

19-6_

rir'-:-r,=
456

5 -O'ring

9 5 10 11 12

l?

i '1 6

nre. qw_11 .
5 1 5 \.

6 - Coolant thermostat t Checking:heat the ifernroslal Lwater l| Openng coffrrnences approx ET'C 102"C a Endsapprox. t ooeninqlift min. 7 mm ftt rnq i Dismanl ancl ng + page19-29 7 - Coolant connectingpape + on hoseconnect dlagram i Coolant page1912 I - Connection sleeve I - To heat exchanger + hoseconneclon dlagram a Coolant page 19 12

19-7 -

'a:=1234 5 6 5 7I9 5 10 11

10 - Connector 11 - Coolant temperature sender _G62t W th coolant temperature gauge sender_G2unf a Foreng ne controL pressure cooF In release a lf necessarV beloferemoving ing system ng: I Check e 5051;Vehlc self diagnosLs -VAS 12 - Securingclip a Checktor secureseallng

I
fEfg 006?I 1g-8-

65

78

13 - To top of radiator a aoolanthose conneclorrcltaqran _ paee19 12 a 5ecL, edroradrrto !1rthietd,r n(L.lr, . al,e.f ror se!u/e edr |rlr 14-15Nm l5 - From bottom of radiator rt Cooant hose connection draqrara _ paoe1912 a Secured radiatorvr' retaninac io to th ,t Checkfor secureseating

17 18
&,-', - A- '

19

tEir-o06?l

a D srnantlng andf tting+ paqe1714,

'te.l.l 2?

17 - From heating system heatexchanoer a Coolant hoseconnection diagram-paoe 1912

14 '- )

18 - Central coolant pipe a becured cy inderbtoct to I Cooant hoseconnection clraqram + page1912 19 -Cap a Check with cool ng system tesler VA G 1274 and adapter V.A, 127419 c + page i9 33 t Testpresslre I 4 1.6bar

19

20
_ _ 19-10

1 2 3 4 5 6 5 7 I 9 5 10 11 12

20 - Expansion tank .) Car:yoll eaktesr o;.oo ng sysienr ,/,,ithcoolng syslcn t:sIer VAG 127.1 and adapt-.r'iAG 12l4l1 p;ge l9 33 21 'From coolant connectingpipe ,f Coolant hoseconneclion agram+ d pege19'12 22 -Continued coolant circulationpump

17 18 19

19'36 l Checking page 23 -To turbocompressor + I Cooanthose connect dragrara on p a g e 91 2 1

-v51-

4/

20
19-11 -

diaCoolanthoseconnection gram
1 - Expansion tank I Cafiyou1leaktest of coo ng system with cooing systern tester VA.G 1274 and adapter V.A.G 1274/8 + page19 33 2 -Cap aCheck wth cooing system iester VA.G 1274and adapter\'l.A.G121419 + page19-33 1.4 a Testpressure - 1 6 bar 3 - lntake manifold 4 - Cylinderhead/cylinderblock a After rep aclnE, renewal coolant

19-12-

5 - Heatingsystem heat exchanger a After replacing, rene!(al cooant 6 -Oilcooler I D sn'ani ng ar cjfittng =- pag; t7 '14, tem 22 7 - Upper radiator hose I - Radiator a D smanilrng fin ng + page19 22 and I After replacing, rene\/ al coolant I - Lower radiator hose 10 - Continuedcoolant circulationpump

- v51+ a Checking page19 36

_ 19_13

11- Coolantpump/coolantthermostat a Coolantpump: d smant andfrtting ing + pagelgtl I Thermostat: drsmanting frtting and + pageI9-29 I Checkingheat the ihermostatn water 12 - Exhaustgas turbocompnessor a Exhaust turbocompressor: gas disma n t ln g n df t t in g p a g e 1 1 5 a 2 -

1 9_ 1_ 4

T10007

120029

Coolant: draining and filling

tesiers, tools,workshopsystems, Special instrumentsand auxrllary measuring items required SAT spannefs 8010 I Torq!e Tester a T10007 a T20029 Plers

@v.a.G1306
saT 8010 dtrU11HA dtd]]]-E .--

DriP tfay i VA.G1306

flir-ooorl
.19-15 -

Empty

on expans tanK. caP Open on coolant on insulat _arrowscentraL Remove

the Place VA.G 1306tray under re engrne drainp ug _arrowlrori radator'connectan coo TodraLn anl remove s dralnlng eeveli necessaly hoseto the auxirary

_19-16

'-i-'f---

)li-

,arrow_ owingthe cooant to drain. coo er connectron al Observedisposalregulatrcns ! Filling

a Only use antifreezeadditive G 12accordingto specificationTL lW 771E ldentificatian: purplecolaur. a Thepurple G 12ln accordance with standardTL lW 771F)mav be mixed with the previaus usedrcd G 12antifreezeaddiive. a Onnoaccount mustG 12be mixedwith otheranti-freeze additives. a ll the fluid in expansiontank is brown, G 12 hasbeen mixed with othet anti-freeze additives.ln this case the caolant must be

.-

_ 19-17

G 12 and anti-freeze additives marked ',ln accordance with TL lW 772D" prc,lery hast and conoton ddnao. scahngand atsa,a.se boittngDa;h'OIcaalah fa. fD.S,easo, lt' s] Sler musI De tttledatt L year round with antt-freeze and corrosion protectian addjtives. Because af ns high bailing point, the coalant improves engine reliability under heavy wotk laads, pafticula y in cauntries wiih tropical Thea.t, lrcezeprc-'clton shaJe oc guaBnteedto apgo\. 25. C tn counrrtcsA 4f aft ltc Aeathet up Ia appto, -35.C) Coolantcancentrationmust nat be reducedby adding watet, even tn warmerseasansortnwarmer countries,Theantt_freeze additive/ coolant ratio must be at least40 %.

_ . 1 9 -1 8 _

a lf far cli|Jatrc ressans a greater frcst pratectton ts requtred, he amounl of G 12carlbe tncteased,bJt anb,up to60 % (ftost ptotec tian to abaut 4A"C) With a greater cancentreton engtne coorng prcpe)1ies dinlinished. are and anti-freeze headgasl.etfra3 cyitnderhead or cYlindet a tf radiator, heet exchangea replaced,do not reuse ald coalant. been mlxtureratros: Rgcommended

Anti-freeze protection until -2 5 ' C

Anti-freeze proportion 40 va 50%

G 121) Waterl

2.Oltl 2.5 tl

3.0ltr. 2 . 5 lt r.

r)AmoLrnt coolant: litres; t may varyaccording the vehicle to 5.0 of equ pment.

19-19 -

Screw bleedingscrew -arrow into the radiator.

_f re;E

Fltcoolanthoseontoolcoolerconnectlonandsecurewtnasprng iype clampusingp lersVA.G 1306.

19-20-

Closeexpanstof lank cap. Starteng ne and r!n engrne appror 2,000rpnr ior airoLri lrir . ar : Fun engrne unti radiator cuts n. fan Checkcoolant levelandtop up if necessary. When the engine s at normatoperattngtemperatLrre, thecoolanteve m!stbeonthe max. mark,and when the eng ne is co d, betweenthe m n. and max. marKs.

5[

).at

t 9 _2 1 _

Radiator: removingand installing

Specialtools,workshop systems,testers,measuring instruments and auxiliaryitems required sAT 80'10 a Torque spanners 8010 SAT

mTn1n]:-=
[]in]H-E ..".

t!!{t2a

T20029 plrers . T20029

| @-;a 19-22 -

Removal Alwavs rcplaceA rings. n vehrcles coded with radio, noieofthecode, necessary, take f find it. ' W th gnitron swrtched d sconnect off battery earthstrap. + coolant page19-15. - Drain upper ant hosefromradator+ page19-3, coo itern3, and - Remove + the owercoolant hose page194,item12,withpliers T20029. pump Remove continued the coolant rculation c the -V51-and hoses + page 13,itern10. T9

19-23-

the - Separate thermoswitch connector + page 19-5, item13. -Fl8off fan fan ilem - Pullconnectors radiator andadditiona + page19-4, 10,item7.

pump-V5T pagel9-4, the - Remove continued coolant circulation -+ rlem6. Femove fro.t b,nper fn,n9: + General group BodyRepairs-installation exterior; work, Repair 63; Front llning Le6n bumper for Cupra R;front bumper ng:removing lin andinstallino pos drng 'oc. carfler'nto se'vrce tron: + Genera group BodyRepairs-installation exter Repair work, or; 50; posirepairs, Generalbody front; Lock carrier Le6n F: Cupra servlce tion - Lights:removal + E ectricasystem;Repair group94; L ghts,bulbs, switches external;Headlights: removing instalhng and

19-24-

- Removeth_e i aandLrit ; secured lo the racl6ior by ,l bolts + page - Remove screwsthai secure the the rcdiator the ockcarrer a|lcl to fenrove raaj the atorcarefuiy. Vehcleswith aif conditioning: - Secure condensor the conveniently the lockcarrier to panel. - Unscrewthe 5 boits-arfows which securethe condenser the to 'ad atot a d ..-'to!. he ,ad aro-.d,eru tl' -\

Attention! The ah conditioning cooling circuit must not be opened. Note: Topreventdamage candenser refigeration pipes/hases, err to and surethat thepipesand hoses not stretched,kinked or bent. are

_ 19_25

Inslallation Note: Always replace O+ings. - ftt-9 eoac..r..o1_e.aoiaro roagat9-5,rien posrt Trnrng on - With helpof a secondmechanic, all the oo|rs. frt Contine assemblyn reverse orderof the d smantling procedure ,Vofes. a lf the battery is reconnected checkthe vehicle equipment tadia / tadiaand na\.garonsistem -laat poAA! AindaLs,.fa av\t.q nstructron Manual a ather measures aftet rcconnecting the valtage supply + page 2439 11.nonngthe

_ 19-26

Coolant pump: removing and installing

sAT 8010 [][CGi.:-E,_"Special tools,workshop systems, testers. measuring instruments and auxiliaryitems required I TorquespannersSA.T 8010

trlrE&+,h
{]0filj:;r;

Removal

Always replace O ings.

i ullP;l

w - Invehicles th codedradro, takenoteofthe code,if necessafy, find

tL

Wrth gnit on switched off disconnectbattery earth strap Draincoolant page 1915. + Toothedbelt: removing + page 13-29. pLranp and removecooant pump 2 . Unboltcoolant -1-

19"27 _

lnstallation - Mo sten new O-ringwlth coolant lnsertcoolantpump -2'onto cylinder blockand tightensecuring _ boltsl-to 15 Nm. Contine assemblyn reverse procedure orderof the dismantltng

irotes.
a lf the baftetyis reconnected (radio checkthe vehicle equipment / radiaand navigation powet wndaws),following: ststem, clock, + nstruction Manual a Other measuresafter reconnectngthe voltagesupply+ page 24-39.

19-28 -

sAT 8010

Coolant thermostat: removing and installing

Special tools,workshopsystems, jnstruments testers,measuring and auxttlaryitems required a Torque spanners SATg0lO

0$ar[+_-,;-h"_

trcorn+*r

."'""'f @ z ml

T20029 a T20029 pliers

fw2sI

_ 19"29

Removal

Always replaceOrings. - Invehcles withcoded o,takenote rad ofthecode, necessary, if f nd

]l .

With ignition switched off d sconnect battery earth strap. Draincooant+ pageT9 t5 Remove the bo ts -arrowsand removelne coveT t,.

Remove connector,arrow- the exnausl temperature the of gas sender -c235-.

_ 19_30

Pul coolanlhose 'l- oii the brac[et 4 1re o Femovebrackel'4 {rom the in el nranifo _2 3_and releas'o dlpsticlguidetube-4-

flange 3- and removecon bolts4 of connectrng securing - Ljnboh -1 eeve 3_with gasket-2-andthe lhermostat nectings

1 9 -3 1 -

lnstallation

The bftce an the thermostat must be almost verttcal ' Molsten the new O r ng -2- wfth coolant sleeve and turn -3Fh the thermostai 1_to the connection (90 ") lo the flght. r/4turn

Fit the connectionsleeve -3_wlth the thefmostat .1 onto cyllndel blockand tighlenbolts-4-to 15 Nm procedure ordefof the dLsmanllng assemblyn reverse Contine ,Votesi a ]f the baftery is rccannectedcheck the vehtcleequipment (radio/ radia and navigatiansistem,clack,power windows) following: Manual lnslruction a Ather measures after reconnecting the voltage supplY + page 24 39.

19-32-

Cooling system water tightness: checking

Special tools,workshopsystems, testers, measuring instruments and auxiliarv items required I Tester SAT1274 a VA.G127418 Adapter a VA.G127419 Adapter

frt r-oor+l
_ _19_33

Checkingconditions . Eng ai service ne temperature. Checkingprocess

Aftention! Steam can be released when rcmoving the cap from the expansron tan(, I he cap shoulcl be covercd with a cloth and opened carefullv

- Opencapon cooantexpansion tank. FittesterSAT 1274 with adapror VA_G 1274lg expansron . n tank Wrththetester pumpa pressure I bafshould created. hand of be f the pressure falls: - Look the leak n the fittng andel minate fauh. for the

_ 19_34

Checking the pressure relief valve in the lockrng cap tn F t tester SAT1274with adaptorVA G 121419 lacl' ng cap open at shouLd - Operatehand pump The pressurereief vaLve '14...1.6 bar

--

19-35 -

pump -V51-:checkcoolantcirculation Continued ing

@ry
rM4nl

V.A.G1527B

instruments measuring SDecialtools,workshopsystems'testers, a;d auxiliaryitems required test lamp B a VA.G1527 Diode

Note: pump-V51- secutedta the nght' is citcutation coalant Thecantinued fan radiator in the ai duct the beside addiional

19-36 -

Checkingconditions . Fusefor the cont nuedcoo anl clrauationpuntpOli + Cufientfiow diagrams. eclf ca fau t frndng anct E Fttting iocatrons Checking process - Sw tch on igntion O Continued coolant circLrlat pump V5i-sho!tdwork(shoLrldbe on visiby and audibty worklng) f the pump does notwofk: Swtch off ignition. Disconnect continued the coolant rculat pump connector. c on 2. 2 f[,+61

_ 19_37

- Swtchon rgntron. a LEDrnustightup. LEDightsup: RepLace continued coolant pump-VSl,. clrculation lf the LEDdoesnot hght upi - Carryout the following checks related a pointl to Vehicles w;thout air conditioning: trnued anl circulat pump-V5l to the relay coo on Current d agrams, flow Electrical findng andFitting fault ocatlons

11112:13j
'i-r -Ei !-r

. Check tagesuppy to the re ay vo + Current d agrams, flow Electrical findrng Fittng ocatrons faLrlt and

T"rol

_ 19_38

Vehicles with air conditioning: . Checkthe w ring of contacl2 of the coolant fan controlun t connector-J293 (n the enginebay,iront leit hand)
' '6 n l r r o t u r 'o J r o r n c rl6iur.o la. ' rr r. l-. q o .o

. Check voltagesupply the radatorfan contlolun t -J293'. to the locations + Current ow diagfams, ectrcalfauli f nd ng and Frtling f E Continuation lor both versions . Check opencircu(from contact1 of the connector earth to for f E Cufrent ow d agrams, ectrcalfaultflnd ng and Ffiing loctions f no faultis found: orthe controlun tforthe coolrelayforlhecooLantfan - RepLacethe ant fan -J293.

19-39 -

Radiatorfans -V7- and -V35-:checking

VA.G 1

measuring instruments Specialtools,workshopsystems.testers, and auxiliaryitems required or meas!ring VA.G1594A VA.G1594C set i Auxiiary a Current flow diagram Checkingconditions . Basc t!ses should present problems no
f"!!@rl

. Radiator thermoswitch and-F54-, OK. fan -F]8

process Checking F54-.

19-40 -

-. Switch ignition on - Brdge contacts -1,and ot theconnector -2 termtna,ustno auxr,iarv cabtes fromVA.c 15944or VA.G r sgaC.naoiatoi tini lvil'rn"i,. vJc- s,)ouKbegrn run at speedL to - Bfldge contacts and3- of the connector -2telmtnat usrnq auxrliarv +rom cabtes VA.c tb94A or VA.c rSg+C. naOiatoi faii lri-_ an-i'_ \BFshould beginto run at speed2. lf fansdo not runat 1st or 2nd speeds: - Findandelimrnate wtringopenctrcuit accordrnq to: + uurrentflow diagrams, Electricaltauk frnding Fitting a;d tocatons lf no wiringfaultis detected: radiator fans-W- or -V3S-. - Replace

1941 _

Fuelsupply system components:removing and installing

Arofasi a Hose connectionsare secured with either sprtngitype or clamFr rype ctlps. a Alw?ysreplaceclamptype clips with spring-typeclips. a Fuel hoses in engine compaftment must only be secured with sping-type clips. The use of clamp or screw-typeclips is not per missibte. a To{it spting-type.hps phersT20029. use + sdfetyprecautrons page20-12 Observe + rulesJorcleanliness page20-13 Observe parts andfuel filter Bemoving fittingfuel tankwith accessofy and page203

2O-1-

+ 20-29 fuel Crash shutoff iunctron page powercontrol(EPC): checking page204 Electronic charcoalfilter system+ page _ components the activated of Bepairing 2055

2O-2-

465 *i'l.

?. -tffi

Fuel tank with accessoryparts and fuel filter: removing and installing
1 ' O-ring 2 - cravity/overload valve i) To remove valve unc ip upwards out

22
21' 20-)---.;::) ,-Ao l

I . . a

Checkvatve thfoughflow ior Perpendicu va ve: open ar va ve tited 45 .i c osed Thegravtyloverloadvalvecan onlybe Iep aceo tooetherw th the breath-^r tube ltem 3

18

16

IE

I 14 13 t ezo-oo+s
20_3_

til)
23

1 8

9 t0
3 - Breatherpipe a Clpped onlotopoJfueltank .f a Tothe actrvated charcoatlter in the engrne bay I Check secure for seating 4 " Ca p 5 -Gasket I Replace damaged f 6 -1 . 5 Nm

21-'1 20 =+
19 18

,"S

7 - Tank flap unit t Withdustcover 8 - greathervalve a Toremove valveunclp sideways out ol suppoft a Beforenstalng, unscrew cap,tem a Check + page 9 F g. 2 ng 20

IO

15
2O4 _

3 - Earth connection I Cf eckior secureseal ng I F rtirg post or =oage20-10 Fg : 10-10Nm 11 - Breather pipe fWhte a Clppedonio s de of fue tank a Checkfor secureseatng a Secure with spr ng type clips 12 - Fueltank t D snrantl andfift ng + page20 23 ng 13 - Spring washer a Checkfor secufeseatrng 14 - Heat shield a Forfueltank

14 13 t E2oroo4s-l
20-5 -

6 7

tl)

1 8 9 10

l5 -2 5 Nm strap 16 - Securing i Notedfferng lengths y t Assemb posltion: arfow(openthe po rng) nts n the d recton of trave pipe/hose 17- Supply a B ack bay a Tothe fuelrai in the engine for a Check secure seating 18- Fuelfilter + 20'28 a Fene\r' page t Assembyposition: arrowindicates theflowdrrection

19 18

1a 13 tEro-oo-as-

20-6 -

I?3

t"..gr',

19 - Clip t To iLr-r{ her I F il na positon + p.ge 20 ll, tern 4 20 - O-ring t Fepace if dar.aged I Coatwith fue when instalrng

23 22 21 20
to

21 -Fuel delivery unit with fuel qauoe sender a D smantlnq .nd i ltrng.- page20 I a Hemovrnq and ftjinq ihe iue leve sendef+ page20 22 r Checklng pump page20 30 fle I Note fttinq postion-on fue tank + pege20 I, F g. 1 a Ciean strainer so ted ii

18

1a 13 t Ero-noa5-l
2O-7-

\( i ki-" j
"-!,,\.F8'
23 21 20

l-,

18

22 ' Unionbolt a 8 0 Nm a Remove and /nsta with tool I u40055A 23 - Supply pipe/hose a Black I Between fuel delrvery and the unit thefue fiter i Check secufe for seat ng 24 - Returnpipe a B ue or wth bluemark ngs a Between fuelrai andthefuelde, the tvery t un O Clrpped s de of fueltank onto a Secure withspring,type c ips a Check secure for seating

14 .13 ezo-oolil
_ 20-8

Fig. 1

Fitting position o{ Iuel delivery unit flange

or] a t on Marlinar sendernrLrst ign \^r _ the marking iue tank p Biueor bLue niarked return pe -l -1ocofnecl on wrth cier'tii uiL-i-. cal wilh dentficaion -VB acksuppy p pe -2 to connectron Note: retum Aftet installingfuel delivery unti flange,checkthat the sLtpply, arc still clipped onta the fueltank. and breatherpip-as

Fig. 2

Checking breather valve

Lever rn rest positLon: closed Leverpushedin directon of arrow:open

Before installingvent valveremave fueltank cap.

tt:ou;l

20-9 -

'I

Fig. 3

Fitting position of earth connection

F 1 earthconnection shown n the illustfation. as n - First,hookthe contacttab -4 for the eafth connecllon the fuel hole4;then, pressft the spacer 5. tank securing Hookthe earthconnection the securng c ip -3-of the fue tank to f ller. fits eafthconnection coffectytothe - lVakesureconnector-2-ofthe fuel tank fi ler rneta r ng '1'. the checkthe electrc connections between metaL - Afterassernbllng, partof the bodywork, ring in rhe flel tank f llerand a non painted usingm!himeterVA.G 1526Aor VA.G 1715. Specifcation:approx.0 Q

.--20-10

Fig. 4

Fitting position of fuel {ilter screw-type clip

F t the screw-type ip as shown in the rtustration c - Fnsure thatrhereis suf{cientspace betweenscrewfiange andiuel tank. Note: The figurc shows the fuelfiltet ftum the f@nt.

20-lt _

Safetyprecautions when workingon the fuel supplysystem

a For safetyTeasons, Temove fuse No.28 from fuse holderbefore ooe- ng tqe r-el svs Fm ds -ha t-al ou-p .an be.c-,/ated o) L.e dnvers door contactsw tch

Attention ! Fuel supply pipes are under pressute Belore removidg fuel hoseconnectionswrap a cloth arcund the connection, Then release pressure by carefully pu ing fuel hose frcm connection. Wh e n re mo v in g an s t a g t h e f u e lg a u g e s e n d e ro r f u e l p u m p l f u e l n d lin deivery!nit) froma {ullor parlly .fuel ful tankthe fo lowing mustbe

_ 20_12

tystem and swltchonerhauslexiracti'lr 1 BeiorecomnrenclrigvvorL in opening the fueltank closeto the sender l',oa" ptu"" an ""tr""tlon iuel l!mes escaplng to extract olrq d s I l{ no e.h:Lls1F'IIarron9ys1e-n dva'l.DlF "drai'" a' '/n "' can gradler lhaa l! rr a motor', nol n d.'r o / ' v\lLn o,rpla -e_16n. glovesl a Avoidskincontactwithfuel' wear tuel-reslstant

Rulesfor cleanliness
system, When working on the fuel supply/injection "5 tronto the followlng rules : pay caretulatten

areasbeforediscon cleanall un ons and the adjacent a Thoroughly necting. cover a Place parts that have been removed on a clean sLrface and them. Use lintfree clothsl

20-13-

a'loalsa'd comoo' oe can,lol -orpreteoin onesess'or' a lt reoatrs rhe , h J u , " e il o p F ' s h o -d o ' (o v ' ' e d o r ' t o re ow r l _ " " n i. of cate. greatest cornoole^1s cLeaa t o-ly,nstall priofto installatron partsimmediately replacement Onlyunpack etc') Do not usepartsthat havebeenstoredloose{e g in toolboxes a Whenthe systemis open: air Do not work with compressed if this canbe avoided necessary !nless absolutely Do not movevehicle

20-14-

Generalassemblydiagram of the fuel delivery unit and fuel gauge sender

1 - Fueldelivery with sealing unit tlange . Lrsmanlngandttttnq paqe 1A 20 pump fue system: a Fuel and checking page 20-30 1Check holdrng ng pressufe page + 24 65 2 - O-ring a Fepace damaged ii a Coat withfue wheninsta ling

fAro-537dl
_ _ 20_15

3 - Returnpipe a Blue withb uemarkings or a Fromfuel rai a Goes the connection to "F marked Inthe seaingf ange a To femovefrom the seaing ftange, pressthe ockng button 4 -Supplypipe/hose a Black a Tothe fue filter 'V" a Goes the connect marked to on in the sealingange f a To removefrom the sea ng flange, press ockng button the

_ 20_16

5 -4-pin connector t Forfue gaugesender puir-rp andfueL 6 - Union bolt | 80 Nrn a Remove and Install wlth t!rning lool

u 40055A

7 - Fuel gauge sender a Dismantling lltting+ page2At2 and

I
I

1
I

Fueldeliveryunit removingand installing

u-40055A
testers,measuring instruments tools,workshopsystems, Special and auxiliaryitems required o Turn toolU{0055A ng

saT8010
flTlnt]]j::E,""."-

SAT a Torque spanners 8010

nmntl]:}-=

. **

I !!tnP-l

----

20_18+

Removing Frrst check whett er a co.ted adrois firled. fthsisrhecasecons!lt the antitheftcodrng. Note safetyprecautrons befofestaningwork + page20,12 - Wth the gniton swtched oJfdsconnectbateryearthstrap - Move reafseat forward. - Bemove coverfrornfuel deltvery t unuerfearseat. un

Attention! Fuelsupply pipesarc under pressure Beforeremovingfuel hose connections wrap a cloth around the connection, Tien rctease pressurc by carcfully pulling fuel hose from connection.

20,19_

ply pipes (black) -3-, press ocking buttons to do th s.

u-40055 A
Place turn ng tool U-40055 on unionnut and unscrew from the A I llange. Pullfuel delivery unit and sealout of the openng n fuel tank. lf the dehveryunit ista be rcnewed thendain ald deliveryunitbefare

_ 2O-2O

Fitting rn ord-'t the - Installng fue de vgry untt s canledoLrt ihe reverse sender ls delivery unit, check that ihe fuel gaLtge a An fifting the fLtel a Coat flange O+ing with luel when fitting. a Ensurefuel hosesate seated securely. position of fuel deliver| unit flange. Themarkingon a Note installatbn flangemust align with marking on fuel tank arows. return and a Aftet installingfuel delivery unit, check that the supplY, breatherpipes are still clipped anta fueltank. suppy open aiter the - Perform work seqlence ProcedLrre voltage page24-39. circuit" -

2 0 -2 1 -

removing and installing Fuellevelsender:

Removing fue de iveryunit+ page2012 - Remove 'for terminals wires-3-and -4and removethe connector - Release and Lift retaining tabs -1- and '2- with a screwdrlver p!ll fuel level senderout downwards -arrows-. Fitting orderbut noie iollowlng: lnstaI in reverse Lrnit and - Insertfuel levelsenderin the guideson the fuel delivery push Lrp | |t engages. unt fltted - Makesurethat the tabs of the sendercabes are securely ' Fitfuel delivery t + page20-18. un

20-22-

Fuel tank: removing and installing

SAT 1O4O

Speciallools, wo rk shop syste m s, testers, measuring instrumenls ano auxttrary rtems required a Hydraulic coiumnjack SATj040

t;Ar-l

saT 8010
i Torque spanners 8Ol0 SAT

f wc,@t

20-23_

Removing - Note ssfetyprecaut ons beforestan n9 work + page20 12. - F rstcheckwhethera codedrado isftted. lith s sthe caseconsult the anti-theftcoding. With the lgnit on switched of{ disconnectbattery earth strap. Remove fuel filer cap. - Drain fue tank.cleanfue fjler and surroLJnding area. - Unboltand remove tank flap un t. - Move rear seat forward. - Femovecoverfrom iuel de iveryunit underrearsea1. - Femove connectorfrom flange -arrow-.

20-24_

srale r.rheeL housng mor 3 rg: .r - Fenrovrr lhe raarrl.lhi raflcl r v,/orkexlerorl Repa group66; Gjnstslletlon Genera6ody Flepa - Exteriorequ ngrno ldngs;Re:'whee housrng pnrent;Wheelhous nstalrng and mou dings:removing bolts arrows the Bemove {ue tark fLller rearaxle: - Remove \"ehcleswith fronl wheeldrve:
' q--naqqed.a p" q' o-pa:. Fe ng.Jro t/v16ol ' ndro -t e^d t it eP' ' on1 ' 1lhee'd' / '1 l o. reoo no .' e i ' _ " eo " ^r"

re components: Exhaustsystem group26; Exhaustsystem; 5 FepaLr and moving installlng

R emov ng and f tti ng the centraland rear exh6ust system sLlencer s;

20-25 -

the Removethe suppiytribe 1 (black), ret!rn tLlbe-2 lblue)and the buttons the pLpe'3by brealher {white), pressrng lockrng

Aftention! Beforercmoving fuel FuelsuDplv pipesarc under pressure Thenrearcundthe connection. wrap a cloth conn6,aions hose pressurc by carefutly Pu ing fuel hose from connection' Iease the - Bemove owerprotecton from the fuel tank fuel this slrapsWhendolng support the - Remove lueltanksuppoft jackSAT 1040 lc tankwith hydrau column fuel - Remove tank.

20.26, -

Fitting nstaI in reverse orderbirt notefolow ng: t Breather fle hosesareio be instaledltnk irea and a Secure hoseswith spr ng-iype ciarnps. a Do not confusethe fue ptpeswth thoseoi the returnpipeor the a Checkfittingposrtton earthconnection page20.10,Frg. 3 of + t Tightenthe bolts arrows-. Tightening torque:lO Nm a Fitting rearax e: Vehicleswith front wheel drive: + Runninggeal, axles, steering, frontwheelandfour whee drive;Fe_ pairgroup 42; Rearaxle: reparing (vehicles with iront whee d;ive)

20-27_

Note: Alter installing fuel tank, check that the suppl' retuh and breather ptpes arc sttllclpped onto the fueltank. - Performthe work sequence "Procedureafter voltage supply open crrcuit"+ page24-39.

Fuelfilter: replace
Removing pipes by pressing lockrng - Separate -l-, the ourons. - Loosen fue iiltefsecur clamp2,. the ng - Separate fuelfilter. the Fitting - nstal in reverse order.

20-24_

Crash fuel shut off

Function ofJ vv are Vehicles th airbags fittedwlth a cfashiuel shLrt system This af reducesthedangerof re nacrashasthefue pumpisswltchedoff va the luelpump relay J17-. p o/ida< r p'or'eder o,1' cIa t. " to the f!el pump s actvatedfor 2 seconds When the dooris opened in bu ld up the pressure the fuel system th. S m-haneo-sly )'l.n the When opening lue system: observe safety precautons + page 20-12 fuel pump relay-J17: - Checking + VAS5051;Vehicle f-diagnosls se

20-29-

sAT 1348,-3

Fuelpump and fuel system: checking

testers, tools,workshopsystems. Special measuring instruments and auxiliary items required a Adaptor cableSAT1348/33 o Turnng too U-40055A gauge Pressure a VA.G1318 Adapter a VA.G1318/l Adapter a VA.G1318/11
9t t

Adapter a VA.G1318/17

E-:t

,1

fi-i'=r=-=-:fi'E

re.==q,

ap
20"30-

a VA.c I31823 Adapter t FenrolecontrolVA.c I348l3A

{.,!at-=-:=E!:

I Auxilery measLr|ng VA.G tE94A or set

r594C

a VA.G 1715 M! timeter

tL2o-omrl
-20-31_

Checkingconditions . Bttery tageat east12.7 vo V

. Allelectric consumers, ights reafwindscreen e.9.r and heatermust be switched off . lJ the vehicle equipped is with an ar condttioner, must be ths swrtched ofl Observe descnptian crashfuelshut-off+ page2G29. of Checkfunction and voltage supply Tocarryout thiswark the battery earthstrap mustbe disconnected. Thevehicle shauldbe checked a fittedradio.lf necessary for abtain tadiaanti theftcodefirc|

20-32_

iJa,r: rea s:al f.iward Remov-o coverffcm luel delvefy !nrt ufder rearseat - S!!tclionigntlcn.Thefuelpunrpshouldbehardtcsta'11if th:test '"s lo b. repe".ed.,\'oI fo ot reo 6 qo o d.l li the iuel pump does not run: - Switch off gn tion - Femovecoverirom fuse holder F..no/e fi-e no 28'o rhe - ', 'oldel

va.G 1348/34 =

ConnectTemotecontrolVA.G 1348/34wth adaptercabe SAT 1348/3-3 contact 28a to fLlelpump and batiery posrtlvetermrna to (+).

20-33_

remotecontrol. - Operate Fuelpumpruns: +VAS 5051 Vehc e sefiragnosis ; Fuelplmp does not run: - PJI 4-o n con eclort-on 'u.l at . 'la-g. VA.G 1715us ng auxiiarycables - Connectmr]ltimeter from VA.G 1594A orVA.G 1594C to the outercontacts the connector. of remotecontro. - Operate Speci'f on: Approx.battery voltage cat

20-34-

lf the specificat s r,.rtobtaneC: on Locate andelrminate shortcircurt the folto,"!rng c!rrert iiow d athe grams. f the spec{ cat of ts obtaned (votage supplyOK ):

u-40055 A
Place too U-40055 on Lrnion and unscrew from the flange. A nut it - Checkihat the e ectr cal wtres betweenf angeand fue pump are t no open circuit can be found: Feplace fue de very un t + page2O-18.

_ 20_35

Checkingdeliveryrate Checking conditions . Fuelpumpvohage supply O.K. . Remote contfolVA.G 1348/34 connec.ted o Fuel pressure hold pressure + page systern and ng O.K. 24s Checkingprocess pipe'1- by presslng locklng - Separate supply fue the buttons. Aftention! Fuel supply pipes are under prcssure Before removing tuel hoseconnections wrap a cloth aroundtheconnection. Thenrclease pressure by carefully pu ing fuel hose from connection.

_ 20_36

vA.G 1318
'1318/11 1318123 VA.G 1318/23 the fuelsuppy p pe to ontothe adapter G 1318/11 rhe - Pushthe hoseVA G 1318/1 VA on
pt 6 ..-oduo6JndhodloqFt d-n6ac. g.o ro e,

Open shlt-off tap on pressure gauge.The lever\/rl rndtcate ftow direction-A'. - Operateremote controlVA G 1348/3,4 siowly close cLrt-off and tap, LrntI pressuregauge shows a read ng of 3 bar. - From th s point on do not move pos tton of cut off tap - Emptythe measuring container.

v A .G'1 3 1 8 /17

f @@t

- The quanttyo'ffueldelivered the iuel pump is dependent by upon batteryvoltage.Therefore connectthe rnuttmetefwith adapter cables from VA.G 1594to the veh ce batterv. - Operateremote contro VA.G 1348/4for 30 secondsand measure batteryvo tage.

20-37_

- Compare quant of fueldelivered ih spec the ty w ficat on *) Vlinimum delvery cm3/30 s pumpwith engine Ln "*) Voltage fuel off (approx.volts andthe pumpworking 2 lessthanbatleryvoltage)
TMjml

Example: During test,a votageof 12.5 the voltsis measufed the battery. at As thevoltage atthepump approx.volts is 2 lessthan battefyvohage, the th s w ll equate a m nimum to delivery 200c.c./30 of s 'Ihe rrr' . ' n - o er. e ' yt a le s -o t d n o re o e - Ch e c k t h e f up rp e s lo t h e f it e rf o rp o s s ib e c o n s t ric ti o n s l k l n k s ) o r
D OC K ageS .

lf the fuelp pesareO.K.: the - Check fue de rverybefore f ier. the

20-38 -

v.A.G1318 vA.G 1318/17

vA.G 131a/l1
VA,G 131 P!lloff supplyprpe/lrose off nlel to TLrelftfter, lpressbuions cn hosecor_rp ic do thjs ings

Attention! Fuel supply pipes arc under pressurc Befote rcmoving fuet hoseconnections wrap a clotharcund theconnection.Thenreteaseprcssurcby carefullypuling fuel hosefrom connection. pressLrre Connect gauge VA.c t31Bwth adapter 13tg/17 fuel to prpe. supply Couple adaptorVA.G 1318/11 VA.c 1318/t the pressure and ro gauge p acetne endoT pressure ano the regulator a measuring In - Openshut-off on pfessure tap gauge. The everpo nts n d rectton

_ 20_39

- Operateremote control VA.G 1348,4and s owly close cutff tap, unt I pressure gaugeshowsa readng o{ approx. bar. 3 Fromthts point on do not anovepos tron of cut-off tap. - Empty the measuring contaner - The quantty of fuel delveredby the flel lrurnprs oepenoent upon batteryvoltage.There{ore connectthe mu timeter wth adapter cables irom VA.G 1594to the vehiclebattery. remotecontrolVA.G - Operate T348/34for seconds 30 andmeasLtre oatteryvoltage Repeatde ivery rate check. It the minimurn iveryTate now attaneo: de ts - Fepace the fuel filter f the m nimumdelivery raters againnot at(aned: - Remove luel delivery t and checkthe fllterfor dift. the un

_ 2O-4t0

has beeI de1e.1ed: Onlywhen up to now nc iaLrk page20 18. yoh f the delvery ratehasbeen atalnedbut nevertheless suspscla fai fue delivery systemfau t le.g.Intermittent ure of fuelde iverysystem): fue delvery unfi Feplace draw of the fuel pump as follows: Checkthe clrrrent

vA.G 1715

m:

fuel all - Reconnect dlsconnected pipes. VA to clamp,connectmultlmeter G 1715 Bv meansof the cLrrrent (external contacts the flange of pump suppy cables o;e of the fLrel connector). ' Starttheengineand run at idlingspeed.

20-41-

the drawoi the fuelpump - Measure current max. Specificatlon: 8 amps. Note: you is lf the fuet systemmalfunction intermittent, canperformthe 2nd person checkduringa test drive whh the help of a drawis exceeded: lf the current 2018 unit fuel - RepLace delivery + page

2042-

Electronicpower control

(Epc)

1 - Bracket i RearcvLfg instaling and s Brakesystem;Repa group46; Brakes, r rnechanrcs; Brakepads:genera assem bly d agfam 2 -Connector a Black, prn 6 3-10Nm

i:
tt.,l o-ooi5l

4 - Accelerator pedal position senders G79-and -G185t To remove, t is necessaryto f rst re rnove the footwel cover a Checking page2047 + 5 - Bracket a n footwellcover 1 Clpped onto acceleratof peda poston sender

20-43 _

Function EPC of system

Wth the EPCsystemthe throtilevalve s not operated a cabe by Thereis no mechan connection ca betweenaccelerator throlte and valve Thepositron theacceerator transmtlted theengine of is to contro unit by two acceeratorposition senderslvariable stofs togetherin a res housing) whichare connected the accelerator to peda (drivers Theposition ofthe accelerator requLrerneni) maininput s the valueior the englnecontro un t The throttlevave s operated overthe completerevolution and oad range an e ectrc motorlthrotte valve by positoner)nthethrotteva ve The throtlle va ve s operatedby the throttle valve pos lloner which is controled by the 9ng ne contro unit

20-44 _

andlhe lgnitron swtcheoon lleen_ s rs Whenthe enlline nol runnlng by valveexacty as pfescnbed the oinecontro unitmovesthe throttle when the acceler pedalposrtion senderThismeans'that ;ccelerator opens the halfwaythe throttlevaive posrtioner ator is depressed y valveby the sameamount,the throtie s then approximale throttle nar open When the engineis r!nninq(underload)theenginecontrolunit can pedal oithe accelerator valveIndependently the openor close throttle

I
I I

Thismeansthatthethrottlevalvecanalreadybecompletelyopeneven I pedalrs only depressed halfway This avoids thoughthe accelerator \o.rng lo."es'allsed bv tc6 tF onle /a vF ' the After evaluating torque requirementsof variouscomponents (e g and ABS/ESP so on),the englne ng, air condition automatic Aearbox, angle{or the valveopening the control unitcalculates optima throttle respectrve snuatron.

I I

20-45-

and em consumptlon exhaust ss onle ThisaLsogivesvastlylmproved load condntons velsat ceftain of that the EPC"is comprised one or two to l! is incorrecl believe of which comprised allcomls is TheEPC a system, only. cornponents ofthe mon controlor tortheposltion have lnfluence, an which oonents pedalposition the sender' throttle e.g.the accelerator throttlevalve, controLlnI lamp, engrne the warninq the valve control unit, EPC

20-46-

v.a.c 155i

vA_G 1598/31

Acceleratorpedal position senders:checking

Special tools,workshopsystems, testers, measuring instruments and auxiliarV items required a Handmultimetef G 15264or mut VA ffieter vA.G l7l5 I Fault feader VA.G1551 vehtc system or e tester VA.G 1552 with cabte VAG 1 5 5 1 /B 3 a A u x la ry me a s u rins e l V A. c 1 5 9 4 4 r g o vA.G 1594C a Test VA.c 1598/31 box a Currentow d agrams i

ffi
vA.G 1526A

fl2-4-oo1o I
20,47 _

Functioning Bothacce ratorpeda positon sendrs le -G79 and-G18b,ontheacce, eratorpedalpassthe drver's requrementson to the engtne conlro unrtrndependently oneanother, of Bothsenders installed are together In a srngle hoLrsing Checking conditions . BatleryvoLtage east 12.7V at Checking process - Connect fault feaderVAG 155j (VA.GjS52) Starlengine and se lect Address code" 01 to se ect eng ne contro !nit.
Ba p i d at t r ans ler d H EL P

- Presskeys0and Sforthefuncton'Read measured vaue bock,' and conf rm entry with O key.

_ 20_48

Readmeasured !al,reblock Eiler numbergroupvalues XY'X

Inolcated dispay: on - Pfesskeys0, 6 and 2 for "Display groupnumber62" and confirn entry with O key.

Beadmasured !e block va 1234

62

(1.. indrcated d splay: 4=dsplayfields) on Checkspecification sende-I -Gl9 ar id ing sioo In d sptay of zo.r

3:

Specifrcation: 7o 3...100
4:

Check spec fication sender -G1Bb-at of 2 idlinq stopindisplayzone

Specriicatron: 3 ..l0Oqo No'; The engine control unit calculates the voltage vatues of the anglesendern percent relativeto 5 Voltanddisplaystheseas a percentage figure (5 Volt supply voltage equates to tOO yo).

2049

pedalslowlyuntilfullydepressed ob. - Operate accelerator the and servethe percentage figures n dispay zones and4: 3 Specification: 3...100 % Note: percentfigures display The in zone3and4 mustriseevenly. Thetoler anceranqets not covered completely. - Press- key. - Press keys0 and6 ior the "Endoutput"function confjrminp{rj and wih rhe O /ey. - Switchofi ignition. ts not 'ttsespec'ficatron obtatneo pedalposition accelerator - Check sender voltage suppiyandwirine + connections page 20-51.

20-50 -

Checkaccelerator pedal position sendervoltage suppty and wir_ Renrove shef or dlvei s s de. ihe Gereralbody fepars-tnstalat \,!oii, inrenor, on Repa groiip68; I r - ler or equrpment; she f, covers 3ndif ms; Lowerpenels bestde the sreerng cot!mn: removal Disconnect pin connector acceeralorpeda post on senders 6 lof lrornthe accelerator pedal Switchon gnition Connect t meterto measufe mLr voltag_a the fo low ng contacts at of

6-pin connector, contact

Measureto
Earth

l-'*al

2 2
Specf cai on: at Least V 4.5

Ea(h Contact 3

_ 20_51

- Switchoff gnLtron. ll the specrflcations not attarned: are - Connecttest boxVA.G1598/31 tocontro untwnngharness wthout connecting eng ne contro lntt + page24 36 the

currentiowdagram.

6-pin connector, conlact

1

Testbox VA.c 1598/31, test box socket 72 /3 36

35

2
tr.ft I

3 5
6

33

20-52_

Wireresislance: O Max. 1,5 positive eafth. or - Additionally check wifingfor shortto battery the check wiresfor shortto one another. - Addilionally lf no wiringfa!lt is detected: pedalpositlon + sender page2043, item 4. - Benowaccelerator

2063 --

filter system Activatedcharcoal

irotes a Hose connectionsare secuted with either spritqtype ot clafip type clgs. a Always replace clametype clips with spting.typ clips. a Tofft spring-typeclips use ptie6 T2Un9. + safetyprecautions pag2G12 Observe + rulesfor cleanliness pags20-13 Observe

20-54-

Servicingparts of the activated charcoalfilter system: rgt.lrirt

-@l

tl
tl
CD

1 - Rubber bush 2 -Activated charcoal filter system

tt.i.o o ofo. , a n L . 6 . -- Fr , _

r-

rnenl,nght I Securedto body a Toro-no.e u boLrrh6Oo16 .Foril .V 6n a.o /o orn ebod)ror, aW.r .re.ol- od.".I \80. o the activatedcharcoalf ilter systenr a When the engine swarmthevave rVr bea . ,"r.d'on .'eeig ,e, or tro unit (pLrlsed) 3 -Bush 4 - Washer 5-10Nm

f Aro O3r?l

20_55 _

8
/zil '4U

+t*t

."'1odttu-r

""\

ll

6 - Connector a Black,2-pln a Wilh the so eno d valve1 forthe acti system-N80vatedcharcoalfiller 7 - greather connection a Checkfof secureseatrng on a From gfevityvalve tirelueltank the + page20 3, item 2 I - Non-return valve a Observe fittrng positon (lghvdark on, pa.t): shownin the lllustrat the as the arrowindicaies flow dlrection. I -To the turbocompressor inlet pipe

I'

r-
T;t;;w r _=.20"56----

/t ,U

.-) //+'Y

t r.|ftPt

-\

10-From the gravity valve on the fuel tank 11 - Non-return valve a Obsefve iiiifg position (ight/daI part): shownin the ilustrairon, as the arrow ndrcates flow direction the 12 - To throttle valve control part

l
@ I

Ie

11 12

1
h2o,m-97l 20-57 -

saT 1368/1

Fuel tank breather:checking

Special tools,workshopsystems, testers, measuring instrumentsand auxiliary items required
i4!lI ll

a SAT1368/1 Adapter a SAT 1390 ManuapLrmp t VA.G1368 VacLrlm tester

f mtt 20-58--

Checkir:g process

va.G. 1368

- Felease breather the tubefor the activaled charcoallter systern f - Connect handvacuumpump SAT1390to activaled charcoalfilier system-1 wrlh an auxilarytube 2, pipe -3-which eadslrom fue lank to activaled - Uncouple breather charcoai filterand connecttt to vacuumtesterVA.G i36g -connection A-. To do this, use SAT1368/t adapter.

sATr 368/1

Connect VA.G 1368vacuLrm the meter {onnect on B- to breather ptp-4 leadingto activatedcharcoa the fi tersystem. Todothis, use SAT1368/1adapter. - Putvacuumtesterin postion B. nit atethefina controldagnosis acttvatethe and activalecl rcoa cha filtersoleno valve1 N80-: d + VAS5051;Vehicle f-diagnosLs se

_ 20_s9

pun-rp 1390 Operate vacuum hand SAT severa mes. t Vacuum must vA.G. 1368 f vacuum ldsup: bu - Check breathlng connect at the bottomof the activated on charcoal f itersystem andclean necessary. lif f vacuum doesnotbuld up: Unscrew fLler fLre cap. sAT 1368/1 pump - Connect vacuum hand 1390 vacuum SAT to tester VA.G 1368 connect B . on posit - Setvacuum tester -A/Bto on.

sAT1390
TE,i-;l

pump hand - Operate vacuum SAT 1390 severaltimes. Vacuum must notbLr up. ld

20-60_

lf vacuum builds up: - Check breather valve+ page20-9,Fig. 2. pipe/hose - Check -3-irom fueltank for blookage. lf vacuum doesnot buildup: fuelfiller cap. - Unscrew pump$Tl3g0 severs'times. vacuum hand Vacuum must - Operate not buildup. Not': lf the fuel level in the tank is low the SAT1390hand vacuumpump rnustbe operated 20...30times. apprcx. lf \racuum buildsup: the cap. -,Eeplace fueliiller '

20161 -

liuSrerchalgingsystcn-ir,rith e;:haust garsiuril6cor.r'ipressol Rules cleanliness for

For .o,.,oo nq ! l ui 6s oi ean e5 .::

a Tl roroughy a eaf a Lt| (]| :: a .l thE ai ll 3.a.i : ar?sl reTor : i : . . ! r i,

necrng

a P ace partsihni I ave be,^n errov--d a cleal s|rrJace aoler o., an.l tfenr Use nt free clothsl 1 i repairs c!nnoi be aompleiedrio e seasiDn, 1partsanclco-iiroa nents that are left open sholld be coveredor stored vvtththe greatest care. ol I Onlyinstall cleancomponentsOnly unpack acementpartsimrep prior to rnstallaton. not lse pa(s that have been mediately Do stored oose (e.9.in tool boxesetc.). a lf the sysiem s open,do not use compressed anddo not move air

21-1 -

14 13

16 ----o,

"+"rp

17

Turbocompressor: removing and installing

1 - 1 0Nm 2 - Oil return pipe I Towards sur.lp 3 -1 0 Nm I Onfifringapply locl<ing agent 4 -Gasket 5 -1 0 Nm 6 -1 0 Nm a Do notadjust setting ,l Loosen is not permitted ng

-18

10
9-

24 5

2a
32 31 30 29
tAri oo%l

, . , i , : r 'i t . : ' it::: ... t:rt..:Lri.. i F:ri - l r l L o i !: l ! ii::.:;:-: . ir :,. t:ri ,.r

.:

1:

18 .19 g '''
ZU

e - fxhaust EaslufboconlPressor .f lr .ni r! :r.i i i]|rlt : pige r -l 9-25ttm 'i0 - Gasket + flote the f1t rg posll!.ir 11 -10Nm

22 - \,-23 24 25

l2 - Hollow bolt 130 Nm

.,:d,
'\ 26 '-27 28 32 31 30 29
tArt.0016l 21-3 -

--= li
lo-\;

16---.,._-.::=\\rtt9 f.., l

17
18

13 - Oil supply pipe t From the ol fiter brackel: rtem.13 17-12, 14 - Ribe head bolt a30Nm

page

"-)-"
?

,(g 5
..r-:

litr

10
9

'-

a Remove and InstaL wth socket spanner SAT8050 t App y locliing{ uid ior hot working boltsto threadsand contactsurlace of cylnder head a Lockng fluldfof hot work ng bo ts G5 lsee sparescaralogLJel 15 - Exhaust mani{old I Dismairtl andlitt ng + page26-10 ng

22

'16- 23 Nm 17 - Hollow bolt

25

r 30 Nrn

18 - Gasket a Note the fLt ng pcst cn

32 31 30 29

fAtl oor6l
21-4 -

''? $: fl.,r.. l,.l1 e :i. l.l iL. a.,olar,treiuft I'ipe

,i'ir-'
I
6

21 -20 Nm 22 - Hollow trolt a :[) l] _n 23-10Nm 24 - Coolant supply pipe 25'Hollow bolt a35Nm

22 7

'i 4
3'+ ,/:' _

24 25

26 - Lambda probe a55Nm i) Beforecatalyticconverter a The threadshoud ontybe lubricared wth the lockrng ftuidfor hot working bolts.The fllridmust not get intothe siotson the probebody t Locking fluidfor hot wofkingboltsGs (seespares cataogue)

rl

2
1

_ 21-5

14
le

27 -40 Nm

17
1q

12

28 - Fronl exhaust pipe a Withreleasrng element o Do not bendthe releas elernent ng more than'10'(otherw it coud be se oamageo) a Dismantling frt nq page 1l and 26 29 -30 Nm a Useorigrnal bolts ony 3 0 -2 0 Nm 31 - Bracket a Forturboccmpressor

22

32 ' Gasket

4
\ 2

26 27 2A

32 31 30 29

,+-i-oo16l
21-6 -

1).r.:xi:! Speeia!io'ri3w\'rl,shopsf.'i:riLs,ieei:rs.i..:-;.:i:iir:Jr!:si: zind ar!xiliary items reg ;re.l a 5.l i ltlS[r :...l'.1-!],irr,,Fr

t;"*;.l

I Tle tLtrboconpLas.ar tenr \.ed ,-lau'nward. t:. t All lherrnel ttDi--.Ik]l sleeves rerrb.,lti u.t Le rc itn--.] in he s:tre !l3ac arltr;;;:;i1t1),: r h vehicles n tll ,:oded ra'-lt.)/ coded raLlia;rii nevigatiat)svsterrt (Rl'lS),taLe nat. af d1e.irr.le.if /r.'r.ess6/)l ri 'rd

earih strap. - With gn t on swtched off d sconf ect Lrattery

,o 3 rri l [

' ]i IEF-:F- \'

-- [

Di d.:.-rb i.g rha 6 g n-. o.o. d orr. Removethe right'handdrlve shaft: FLrnnlnggear,axles,steerifg,ironlwhee andfourwheeldrve; Re - pairgfolrp40; Driveshaft:remov rg and instaling

pipe {foni exhausr - Remove

page26 '11.

It is not necessaty to remave the suLrfrarne, lust push the front ex heust ppe ta an,oside sa i does nat tnteiere during dtsassembly. page 19 15. coolant supplyplpe 4 from the cy inderblock; atten- Unscreu,the tion: on doingthis a largeamountoi coo ant wil pourout. - Drcincoo ant gastLrrbocompressor reiurnpipe-1-. oll - Unbot the exhaust

p:pro r'. ):nd.'bo. - I xol. b ".I e. -)- o' .ne turnsldo Loosen t -2-of the lurbocompfessor bo bracketabouttwo not removeconrpletely). oe o.at e .oe-o o^-or h.,. oo.or pe..o e L".5rgJ'o.-le
. o o a --2,r-

21-a-

Rernove bo ts a rows ftontreairconclurtb.acl.etandremove the the bracket.

21-9-

- Femove s!pport barfor the thermalprorecI steeve the _arrows on . - Remove turbocompressor the oltlet arrconoui t!oe - Reeasethe therma insulat and remove. on

air mass me1eT. Femoveboits-2 and 3- and removethe airf lter casing.

_ 2 1 -1 0

i ,i :, ,,re!i l ' r:r:1 Lf .:,i i .,, .rri i .-:, ! t.rl ,6t . i i Fe.rove the , I r..,..i i :r.,

v:,i ;:.

i , 1E ai ::i Li ,L::lr r r t l;

val ve -:- i fi ,n i fe : i i r et l) ie '6 .

pressurE solena, ide Ferrovg conneci c) -:. al i fa si rl :rai chargi ng

v:lve +.175-. ng Benove foss -4- a ai -5- irom t re sLrperchafg pressure sole r or.levalve l'.175 rr 0\6 l- L nl-i lro.6 . 6laa. g I _l_".e . ut ", ^.,r,J gas the llanqethal securesit to rhe exhaLrst tu-bocompressor

21-11-

1 Unboitthecoolantreturnpipe andtheolsupplypipe-2-iromthe with turbocornpressor an 8 mm Alen key.

' a ,j

haust manifold.

2 1 -1 2 -

L:r.5ar, L.rilr l .. - FtE ,-r"ai . i, i,:, Installation

i S ear/erhe,o.... t-

,taer t., .e. br

" .r,,./,

.o.,.

rta np. . : r ot . q, . . 1a. cJ

a Th--haa- < t-e.o,d,.o-,s t e lteF ttan on and g+.se

o,,t,- - tpo, ndtrt r.)..*f , Fefo c d.rp nbt;ng.

I The supercheryiDg systen ntust be frce of leaks I Always replace gaskets, O,rjngs and self-tocking nuts. a Fill the exhaustgas tutboconprcssor with engineailthtoLtghthe oil supptyptpe connectrcn.

21-13_

Before ftting the turbocompressor, on the coo ant sLrpply bolt tube and tfre tubocompressor securng f ange - Fit the turbocompressorfrom below in the same pos t on as t was assembled and move it on the bracket; handtightenboh,arrow'. Contineassemblyin reverse orderof the dismantlngprocedure Notes: a lf the battery B reconnectedcheck the vehicleequipment lradio/ radta and navlgation sistem, clock, power windows), fo owhg: + Instruction Manual ,t Other measures after reconnecting the wtage supply + page 2439.

2 1 _1 _ 4

1Z

[!it.erccoiei sYstenlpans: ternovir.!, installing and

as.e$rl'l)'diagisnl Gen-.ral Part I 1 ' Pressure hose

a'.)

(r/ ' - -.!.rl

14
t5

2'To intercooler 3-20Nff 4 - Lower bracket for prcssure pipe 5 - Pressure pipe

16 17 't8

pipe 6 - Upper bracketfor pnessune 7 -20 Nm

21 20

fArl-oos-sl
21-15 -

10

11 12

8 -2 0 Nm I - Upper bracketlor pressurepipe 10- Pressure hose 11- Exhaustgas turbocompressor 12 -To the sump breathet 13 - Pressure regulator valve{or cylinder block breather 14-Pressure box for regulating superpressure charging

16

27
/

-4c\

18

21 20

@r- oor8l 21-16-

10

11

'12

1l

L i.. i,..3+

':a . Ta ti.e ai. filisr 17 - To the turbocon]pressor air re.!i.,-''? tion valve -N2491a - Mechanicalair recircutation valve

J.-r.,

19 - Connectingelement 20 -Air recirculation valvefor turbocompressor -N24921 - Lower bracket for pressure pipe

21 20

fAzLorB-l
21-17_

78

Part ll 1 - Pressure hose 2 - Right-hand intercooler duct air

))

EU

tu$

t5 to

18
1q

3 - Righi-handintercooler a Dismantlng fittng page and 21-24 4 - Rubbel no2zle a Withbush 5 -1 0 Nm 6 -To turbocompressor 7 -1 0 Nm I - Right-handintercoolerbracket I -To intake manifold 10- Rubber nozzle a Wt h b u s h

0 14 113

20 21 22

25 24 23
TFrl nn"n l

21-14_

1-l - 10 $J!:r 'if greclret t !e i li. i.ii :, ,: .r ,:. .i Lr-

13 ' Bnsh
lo
/ -l I

14 - Ruhber no?zle i5 - Pressltre hose 16-x0Nm '17- 10 Nm 1a - Supercharging presslrre sender I Fep ace the O rrng I d.l-rraged 19 - Pressure pipe 20 - Prcssure hose

_
.,r-

18
19

-,.--1o
:,,

14 't1 t3 12

-20 2-l 22

29

2A

25 24 23 tEr'r oo3o I
_ 21-19 _

7 89

21 -10Nm 22 - Rubber nozzle

t5

23 - Left-hand intercooler a Dlsmantling i ttinq page21 21 and 24- 10 Nm 25 -Rubber nozzle 26 - lntercooler bracket 27 - Left-hand intercooler air duct 28 - Flange 29 - Connectionpipe 30 - Silentbloc

14 13

18 19 20 21

29

29

2A
f tr:mul _ 21-20_

Disr.,enrlirtg

..J

.,

a Eefarcrcpairnli oi |esi/r!, .11:,1, ppes ar.j tta.:esfoi i:Dl ectas 6//

selj1lJl\/ end tear':;.

I Thesleevesand hase f.)t t]1esuperchagtrlgsystem shau l,e free s t ld tron ojl and dtea!;ebefcre E-.se/1lb/i/rcr. | lt rehicles witlt .oded raLlia/.oded radta and navigattotlsystenl lql'ls). take nate of tlle cade, tf nec_ossary, tt. fnd Left-hand intercooler: - With igniton switched disconnect off, batleryeafthstrapand then the posftive terminal.

.=G r

Fernovesecur ng bolts arrows and remove cover I -

21-21_

Unclp the fuseholder support frame -arrowsOpen and removethe protect ve battery cover -'l-. Removebolt'2-, support plate -3- anclremove the battery.

Removethe bettery holdef -aTTows-

_ 2.t-22

: r . ' r . . ': L .

rr:rl i I L ;i .r)i ": I r;: . , 1 r i l J. li :F-t,.., i L , ! r t - 'i o / r ! ii,Ei

|r l'. r' :l: il.r r-./ralt.ii! ' t...r1. : ;4 ,; ;li, 'il il;i:,: .i r,i': F ri ililrn'l,eri ri!lic !.ori'_ lr: F l ; t L i , hearllglt lefl'lrand a. n.rve

pipeof ihe nter f bolts'2 a 1dloosen lang-' 1- of the Lpper Remove

the Drsconnect alr conduitfrom the intercooler the lo\'tersecunng Loosenflange 1 of the lower a I hose rernove ntercooler' bolt-2 and removethe

Right-hand intercooler: headlrght righl_hand Remove of 2-and oosenflange-1 theuppefplpeofthelnter Renlovebolts

21-24

' DisconneLt 6 r .onitt i fro 1r e intefcoo the el LOOS6i llangel,()itt,atowe !r f,rs,r, rer|rrve l.vver the se,L 1.r!r bot -2-and tefirove Intercooler. the Installation Instalin reverce order the dismaitling of proceoure Notes: I lf the baftery is reconnectedclrcck the vehicleequipment lra,jio/ radioand navigationsistem, clock,power windows),following the indicationsin the Operctinglnstructions. a Other measures after rccannecting the vottage supply + page 2439.

21-25_

Safety precautions
Obselve follow-g tf restandreasur,ngInst.unen!s required the are Ounng teslonve: a I Test and measuringinstrumentsmust be securedto rear seat and operatedby a 2nd person from rhrs tocatton. a 'f lesl and .reasuring Insttuments operateo are f-om rronl passenger'sseatandthe vehicle invoved i. an acctoenl, is theret>a posstbililyrhatthe person ,ijuries srtting rhrsseatrray recerre i.r ser,oLs if the ai|bag is triggered

21-26_

-t ,la

Cannecti{rn diaErarnfor'tl-'e fleEulation the superof pressu and v&cre eharging urrm control /r-..
1 'Fronl the fueltank 2 ' Aetivated charcoalfilter canister t With :iole roidva ve f of acl vaie.lchaf cc,a f ltef 1!!0 3 - Non-return valve I Betvveen activated tlre charcoalliief :rir.r r1-. r,l--lpfie rr ifort of the -..": gas haLrsi tufbocompressol a Assemblyposltior (Llgh1/dark side)l as shownin the il ustration, afrow ilre ind catesthe llow dlrectron.

i.i )

21

lq

fA24 oassl
21-27 -

4 - Exhaust gas turbocompressor pressure a Checiing the sLrpercharging page2l '36 5 - Pressure capsule for regulating supercharging pressure + r Checking page21 50

I 10 11 12

air valve 6 - Mechanical recirculalion a Checking page21-41 7 - Brake servo I - Non-return valve t Bet\ /een br3ke servo and intake manifold: y ght/darksrde). I Assenrb positlon1l as shown n the llstrat on,the arrow rndcatesthe flow direction I - Solenoid valve to limit supercharging pressure -N75+ a Checking page21-47

14
tc

16 17

21-28-

d
.:ir ft:ss fiL-3ier 141 -Glar l1 -'.i: filter

rJ
)l
9 10

1? Fressure regulator valvefci cytiider block breather 13 - Vacuumreserve tank a goted',r ihe cyl r.tef lead cove 14 - Left-hand intercooler 15 - Fuel pressure regutator

12

16 -Throttle valvecontrot unit ,J33e17 - Intake manifold

'I

16 17
fA2-4 o45il _ 21_29_

18 - Cylinderblock breather 19 - Non-return valve I Assemb position( rqhvdarks de): y as shownrnthe I lustral the arrow on, rndcatesthe f ow d recton.

9 '10 11 12

20'Air recirculationsolenoid valve for turbocompressor -N249a Frltng locaton Fig 1,page21-3,] t Checkng 5 page21 4r1 21 - Non'return valve i) Between sctivated charcoalfjlter systera and rntake manifod t Assenrblypostlon ( givdark side): as shownrnthe tl ustration, arrow the ndrcates flow dlrection. the 22 - Right-hand intercooler

'14
t5

16 17 20 19
lAr4-oait
_ _ 21-30

Fig. r

Fiiring lr,caii.,n oi tlie air rcdrcuictior, s.d6noid valve for the turbocompressor'I{249-

.| Fitirnooaatiol r tfLecvhnaler hea.lcciver 'i To the Lrnof or in ei franrfol.l tank 2 -Vacuumres-orve 3 To the mechanrca rec rcularion ve arr va 4 -Air recirclrlation +.,1249 solenod valve {or tufb.rcompressor

21-31 -

Testing conditions exhaustgassupercharging for system

. Cooanttemperature, 80"C. min. a lntefrogate engine controlunt faultmemory. . Theremust be no leakson the inletandexhaust des.Effects s of possible + leaks page 21-33 . Thecontrolpipe the supercharging pressure to regulation must valve nor -eitherbe brocLed be looseor lealing . Theengineand injection system be i.e.there should inpedectstate, pressure. be e.g.in the compfessron should nofaults

21-32-

Effects of possible leaks in the supercharging system

A - Leaksafterthe air mass metet Possible fault causes: . Junction hosebetweentheal metersandtheexhaustgasturmass bocompressot . Junction hose the cfankshaft to casing breather. . Junction hoseto the activated charcoal lilter system Repereussions: Beduction power in

_ 21_33

B - Leaksafter the exhaustgas turbocompresso. (inlet side) Possible fauh causes: . Junction hoses between intercoolers theexhaust the gasturboand comptessor. o Junction hosebetweenintercoolef lntakemanifold. and

. Supercharging pressure gasket (in sender pipe) -G31- the pressure . Gasket between throttlevalvecontrolunitand lnletmanifold . Gasket betweenintakemanifold cylinder and head . Junction hosefrom the mechanical gas exhaust recirculation valve . Junction hosetothe solenoid pressufe valve limitsupercharging to -N75,. Repercu3sionr pressure low Supercharging too

21-34_

ii, il ,. . t.* :'?,jE) ! ' Leaks aiter the exliausi gas iit rrLr,c.r r',1!t'Erts'rr'

Fossihle fault causesi a.rit TLrrL ocorlrpresso/9)ll_ y'i Erl,sustrianilold,/. r.ler Repercussion: StlFssnreL' exhaL n cases pess fetooJow n c:er_ta Supefcharging ikces of soot lrrthe el lllne l];llr

21-35-

Superchargingpressurecontrol: checking
measuringinstruments Specialtools,workshopsVstems,testers, and auxiliaryitems required test I Turbocompressor unitVA G 1397A Checkingconditions and af and a Correct sealing placement allthe hoses wiing checked' s/des an a There must be na leaks the inletand exhaust
rM 06l

80"C temperature, a Minimumcoolant Checkingprocess

21-36-

D r.a:i ! ,rr 1l!t i i .

*""r G Ahose iJ',f;"#H:ii lF,ly:?HillJ::'- vA 13e7

:;Jli,'ff if,T."'.:'":ffi :t:.""?:[i'"iJ*, Tiff Aft i:li:fi

21-37_

- Actrvale turbocompressortester selectmeasufementrange the and postton l- {absolute pressure). - Fit measurement hoseto connection sleeve l_. a The hoses must b- t,nFcl absatrLet\ tpdt tree. OtnerA;se the measurementswtI not be e^act ,, Make sure the measurement hose 6 notcrushed by the bannet or a press memolr '.\ M on tke tdrbocamprcssotresLet rnemohse to ft16 Dsr fieasuted value u.Il M I E,essed again ot tae testet s a The memo sed vatueis displayect with a flashing decimal paintin the display feld.

vA.G 1397/4
I v n- M I

_-

_-21_38

iesiet ilr)?s belo\ t a a ii lh. l.na t, \.ali3!a ,'f tt. rtnlf i:.1mri.essot lt li.)pla't"'l i') LIE tti'l:'i lei' lt'N'L ,:pexifie.ll.)ve., en.tffr.\\'wii \:;. Et rl iic .tsf-lav. rsti a Eefor-.testinq, [t]e vehi.le sh.Llldbe dtiven n)oderae a' )tl iiaiiii ljJlL:s) 'nnittttit .ralJpttpat far at leasir 11 le g. \uttttL'Lh vrhilednvilg an drsplayed utg the r?/de-s a Due ta the Deeilof obs./ tt /, lre ,eear'-;r assislsrt pressLrLe fullthrottle at superchargin!1 - I'leasure f - AcceleraLeo|lr 2,000 pill to fuL throllleln 3rd geer' - At 3,000 rpri press nrerory key M on I Specflcation VA.G 1397Al on the tlrbocompfessc'r

rm @ @

1,700...2,000bar Pressure

v.A.G1397/A
F,@N

21-39-

pressLlreexceeoeo: ls If superchargrng pressure _2solenolde connector fromthe supercharging Remove valve-N75 -1-. an0 the hose(between turbocompressor Inrerthe - Check junction capsule of cooler) the valveto the pressure (for capsule the super - Checkthe securesealingof the pressure valve) the turbocompressor' in pressure regulation charging of the - Check smoothactionof the shafthouslng the supercharging l{ itis intheturbocompressor' stiffreplace pressureregulationvalve turllocomPressor. pressure not reached: is lf thereis nofa!lt or the supercharging pressLrre + page -N75to valve limitsupercharging solenoid - Check 2 1 4 7.

21'40 -

Meciranicalair recireuiationvaive:clteckiriE
+ I/-refi a:r_l i ar)/t;!.i r-.i r:l J.:r-;r::.i r.r/;i ra,,!3h,E r' :IIi :rta: : : _: ,. ...< ^, d.r,J g. l .t b. 1a ji. ., , ;.t r.. taal pdu\,. 1, ,t..1 att.gtr .. ,.- ,F t. ot . a, - 1.. . , . ) . . e vat.ve.lhus the tLtri)oarJntprcssar lepi ar a ligher nunibet of rcvc,lts ) Th-^mechanicai athaLEt ga reciculetian valve is c()ntrclect hy tte exhaust gas tLtrbacanl)ressot air recirculatian valve 1,1219. a lf the engine does not suppfy' enough po\aet or there are sudden eveL sals in load, it will be necessary ta check the ai reciculatpn valve

sAT1390

Specialtools,workshopsystems,teste.s, measuring instruments and auxiliaryitems required a SAT 1390 Hand pump vacuum

o e, r l[{ 0

| ",'P;t

2141 _

Checking process Drsassemb the engrne ing cover arrows

F'-he S^- 3o0,".Lru^i p.-rp ro t\e o r.c rc.tat:o-Jo ,e

21-42_

i - Worl il,. ,,a.LLrip.r ,t s Tire:, r-r i:l alion!,.i,.le :ir ,l :,i'i :r arr

Aite 3! :ecord:, aci vateI re Ileirir4l vn re.]l ir'e rla iudi,/a!!Ll,'r pLnrp. , va,lve rcLidc cs-. arTa\ . s Tlrea i feci cu etLcr, ngtospeclfi valve iotopen olcloseaccord {lhealr feclrcr latron cloes r./a!ve does rrotsea co ecly i its holsingwth of clisc aarions f th,a va the air recirculetio ve closed: R,ap the a r recrculaton valveandsecLfe the hosecorrnections ace w trl c ps.

21-43 -

solenoidvalvefor turbocompresAir recirculation checking sor -N249-:

VA.G 1526A

instruments testers,measuring Special tools,workshopsVstems, and auxiliaryitems required a VA G 1526Hand multimeter

awo.H;l

C I Auxliary measurlng VA.G1594 set

tr@4a
21-44-

Tesi conditions . F lr: c.,firoidia! -.:- . .:r -:d. t 1 + VAS5051;Veh.Je5. i.ti.. r.s Checking process - Sv,/ltch rgniton. off . Femovethe engineccveTEfTc!.",s

Disconnect connector ol the turbocompressorr recrculatton -2a valve N249,1-.

21-45_

-Ja-

_GJ4

- Meas!reresistance betweenthe solenoid coniactsN249_, specf! caIor'_21...24 I lf the specificat rs not obtained: on Renewthe turbocompressor recirculat valve-N24g_ air on - Interrogate fault memory: + VAS5051;Vehc e setfi agnosis lf the specification obtaned: is - Check_the f cal onsjn the measured spec value ocksfortheregula_ b tronof sLtpercharg pressurel ng + VAS5051;Vehcle setfiiagnosis

]E

21-46_

ptessureSolenoid valveis tinrit supsrc.lrarglng chec!(ing ['tr75-:

VA.G i526 A

SpeciaI tools, workshop syste ms, testers' nreasuring insttu nretlts and auxiliaryitenls requiled rru r M3nLraL i r.r'.re Vli.; i5201

vA.G 1594

seiVA.G1594C meas!rlng a Auxiliary

f$ma 21-47 -

Test conditions out . Final carried dlagnosis control self diagnosrs + VAS5051;Vehlcle

{ " \ \ I 4- @ - \ \ ((3)r \l \__.:=-rj

Checking process - Switch off ignitron. - Removethe etlglne coveT-arfows

pressure d soleno -2 Removeconnector trom the supercharging valve N75-, 1

21-48 -

'f l

r 'E a r s L ] | ef a s s l r ] 1 _ ; l ] , i r r i \ r ! - ! r t t

.ation:25 35 !l ll t re specifcatron n.t ohla |ed rs

-r:rrlFinoril..

::r.i:

l i l:

,. r e l l

- Fepacethe soleri.,rcl ve lo lir I i sLrt. ch:rgingpressure va -f.,175- Interrogate t meiory faLr + VAS5051;Vehcle self:l agrosis f the specificat is obtaned: on Checfithe specifical in the measLrred ireblocks ons va forthe regulatronol sLrpercharging pressure: + VAS5051;Vehic self-diagnosis e

_ 21_49

Pressure capsule regulating for supercharging pressure: checking

Testconditions . Engine temperature be at least .C. oi must 60 Checkingprocess connector from the supercharging - Femove -2 pressure soenoid v av e N7 5 . 1 -.

Staftengne andqucklyincrease engrne revolutions the max10 mum.Thesupercharging pressure regLr on valvecontrolrod -2at

_ 2.1_50

l i i l ,-

.Ji ,, . d,,'

r.

.,

smoothaction.lf it is jammed,.oplace turbocompressor rf the control doesnorInoveevenihough lever rod ihe workssnoothly: - Replacoturbocomprcssor - lnterogating efasing and faultmemory: + VAS5051;Vehicle selfdiagnosis

_ 2t_51

':: .

i011 12

Ini*r:tIcrrr system:repairing
Fitting loeatio|is overvie!,v
'I r-arn['da probe aftr .atalyti. corverter -G130"with heaterlor Lambda probe 1 after catalytic c onuetter -Z2g1 F ti l.t ocali.jn Fi! 3 + I Ch.jclLambd:probe 1dLambda a re !luhiion:fter caldyt c converterl ,= \Ai 505]; Vel.lE sc-il! alln.rs s I Ctreck rhe Lanbda lrrobe heaing anercatalvttc convertef: ==VAS5051 Vehic se i-ctiaSnosis e ; I Fe nove anci nstal with spa)rer

u40080

a Grease thfeadonly\,!th "G5" 'cS" must not get nto the sots on the

29

28 27

26 25 24 23 22 21 20

19
fAr4:G54 I
24"1 _

ttJI,,., i

9 1011

i.l.r iir l.-J-r

2 - 4-pin connector a Lambda probe alter catalylrccon vefier cl30- and heater Lambda for pfobe I altercata yt c convertef-229 a F tting ocaton-Fg.3 3 - Lambda probe -G39- with heater tor Lambda probe -219a n the front exhaust pipe 1 Check probe Lambda andLambda re gu atron before catalyticconverter + VAS 5051; Vehicleself-cl agnoss I Check age ng of Lambda probe berore catayt c converter + VAS5051 Vehicle f d agnosis se ; a ChecktheLambda probeheatngbelore cala )l c convefter: + VAS5051;Vehic se firagnosis e

t5

14
to

17
l6

29

28 27

26 25 24 23 22 21 20

irll

t9

1.D 12 i1.

+ F.: r. r:

d ,l

| ):t

r , : , i i i '! : r

: ,,!,

i 1r a-nsE l L r:r.l orrl v rr' l tl i rr:.t ,i :,t:i i ,:, i

4 - 6-pirrconnector l' For Larnbdalnobe -G'19 an.l he.itef ior LanrbCa frobe Zl9 5 - Control unit for Motroric _J220t Checli ,an9re control Lrnt voltage sr PPY -: Fage24 4'J In a Proceclure after inlerrLptlon voitpag-6 :r9 24 age suppy s sef 5051;Vehicle diagnos -VAS 6 - lgnition coil -N-, -N128-,-N158-and -N163ng I Check + paqe28-25

't4
lo

'17 18

26 25 24 23 22 21 20

19
I Ar-4:a45tl
24-3 -

8 9 1011

tlll i.ll I

il, .l-rll,

7 -Air circulation valve for turbocompressor -N249Fig. 1 a Fitlng locaton + t Checklng Page21 44 8 - Accelerator pedal position sencler ' G79- and accelerator pedal position sender2 -G185locaton- Fig. 2 a Fitllng a Checklng: selfil agnoss = VAS5051;VehcLe I - Brake lightswitch -F-and brake pedal switch -F47a Fitlingocatlon F g. 6 10 - Clutch pedal switch -F36+ location Fig 7 a Fitting

26 25 24 23 22 21 20
24-4-

89

1 9r i r z

l ,l ,'l'

'ii

i :r! F3nel i nsel l . i ' f t, !!.r r, !r :, , ai r:::::::i -r ..,J,t I ;.i i

n-: i

t :tt ii,

: ! il

rr i:,-l.a,i '12- Motronic currentsupply relay ,J271_ o l-,rtig tocaton : Frq 4 + Ch-..kifg page 28 9 -. 13 -A,r mass meter -c70+ Che.king: + VAS5051;Vehic setfd altnos e s 14 - Solenoid valve to limit supercharoing pressure -N75a Checking page2t .17 +

ia

14 15
to

.'', i'--:.'-l

/ ':i

17 18

29

26 25 24 23 22 2"t 20

t9 tnz4 o?6nl
24-s_

15 - Coolant temperature sender -G62a Checling: VAS5051 Vehc e self.l agnoss ; a I necessary release pressuTe coo in llg syslem beTorefernovtng 16 - Valve 1 lor variable distribution -N205I Checkng + pege15 78 17 - Fuel pressure regulator I Checking page24 65 18 - Knock sensor2 -G66, t Checkng + page2e-34 19 ' Sr.rpercharging pressure sender a Boltedto the pressure pe + page p 21-19, irem l9

.i:,

.i

:i r

!n3i .,1. !i r+ .i s.i ,;' -t' i i i -: + ljiI . .- i .!i : rr ' l ::

, r . , / : ! , : , . , l - l .- : r \r\|t i liii : ! i : i : ! , 1 . 1 ! : ,lrL I l l L . , t l e '. / 5 l t E . . ':tl

2i " Thrci rl v:ti re corrtrol $r' i l ' .1:1i,

: alliT_ nii. arq. :,ende 2 ' riLna: /: !':. lrrr_ll. u'ri 'i]88 tC e.l ! .: \/r.. Ftq I \/.l.ji.l.:.FLirlragfcss ( lr a.a:-a,ilef,l.laalrrar.arry.ruttrL.. i se : VAS5051r'.G1cl,. l{laq rosis 22 - lntake air temperatLtte sender -G42a Checi 19: aq self_d rosis +VAS 5051;VehLcle =i 16
ad;!taI oiil

.,:: I .,.1

29

2A

26 25 24 23 22 21 20

19 f t24--a45lal

24-7-

9 1011

ii. ,1,r.Jr

lli':' I

23 -3-pinconnector lG e y senderG28 speed a Forenglne 24 - Exhaust gas temperature sender 1 ,G235"

a 6le-np6 a L u r a . e n o 6 'L onI e ul-

bocomplessoT 25 - Iniectors -N3O-,'N3'l-. "N32- and -N33a CheckLng Page24-52 - a a D'r .-r'rnq l 0 ng ' oaqe,l-l

13
l4

:=

16 18

26 - Knock sensor1 _G61a Checking Pege28 34 27 - Prcssure switch / power assisted steering -Fg8I Frtlng locelon+ F g 5

29

28 27

26 25 24 23 22 21 20

19

iir t1

:i

- i-i.:il !:er,.le! -G.!ar + , l :,:ri !r- i j i :i

:! -S o{ en.i i .l ral ve 1 {.r aci : ir : . , r . i . i, r F .oel fi l ter -N 81. ? i .l .' rl . r! . r' i !, 5U 5- ; V ,. ri ( E :retj i l n.r r1] sLs

:= 16 =17

29

28 27

26 25 24 23 22 21 20

19
24-9 _

Fig. 1

Fittinglocationoftheairrecirculationvatvefortheturbocompressor -N249-

F ttinglocrt on: I the cy nder hadcover 1 To the unicnon rnletmanifotd 2 -Vacuumreservoir 3 To the mechanical exhaustgas recircutar va ve on 4 Air f-.circu ationvalvefor turbocompressof -N249

Fig. 2

Fifting location of accelerator pedal posifion sender -G79- and accelerator pedal position sender 2 -G185-

The illustrationrepresentsdistributrcnin left hand-driv-6 vehicles

Fig. 3 r-La

i:iiiiri! l.,ratirn ij.i Lna L:rrrltde i,r.l.ir. 3lier catai!.ii. ri-"iverter -G130- Enld (:6r'!tiector prrictive cover ,:_:j , ' ri :r 'il" ll i ti r, i :r!r,r. l i l i c ..:ri :,l ,r.r, a! .' a,i :

pftrrcci ve cai , 2 [ o 1rre.i i .,I rrbol l th e pr '( r lecT o accegsthe Lerrbd: prar,e f.raaal rT:nal fa:i er, i l l L Inr ,l sl dc i rrfows rv ecoverorthev.hi cl eunderb.,.l y,

-J271locaton: n the dashboard, the ei1 on Fitting Note: To rcmove the protective cover in vehicles with cross member betweenthe suspensiantuffets, releasethe relayholclerfrom thedash nect the airmassmeter catl boardand move downwards Alsodiscon nector (if fitted)

24-11-

Fig. 5

Fitting location of pressureswitch / power assisted steering-F88-

F ig , 6

Fitting location oI brake light switch -F-and brakepedal switch -F47-

24-12 -

/r
' :: I ' 1 tl

F'9. ?

Fidir'g f:ca1idf. .i i i!'rri, fredai :\.,.ii.ir -F36-

ii

24_13_

Air filter:dismantling and assembling

1 - O-ring a Fenewf darnaged 2 -Air massmeter-G70a Sensor and connectoT contacts ar goldp ated

4 2
1

3 -l0 Nm 4 -Air duct 5 -5-pinconnector a Senso' :1d .onnec contdcts o atc goldplated 6 -6 Nm 7 -Air filter upperpa.t I - Filter cartridge

f Fr;:.r,rc] 24-14_

S -'rC l.l:ii 'iO- Air intai.e .!r',rt

eti
fi ii.. r.,.:','. .,.-);rt..
t ,,1 /

11 . Air filte. t^',,,'{'rt t.'t 12-1CNm

-8

l--;-rorl
24-15-

disFuelrail with iniectors: mantlingand assembling

-,_8 /Yf.

\9

.-.,'.'. V

-9

piecefor iniector 1 - Intermediate r3 Nm I On fitting,applylockng f LridD 000 600A2 2 - O-ring

12

. B . oi . r.> .of. ,g n engrne orl

,LA

.l r

.n

)8

14
[,r -_-.
t4

3 - Iniectors-N30-.-N31-,-N32-and -N33rate+ irage24_59 o Checknjectlon 4 - Supplyhose 5 - Relurnhose

24-16 -

6 a-' i ri r,* ci .r i .r i rj eci .i .

? - 10 I{ iil

A Fuel pressure regulator I a i,!-.rl.ir!t-. trirqe24,65 9 - O'ring t Beloreirili i _atr. sleir enqire oi 10 - O-ring t Betore tstal ng rnosten erlgne o l 11 - Retain;ngclip I E|rsure tight fit 12 - Fuel rail

21

20

19

1I

IME_a%lieenl
_ 24-'17_

13 - O-ring

-a

t Before nstal ng mosten wilh cean eng ne o 14 - Retainingclip I Ensureseated correctlyat nJector andlue ra l

11

15-15Nm 16 -Throttle valve control unit -J338a Wilh throttle valve controlun G186, t angesender 1-lorthroite va ve con lfc LrnltG187and angl-o sender 2 lor throtte va ve controlunii -G188 r Checklng: VAS5051'Vehcle selfi agnosis I n caseof repacement, carrycut the aoaptatton VAS5051;Vehrc se i dr:gnos e s -

'12

"-r
1

A-16

14

r 15

.J*

16 17
!i24-or-6-il _ 24-18_

'r;-. c;:skei 're - i0 nlm

5 ---- - .

19 - lntake ai| temperature sender -G42r L_nealirnq: = VAn 5t5l : Vehc e ierl-.rragnosis 20 -O-ring 21 - lntake manifold I Femove+ page15 7

A)8

7'
'I

21 20 19

t A24-ot6I
24-19_

noteson iniection General

a Fuel hoses in engine campaftment must only be secured with spting type chps. The use of clamp or screw type clips is nat pera For trauble free operattonaf the electncalcomponentsa voltagea) dt least 12 / V is neces-a!\ . Do not use sealantscontainng slicone. Particles slicone clrawn of into the engtne, will not be bunt in the engine and damage the a \ehi.t6s A nh ar d rbag are ffied A fih a (,asnfrel shuioft. Tn6 sr stem reduces the tisk of a vehiclebuntng in the event af a crash irt that the fuei pump is switched aff by the fuel pump relay.At the same time this improves the vehicle starting. When the door iefor openedthe fuelpump is acttvat-'d 2 secandsta build up pressure tn the tuel system.

24-20-

::i i ri r' i ,r:.:,ui r,:,: R .: 1.,f. e: l ,;:.:

- t,!.i r.

: l

- i r:i ::.:rj ::l :!

T;c rr a?i :lati = p:,,:j:i

Safety precautions
Waming! Thefuel system is undet pressure.Beforc opening the system place a cloth around the connection. fhen releasi ptessurc bv carcfully loosening the connection-

Toprevent esto persons intur afd/or damage theinjection igni to end nonsystem, folow ng mustbe observedl the a Forsafetyreasons remove no.28from hoderbefore fuse fuse openIng pump beactivated thefuel system thefuel as can bythednvels doorcontact swttch,

24-21_

a Dur ng some checks it is possiblethat the control unit wil re cogniseand store a fau t. Forth is reason, fault memory raustbe nterroga-edandera.edaf.rft s t.q"l tesrst.d epa s.Aher t"e ta.t me"o.v e ds.d, ll b. ne.e,5a,vro ge.erateIhe ^ VAS5051;Vehic selJdagnoss e a Do not touchor disconnect igniton wrringwhen tre engineis run, ningor beingturnedai starterspeed. a The ignition must be switched be{ore off connect or d sconnect ng lng lnlection ignt on systemw ringor testercabLes. or a On y wash the enginewith the ignrtion off. a Disconnectand connectthe batleryonywththe rgnitron otheG ofi, wrse tfre engrne contro Lln(cou d be damaged. Obre \ethefo owlgt'(ac-andr ouflnoa test oflve: easufl 9,Ilu1-la tra e eo-r.ed

24-22_

,.r. + t:L: i l , -.: ,:,' r. r. l -. opei stei l j ' ,.,. l fd L,! s.r i :' i r. _j : Lrrai r. I

llestandrrreasL|.lins'rfLrrii:ri:_;,teolreaiedirof,rfror'ripas:Et,o:t 5 a,.atelclthevel.rclei5 nvol,.,:ar ac.irl i re [ie sot]s t n! trl ,s naf 11, seatlr-Lay receve!e iors ir lurie-.rithealr:,:gs1-rggered 1 lf the -6l|9rie s io ire rullt-:d ar siafier slJee.l,w thout stari ig: Femove the 4.pir conneclrrr!'J from ail the :1nit .o ls -2of

fuse 32. - Bemove Note: Remaving fuse No.32 intenLtpts voltagesupply to the injectars. the

24-23 -

Rulesfor cleanliness
When working on the fue supp y/injecton system, pay carefu attention to the folow ng "6 rules": a Thoroughly cleanall unlonsand the adjacent areasbeforedisconnec!ng, I Placepartsthat havebeen rernoved a c ean sudaceand cover_ on them. Use lnt-freecloths I o lf repairs cannot compJeted one session, be n allparts andcomponents that are eft open should be coveredor stcred wth the, greatest of care. a OnLv insta'lLleon corrpon. t_ partsimmedlaie priorto instal on y Only unpack repiacemenl al Do.or .se oanstqal haveoeonc o eo oo)e e g. t- Ioo bo,a. a1( |

24-24 _

I WlrerLt|esy.iierI i-i r,l:re,l trc nct worl !v tl-rca,rirpresaed ii this a;i !e avlrqai.,i a Do rrot nt,Jvevehicieurrles; diisvlurelyrEccssary a Separateelecincalconnectors. Protectthem from d ft and water Only connect if dry

24-25_

Technical data
Eqghe cod.
ldling dleck ldlingspeedrl

AMK 700..820

Engine controlunit2) System PunIg 2) Gove|ned engine speed r) Non-adjustable ?)Lalest number enq.ne pan for cont,ol unit Parts Catalogue 1/min

Motronic ME75 rML 906032 fromapprox. 6800

2+26_

Checking comPo!.!eftts adapting Cornponents f uncti<.'t.rs: and

i
vas s05l

Specialtools, worl'shc.p sysleii;,i;tt;i-r,

Inca-iuliii!

i::'<:riir'.nrta

and auxiliarv itenrs required :, s, i VAS5051VelrcleD agn'rs l-estrrr! rii lrionnat on Syst;Lrl cable\AS 5051/1.,r VAS5051/3 a Dagnosis lalrlt On the VAS5051iesle seLe.t 'G,-rided f nd rr!1" Chcea I the controlu rirs havebeen Llte roqated: Press the go to' bulton. qee-L . 616t, 9 u - Select"Engine" - SelecI inq ne cooe sysiems01". Select" Selfdiagnosis :on /.orpo arls

24-27-

"Engne management . - Select "Functrons . Select to the - Select lunctionof component adaptandfollowthe instru( equ rneasuring d agnosis pmen* and testing, of 5051 tions theVAS

an( Enginecontrolunit fault memory:consulting clearing

vas 50sl
Fault memory:consulting measuringinstruments Specialtools,workshopsystems,testers, and auxiliaryitems required System and niormatlon s, r VAS5051Vehcle Diagnos Testing VAS 5051/1 VAS5051/3 or t Diagnosis cable

r,@;al

ng s, cle the 5051Veh Dlagnos Test andlnlormatr._ - Connect VAS System follows: as

24-24-

1-i,.:n !i,,'. .r -: q L]l:!iL. : !,r i_e .-ii.,i n;.i. ;i:i, iinli,,r;

ar., : .: .: -,.1

:l l-,r!..:,rr:1,: r,r :

a - Starten!Jr'rer.i run ai i;inlts.re--C

lf the enginedaes not staft, tun ihe engine wnh the starier raotatfai at least 5 secand;. Da roi swnch off ih iatniii.h ur)Jei an\ citcLl.| S-.lectoperalingmode: Pressbuttonon the VAS5051 display "Ve rice se i-diagnos for s" Selecivehicle system:

- t-

Briefiypressselecton 01 - Engine electronic system' on screen

The contro unit dentfication andcodingare ndicated the display on

24-29-

Press > to continue. key Select agnostrc d function: Indicated VAS5051 on press screen ' Briefly "02 o. fLrnction - lnterrogate -1'thed agnosis

! lE:l

lr-" lL-

r;i;ral

'l
1

nd catedon vAS 5057 1 'Contents iaut memofy oi a 0 faults recognised

o X Fai-llt(s) recognised

rat-* l

24-30-

2 Fa)ll

a Fa!ltiocation a Type fault of i IdJl.b eerere.og'.rcFLl. Printthe conientsof the screen the selfilagnosisprotocol. or "02 Endfunction - " Inteaogaiing roemory"by briefly pressinq fault - Rectify allfaults - Bfletlypressaga.ror the dragnosis lunction 02 - nre.rogate fault memory' anderasethe faultmemory+ page2433. press the diagnosis "06 - Briefly on function - Endoutput'.

2441_

- lf the faultmemoryis erased, will be necessary generate it to th reaorness cooe: + VAS 5051;Vehicle selfiiagnosis lf no faultswere recognised: pressinf - Endtunctron 02 - " Inrerrogat'ng mernorv"bybriefly fauh presson the dlagnosis function"06 - Endoutput". - Briefly ,Vofgsi a ll no faults are recorded,do not clear fault memory as readinest.._ code wojld be set to zero. a lf the fault memory is emsed, it will be necessaryto generatethl rcadinesscode again: + VAS 5051; Vehicle selfiiagnosrs

24-32-

Fauli niemory: ei.:ia Specialtools.workshopsystenrs,testers. iriea!t,rir,g insirLirir?na: and auxiliaryitems required a VAS 5051 Veh c e [,La!] os s, i.r:rt q ar ct nf.rflral.n :ivs1-.i t Diagfosis cableVAS5|5 /t or V/.,S 5!at/,: Prcrequisitesi . Faui rnerirofy has freer-r consL ted = . Al faLrltshave been repa red )irqe24,:8

Aler rav ng rter'ogdt.otlre duh -ien ot,,. Indicatedon V,AS 5051 Brieflypfesson screen 1 the dragnosis function ,05 - Erase fault

rAji@

24-33_

lndicated VAS on 5051 'l (before a No indlcation erasing)

a Fault memory erased

fM;:@ I

Note: lf display field-1-displays message Fault the " memorywasnot interrogated" thismeansthatthewarksequence incorrect.ltis , was anly possible erasethe faultmemaryif it hasfist beeninterrogated. ta 2 - Nole: Doyouwishto startthe functon? Warningl data be erased the wil Breflypress "OK" keyin ndication,2-. the ' - EndfLrnct "05 " Eras 'fault on ng memory by breflypressing

24-34_

1-rr.ti t::i i f:

:,

.. ..r:ri , ...i .-

i i ,:

:.:

-,. t::i ,.:' l

?; '

I ln thts \^,a\,\/ar carj craEe faLllt tl',i !.rete rni:t11otii:eililLtxiti! rtie fault ehnil?ii'jr latoc"ss, e.g \ 11?itt"t navn)o .,c'rrlecrat s. a lf th e l a u lt m e m.r l is e/?-sed, ri LL,/ l-,e rttes s at Y 10 g . e t Ete t h -a readiness coale agaih: + VAS 5051 ; Vh c e self d agn,.j".e

24-35-

with test box cables and components Checking v.A.G1598/31

v.A.G 1598/31

instruments tesiers,measuring tools,workshopsystems. Special and auxiliaryitems rcquired a TestboxVA.G159881 NotP.s: strnultais a Testbox VA.G1598/31 despnedsa that it canconnect to canttolunitanclto the neously the wiing harness the engine to

r'VMan

to a This hasthe advantage that ihe engineconttolunit continues (e.9.measurtng stgnals functionfullywith the test box connected is whilethe engine running). contralunittothe test cannect engine the a Theneedta additianally tesl n boxis indicated the cotrespandtng ptocesses.

24-36 -

l \A ays usd i h.att' i l i ..t),n1.-.:(rnrg:rei U .l ,-r ta. r L ir corl )e;l / Ji,.:.!r iit! etLrpttei)t te li arr.r.. r. ,,r , .: ' i.ieriual nrltif)etei YA t) 1526.:t ,. i: ) Tttecorttecttr t:;r' taci tni i rter.-r .,./i . i rj , r !, . r,,:

i:,

Switchoff gnition. Renrovew per arr'rs a-d io!.rl par e . Elecrrical sysi,.rn;Fepa group 92; Wirrclscreen - Windscreen per:removng and nstalling w - Loosen connectors separate the and thernffom the contfo unit. Thetest boxearthclp should confectedto the battery be negative. outthetest as descrbedin the corresponding processes, - Carry test

vA,G 1598/31

24-37_

Atention! To avoid destroying the electronic componenE, betorc connecting the measufing cable. the coftesponding measurtng nnge must be chosen and the testing conditions adhered to. Impoftant noE: After recannecting the engine control unit, the fallowing operatians must be carriedout: a Adapting the throttle valve control unit -J339: + VAS5051;Vehicle selfdlagnos s a lnterrcgatefault memory and erase if necessary + page 24-28. a ]f the fault memory is ercsed, it will be necessaryto generate the readinesscade: VAS5051;Vehic sefiragnosis e -

24-38_

after interruptioll ilr i'ottaEesupFiv Procedure

1 ..rel',,,..' 1, d ..,..1, nlileag.,v. i.eil lv r'-rperf'rnrr:in'enrai/l-rese o-ri\rel,icle depenclng verely afiected Aiier rcconneclingth-'Iiower sttpply, the follorvi)ll aperettonsmust a Adapting the thtoftle vaivecor'tral unn J333 : self'dlagnosis +VAS 5051;Vehicle a lnterrogatefault memoty and ercseii Deces$ry + page 2+28 a lf the fault memary is eased, i will be necessaryto generate the rcadinesscade: + VAS5051 Vehcle selidLagnosLs ;

24-39-

Control unit voltage suPPlY: checking

testers, tools,workshopsystems. SDecial measuring instruments and auxiliary items required o t h " n d r-rr' rr. re V A . C 1 52 6 a r m - l l VA.G1715 meter o n a A , J , rla r) e a s u r, . g e l V A G 1 5 9 1 4 ' 1594C a TestboxVA.G1598/31 flow I Current dtagrams

2440 -

Checlting coirlitions * Tl,fu:-esln :t L. ,:

I . Baile,j ".lir!, rLr!, ir.;.1!.,!. t,; .l

A l e l e c t r c c a r f s L m e r s , e ! . : I g h i g a i j a j r e a t \ 4 / t ) L l S a r T , r ern :r e r I n u st e

be swrtchedofi

. Vehicles Jitted wirf ai cofdi|c,r ng InLrst irve I orscofnecre.l I . Altern;tor C) f. Checking process Connect test boxVA G 1598/3'l control to unrtwir ng harness, with out connectngihe eng ne contro unii + page24,36

vA.G 1598/31

24"41_

Notes: a Positivevoltageis supplietJta the engine control unit thraugh the two contacts and 121(termina! aTl contact62 (terminal 3 15) 30. a Negativeualtageis suppliedto the errginecontrol unit thraugh the contacts1 and2. Measure voltage themLrhimeter theauxliary esof the with and cab VA.G1594 or VA.G1594 as fo tows: A C Testbox VA.G 1598/31, test box socket 1 2 Measure to

posrtrve Battery pos Battery trve

Engne groLJ nd

Specfcatron: approx. batteryvoltage - Switch ignit on on

24-42_

-restbox VA.G 'i598/31, test box

121 )

ErElllegroLrrd

r)Afterdscon,e.rr,g tl,e rg rilic,n, cLr nr,t:Lrpply reay for \4c' the to suppjycurrent iefrn ns 121oftheengife lc,nic-J271'v.rlstill . .,, . , | y ap!ro). ba11e v.'Ia!]e Speci{rcalion: Switchoii lgnlior. are lf the specilications not attained: to to - Checkwring connections relayplateaccording currentllow dragram: fault finding and fitt ng locations Cuirent flow d agrams. ELectfical J271 c!rrent supplyrelay+ page28-9the IVotronic Check

2443 -

air) Checkintakeair systemfor leaks(unmetered

Testwith engineleak detectorsprayG 001800 A1 vAs 5051 g testers,measurin instruments Special tools,workshopsystems, items required and auxiliary System Testing Informatlon and Diagnosls, a VAS 5051 Vehicle or 5051/3 5051/1 VAS a Diagnosis VAS cable A,otes: spray in systemwill causethe leakdetectot a Thevacuum the intake sprayre air. to be dnwn in with the unmetercd Theleakdetector ta Thisleads a draptn engtne of ducesthellammability themixture. prabereadtng oI and ta a change Lambda speed to. mustbe adhered listedon the container a Thesafetyprecautions

rwnml

2444-

theeking pfouess :/
i , o . n e c i t i e V A s . | . r i 1 '. l ] L ] l - : i | . l j ', ] : i : 'l l : : i : : i

Systetr as f,:,lrrr^",s: - Openthe ao',,et t'e dragia,sis rneqlar ol c{,

I _ _J-,1 _-> _,,:I \-

t.-

tT -l

l1

li

rllFrl

nectlon. Startengineand 1n at d ng speect.

_!.

l-':

--:_: ::

TiRA

/elili i--q

il

ll I

ll t

Select operatng nrode: - P ess bLrtton tl e VAS5051display "Vehc e se f-cliagnosrs,'. on for Selectvehcle system: - Brefly press seection 01 , Engineelectronrc system, on the The control t identificat and codingare nd catedon the d splay un on Briefy press the key >

2445 _

J-54ffi-

Selectd agnostic function lnd cated on VAS 5051 'funct "08 - Read - Brieflypresson the screen'1- the d agnosis on measured valueblock".

< | . ]]* *
TAji@ I

Indicated VAS on 5051 group 1 - Enter value nLrmber = Maximum value 255 on - Enter keyboard "001 forthe"va ue groupnumber -2001 and confirmby pressing ef y keyO. br tl

ftu

24-46_

crfaied !.n \'1.:, : r,: ai:r[.i. i1..m!r :.. i . . .-: ,: :i.,.:ed /E4 . T:ii] en:!rfa eali.la:y:ienratir:aly:ip r;fis.1i . i'-.alasj'ster'|'.rxt ay

f ''

i l ''La--it ! l
ti!ff I

f the eng |le spee.l deLr-Ea!ie:: f,/ sp e!:: - C jal. ayeal3 ci lrtal:esysleinla ia:f! rna recT f necess va blD.li i:rressing brieflythe - Erdfurction "0S Reedmeasured Lre

lndlcated VAS5051 on "06 EndoLr{- Briefypressonselection-l-thediagnossfunction puI - Swltch off ignlt on.

fei@l

24-47 -

Enginespeedsender-G28-: checking
Note: Theenginespeedsender -G2e.is a speed ]f andreference marksendet. thereis no sigwill . nalfrom-G28-, engine nat staft lf the the speed signal fails when the engine is running,the engine stalls. Fitting location page247, iren 20 testers, Special tools.workshopsystems, measuring instruments and auxillary items required a Handmultimeter VA.G 1526A mutor rneter G 1715 VA a Auxlliary measuring VA.G 159440r sei 1594C a TestboxVA.G1598/31 a Current dragrams flow

l-wro-om3l
24-44 -

Cirecliing process S ei cr. d e.fl r. ..: l -,, i r.e' ,..,

D gconnecttf..gre,,: [,:a,i ].:,l tri ..:.,, r.:i ni i .,!:r!l r-esl ,eaajsi r r : il ;i

- Measurethe resistance between conlacis2+3 of cornectorto Specif on: 730 ... 1000g) cat

The resistancevalueof the enginespeed senderrefers to a temperatute af 20 "C. The resistanceises when the temperatureincreases.

24-45_

lf the specifica|on not obtainedl is eng ne speedsender,G2S-. - Replace lf the specrfication obtaned: is - Adjustthe mult meterto measure resistance connect and between contacts and 1 (screening), wel as betweencontacts and 1 2 as 3 ng). lscreen 6 Specification: Q (no contlnuityl

1 -,*t

lf the specifcation s not obtaned: - Repace enginespeedsender-G28 . f the specification obtained: is - ConnecttestboxVAGlS9S/31 tocontrolunitwirngharness,without connectrng engrne tire controlun t + page24,36.

_ 24_50

a.-

r,i ,r

l ! ! r:! i !::.

l (: i L,o i ''j r l r:

: ' il :

it .,.:e.i .i ri

3-pin connector' contact

Testbox !:AG test 1598/31, box 103 90

I (screenrng)
2 (earii,) 3 (srqn3l) rla)i 1 5l) Wire -eslstancer

a2

wires for shortto one anolre ' clreck - Addltionally lf no wrnngtaultls detected: Fenewenginecontrolunlt: selfiragnosrs + VAS5051;Vehlcle

24-5'l -

lniectors:checking
tes_ters' tools,workshopsYstems, Soecial measuringinstrumentsand auxlllarv items requirecl VA.G 15264or multi_ a Handmultimeter VA.G1715 meter VA test I Diode lamp G 15278
a aL i a , rreag- ng 5' - V A o 'b944 o

1594C a TestboxVA G 1598/31 flow a Current dlagrams

f cr4-@l

24-52

Vlamang! The tuel sysiefit is rrnder prcss.tle Eef&re.I'.iriig1 il.r sfrieri tlace a cloth around the cantiection. Then releese pre:,st,t: by carcfully Iooseu;hg tlie confl ecl;o n. Checking resistance of iniectors Removethe c.rnnectc,r florn iiie njeatof to be lested. r- ..1 rF< a
<.6.i f.rr^. rt

= _l ,1tr.- . L. ..
l t_ a, 1:r ,r,^.n l on narl r rl _ej '

Resistancevalueis validfor 20"C apptox. ln the case of htgher temperaturesthe resistancevalueincreases lf the specifrcation not obtained: is Renew defectve injector

2+53-

'I :
l + rha .na.'fi .,r ^. < ^hl r non

- checkvo tagesupply. Checkingvoltagesupply Checkconditions: . Fuse32 for injectors OK

i'

. Fuel pump relay'J17OK Bemove connectors irom a I Injectors. diode testlampVA.G 1527 to the iijector B connecto'as Connect follows:

]T
I

Connector, contact

Measure to ground Engine

' Opefate the starterand check the voltagesupply the lnlector for The LFD mlst lght-up

24-54-

li il, ;- ! E t , d i e :

nor

!r , Ll

S!\ , i c l : . , f : r g i l t l .

'r'".1 '

'

I'tr-:"

_
Io ); '

n]a, 1,5 !, Vvirefesistance: rts LEDli,u uP: oi - Checl:activaton inlectc'rs Checking activation Check conditions: . lnjector resistance OK Checking Process them f rom the injectol con' - Pullthe rubbersleevesback' separating connectorson nectors, but leavingthe

24-55-

V.A.G1527B

nlector diodetest lamp VA.G T527 B to contacts of the Connect connectorbeing checked Note; vehicle G G test Llse PrabesUA 1591AorUA 15g4C if the hassealed

start) so the operate startermotorion dorng the enginemay - Briefly ol activatron Inleclor' and check

The LEDmustflicker Note:

::;i: :::, :,:; :::,:;', :i;,;i:',":: #:2,i,:n:';' :';';,i: ",;:;i',:,::'

si'n,ng weol tv. ii(tearng rtei' 'nte"s't\ &hFn acttvaled

24-56 -

: L;Lr al,ra,a, . i:

:iiL r.iii:.i:,.,. ll- : t!!|j,: .r!ri a:on )ecilra_r rli-: a r_r.o -at

:rr:,r .

,..1a.'::) ::,::

C\e-( ihe w ri_9 oeiwe^r te)l bo, and 2-o,nconneLtor. njecol tors,usrng current ow diaqram f

cvl.

IniectoJ connector, contad 2

TestboxVA.c 1598/31, box test socket

96 89

2
3 4

2 2

97
88

24-57_

Wire resistancer max 1,5 Q Additiona check ly wifes for shoft to one another

areoK.:

lf thereis no faullin the w lng andthe reststance measuremenl values

- RenewenginecontrolLrntt: VAS5051;Vehic self diagnosis e -

_ 24_54

--

____- --]-

tlie cil l:riectors: e(:k-;nE ir'lectors for leaksar*d amcruntiniected

Special tools, worl(shop systems' testers, nTeasurinq instrr.rnrentsand auxiliai'y items require.l corlri VA G 13'13/3A t Fiernote . VA G l;4iil:2 AJal,ie cahle
a L . 'r , - 6 1 5 9 1 iC i,.r ': A' C9l^ r'

I TestboxVA.G 1598/31 a.AClo0. e.e flowthrough. L.F,ng nra..io-

24-59 -

Checking conditions: ng check + page245 . The fuel pressure must be in order, Checking process fromthe nletmani etewiththe lnjeclors Rernovethefuelrailcomp fold.The {uel hosesstay connected harnesswrtn to test boxVA G 1598,1 controlunitwiring - Connect + page24_36 !nii ng oLrt connect the englnecontroL Checking for leaks G 1 the - Bridge contacts + 65 of the test boxwth the a d of the VA cabes. 15944or 1594C irom all Inlectofs. connectors - Remove - Sw tch on rgnLton.

24-60 -

) , f ! e , ! ! \ 1 . r ! a t r n a l?
. . ! ./. . .

lliir-.i,,i,r
..

ir,;.itralr::

::\tlii..
.,

r , i L ,/r r r .

., - r .
l

vclrcge ra'rn thatj]na.iii,LtbL-'..The rFllaiiv" conies frctnt the cel:,te bidge n)ade in the Esi bo. Checkngtfe rqectorslor eakslvisLraliv) itr f!e olrnrF{unct V\i or ing,only 1 or 2 dropslper nJector) sholld c.,r.n" o,,i i,l Jnu;;i; lf ihe iue ioss s ltfeaier: - S,"/_ o".gn'onr orang^ t.16e.1 .o.,,1. ..

Always renew A-nngs as a rule.

24-61_

Checkiniectionrate P ace injectorto checked a measuring be the in containerfrom VA.G 1602. fror t\e in,ecrql pslnta.a",ed enoneearLn a Connec conlaci "" a s i-lg . \ . . a o . c -ro -1 V A l5 9 ro r v . lC r! S ; i -o " G second contact rniector batefv oosttive o{ - connect.the to usinoan aux.-cable remotecontrolVA.G to 1348/34 wnn'il" .Oipt* liOf" vA.G 1348/3-2. 1 the - Bridge contacts + 65 oi thetest boxwth the ardot the VA.c 1594 or 1594 cables. A C

va.G.t348/3A r4r-@l

on - Swilch ignition.
Afiel sA;rching on the igntr.iah.the t,ret ou-nD wt. aa Aott no ao.lfiu ous\ despt,le lhe englne taetrq stattona-r tot he,aIav,,ig reason. 4l?: s:\!;ia.tng lne pn'tton he [,ei p!-tD , eta|e( et@; pos,tive ?n \a.Iaoe t-om rl e 11r(uan aa.. I,e ^-ga-.\. an.s f' o m t ne cdat e bridge made n the test bax.

,4-62 _

. a)pEraiE ote.,tiltroL v!a .,

i:r_il/i!.irr:rr'ii:l

il-

I n;irial i. -:ivvlt tl eolierrrj:.iio:.r 'rr:\\'ln!.: I i,j r ',r.rr -:ir tlre stirnuated all tlre inlect.rls, FLace fv? nreasuflig - Aiter having flai su$aia a)i .t lza if::r'roLrrts of {Llelir_ a contarrersaTr lected. per Spe(ificatlof, irj;.iol: 179j. 1.ll11!. stop is ilre of ]f the value anyoflhe inleclors oL.ltside speclfications, the pump (switch ignition) renewtlre faultyirrjector and off fuel with the do values allthe lnjectors not correspond of lf the measured pressureof the fuel system + page 24-65 checkthe specification, On checking the fuel iniected, it is also necessary to check the spray pattern. Thejet should be the same for all the iniectars

24-63-

the inlo and Fitthe injectors thefue fa I,taking accounl following: the ot {to I Beplace O-rings anyjolntopened replace front O-ring the clrcumplastic ontheInjectorhead underany cap donotremovethe place O-ring overthe cap) the stance, oil. withclean engrne coaled be a TheO-rings should lightly a Replace O-rings. position the fuel rail into and vertically inthe correct injectors a Insert wlth andimmobilse the cllps. manfold evenly injectors intake onto a Fitfuelrailwithsecured

24-64-

t*- -

.l-r ta.'l

t=

i:i

i@))i
ll e

Ch e c kt [ r e p r e s : u . iL ,i L r ei L l *t supply system anclthe ['.,!.ling pressur e

Special tools,\,vorkshoF systems, testers. measuring instruments and auxiliarv items required a Adaptofca:Jle SAT1348i.j 3 t VA.G1313 Pressure aaUge I VA.G1318/lAdapre

i l e i t-rc

a VA G 1318/llAdapter t VA.G1318/17 Adaprer a VA G 1318/23 Adapter

va.G 1313/23

{}{l:ro

ep
_ 24_65_

vA.G 1318/9

. vA G 1318/9

t'*a

a Bemote controVA.Gt34B/3A

fq-*;l

24-66 _

I ' Li- . ] , . r 'a i i . [ i ] . s : o . rii:.lL:il r: iiri:! CliecLirrg cai'.1;iiilt:

T l L 'r r ! ; : |.:ri -i.,

:rr : ifi

ir i::Lj:

l '

. Fu-.i plrnp relay 'll7 [.rl . FuelPUnrP Oll . f uel fiier al. . Min. battery voiage I2 7 V

24-67-

Checking Process the pressure' to - Openthe fuel tank cap briefly feduce on fuel supplypipeI -, pressbuttons f!el hosecouplings ' Femove to do this

and T318/9 VA G gaugeVA G I3l I with adapter pressure - Connect to P 1318/17 the fuel suPP]Y Pe gaugeThe hande pointsin drrectlon tap - Openshut-off on pressure ol flow ' Slartthe engineand run at idhngspeed

24-68-

. ri _.ri i ._ri _ .i :t

' l :, J [ . it ] : r r i:

FLl l tl eva.u!.ni rar!e i -._,ti i rF rra5Lrr!r!.tl :i ,I s!re sfr.Lrt(:1cra,i :! tr S peci fcattol :ptr... S h| | t off engi fe l i i re spea i i Gt or : I 01 cl j ti l ed: - Switch oft rgn tion 3 L:tf

quantity - Check supptied fue pump: page 36. by 20 i the specificat areobtained: ons Swrtch gnrton olf pressur-o on gauge After 10 minutesthe pressLrre Observe drop mustnotdrop below bar. 2 lf the pressufe drops below bar: 2

24_69_

v.A.G1318

- 5r;rlrho..o .and.u.a1 rdt,.gcpeedun, apressu-aotdppto,. J Oa-ra oee.tar. ,o. oo 6nono a.d.ose off ]1e cJ__olao ltever r ght angleto direction f ow arrow). at of - Observepfesslr-o drop on gauge.After lO minutesthe pressure must not dropbelow2 bar. lf the pressure does not drop: - Checkfuel pump non-return valve page24 7.1. -

vA.G 1318/9

f the pressure drops n: aga pressure gauge - Open VA.Gt31gshur-off (handie clirect of tap in on r owl. the - Start engine runat dlngspeed. and

ii"t
'-7',-t-\
i I

:A.G1318/17
ur6e3

- Swtch gnrtion after pressure buijt A1 same me off the has up. the t cramp trrereturn ofi hose(withbluemark ng).

24-70 _

... :: = . ] . : :' :.r . :.]] .l :]

'. ,,

"..

: , - ...'.,,.1
l,j.i.,r! i.il

s, al,e.l:plpeL. rre.iL.) ,,, rL !r:.rr fire d st Lr ii,r.' r!

VA.G 1'jl8 ar,dacj.ijtos areI efneir.t ly Cfecltlre piess, e 96Lrge

b\/ e Ieduat..'ttepressLt!e apentng Eefoterem..vingthe pressLu gaLtg-a, he tap Oti dotDg5a,plsce a cantaiilel whetc the pipes v','tll the cutafi Checking fuel pump non-return valve ho coverlrom fLrse der. Remove fuse no 28 from the Juseho der Remove

24-71-

Connect remole control VA.G 1348/3Awith adapterSAT1348/3-3 terminal(+) to contact28ato fuel pump and batteryposilive

sAT1348/ts-3
vA.G 1318

1 3 1 81 n 1314t23

Attention! Fuel supply pipes are under Pressure Beforc removing fuel a hoseconnectionswtap cloth arcundtheconnection.ThenreIeasepressure by carefully pu ing fuel hose from connection, gauge 1318/17 lo pressure withadapter v.A.G vA.G 1318 connect f{rel uppy prpe. s

vA.G1318n7
24-72-

A,G131e/11 A.G131a123

Frlaclart,r\'1!,.|l a,/:t.r rl\,11,a :r.]r/:li,i i:, ,it d,rtra.. -

Et,j.:::,r-!:

.r:

ClosepressLrfe gE a|lr{,ii ia[r llever ra]!,i te ia :lt ; I r,r,.,1 crat at :r',c flow -B-). Operate iltea,:,nil.,l:t s r,,r1iIiervalsfnl3 a,?: sLI9 .i : ltFi h: s re
DLlll Up.

Attention! Danger of spray when opening the shut-off tap. hold container ovet the prcssure gauge free connection

vA.G I3t8/t7

vA.G131e/1
f M,orct

li pressure ds up too h gh, lowerexcesspressure carefully bLr by opening shutofftap. the pressure - Observe dropon gauge. After10minutes pressure the mustnotdropbelow bar. 2.5

24-73_

lf the pressure dropsfurther: p - Check pe connections leaks. for i no leaks found: are fue - Replace delivery + page unit 20-18.

_ 24_74

srlLi Exhaust svstt]1 c(!n I po! lei!t::: |+i'11ir'ril't!;

iftstat!inE
a X /w rr)s ,a/ri i .e q:r:r' .i s n,r! :' err /ur' rr r:r" ' _ ' "t _ . a ,l ncr\.J ') . r, de,5r' t J atct' t c. . . ao !' t( ;" ..r-.r, '. j t ; dlalr eot \ 1 ' o.h1 ,< tt!e at !4/art 6rd the -slrppori:rEt-' evenlj' l'l3tled exhaLrst s]'5' I l\lote ltte assenlbl'y' posillirns an1 d,rren-sioDs of th_a t pipe should not f)e bent The anicLlete.l se ctk,n it t the t'ran1e'.hau3i 1(F or it caLld be danleged nore than beheard' I lf, after assemblingthe exhaustsystem, harsh noises can adjust the engine btackets

26-r-

1-25Nm 2 ' Front exhaust PiPe a Wrth articulatedsection a Do not bend the artlculatedsectlon it morethan 1O',otherwise couldI damaged a Protectaqainst lmPactor knocKs + andfitting page26 " r Disrnantlrng a Fit and adjust the exhaustsyste I wlthout subieclng d 10 sttess = page26-26 3 -40 Nm _ 4 - Lambda probe before catalytic c( verter -G39a Checking: e VAS5051 Vehlc self'diagnosrs | threadonlywlth "G5" "G'" I Grease must noi get lnlo the slots on tne Probebody and installwithU'40080I Remove nLpopen 1 Lfthe sealngring s leakrng, o ring and replace'the

11 12

14

.tE

-zg

\zz

20
26-2 -

.4

10

5 - Gasket 6 - Bracket t Secured to the subJrariE cio.l men'rber Frg. 2 7 '25 Nm I -Suspensionelement a Renewif damaged I - Gasket 10-10Nm

rt1tll -! v'

t--'
"12 13 14

to
-_ l E

11 -Heatshield

20
tEr6 oonl
26-3 -

11 12 '13 14

l2-Lambda probe after catalytic cor verter -G130a 50 Nrn a Checkng: VAS5051 Vehic se f-diagnosis e ; a Grease threadonlyw th "G5". "G5 .r.st 01 ger i_ro -i. sorc o- Ic; probe body a Remove and instalwtth U40080 a lf the sed ng r. q rsl^a.r-g 4pope ano feprace o-rng rne 13 - Double catalytic converter o Belor. 'rr 'q. Insral upper reo

20
26-4 -

7A I
d
I

10

14.Bolt 15-25Nm

{N

16-40Nm

/"-11

't3
1

17 - Suspensionelement t Note f itng postion + i g. 5 i Ft and adlust fear silencerwithoLrr sublecting to stress: Fig 3 it 18 - Front silencer i As standard, the front and rear s encers are a stngie component. When repair the frontand rearsrng, encersare supp ed indivduallywth a doube clamp for connectlng to gether Cut the exhaust pipe perpendiculafyat the nd cated porntwth too U'40075+ Fig. 4

14
'1 6

r ,- 15

20
IF,A n

26,5_

19- Suspension element a Renewf damaged

11

13
1

14

20 - Rear silencer a As standard, iront and rearsi the lenceTs aTe a single component. Whenrepair thefrontandrear ng, silencers supped indivldually are wrth a doube clampfor connecting togetherCutthe exhaust pe perpenp po d cu ary at the indrcaled nt wth too U-40075 F g. 4 21 - Suspension element a Renew damaged if 2 2 -2 5 Nm

11 10

-,,9 -

,-9

,t

&W .U
Lr.
20

t-

[1e

2 3 -2 5 Nm 24 - Tunnelbridge

t F,a-anti-l 26-6 -

Fig. 1

Fitting position of doubte ctamp

a The bolted jornlfacesforward

2A

3--Q IJ E

Fig.2 Frontexhaustpipe bracket 1 - Suspension element 2 25 Nm 3 -2 5 Nm 4 - Bracket 5 - Front exhaust pipe

26-7 -

Fig.3

Install and adiust rear silencer without subiecting to st.ess

{ Om61s on X -thosarreon e{Ta-o.ghi ..

_ T h e . n o u n llgp 1 < . o . a v a u s t p , o e ^ r. s l r, n p a -a t ew r r r L u n - e l ,
O ' Oge

Fig. 4

Cutting point on exhaust pipe

Cr e",ausr oioeat 9.t d-glesal reoarar po nt d> trdtcdted no o/ rne rrow 2 use ptters 4_40075 ' O,'1Tr-glr.do.loeclarplo,epa s,trrLr.tbecolecr,yposil|oleo . {-o6'wee. lte ctden-arl ngs .a,,o,1/. a. o 3 - ghr.-edlo 40 \_

Fig. 5

element lnstallationposition of suspension

forwards. element irrow- poinls sideonfoot of suspension - Angled

26-9 -

Exhaustmanifold: removing and installing

Romoval + the - Dismantling turbocompressor page21_2. nuts-1-. manifold all - Bemove exhaust the - Rmove $shersandthe exhau$manifold. Ingt6llation Note: Always replacegasketsand self-loc*ing nuts. manifold nutsto 25 Nm the - Tighten exhaust procedure in ordrof the dismantling assembly reverse Continue

26-10 -

@6+:_,"-"..,,* fiftdl]}:E ar0i+.ii ..*

Front exhaust pipe: removing and installing

Specialtools. workshopsystems, testers. measunng rnstruments and auxiliarv items required I Hydraulc column SAT 1040 lack a TorqLre spanners e01O SAT a Base T20145 a Holdlng T20161 too

t Lr6oooel
_ _ 26_11

Dismantling

a All cabieties .whichare apenedor cut apen when removingengine, fi)ust be replacedin the same pasitt()nwhen re_installingl ' a ln vehicles whh coded radia/ caded radia and navigation system (RNS),take note af the code, if necessary,find it. - With ignition tchedoff disconnect sw batery eann $rap. Separate 4-pinconnector from the Larnbda probe and leavethe cablev sible.

Unbolt the front right,hand whee Remove central insulation -aTrows-.

26-12_

Fer ove r!l[ ]_ari, _:rrai'ar_:irrous

2)

rf
< Remorele1-5" d' .a o ." on'

26-13-

N a-:) ,r\.
\".

support F fst unboltbois -A-and then -3-ol the pendulum

pendulum supporl Remove

the the bolts-2-securlng PASbox to the unitsubJrame - Bemove boxlrom the unrlsub frame,leverngwith a screw_ the - Release PAS driver. andhc d ic - P acea hydrau co umnlackSAT1040with baseT20145 the unitsub-frarne. under lngtool T20161 screws 1 3nd-3-lrornthe Llnl sub-lrame. - Rernove

26-14 -

"1 ., rronl e\ rtaLrst pipe

. a.ouo.

c.,.

.,'':-,;!1L1=
-'i-i

Secure steering the bo\ to the vehtce convereri y. Unbot the proiecive cover 2_, arrows. Di..o-nor I In6 a.rbooo,ooo .o-. error

ilTilr5j;::

"

catatytic converrer thefront trom exhaust pipe

U nbol ' l _6doLo. (d_at.r.,LonJe.l al ei a l ,o n, 11eI . onr s. len. el rl cageel b 5. oos. l l a d l 6 , ^ o,6f-ttv r6no..1,1. do , bic, at al\ , at c :i U nbol t the fronl exhaust pi pe from the turbocompressorout let .

---

26_15 -_

a Theupper front e\haust ptpe securno bal

;i ;",i ;";::i illll ij i:! i !:,:,f! :\ ::i2: , i| 1"2 : :f 1, ,"; ;,

,,0" not be ' '::,3'.i;::;"; zi";::iio,l3,Jl1:;;;*' shou'd bent

a lf there is not enaugh roam to remove t

I
-

;;,. ;;;; ::,;z #:,:?x:"il{f i,:"i,"if; -";" ; "; ;: ;;"; ;:;::f" "
**-*' fl'n 3;:'-1"'f
D rnr- g g.A a. o,s. 5r.e. -9, I.onl w hee ano to.r. ^nee t '' n '"""',"" 'e ass'sieoiiee, ,t,1i,1,';^u dJ, e, De_

'l =

. oe-o\eine-o

te,-d-st p,pe\ r-.are

lnstallation

jJ-

2-

replacegasl:etsand se t''l..king n|tr Ai,,",'ays bolls,place PAS the boxon the sub' replac the subJrame ng Before J o-neand hon4tr F o _. 2 e.U, g .'e FASbo o 6 '',b

a Thethreadedbush-1 shouldbe fixed tn the arificeof the suEftame a Thetubber stap an the atherside shouldbe seatedin itscavil tn the

26-17 -

L
=

a lf it was necessaryto remave bolt-1 securingihe steeringcalumn jaint sacket to rcmave the frcnt to the PASbax with the univercal pipe, renevr the boit and ttghten b 3A Nm. exhaust + Runnjnggear, axles, steeringfronlwheelandfourwhee drive;Re repair;Powerassisted steeF pairgroup4S; Power stedsteering: ass ing box: removing and nsta Ing

bed as F t the subJrame descr beow:

and tqhten by hand Ft the slbframe to the assemby position (usingnew bo ts). TjghtenboLts of lhe PASbox to 25 Nm. -2Tightensubjrame bo ts -3-10 100Nm - rL lLrrn 190'1. 'gnre bo . -o 100\' + z r-'- 91'

26-18 -

- T ghtennevvpncl!lurr s!pportbolts-a.rows to.1O 8Nm + rL turn (901.

nueasSemDry revefse Cont rn orderof the dismantling procedure Notes: (radrc a lf the batteryB reconnected equipment checkthe vehicle / radioand navtgatian system, clock,power winclaws),fallowng: lvlanual lnstructlon a other measures the aftet rccannecting valtagesupply+ page 2439.

_ 26-19

gas removExhaust temperature sender-G235-: ing and installing

instruments Special tools,workshopsystems. testers,measuring and auxiliaryitems required sAT 8010 a TorqLre SAT spanners 8010

,tmmm:.-E
irTn]]]]]:flE ,,,-",

Dismantling a Allcabletleswhich opened cut openwhenremoving engine, ate or must be replaced the samepasitionwhenre installing. in a ln vehicles with caded rcdto/ coded radio and navigatiansystem (RNS), find takenoteof the code,if necessary, it. a Thesenderand the turbacomprcssar cannection tube is a single
-w2dt

bater) ea-lF sUap. oH - Wt' gnrio-srvrlched d:sconaoci

26f20 -

sernovecenlral nsuatcn arlovts

gasternpeiai!resender-G235_ for the exhaust

26-21--

Removethe boLts arrows-and remove the covel -1

gas tempetaruf Removethe connector-arrow-of the exhaust sender G235.

26-22-

Pulrcoolant hose I

o11 bracli-.r-4 tie

Benrove bolls 2-and-3 and removebralel x the

Femoveboltsrrows- of the exhaust gas temperaiufe sender-1 -G235from the inletmanifo and rem;ve rne senoer. d

26-23 _

Installation nstalrnreverse order the dismantling of procedure Notes: a If the batteryis reconnected (radio checkthe vehrcte equipment / radio and navtgation system, clock,pawer wjndows),fo owing: + InstTuctron Manual I Othet measures after reconnecting voltagesupply+ page the 2439.

_ 26,-24

for system:checking leaks Exhaust

and run at rdIng speecl Sta.tengine or with cloths caps) ' - SeaLtheendiubeswhilecheckingforleaks(e'g atloints cylinderhead/exhaustmanifold by lor Check leaks listening converter/sllencersgaskeVturbocompressor/catalytic fo!nd. anY FepaLr leaks

26-25-

system:lnstalland adiustwithout subExhaust iecting to stress

with a doubleclampbetweenthefrontand reatsilencers Vehicles theexhaustsystemdirnensionsof and . Notetheassemblyposillons be . Theexhaust shouid coldwhenadlusted system l the - Release boltsof thedoubleclamp+page26-1'Fig
D roo ot ,9 a:5 I I nr.

a Fl t ng posl ti on of doubl e cl amp + page 26-7' Fl g l

r;6@n

to boltsunformly 40 Nm clamp the - Trghten double

26-26 -

Cettre the end exhaust pipes as -a-on the right. - At the samettme makesuredistance of the bumper -bcu o tre . enctptpests attained.
:_

a Distance 35 mm b= to pointsoJthe rearsithe - lt maybe necessary loosen susponsion lencer centrethe end pipes. lo

26"27 -

lgnition system: repairing Generalinformation:ignition system

i Theengine control is equipped selfiiagnosis. unit with rqe a D'sconnecling connect.ng batlFry'nJ51 oe oone aro only wrrh the ignition swltched olherwise engine off, the controL it could be un oa'nageo a Fortroublejree a voltage of operation ofthe electricalcomponents 12.7 is necessary. V at least a During some checks ispossiblethatthe it controlunitwillrecogn se andstorea faut. Therefore aftercompletrng checks repairs all and lf the faultmemorymustbe interrogated if necessary and erased. the _ the fault memoryis erased,it wrll be necessary generate to faultmemory+ 24-28. readiness code.lnterrogate

2A-1-

a lf theengine starts, forashonperiod runs andthen stops, afterfault repalrs component finding, or tests,thenthe faultmayliewith the immobiliserwh isblockingthe ch engine control it.Thefault rnem- u. and ory mustbe inteffogated if necessary conlrolunitadapted. the precautions page28 + Safety Testdata,sparkplugs+ page28-8

2A-2-

lgnition system components: removing and installing

1 - Connector a B la c k , 4 in p 2 -lgnition coil with output staoe_N_, -N128-, and -N163_ -N158, r Checking page + 2g-2S 3 -Spa* plug a 3 0 Nm I Rerfoveand rnstallwth soanner 1200?a a Typeande ectrode + page2B_g gap 4 - Connector a Contacts d plated go a Forknock sensor c6i- andknock i sensor -c662

12 11 10
glt

fErs-oors I
28_3_

rs--
1a-/,::j

5 -2 0 Nm a Tlghtening torque influences the Tunctron the knock of sensor 6 - Knocksensor1 -G61a Sensor and connector coftactsare go d-plated a Checking page28-34 + 7 - Knocksensor2 -G66a sensorand connector contacts are gold-ptated a Checking page28-34 + 8 - Connector a Black, n 3,p 9 -1 0 Nm 10- Hall sender-c40O Checking page t8 + 28

+* g-,+
\<=]I J^

'tl 10

a Car'
F
| ,-J

s __,_--{

244 _

'11 25 Nm -

15

-'---r!
E::::]::4 ((.

12 - Washer a coneshape 13 - Rotor I ForHal sender -G,10notef x ng arrangea When nstal|ng 14 - Earthcable
_ -t

14----- '/

w
12 11

T7

1 5 -1 0 Nm onlywhen gnthe a Tghten oosen or tion is off

I
1,-

l t Er8-oors 2a-5-

Safety precautions
ano dnd r_lL ropre,/e_i e5 0 pa'sons oroanogeto L'ein.ecfon rgn mustbe observed: folowing the tionsystem, rs whentheengine run- ignition wiring or a Do nottouch disconnect at starter speed. turned ningor being or ofi mustbe switched beioreconnecting dLsconnecta Theignition cables tester or incLLrding voltage hlgh cables, ingigntlonsystem cables. w speed, thoutstal!ng'eg: is at a lf the engrne io beturned startet injector con- pressure coiland testing, ignitlon the forcompression nectorsmustbe removed. '

it Durng somechecks is possiblethatthe rt controlunltwLlrecognise and store a fault. Therefofe after completingall checksand repairs the Jaultmemory must be intefrogatedand if necessaryefased. lf the fault memory is erased, it will be necessaryto generate the readlnesscode. Interrogatefault memory + page 24-28. a Only wash the engine wrth the ignitionof{.

2A-7-

Testdata, spark plugs

Edginecodg Firing order SPark Plugsl)2) 101000 063 AA Manufacturer's designation NGKPFR 60 Electrode ma^. 0 . 8 mm 9ap Tightening torque 30 Nm r)Remove replace spark plugs and the withtoolT2OO2B 2)Up-toiatefigures: + PansCatalog!e AMK 'ti4-2

2A-A-

"""'ffi'
i-q*?e/

Voltage supply relaYto control unit -J271-:checking

lools, workshopsystems,tester9, SDecial measuring instn ments and auxiliary items required a r u rn..e vA ! -ond VA G 1715 meter
-ra!.U,

--jr=S/

rs ; ,//

lclo^ or ' \ qglA o

a A . , 't o r l

o 5o. /A.-

1594C a TestboxVA.G1598/31 flow a Current d agrams fhe.L,terrsupP\ .ela\ fo' s\ 'LemJ2 I

suD D h-sct qenl rol he o npuL < tdges o1 l' ' gn,i a!. ats. as v' al t dt tt' c' otrc car '! 'l unit throuqh contact 121

fw-ri offil
28-9 -

checking process the - Disassembling enginecover arrows-

2a-10-

MeasLrre voltage th lhe nruiiffieter w the andthe auri aryc:blesof VA G 1594A or VA G 1594C as folows: Connector, contact
I

Measue to ground Engine

- Switchon ignition. ication: approx. baftery voltage Specif

T@l
lf the specificaton not obtained: is - Switchoif gn tion. the supply relayrrow-underthecover, the left on - Separate voltage of the dashboard. Note: To remove the protective covet in vehicles with ctoss member between the suspensiontunets, releasethe relayholderfram thedashboardand move downwards.Also disconnecttheatr massmeter con-

2A-11-

and Check connectionbetweencontacl2 of the relayhoLder the contact of the ignition 1 coil: + Current flowdiagrams. Electrical findng andfitting fault locations is lf the wiring OK: supplyfor Motronic'J271-currentsupply page relay - TestvoLtage 2A-9. 28 on c-J27T supply relay+page 15. -current - Testactivat of Motron T-@l

2&12-

Checkingvoltage suPPlY - SwLichof'f gn r.' elI relayarrow Lrnderthecovef'onthe iagesLlppiy - Separatethevo of the dashboard Ta remave the pratective cover in vehicles wtth crass member be turres releasethe telay holder frcm the dasn tween the suspensron nlass melercon baardand mave downwatds Alsadiscannecithea1r

of and w - Meas!rethe voltage ththe multimeter the auxlLarycables VA.G 1594A or VA.G 1594C as lolows'

Retayplate underthe left-handcoverof the contact dashboard, 3 re4 o"* I

to Measure Eng ground ne ground Engine

approx batery voltage Speclfication:

2A'13 -

f the specfica|on s nol o[itaned: checks: Car.you1thefollowing Check fuse 37

s164 s163 5162

iLrserrox - Checkflrse S134 (110Al nthema n battery -rle'"1"-a o "e C'loct1a-r e^,. g.onre 1o,.,l-o L-'oo J' ro rne odr6 , ._e -: 30 go ng In o-o1{ rse Sl34 and'-'e r-edacrdco/6ro -o e!!c liii"q",,ppl "'".--:-i,roei board)s broken: 'fau and I tting lccaiions Currenitto* AlagramsElectricaL t flnding -

s 1 3 3s 1 3 2S 1 3 1

28-14-

Checking activation SwLtch rgniton ofi / Separaie vo tagesLrpply ay-arro\ underthe ihe re cover, on e 3.ii hands de oi the dashboard Note:

li.I_li-_r

1i

Ta renove the pratective cover in vehicles wtth ctass membet between the suspensianturrets,releasethe relayholderfram the desh baardandmavedawnwatds. Alsodtsconnectthe atr massmercrcon

A V A . G1 5 9 4 o rV A . G1 5 9 4 Ca s f o lo ws : Relayplate underthe left-ha.d coverof the dashboard, contact 5 Measureto

Battery positive

tesal

28-15-

Sw tch on gnltion. baiteryvoltage Specficatronapprox. lf lhe specrf cationrs not obtained: Swnch oft ignit on. test box\1A.G 1598/3'l tocontro unitwinngharness,wlth- Connect ng t out connect the enginecontro Lrn + page24-36.

or for - Checkthe fo low ng w r ng connection open clrcurt shofi to earthor shortto postve:

Relayplate underthe left-handcoverof the dashboard, contact 5

Testbox VA.G 1598/31, test box socket 21

r;;e-l

28-16-

.ipef . f.- : or shorl.!rc! 1 ll neces::ry eirnir:rtethe lirrrr'r! t f no faLr is tound: the - Replace Motronc J271 .!r:ent suppY re a,\'

2A-17 -

V.AG 1527B

Hall sender -G40-:checking

+ Lnsla lationposition page24 9, ile.r,28 testers, Soecial tools,workshopsYstems, measuring instruments and auxiliary items required oI VA.G 1526A multI Handmultimeter 1 me t e rV A . G 7 1 5 VA.G15278 a Diode testlamp a ALr\ ha'\ meos-:no seLVA C '5914 o I TeslboxVA.G1598/31 i) Current dlagrams flow

@ry

2A-14-

TlrHal sender,G40- nioflIs of the gn tion posinon cy lnder1 of qeira li s-ler stoo) i,. lno.. EJUd.on .d,t,eo,o \ 'ne lg' n.'on '6ld dedd ^o.r'g t r, no or 96r oorstoe to. o t\ o rr L,e aS Il.. osrgraLro4olL\.rders. nFt_ boLo.no.e<soro..r(.a ongp e_),,e WithouttheHalsendertransm ssion, engtne icont nueto work the w and can be restarted li the faLrlt is.identified, eng n control the unrtw ll actrvate gn tion an sparkper cylnderfor eachturn oi the cranksnan Checking conditions . Thefusesmust be OK. . Batlery voltageat least 12 7 V . Hail sender screwed on tight

_ 28-19

Checkingprocess - Pul therubber sleeves back, separating fiom the Halsender them connector, eaving termnals but the connected. VA.G 1527 B sender srgnal) contact (positive). and I No':
The contacts af the termnalare numbered on the back of the con- Operatethe stafter for a few seconds. The LEDmust flicker Note: The voltage testers with a law cuftent absorptiondo nat extinguish Completel,d)ting he aatt,/at'an Lneengineco"t,At unn. he; SG\ ol Sntntngwpat tv. tnc eastngthen tntensi-\ a(\vdted ^he.

28-20_

lf rhe LEDdoes not fLclerl Checking voltage suPPlY I-from the Hal sender conneclor - Remove ,'\ of cables with the mu t meterandthe auxiiary the - Measure vollage or VA.G 1594.A VA G 1594C as tollows:

'--\i\-

connector-1-,contact T
- Switchon ignition. approx.5 V Speclficatlon: Cheekthe signalcable

Measureto ground Engine

oi cables and with the multimeter the auxillary the MeasLrre voltage 1594A or VA b 1594L as folows: VA G

Connector contact -1-. 2

Measureto ground Engine

2 A -2 1 -

- Switchon ignitron. approx.battery voltage Specificatlon: Check the earth cable for wiringconnectlon open or shoft circLrits: the - Check following

Connedor -1-,contad 3

Measureto ground Engine

ellminatethe wiring open circuit or short circu t - lf necessary, are lf althe specificallons aitainedand the LED does not flicker contacts 1 and 2 wLththe startermotoractivated i-"u*tlng'bet*""n connecteo): andthe connectors -G40Hallsendef - Replace ons f the speci{ical are not aftalnedl

2A-22 -

Checktheconnections between the Hall senderand the engine controlunit Connect tesl box\1A.G 1b98/31 tc,controun twring harn--ss. wth_ out connect the engrne ng convol un t page24 36. -

Connector, contact

Test box V.A,G 1598/31, test box socket 9B 86

108

1{positive)

2 (sgnal) 3 (earth) Wireresistance: 1,5e max.

_ 2a-23

lfaftererasng-he'"-inen ofy.a.auftsagt,rdsotayed-ed,eoro-.e carsnan senso''!. sendea even.ho.g. l^. lo,.nercheo s were correcl that tauttmay be ihe {olowrnq - The Hallsenderrotoris tw sted. - Loosen the-Hallsender check the rotoris correctly and if fittedtothe camshaft(if inco(ectly frtted,the ockingtab is crushedon tlghten_ ng the secunng bolt). - ll the fotor posltlon s correct, checkthe co esponoenceDeiween crankshaft/ carnshafl.

28-24_

lqnition coils with output siages -N-, -Nl28-, -N158-and -N163-checking

lgnition caits and thei respective autput stages ate one untt Soecial tools, workshopsVstems, testers, measuring instnrments and auxiliar! items required .r a Hano --1 , 6-0r v/A( VA.G 'i715 meter lE26A or rnur

test lampVA.G 15278 a Drocle set VA G 15944 or measuring a AuxilLary 1594C I Testbox VA.G 1598/31 flow diagrams I Cufrent

2A-25 -

Checking conditions . The fusesmust be OK . Battery at voltEge leasl12 7 V heatermLrsl rearwlndscreen eg . Al electricconsumers, :lightsand be swltched ofi. + OK, checkinq page24 48 . Engine speedsender -G28> . Ha I sender-G40OK,checking page28 T8 Checking Process on whrchcyl|ndefs maliLrnct ng or laulty'do as To determlne t faultsrecogn on: - Checkignilon/comb!stion self-diagnosrs > VAS5051;VehLcle faultsare detected: f gn llon/combustion beendetected' - Contin!etest ng the cylnderwhere the fa!lt has follows

28-26 -

it no gniton/conbLrst;oi ts are cietEciad 13u - Wrththeeng ne on, rerrtove rjectorcor r ectorsonebv ane,ob_ the servrng behavour ol the engine the or: - Comparethe sparkpl!gs of atlcylinders seetfthe electrocles and are j{ the faultycylinder has been dentified: plug - Exchangethespark ofthe fa!lty cylinderforthat ofanother cyl nder lf the fallt goeswith the sparkplug: - Replace sparkplug. the ll the fault remains the same cy nder: in - Exchange coil of the faultycylinder that of another inder. the for cy lf the faut goeswith the coil: - Renewthe gn tion coil.

_ 2A-27

Check earth connections Removethe 4-ptnconnectorl- from the ignitioncoi 2_ to checked.

m
| *;*l

Connectot contact

Measure to positive Baftery

Batterypositive

_ 2A-24

The LEDmust rght{rP !P: li {he LEDdoes not lLgnt + suppLv page28-29 - Checkvoitage

\-1

Checking voltage suPP|Y and the auxLlrary voltagewith the multimetef the supply - Measure 1594between: of cables VA.G

contact Connector, 1
- Switch on lgnlt on

Measureto
grouncl Fngine

voltage approxbattery Specification: ls lflhe speciflcation obtarneol coilsfinaloutputstageactivation page28-31 Checkignition -

2A-29 -

rs l{ the specflcatlon not obtarned: onthelefltrnderthecover' arrow_ supplyrelay Separatethevoltage handside of the dashboaro with crass member be' To removethe protective cover tn vehi,cles jt" tetay'aoerf'am lhedash' oe rctease ,*-"n 'oi"ra naas fiate' ( on oo n^ 6, uni ",rronrion,uftels4t 5p 6t5l 6npscr tha ai ", ^o, "

checks: the CarryoLrt following and holder con2 contact ofthe relay between connection - Checkthe for open crrcuf: tact 1 of the gn tlon coil _arJ'Ltno'.9 a_d tling'ocaL'on' oaq an s. Frecrrcar -ir.""i;o" + page28-9' y c Checkthe lvlotron -J27T'currentslpp relay

2A-3D -

f tests are Ol:: - Checkrgnition corlsfrnao|ripuisrageactivat = on Check final output stage activation - Pulloff connectors from aI the inlectors. On checkingda nat inject fLtelso as nat ta damage the catalyticcoft ve.rter. this reasan the connectarsshoLld be-separatedirom For ihe - Removethe 4pn connector irom the rgntion coil -2 to be lchecked. 2g Lrage :l

--

28-31--

- Connect diode larnpVA.G B to contactsand3 of thecon_ test l b27 2 nector. Briefy operalestarterTheLEDmLrst icker I TheLEDdoesnotf[cker: ' Check voltage supply page 29 2g -

f;dl

our con, ecr -o t1e eng ne co. r.o unn * paqe2l_j6

2a-32_

contact Connector. 3 (cyl 1) 2) 3 {cyl. 3 (c y l. 3 )

Testbox VA.G test box 1598/31, socket 102

e5
103

ts;;l

3{cy.4)
max. 1,5 e2 W re resistance: or the e lf necessary, irninate wiringopen clrcuit shortclrcult lf no lau t is found: igniton co I wLthoutputstageassembly - Replace

28-33 -

and -G66-: Knocksensors -G61checking

locatlon: Fitting -66' page 8. {e'r 26 24 24, item18 -G66+ page testels, tools,workshopsystems, Special measuring instruments and auxiliarY items required a hano nit,nele VA.G -5164or m"'u 1 me t e rV A . G 7 1 5 or set measuring VA.G 1594,4 I Auxilary 1594C o TestboxVA.G1598/31 flowdiagrams I Current

fw-ro-oo33l
28-34.-

's F .

rEr .too-,

ta...o

a.no -/o..-...o

oq_

o ...,\

a Anly Eold-plaied cor)tacismay be ,)sed whe, se.r:/rg i/re t nod sensor cannectorcontacts t Check lh-6k ock sensor cannectorta the wiing harnessfar corCheckingconditions
. . . . o J 1 6 o g n . 6 0 o \ s a t_ o r a g n o . , _ oJ I f o or Doth..o. p ; o e Z Z l a^ e d u l 'r e n o , r o n u l o r-o r eding

Checking process Pul connector the knocksensorto be checked. off Swtch mutimeterVA.G i526 A to ressrancemeasuTement and connectit to contacts1 and2 0l the knocK sensor. Specficaton: CJ

_ 28_35

orrlconnecttng eng ne controlUnt + page24_36. the

Check the fo low ng w ringconnections open or shortcircuts: for Knock sensofI G61-(cyInders1/2): Conflector. contact

Testbox VA.G 1598/31, test box soc(et

106 99

1 (s ig n a ll
i i,-r 5-!21 |

2 /earth)

28-36

3/4)l 2 Knock sensor 466- (cylinders Connrc{or, cotitlct kboxVA.G 1598^ll, t .t bot( 3ockat 107 99

1 {signa0
2 (earih)

the eliminats wiringopencircuitor shortcircult - ll ilecessary, lf no lallt is tound: !nit. control engine - Renew

a-37 -

seFvrce

Technical Bulletinto WorkshopManual

), Toledo1999 Leon
Engine

AMK BAM

'

BOOklet

(S-valve) 4-cyl. injection engine, Edition 06.02

Enterin RepairGrouplist RepairGroup A1l Affected: All

BulletinNo.

E) E) a

RecordtheBAM engine denttfication letterc the title page, theHepairGroupreference. on

Lhccatd dnd th- tatl.ng srcct tdblp. \.

Record'See Technical BeportNa. 1" on pagesA02, 00-3and24-26.: ..-,..' Cro:f out pagesl3-5, 13 11to 13-14, 7 andwtite on these pages SeeTechnical 1g Repart '', No. 1

Subject
process"Ribbedbelt: removtng Modification and fitting" far all engines. New engineswith BAM enginecodesarebeingintraduced.Regarding manufacture, BAM en the gne is similarto theAM K engine,with the exception the modifications of dacumented the incluin ded Technical Beport.

Contents

Bulletin Booklet page from page

Technica data
- E n g i n e a ta d

1 T

00-1 oo-2 13-1

13-5

Engine: assembly disassembly and

- Poy -V-beit: smantling fltting d and

3
4

Cool system ng components:smantl andfltt ng d ng

- Cooing system cornponents, ne side eng

B
B

19-1
19-7 24-1 2426

nject system: on repair ng

Techf ca cata

10
10

D..r^.r-

E r r +; ^ ^ .

1lrlf

Technical data
Enginedata
Enginecode
limitsaccording ExhaLrsl emission to

BAM EU3Standard 1741 165/6000

cm3

D splacement TorqLre D ameter Stroke Compression ratio OCT Inlec!on gnrtron Knock control Varabledistribution

Nm/.nin 240/2200. ..5500 A mfi.,

81,0 86,4

rr min. 98 unleaded Motronlc ME75 Motronic ME75 yes

Variable intake manifold , Exceptionally, minimum octane. OCl but with somepowerloss 95

Enginecode SelfTAGdiagnos s Lambda regulation Catalytic convener gas Exhaust reclrculation Supercharging Secondary syslem air

BAM yes no yes

D8124807030001

12

r.f' .\i

E n g in e :a s s e m b lya n d d isa ss e m b ly

atd

g
ll

li

5--.
7 8 10 11 12 13 14 16

17 - O-ring a FePace I oamageal 18 - Coolantthermostat l Verilcarlol : heat tre t!e;morlat n a a a t I Begrflnlt ol openng: AN4(efglne approx87'C BAM engine approx80'C Ope1ng lft mrn.I mnl .l9 Disnrent andf 11lng pag-a 29 lng

19 -45 Nm 20 - Additional subframe brackets a Disassembingand assembrng page13 T7 2l -45 Nm 22 - Bight hand side engine bracket

2'l

20 19

18 17

I Ein:nn6;l

Poly -V-belt:removing and fitting

T20167 Specialtools, workshop system s, testers, measuring instruments and auxiliary items required. a Reiainlng iool 120167 a Befare remavingthe Paly V Belt, mark the DOR ldircctian of raia a tioni ustatg permanentmarKerar ctaYan a lf the belthas been used and is made ta wark tn ihe appasitedtrec tian t! may be destroyed

f !!@*l

Removing - D a.". b g:5e.19. o.. .-'

ta 2,raa7030001

Torelevelens onontheribbed betl, turnthe tensoningdevcenthe d rectronof the -arrow .

DB2480703000r

' Flerr":

an !i_i lr:r al t!! art 3 orra

Fiefcre I bhcd beit lnstallation

E sure, belo/e irsr://r/)gtltbed bel!. that ail anctllaneslal!-otnaia.. ar condillonercornptes!:.)a PAS van-. punp)ate secued tphtly. - F t ihe PolyV be t to th--cfsiksheir and vanepump pu eys. F r the r bbed be t to the a le.iator p! ey asl T20l67irom is alch nli a 'ow andloosenlfetenson- Removetoo rng0evce. thal filled. - EnsLrre l re Poy V s correctly ContrnLre assemblyn reverse orderof the drsmantrg procedirfe Stafiengine and checkhow be t rs runfinel.

*7-=---=--==-=f
i

12 3 4

5 6 5

7 I I 5

10 11 12

Cooling system components: removing and fitting

Coolingsystemcomponents. engineside 5 - O-rtns a Replacemenl 6 - Coolant thermostat a Verfication heat the ihermostalln : waieT I Begnn ng of opening I AMK eng net approx87 "C t BAM eng ne: approx80 'C lOpenng iftmn 7mm a Dlsniant andf tting page19-29 ing 7 - Rigid connectinghose a Cooant hose connectron agrarn : d page19-12

19

14 20 r-;;;-;]
D3r2.18117C30001

.".-T=
I - Connecting sleeve

12 3 4

5 6 5

7 I 9 5

10 11

13

9 -To heat exchanger 'l Cooant hoseconnectond agfam= page I9J2

--1,.-q-:

17 18 19

14

Inlection system: repairing

Technicaldata Enginecode ldlng check ld ing speed1) Engine control t 2) un Syslem 'I rpm

BAM 700...820 Moironic ME75 1 ML9 0 60 32A

'l rpm

Governed engine speed , Not adlLrstabie '-oie oa- . .^ oF. o e. q , 6 co-tto ut .. Parts Calaoque

irom approx. 6800

DB24807030001

10