Engine Adr Aeb Anb Apt Apu Arg Atw Afy Repair Manual Eng

Service
Workshop Manual
Passat 1997 ➤
Passat Variant 1997 ➤
4-cylinder injection engine (5-valve)
Engine ID ADR AEB ANB APT APU ARG ATW AFY
Edition 01.2014
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Passat 1997 ➤ , Passat Variant 1997 ➤
4-cylinder injection engine (5-valve) - Edition 01.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Part I - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Part II - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Part lll: assembly overview - old toothed belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Part lV: assembly overview - new toothed belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Removing and installing air conditioner compressor poly V-belt . . . . . . . . . . . . . . . . . . . . 19
1.6 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 21
2.1 Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Pulling needle roller bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Checking pistons, piston rings and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4 Renewing camshaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.6 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.8 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Assembly overview - parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents i
1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 80
1.3 Assembly overview - coolant pump and compact bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.4 Assembly overview - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.5 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.8 Removing and installing viscous fan coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.9 Removing and installing viscous fan mounting bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.10 Removing and installing coolant pump V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.4 Removing and installing fuel delivery unit, front-wheel drive vehicles . . . . . . . . . . . . . . . . 103
1.5 Removing and installing fuel delivery unit, four-wheel drive vehicles . . . . . . . . . . . . . . . . . . 105
1.6 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.7 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3 Assembly overview - electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4 Accelerator mechanism (throttle cable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.1 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2 Adjusting accelerator cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Charge air system with turbocharger (engine codes AEB, ANB, APU, AWT only) . . . . . . 126
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Assembly overview - turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.4 Assembly overview - charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.5 Schematic diagram of turbocharging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2 Checking charge pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.1 Checking charge pressure control, vehicles without EPC system . . . . . . . . . . . . . . . . . . . . 134
2.2 Checking vacuum unit for charge pressure control valve . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.3 Checking overrun shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.3 Assembly overview - parts of injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.4 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.5 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.6 Assembly overview - intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.7 Assembly overview - throttle valve control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ii Contents

1.10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.1 Checking components with vehicle diagnosis, test and information system VAS 5051A or
vehicle diagnosis and service information system VAS 5052 . . . . . . . . . . . . . . . . . . . . . . 156
2.2 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.3 Checking injectors for leaks and quantity injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.4 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.1 Renewing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.3 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

1 Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.1 Assembly overview - front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.2 Assembly overview - four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.2 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.4 Checking secondary air inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.2 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Contents iii
iv Contents
00 – Technical data
1 Technical data
(VRL006440; Edition 01.2014)
1.1 Engine number

The engine number -arrow- (“code letters” and “serial number”)
can be found to the left on the cylinder block.
Additionally there is a sticker on the cylinder head cover with “en‐
gine code” and “serial number”.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
The engine code is also included on the vehicle data sticker.
Note
The engine code -arrow- is also stamped on the front lifting eye
(visible after removing cover over injectors).
1.2 Engine data

Engine codes ADR AEB AFY ATW
Manufactured 10.96 ► 12.98 10.96 ► 12.98 01.97 ► 04.00 09.99 ► 05.01
Capacity l 1.8 1.8 1.8 1.8
Output kW at rpm92/5800 110/5700 88/5800 110/5700
Torque Nm at rpm 173/ 210/ 165/ 210/
3950 1750...4600 3950 1750...4600
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4 86.4
Compression ratio 10.3 9.5 9.5 9.5
RON 95 unleaded 95 unleaded 91 95 unleaded
Injection system Motronic M3.8.2 Motronic M3.8.2 Motronic M3.8.2 Motronic ME7.5
Ignition system Motronic M3.8.2 Motronic M3.8.2 Motronic M3.8.2 Motronic ME7.5
Emissions fulfil D3 standard, EU D3 standard, EU ECE LEV1)
2 2, TLEV 1)
Knock control yes yes yes yes

Self-diagnosis yes yes yes yes
Lambda control yes yes yes yes
Catalytic converter yes yes no yes
Exhaust gas recirculation no no no no
Turbocharging/supercharging no yes no yes
1. Technical data 1
Engine codes ADR AEB AFY ATW

Variable intake manifold yes no yes no
Camshaft timing control yes no yes no
1) USA/Canada only
Engine codes ANB APT APU ARG

Manufactured 01.99 ► 09.00 01.99 ► 09.00 01.99 ► 09.00 01.99 ► 09.00
Capacity l
1.8 1.8 1.8 1.8
Output kW at rpm
110/5700 92/5800 110/5700 92/5800
Torque Nm at rpm
210/ 173/ 210/ 173/
1750...4600 3950 1750...4600 3950
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4 86.4
Compression ratio 9.5 10.3 9.5 10.3
RON 95 unleaded 95 unleaded 95 unleaded 95 unleaded
Injection system Motronic ME7.5 Motronic ME7.1 Motronic ME7.5 Motronic ME7.1
Ignition system Motronic ME7.5 Motronic ME7.1 Motronic ME7.5 Motronic ME7.1
Emissions fulfil D4 standard MVEG 2 MVEG 2 D3 standard
EPC system yes yes yes yes
Knock control yes yes yes yes
Self-diagnosis yes yes yes yes
Lambda control yes yes yes yes
Exhaust gas recirculation no no no no
Secondary air system yes no no yes2)
Turbocharging/supercharging yes no yes no
Variable intake manifold no yes no yes
Volkswagen Technical Site: https://vwts.ru
2) Only vehicles with automatic gearbox
2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1 Removing and installing engine
Special tools and workshop

equipment required
♦ Gearbox support - 3147-
♦ Hooks - 10 - 222 A /2-
♦ Lifting tackle - 2024 A-
♦ Support bracket - 10 - 222
A- with rack - 10 - 222 A /1-
♦ Support clamp - VW 313-
♦ Engine and gearbox sup‐
port - VW 540-
1. Removing and installing engine 3

♦ Drip tray - V.A.G 1306-

♦ Torque wrench - V.A.G
1331-
1332-
♦ Spring-type clip pliers -
VAS 5024A-
♦ Workshop hoist - V.A.G
1202-
♦ Grease - G 000 100- (vehi‐
cles with manual gearbox)
♦ Cable ties
Special tools and workshop equipment required

♦ Engine and gearbox jack - V.A.G 1383 A-
4 Rep. gr.10 - Removing and installing engine

♦ Mounting - T10062-
1.1 Notes on removing

– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– The engine is removed forwards without gearbox.
– With ignition switched off, disconnect earth strap from battery.
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Remove noise insulation. ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
tion .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper; Removing and installing front bumper .
– Drain coolant ⇒ page 87 .
– Unbolt cooling system expansion tank and lay to side.

– Unbolt power-assisted steering hydraulic oil cooling pipe -ar‐

rows- and lay free. Do not open hydraulic oil circuit.
– Remove lock carrier with attachments ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - front; Removing and
installing lock carrier .
Vehicles with turbocharger
– Remove connecting pipes between turbocharger/charge air
cooler, turbocharger/air filter and charge air cooler/throttle
valve control module.
Vehicles with secondary air system
– Remove connecting hoses between secondary air pump/com‐
bination valve and secondary air pump/air filter.
Continuation for all vehicles
– Remove poly V-belt. ⇒ page 20
– Remove power assisted steering vane pump with compact
bracket and lay to side; hoses remain connected ⇒ Running
gear; Rep. gr. 48 ; Assembly overview: Vane pump, reservoir,
hydraulic lines; Removing and installing vane pump; Vehicles
with 4-cylinder engine .
Vehicles with air conditioner
– Observe additional notes and assembly work. ⇒ page 9
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter
– Remove front exhaust pipe from exhaust manifold.
– Remove front exhaust pipe from catalytic converter.
– Remove catalytic converter from turbocharger.
Vehicles without EPC system

– Disconnect throttle cable at throttle valve control module cable

disc and support bracket -arrows- (do not remove locating clip
on support bracket).
– Remove air filter.
– Disconnect fuel supply and fuel return lines at fuel rail.
WARNING
Fuel supply lines are under pressure! Before loosening hose

connections, wrap a cloth around the connection. Then release
pressure by carefully pulling hose off connection.
– Pull all coolant hoses off engine.

– Remove connecting, vacuum and intake hoses from engine
and turbocharger.
– Pull off/disconnect all electrical connections as necessary
from engine and lay free.
– Remove upper engine/gearbox securing bolts.
– Remove lower securing nuts for left and right engine mount‐
ings.
Vehicles with automatic gearbox
– Separate torque converter from drive plate (3 securing nuts).
Note
After removing the engine, secure the torque converter against

“falling out”.
– To be able to remove lower engine/gearbox securing bolts, lift

engine and gearbox slightly with support - T10062- and engine
and gearbox jack - V.A.G 1383 A- .
– Remove lower engine/gearbox securing bolts.

– Fit support bracket - 10 - 222 A- with hooks - 10 - 222 A /2- as

shown.
– Attach gearbox support - 3147- to the gearbox bell housing
bolt hole (shown in illustration with engine removed).
– Attach lifting tackle - 2024 A- as follows and lift slightly with

workshop hoist - V.A.G 1202- :
Belt pulley end: 4th hole in hook rail at position 1
Flywheel end: 3rd hole in hook rail at position 8
WARNING
Use locking pins -arrows- to secure hooks and locating pins.
Note
♦ The positions marked 1…4 on the bar must be towards the

pulley end.
♦ The holes in the hook rails are counted up from the hook.
– Lift engine out forwards.
Note
Guide engine carefully when removing to prevent damage to the

bodywork.
Before carrying out repair work, secure engine on assembly stand

with engine and gearbox support - VW 540- .
1.2 Notes on installing

Install in reverse order. In the process, note the following:
Vehicles with manual gearbox
– Check clutch release bearing for wear and renew if necessary.
– Lightly grease clutch release bearing and splines on input
shaft with G 000 100 grease (do not grease release bearing
guide sleeve).
– Ensure that the intermediate plate is correctly located on en‐
gine.
– Check whether dowel sleeves for centring engine and gearbox
are in cylinder block and install if necessary.
– Renew engine mounting self-locking nuts.
– Rock engine to align engine mountings stress-free.

– Install air conditioner compressor ⇒ Heating, air conditioning;

Rep. gr. 87 ; Removing and installing compressor bracket .
– Install power assisted steering vane pump ⇒ Running gear;
Rep. gr. 48 ; Assembly overview: Vane pump, reservoir, hy‐
draulic lines; Removing and installing vane pump; Vehicles
with 4-cylinder engine .
– Install poly V-belt ⇒ page 20 .
– Install catalytic converter
– Tighten front exhaust pipe to catalytic converter.
– Install connecting pipes between turbocharger/charge air
cooler, turbocharger/air filter and charge air cooler/throttle
valve control module.
– Install lock carrier with attachments. ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Removing and installing
lock carrier .
– Install front exhaust pipe.
– Adjusting accelerator cable ⇒ page 123 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install starter: ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
– Install air filter.
– Replenish coolant ⇒ page 87 .
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 36 .
– Perform work sequence “voltage supply interrupted”. ⇒ Vehi‐
cle diagnostic tester
– Carry out road test and read all fault memories: ⇒ page 163 .
1.2.1 Additional information and assembly

work for vehicles with air conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Remove retaining clamp(s) for refrigerant lines.

– Remove air conditioner compressor ⇒ Heating, air condition‐

ing; Rep. gr. 87 ; Removing and installing compressor brack‐
et .
– Secure air conditioner compressor to body so that the refrig‐
erant lines are not under tension.
1.3 Specified torques

Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Deviations
Front exhaust pipe with catalytic converter to 30 Nm
exhaust manifold
Catalytic converter to turbocharger3) 25 Nm
Front exhaust pipe to catalytic converter3) 25 Nm
Starter to gearbox 65 Nm
3) Engines with turbocharger
1.3.1 Assembly overview - front engine mounting

1 - Cross tube
❑ With torque reaction
support
2 - Stop buffer
3 - 30 Nm
4 - 25 Nm
5 - Connecting piece
6 - 45 Nm
7 - Bracket
8 - Connecting piece
9 - 45 Nm
10 - 25 Nm
11 - Stop
❑ Allow to move onto stop
buffer under its own
weight and tighten se‐
curing bolts.
12 - 30 Nm

13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦ If large quantities of swarf or metal particles (caused, for ex‐

ample, by partial seizure of the crankshaft or conrod bearings)
are found in the engine oil when performing repairs, clean the
oil passages thoroughly and renew the oil cooler in order to
prevent subsequent damage.
♦ A new toothed belt tensioner has been gradually introduced
from model year 98. The old toothed belt tensioner has been
discontinued.
12 Rep. gr.13 - Crankshaft group

1. Dismantling and assembling engine 13

1.1 Part I - Assembly overview
1 - 25 Nm
2 - Tensioning element for poly
V-belt
❑ Swivel with open-end
spanner to slacken poly
V-belt ⇒ page 20 .
3 - Belt pulley
❑ For viscous fan cou‐
pling.
4 - Belt pulley
❑ For power-assisted
steering vane pump.
5 - V-belt
❑ Removing and installing
⇒ page 94
6 - Belt pulley
❑ V-belt version
7 - 25 Nm
8 - Belt pulley
❑ For coolant pump.
❑ V-belt version
9 - 25 Nm
10 - Belt pulley and vibration
damper
❑ Can only be installed in
one position, holes are
offset.
11 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Removing and installing ⇒ page 20

1.2 Part II - Assembly overview
1 - Cylinder block
sealing flanges and fly‐
wheel/drive plate
⇒ page 21
crankshaft
⇒ page 26 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 30 .
2 - Woodruff key
❑ Check for secure seat‐
ing.
3 - Support
❑ Only engine codes:
AEB, ANB, ATW and
APU
❑ Between turbocharger
and cylinder block
4 - 30 Nm
5 - O-ring
❑ Renew if damaged.
6 - Knock sensor 1 - G61-
7 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
9 - Drive gear
❑ For oil pump.
10 - Cover cap
❑ With play compensation
11 - 25 Nm
12 - Clamp
13 - Gasket
❑ Renew.
14 - Oil filter bracket
15 - 25 Nm
16 - Seal
❑ Renew.
17 - 25 Nm
18 - Crankcase breather
19 - Oil cooler
❑ Coat contact area to oil filter bracket, outside the seal, with AMV 188 100 02
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 12 .

20 - 25 Nm
21 - Oil filter
❑ Loosen with strap wrench.
❑ Tighten by hand.
❑ Observe installation instructions on oil filter.
22 - 10 Nm
23 - Engine speed sender - G28-
24 - 30 Nm
25 - Left engine bracket
26 - 25 Nm
27 - Support
❑ Between compact bracket and cylinder block
28 - 30 Nm
29 - Compact bracket
❑ For coolant pump, thermostat, poly V-belt tensioning roller, alternator and power steering vane pump
❑ Removing and installing viscous fan mounting bush ⇒ page 92 .
30 - Hammer head bolt
31 - Coolant pump
❑ Dismantling and assembling ⇒ page 84 .
32 - Oil sump
❑ Clean sealing surface before fitting.
33 - 20 Nm
❑ Remove and install both rear bolts to gearbox using T-bar and socket, 10 mm - 3185-
34 - Gasket
❑ Renew.
❑ Before fitting coat transition points sealing flange/cylinder block with sealant - D 454 300 A2- .
35 - Coolant hose
❑ Only engine codes: AEB, ANB, ATW and APU
❑ Between turbocharger and cylinder block
36 - Right engine bracket
37 - 30 Nm
1.3 Part lll: assembly overview - old toothed

belt tensioner
Note
When changing the toothed belt, remove old toothed belt ten‐
sioner and install new toothed belt tensioner.

1 - 10 Nm
2 - 10 Nm
3 - 10 Nm
4 - 20 Nm
5 - Toothed belt guard upper
part
6 - Toothed belt
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 38 .
7 - 25 Nm
8 - 10 Nm
9 - Washer
10 - 65 Nm
❑ Use counterhold - 3036-
to loosen and tighten.
11 - Washer
12 - Camshaft pulley
❑ Note installation posi‐
tion: the narrow web of
camshaft pulley faces
outwards and the TDC
marking is visible.
13 - Belt tensioner
14 - 25 Nm
15 - Rear toothed belt guard
16 - 20 Nm
17 - Intermediate shaft sprocket
18 - Washer
19 - Crankshaft toothed belt pulley
20 - 90 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil before installing.
❑ Use counterhold for toothed belt pulley - 3099- to loosen and tighten
❑ Turning further can be done in several stages.
21 - 80 Nm
22 - Toothed belt tensioner
23 - 10 Nm
24 - Idler roller
25 - 25 Nm
26 - Toothed belt guard lower part

1.4 Part lV: assembly overview - new toothed belt tensioner
1 - 10 Nm
2 - 10 Nm
3 - 10 Nm
4 - 20 Nm
5 - Toothed belt guard lower
part
6 - Toothed belt guard upper
part
7 - Toothed belt
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 38 .
8 - 40 Nm
9 - Washer
10 - Lever
11 - 65 Nm
❑ Use counterhold - 3036-
to loosen and tighten.
tion: the narrow web of
camshaft pulley faces
outwards and the TDC
marking is visible.
13 - Belt tensioner
14 - Bearing sleeve
❑ For tensioning roller.
15 - Rear toothed belt guard
16 - 20 Nm
17 - Intermediate shaft sprocket
18 - Washer
19 - Crankshaft toothed belt pulley
20 - 90 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil before installing.
❑ Use counterhold for toothed belt pulley - 3099- to loosen and tighten
❑ Turning further can be done in several stages.

21 - 80 Nm
22 - Toothed belt tensioner
23 - 10 Nm
24 - Idler roller
25 - 25 Nm
26 - 10 Nm
1.5 Removing and installing air conditioner

compressor poly V-belt
♦ Torque wrench - V.A.G 1331-
Note
Before removing the poly V-belt mark the direction of rotation.

When installing belt ensure it is correctly seated in pulleys.
1.5.1 Removing
– Remove poly V-belt ⇒ page 20 .
– Loosen air conditioner compressor poly V-belt tensioner se‐
curing bolts and remove poly V-belt.
1.5.2 Installing
– Fit air conditioner compressor poly V-belt.

– Fit torque wrench and tighten V-belt tensioner to 25 Nm. Hold

torque wrench in this position and tighten bolts -A- to 20 Nm.
1.6 Removing and installing poly V-belt

♦ Locking pin - 3204-
– Bring lock carrier into service position ⇒ General body repairs;

Rep. gr. 50 ; Body - front; Lock carrier service position .
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt swivel tensioner in direction of arrow.
– Lock tensioner with locking pin - 3204- .
– Remove or fit poly V-belt.
Note
When installing poly V-belt, ensure that belt seats correctly in

pulleys.
– Start engine and check that belt runs properly.

2 Removing and installing sealing

flanges and flywheel or drive plate
Note
Repairing clutch ⇒ 5-speed manual gearbox 012/01W; Rep. gr.

30 ; Repairing clutch .
Assembly overview - sealing flange ⇒ page 21 .

Renewing crankshaft oil seal - belt pulley end ⇒ page 22 .
Removing and installing drive plate ⇒ page 24 .
2.1 Assembly overview - sealing flanges and flywheel
1 - Seal
❑ To remove, remove
sealing flange
❑ Install using fitting tool -
10 - 203-
❑ Lightly oil sealing lip of
oil seal
2 - Woodruff key
ing.
3 - 25 Nm
4 - Sealing flange
5 - Gasket
❑ Renew.
6 - Cylinder block
crankshaft
⇒ page 26 .
bling pistons and con‐
rods ⇒ page 30 .
7 - 60 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
8 - Two part flywheel/drive
plate
❑ Remove and install fly‐
wheel using counter‐
hold - 3067-
drive plate
⇒ page 24 .
9 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
2. Removing and installing sealing flanges and flywheel or drive plate 21

10 - 10 Nm
11 - Sealing flange with oil seal
❑ Renew complete only.
❑ Use guide sleeve supplied when fitting.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Do not remove guide sleeve until sealing flange has been slid onto crankshaft journal
12 - Seal
❑ Renewing ⇒ page 22 .
13 - Intermediate shaft
❑ Axial clearance max. 0.25 mm
14 - O-ring
Renew if damaged.
15 - Intermediate shaft sealing flange
2.2 Renewing crankshaft oil seal - pulley end

equipment required
♦ Toothed belt pulley coun‐
terhold - 3099-
♦ Oil seal extractor - 2085-
♦ Puller - T10132-
1331-
1332-

2.2.1 Removing
– Remove poly V-belt and tensioning element ⇒ page 19 .
– Remove toothed belt ⇒ page 38 .
– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3099- .
– To guide seal extractor, screw socket head bolt -T10132/3-

into crankshaft onto stop.
– Screw inner part of oil seal extractor - 2085- two turns (approx.
3 mm) out of outer part and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and while exerting firm pressure screw it into oil seal as
far as possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Remove socket head bolt -T10132/3- from crankshaft.
2.2.2 Installing
– Remove oil residue from crankshaft journal using clean cloth.
– Fit guide sleeve -T10132/1- onto crankshaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.

– Press seal fully in using -T10132/2- and bolt -T10132/3- .

– Install crankshaft toothed belt pulley and lock with counterhold
for toothed belt pulley - 3099- .
– Tighten new securing bolts to 90 Nm and then turn 90° (1/4
turn) further (turning further can be done in several stages).
Installing toothed belt and adjusting valve timing ⇒ page 38 .
– Install poly V-belt and tensioning element ⇒ page 20 .
2.3 Removing and installing drive plate

♦ Clutch counterhold - VW 558-
♦ Hexagon bolt M8×45 and two M10 hexagon nuts

♦ Depth gauge
2.3.1 Loosening and tightening drive plate

– Secure clutch counterhold - VW 558- to drive plate with hex‐
agon bolt M8x45. Insert two M10 hexagon nuts between coun‐
terhold and drive plate.
Installation position of counterhold: -A- to loosen, -B- to tighten.

2.3.2 Installing drive plate

– Fit drive plate using packing plate with recesses -1-.
– Fit new bolts and tighten to 30 Nm.
– Check dimension -a- at three points and calculate average.

Specification: 26…28 mm
If specification is not attained:
– Remove drive plate again and fit shim -2-. Tighten bolts to 30
Nm again.
– Tighten bolts to 60 Nm and turn 90° (1/4 turn) further (turning
further can be done in several stages).

3 Removing and installing crankshaft
Note
Before carrying out repair work, secure engine on assembly stand

with engine and gearbox support - VW 540- .
Assembly overview - crankshaft ⇒ page 26 .

Identification of upper crankshaft bearing ⇒ page 27
Pulling needle bearing out of and driving into crankshaft
⇒ page 28
Crankshaft dimensions ⇒ page 29 .
3.1 Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5

❑ Classification for order‐
ing spare parts
⇒ page 27 .
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
2 - 65 Nm + 90 ° (1/4 turn fur‐
ther
❑ Renew.
❑ Threaded along com‐
plete length.
❑ Tighten to 65 Nm when
measuring crankshaft
radial clearance.
3 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
4 - Bearing shell 3
❑ Classification for order‐
ing spare parts
⇒ page 27 .
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange used bearing shells (mark).
5 - Thrust washer
❑ For bearing cap, bearing 3.
❑ Note fixing arrangement.

6 - Sender wheel
❑ Renew.
❑ For engine speed sender - G28- .
❑ Can only be installed in one position, holes are offset.
7 - 10 Nm + 1/4 turn (90°) further
❑ Renew.
8 - Needle bearing
❑ Pulling out and driving in ⇒ page 28 .
9 - Crankshaft
❑ Axial clearance new: 0.07…0.23 mm, wear limit: 0.30 mm
❑ Check radial clearance with Plastigage new: 0.02…0.06 mm, wear limit: 0.15 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 29 .
Identification of crankshaft upper bearing

Upper bearing shells of the proper thickness are allocated to the
cylinder block in the factory. Coloured dots are used to identify
the thickness of the bearing shells.
Which bearing thickness is to be used at each position is marked
by letters on the lower sealing surface of the cylinder block.
Colour coding
Letter on cylinder Bearing colour
block
B = Blue
R = Red
G = Yellow
Note
♦ Arrow points in direction of travel (forwards).

♦ If the colour marks are not yet stamped in or are no longer
legible, use medium (red) bearing shells.
♦ Lower bearing shells with colour mark “yellow” are always
supplied as spare parts.
3. Removing and installing crankshaft 27

3.2 Pulling needle roller bearing out of and driving into crankshaft

equipment required
♦ Kukko - 21/2- and Kukko -
22/1-
♦ Centring mandrel - 3176-
♦ or drift - VW 207 C-
Note
When installing an engine in a vehicle with a manual gearbox,

always check if the needle bearing is installed in rear of crank‐
shaft, install if necessary.

Removing
– Pull needle roller bearing out using puller -A-, e.g. Kukko -
21/2- and Kukko - 22/1- .
Installing
– Drive in with drift - VW 207 C- or centring mandrel - 3176- .

♦ The lettering on the needle bearing must be visible when in‐
stalled.
Installation depth of needle bearing

♦ Dimension -a- = 1.5 … 1.8 mm.
3.3 Crankshaft dimensions

(Dimensions in mm)
Honing dimen‐ Crankshaft bearing Conrod
sion journal ∅ journal ∅
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042
Stage I 53.75 -0.022 47.55 -0.022
-0.042 -0.042
Stage II 53.50 -0.022 47.30 -0.022
-0.042 -0.042
Stage III 53.25 -0.022 47.05 -0.022
-0.042 -0.042
3. Removing and installing crankshaft 29

4 Dismantling and assembling pistons

and conrods
Assembly overview - pistons and conrods ⇒ page 30
Checking pistons, piston rings and cylinder bores ⇒ page 31 .
Piston and cylinder dimensions ⇒ page 32 .
4.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 31 .
❑ Checking ring-to-groove
clearance ⇒ page 31 .
❑ 2 or 3 part oil scraper
ring, mixed installation
permissible
2 - Piston
❑ Checking ⇒ page 32 .
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring
clamp.
3 - Conrod
❑ Renew as set only.
❑ Mark cylinder number
-B-.
❑ Installation position:
markings -A- face to‐
wards belt pulley end.
4 - Conrod bearing cap
tion.
5 - 30 Nm + 1/4 turn (90°) fur‐
ther
❑ Oil threads and contact surface.
❑ To measure radial clearance, tighten to 30 Nm but not further.
6 - Pressure relief valve, 27 Nm
❑ Opening pressure: 2.5…3.2 bar.
7 - Oil spray jet
❑ For piston cooling.
8 - Bearing shell
❑ Note installation position.
❑ Do not interchange used bearing shells.

❑ Ensure secure seating in retaining lugs
❑ Axial clearance new: 0.05…0.31 mm, wear limit: 0.37 mm
❑ Check radial clearance using Plastigage; new: 0.01…0.06 mm; wear limit: 0.12 mm. Do not rotate crank‐
shaft when checking radial clearance.
9 - Cylinder block
❑ Checking cylinder bores ⇒ page 32 .
❑ Piston and cylinder dimensions ⇒ page 32 .
10 - Conrod bolt
11 - Circlip
12 - Piston pin
❑ If difficult to remove, heat piston to 60 °C.
❑ Remove and install with VW 222a
4.2 Checking pistons, piston rings and cyl‐

inder bores
♦ Feeler gauges
♦ Internal dial test indicator 50…100 mm
♦ External micrometer 75…100 mm
Checking piston ring gap
– Insert ring at right angles from above and push down into cyl‐
inder approx. 15 mm from bottom end of cylinder.
Piston ring Ring gap
New Wear limit
Compression rings mm 0.20...0.40 0.8
Oil scraper ring mm 0.25...0.50 0.8
Checking ring-to-groove clearance

Clean annular groove before check.
Piston ring Clearance
New Wear limit
Compression rings mm 0.06...0.09 0.20
Oil scraper ring mm 0.03...0.06 0.15
4. Dismantling and assembling pistons and conrods 31

Checking piston
Measure piston approx. 10 mm from lower edge of skirt, at 90° to
piston pin axis.
Deviation from nominal dimension max. 0.04 mm
Checking cylinder bores

♦ Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
♦ Use cylinder gauge 50…100 mm
♦ Deviation from nominal dimension max. 0.08 mm
Note
Cylinder bores must not be measured when cylinder block is

mounted on a repair stand with engine and gearbox support - VW
540- , as measurements may then be incorrect.
4.2.1 Piston and cylinder dimensions

Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimension mm 80.9654) 81.01
Stage I mm 81.4654) 81.51
4) Dimension without graphite coating (thickness 0.02 mm). The graphite coating
wears away.

15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
Assembly overview - cylinder head ⇒ page 33 .

Checking cylinder head for distortion ⇒ page 35
Reworking cylinder head sealing surface ⇒ page 35 .
Removing and installing cylinder head ⇒ page 35 .
Removing, installing and tensioning toothed belt ⇒ page 38 .
Checking compression ⇒ page 46 .
1.1 Assembly overview - cylinder head
1. Cylinder head 33
1 - Cover cap
❑ Renew seal if damaged.
2 - 10 Nm
3 - Cylinder head cover
4 - Cylinder head cover gasket
❑ Before fitting coat tran‐
sition points between
bearing cap and cylin‐
der head with sealant -
D 454 300 A2- .
❑ Coat half-moon area
with sealant - D 454 300
A2-
5 - oil deflector
tion: Above inlet cam‐
shaft between No. 1 and
No. 2 cylinders
6 - Cylinder head
❑ Check for distortion
⇒ page 35 .
❑ Reworking sealing sur‐
face ⇒ page 35 .
⇒ page 35
❑ After renewing, renew
entire coolant.
7 - Intake manifold gasket
❑ Renew.
8 - Cylinder head gasket
❑ Renew.
❑ Metal gasket.
❑ After renewing, renew entire coolant.
❑ Note installation position: identification: part No. must be readable from inlet side
9 - 25 Nm
For tensioning roller.
10 - Exhaust manifold gasket

❑ Renew.
11 - Cylinder head bolt
❑ Renew.
❑ Sequence when loosening and tightening ⇒ page 35 .
❑ Remove and install polydrive cylinder head bolts using polydrive key - 3452- or special wrench, long
reach - T10070-
12 - Heat shield
13 - 25 Nm
14 - 10 Nm
34 Rep. gr.15 - Cylinder head, valve gear

Checking cylinder head for distortion

Max. permissible distortion: 0.1 mm.
Reworking cylinder head sealing surface

The dimension for reworking is measured through the holes for
the cylinder head bolts a = minimum 139.2 mm.
1.2 Removing and installing cylinder head
1. Cylinder head 35

equipment required
1332-
VAS 5024 A-
♦ Guide pins - 3450/2A-
♦ Removal tool - 3450/3-
Engines with polydrive cylinder head bolts:

♦ Polydrive key - 3452- or special wrench, long-reach - T10070-
• The engine must be no more than warm to touch.
• The pistons must not be positioned at TDC.
1.2.1 Removing
theft coding.
– With the ignition switched off, disconnect battery earth strap.

– Separate fuel supply and return lines at connection on fuel rail.

The fuel system is pressurised. Therefore, wrap a cloth around
connection before pulling hose off.
– Seal lines so that fuel system is not contaminated by dirt.
– Remove front exhaust pipe or catalytic converter from exhaust
manifold.
– Remove upper toothed belt guard.
– Release tensioner and remove toothed belt from camshaft
pulley.
– Remove cylinder head cover.
– Loosen cylinder head bolts in sequence given and then re‐
move completely.
Note
For polydrive cylinder head bolts use polydrive key - 3452- or

special wrench, long reach - T10070- .
– Carefully remove cylinder head.
1.2.2 Installing
Note
♦ There must be no oil or coolant in the cylinder head bolt pock‐

ets in the cylinder head.
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.
– Set No. 1 cylinder piston to top dead centre and then turn
crankshaft back slightly.
1. Cylinder head 37
– To centralize screw guide pins from 3070 into holes for cylin‐
der head bolts 8 and 10.
– Fit new cylinder head gasket. Inscription (Part No.) must be
readable.
– Fit cylinder head, screw in 8 remaining cylinder head bolts and
tighten by hand.
– Remove guide pins via bolt holes with removal tool from 3070.
To do this, turn removal tool anticlockwise, until the pins are
free.
– Now insert last two cylinder head bolts and tighten them hand-
tight also.
– Tighten cylinder head bolts in tightening sequence as follows:
Note
For polydrive cylinder head bolts use polydrive key - 3452- or

special wrench, long reach - T10070- .
– Pre-tighten all bolts to 40 Nm.

– Then tighten all bolts to 60 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90°) further.
Further assembly is basically the reverse of the dismantling se‐

quence.
Filling with new coolant ⇒ page 87 .
1.3 Removing, installing and tensioning toothed belt


equipment required
♦ Matra pin-wrench - V/159-
1331-
♦ Door hinge alignment tool -
3114-
Vehicles with old toothed belt tensioner ⇒ page 40 .
1. Cylinder head 39
Vehicles with new toothed belt tensioner ⇒ page 43 .
1.3.1 Removing toothed belt, vehicles with old

toothed belt tensioner
Note
When changing the toothed belt, remove old toothed belt ten‐
sioner and install new toothed belt tensioner.

– Remove poly V-belt tensioning element.
– Turn crankshaft to TDC No. 1 cylinder.

– Mark direction of rotation of toothed belt.
– Remove vibration damper/belt pulley.

– Remove lower toothed belt guard.

– Loosen toothed belt tensioner -arrow- and remove toothed

belt.
– Turn crankshaft back slightly.
1.3.2 Installing toothed belt complete

If toothed belt has only been removed from camshaft pulley
⇒ page 42
Note
When camshaft is turned, crankshaft must not be at TDC. Danger

of damage to valves and piston crowns.
– Align mark on camshaft toothed belt pulley with mark on cyl‐

inder head cover.
– Fit toothed belt on crankshaft pulley (note direction of rotation).
– Secure vibration damper/belt pulley with one bolt (note fixing
arrangement).

– Fit toothed belt to tensioning roller and camshaft pulley.
1. Cylinder head 41
– Tension toothed belt, to do this turn tensioner -A- clockwise

using pin wrench -B- (e.g. Matra V159) until the piston -1- has
moved fully out and the tensioner piston -2- has lifted approx.
1 mm.
– Tighten tensioning roller securing nut -3-. Specified torque
setting: 25 Nm
– Turn crankshaft two full turns and check whether camshaft and
crankshaft marks align with their reference points.
– Check whether area -A- aligns with upper edge of piston or

that dimension -D-: is 25…29 mm.
Note
♦ Area -A-: adjustment OK.

♦ Area -B-: wear range
♦ Area -C-: check belt drive and tensioning roller for wear/adjust
toothed belt tension.
– Install upper toothed belt guard.

– Install poly V-belt tensioner. Specified torque setting: 25 Nm
1.3.3 Installing toothed belt

• Toothed belt has only been removed from camshaft pulley
If toothed belt has been completely removed ⇒ page 41
inder head cover.
– Fit toothed belt onto camshaft pulley.

– Tension toothed belt, to do this turn tensioner -A- clockwise

using pin wrench -B- (e.g. Matra V159) until the piston -1- has
moved fully out and the tensioner piston -2- has lifted approx.
1 mm.
– Tighten tensioning roller securing nut -3-. Specified torque
setting: 25 Nm
– Check whether area -A- aligns with upper edge of piston or

that dimension -D-: is 25…29 mm.
Note
♦ Area -A-: adjustment OK.

♦ Area -B-: wear range
♦ Area -C-: check belt drive and tensioning roller for wear/adjust
toothed belt tension.

1.3.4 Removing toothed belt, vehicles with

new toothed belt tensioner
Note
The toothed belt tensioning element is oil damped and can only
be compressed slowly with constant pressure. When doing this
the temperature of the tensioning element must be at least 30 °
C, otherwise it cannot be compressed.
• Coolant temperature at least 30 °C

– Remove poly V-belt tensioning element.

– Mark direction of rotation of toothed belt.
1. Cylinder head 43

– Remove lower toothed belt guard.
– Turn toothed belt tensioning roller -1- in direction of arrow us‐

ing allen key (8 mm) and extension (e.g. -V.A.G 3114- ) until
the drillings in piston and tensioning element housing align and
a locking pin (e.g. 1.5 mm ∅ split-pin) can be pushed into drill‐
ing -2-.
Note
Bolt -3- must not be loosened.
– Remove toothed belt.

1.3.5 Installing toothed belt complete

If toothed belt has only been removed from camshaft pulley
⇒ page 45
Note
When camshaft is turned, crankshaft must not be at TDC. Danger

of damage to valves and piston crowns.

inder head cover.
– Fit toothed belt on crankshaft pulley (note direction of rotation).
– Secure vibration damper/belt pulley with one bolt (note fixing
arrangement).


– Fit toothed belt to tensioning roller and camshaft pulley.
– Tension toothed belt, to do this turn toothed belt tensioner

-1- in direction of arrow using allen key (8 mm) and extension
(e.g. -V.A.G 3114- ) until the locking pin can be pulled out.
Note
– Turn tensioning roller opposite to direction of arrow, until pis‐

ton has moved fully out (use mirror).
– Install toothed belt guard lower part.
– Install vibration damper/belt pulley, torque setting: 25 Nm
1.3.6 Installing toothed belt

• Toothed belt has only been removed from camshaft pulley
If toothed belt has been completely removed ⇒ page 44
inder head cover.
– Fit toothed belt onto camshaft pulley.
1. Cylinder head 45
– Tension toothed belt, to do this turn toothed belt tensioner

-1- in direction of arrow using allen key (8 mm) and extension
(e.g. -V.A.G 3114- ) until the locking pin can be pulled out.
Note
– Turn tensioning roller opposite to direction of arrow, until pis‐

ton has moved fully out (use mirror).
1.4 Checking compression

equipment required
♦ Spark plug socket and ex‐
tension - 3122 B-
1331-
♦ Compression tester - V.A.G
1763-
• Engine oil temperature must be at least 30°C.

1.4.1 Procedure
– Pull connector(s) off ignition coils.
– Remove ignition coils.
Engines without turbocharger:
– Pull spark plug connectors off No.1 and No. 2 cylinders.
– Remove spark plugs using spark plug socket and extension -
3122 B- .
– Have a second mechanic fully depress the accelerator pedal.
– Check compression using compression tester - V.A.G 1763- .
Note
Using compression tester ⇒ operating instructions .
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
Engine codes New Wear limit
ADR, APT, ARG, 9…14 bar 7.5 bar.
AFY
AEB, ANB, APU, 10…13 bar 7.0 bar.
ATW
Permissible difference between all cylinders: max. 3 bar
– Install ignition coils and tighten to 10 Nm.
– Read fault memory: ⇒ page 163
1. Cylinder head 47
2 Repairing valve gear

Assembly overview - valve gear ⇒ page 48 .
Checking camshaft axial clearance ⇒ page 50 .
Reworking valve seats ⇒ page 51 .
Valve dimensions ⇒ page 52 .
Renewing camshaft oil seal ⇒ page 52 .
Checking hydraulic bucket tappets ⇒ page 57 .
Removing and installing camshafts ⇒ page 58 .
Checking valve guides ⇒ page 62 .
Renewing valve stem seals ⇒ page 63 .
2.1 Assembly overview - valve gear
1 - 10 Nm
2 - Inlet camshaft
❑ Checking axial clear‐
ance ⇒ page 50 .
⇒ page 58
❑ Check radial clearance
with Plastigage, wear
limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
3 - Drive chain
❑ Before removing, mark
direction of rotation (in‐
stallation position)
⇒ page 58 .
4 - 10 Nm
5 - O-ring
❑ Renew.
6 - Camshaft control valve 1 -
N205-
ADR, APT, AFY and
ARG
7 - 3 Nm
ADR, APT, AFY and
ARG
8 - Camshaft adjuster
ADR, APT, AFY and
ARG
❑ For engine codes AEB,

ANB, ATW and APU:

chain tensioner
❑ Before removing lock with 3366 ⇒ page 58
9 - Gasket
❑ Bonded rubber seal
❑ Renew.
10 - Cylinder head
❑ Reworking valve seat ⇒ page 51 .
❑ Reworking sealing surface ⇒ page 35 .
❑ Sealing transitions ⇒ page 62 and ⇒ page 62
11 - Valves
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 52 .
12 - Seal
❑ For inlet camshaft.
13 - Screen
❑ For Hall sender.
❑ When installing note fixing arrangement.
14 - Washer
❑ Conical.
15 - 25 Nm
16 - Hall sender
17 - 10 Nm
18 - 65 Nm
❑ Use counterhold - 3036- to loosen and tighten.
❑ Note installation position: the narrow web of camshaft toothed belt pulley faces outwards and the TDC
No. 1 cylinder marking is visible.
20 - Seal
❑ For exhaust camshaft.
21 - Valve guide
22 - Valve stem seal
23 - Valve spring
❑ Removing and installing, with cylinder head removed: installed with 3362 ⇒ page 63
24 - Valve spring plate
Disregard marks on valve spring plate
2. Repairing valve gear 49

25 - Cotters
26 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
❑ Set down with contact surface facing downwards.
❑ Before installing, check camshaft axial clearance ⇒ page 50 .
❑ Oil contact surface.
27 - Inlet camshaft bearing cap
❑ Installation position and installation sequence ⇒ page 58
28 - Double bearing cap
❑ Coat contact surfaces lightly with sealant - D 454 300 A2- .
29 - Exhaust camshaft bearing cap
❑ Installation position and installation sequence ⇒ page 58
❑ Lightly coat contact surface of outer bearing cap with sealant - D 454 300 A2- .
30 - Exhaust camshaft
❑ Checking axial clearance ⇒ page 50 .
❑ Check radial clearance with Plastigage, wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
2.2 Checking camshaft axial clearance

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
Check with bucket tappets and chain removed and No. 2 and 4
bearing caps fitted.
Wear limit: max. 0.2 mm

2.3 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 62 .
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as fol‐

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

for the calculation.
– Measure distance -a- between end of valve stem and upper

edge of cylinder head -1-.
– Calculate maximum permissible reworking dimension from
measured distance and minimum dimension.
Minimum dimension:
Inlet valves (outer) 34.0 mm
Inlet valve (centre) 33.7 mm
Exhaust valve 34.4 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
Measured distance 34.4 mm
- Minimum dimension 34.0 mm
= max. perm. rework dimension 5) 0.4 mm
5) The max. permissible reworking dimension is shown as dimension “b” in the
illustrations for reworking valve seats.

Reworking inlet valve seat

a = ∅ 26.2 mm
b = Max. permissible reworking dimension6)
c = 1.5…1.8 mm
Z = Lower edge of cylinder head
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
Reworking exhaust valve seat

a = ∅ 29.0 mm
b = Max. permissible reworking dimension6)
c = approx. 1.8 mm
Z = Lower edge of cylinder head
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
6) Calculating max. permissible reworking dimension ⇒ page 51 .
2.3.1 Valve dimensions

Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve
∅a mm 26.9 29.9
∅b mm 5.9 5.9
c mm 104.84...105.34 103.64...104.14
α ∠° 45 45
Note
Care must be taken when disposing of old sodium-cooled exhaust

valves. They must be cut through in the centre of the stem with a
hacksaw. When doing this they must not come into contact with
water. After preparing the valves, throw a maximum of ten into a
bucket of water. Then step away immediately, since a chemical
reaction will occur in which the sodium filling burns. After this
treatment, the valves can be scrapped as normal scrap.
2.4 Renewing camshaft oil seals


equipment required
♦ Oil seal extractor - 2085-
♦ Counterhold - 3036-
♦ Assembly tool - T10071-
1331-
1332-
2.4.1 Removing oil seal on camshaft pulley

Remove oil seal on hall sender ⇒ page 56

– Set camshaft pulley to TDC No. 1 cylinder by turning crank‐

shaft. Marking on camshaft toothed belt pulley must align with
mark on cylinder head cover.
pulley.
– Remove camshaft sprocket. When loosening camshaft pulley,

counterhold with 3036.
– Remove Woodruff key from camshaft.
– To guide oil seal extractor, screw securing bolt for camshaft

pulley -arrow- into camshaft by hand to stop.
– Screw inner part of oil seal extractor 2085 two turns (approx.
3 mm) out of outer part and lock using knurled screw.

far as possible.
– Loosen knurled screw and turn inner part against camshaft

2.4.2 Installing oil seal on camshaft pulley
Note
Introduction of PTFE oil seals (identifying features: no circular

spring, wider sealing lip). The sealing lip of this oil seal must not
be oiled or greased.
– Remove oil residue from camshaft journal using a clean rag.

– Fit guide sleeve -T10071/1- onto camshaft journal.
– Slide oil seal over guide sleeve onto camshaft journal.
– Remove guide sleeve.
– Press oil seal in onto stop with press sleeve -T10071/3- . To

do this use bolt -T10071/4- .
– Install camshaft toothed belt pulley. When tightening camshaft

pulley bolt, hold with counterhold 3036. Specified torque set‐
ting: 65 Nm
quence.

2.4.3 Removing oil seal on hall sender

– Pull connector off hall sender -arrow-.
– Remove Hall sender housing.
– Remove Hall sender washer and screen.
– To guide seal extractor, screw bolt - 2085/1- fully into camshaft

by hand.
– Screw inner part of oil seal extractor - 2085- two turns (approx.
3 mm) out of outer part and lock using knurled screw.

far as possible.
– Loosen knurled screw and turn inner part against camshaft
2.4.4 Installing oil seal on hall sender
Note
Introduction of PTFE oil seals (identifying features: no circular

spring, wider sealing lip). The sealing lip of this oil seal must not
be oiled or greased.

– Fit guide sleeve -T10071/5- onto camshaft journal.

– Slide oil seal over guide sleeve onto camshaft journal.
– Remove guide sleeve.
– Press oil seal in onto stop with press sleeve -T10071/3- . To

do this use bolt M8x60 -1-.
– Insert Hall sender screen into notch in inlet camshaft.
– Install washer (cone facing outwards) and tighten securing bolt
to 25 Nm.
– Install Hall sender housing and tighten to 10 Nm.
– Attach Hall sender connector.
2.5 Checking hydraulic bucket tappets

♦ Feeler gauges
♦ Wooden/plastic wedge
Note
♦ Renew defective bucket tappets complete (cannot be adjusted

or repaired).
♦ Irregular valve noise during starting is normal.
Test procedure
– Start engine and run until radiator fan has switched on once.
– Increase engine speed to about 2500 rpm for approx. 2 mi‐
nutes.
If hydraulic bucket tappets are still noisy, locate defective tappet
(s) as follows:
– Rotate crankshaft clockwise until cam of tappet to be checked
is pointing upwards.
– Determine play between cam and bucket tappet.
– If play exceeds 0.2 mm, renew bucket tappet. If play is less
than 0.1 mm or there is no play, continue with check as follows:

– Push bucket tappet down lightly with a wooden or plastic

wedge. If when bucket tappet is pushed down, a 0.2 mm feeler
gauge can be pushed between camshaft and bucket tappet,
bucket tappet must be renewed.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el‐
ements must settle (otherwise valves will strike pistons).
2.6 Removing and installing camshafts

(With cylinder head installed)

equipment required
♦ Counterhold - 3036-
♦ Chain tensioner retainer -
3366-
1332-
♦ Sealant - D 454 300 A2-
2.6.1 Removing

– Set camshaft pulley to TDC No. 1 cylinder by turning crank‐

shaft. Marking on camshaft toothed belt pulley must align with
mark on cylinder head cover.
pulley.
– Remove camshaft sprocket. When loosening camshaft pulley
bolt, hold with counterhold - 3036- .
– Remove Woodruff key from camshaft.
– Remove Hall sender housing.
– Remove Hall sender washer and screen.
– Clean drive chain and camshaft chain sprocket in opposite

area of both arrows on bearing caps and mark installation po‐
sition with a coloured mark.
Note
♦ Do not mark chain by way of centre punch, notch or the like.

♦ The distance between both arrows or the coloured marks is
equal to 16 rollers on the drive chain.
– Secure camshaft adjuster or chain tensioner with chain ten‐

sioner retainer - 3366- .
Note
Tightening the chain tensioner retainer excessively can damage

the camshaft adjuster.
– First remove 3rd and 5th bearing caps from inlet and exhaust
camshafts.
– Remove double bearing cap.
– Remove both bearing caps at chain sprockets on inlet and ex‐
haust camshafts.
– Remove camshaft adjuster/chain tensioner securing bolts.
– Remove 2nd and 4th bearing caps from inlet and exhaust
camshaft alternately and diagonally.
– Remove inlet and exhaust camshafts along with camshaft ad‐
juster or chain tensioner and chain tensioner retainer - 3366- .

2.6.2 Installing
Note
♦ When camshafts are installed, cams for No. 1 cylinder must

point upwards.
♦ When installing the bearing caps, ensure that the cap mark‐
ings can be read from the inlet side of the cylinder head.
– Fit drive chain on camshaft chain sprockets as follows:

If old drive chain is to be reused:
– Align coloured marks -arrows-.
When using new drive chain:
• The distance between notches -A- and -B- on the camshafts

must be exactly 16 rollers of the camshaft chain. The illustra‐
tion shows the exact positions of the 1st and 16th rollers on
the chain sprockets where the chain must be fitted.
• Notch -A- has a slight inward offset with respect to chain roller
-1-.
Caution
♦ The stated number of rollers merely provides assistance

for fitting the drive chain onto the camshafts.
♦ Ensure that the arrows on the bearing caps and the notch‐
es on the camshafts align when inserting camshafts (with
drive chain) into cylinder head.
– Renew rubber/metal gasket for camshaft adjuster/chain ten‐

sioner and lightly coat hatched area with sealant - D 454 300
A2- .
– Slide camshaft adjuster or chain tensioner between drive
chain.
– Oil running surfaces of camshafts.
– Place camshafts with drive chain and camshaft adjuster or
chain tensioner in cylinder head.
– Tighten camshaft adjuster or chain tensioner to 10 Nm (re‐
member dowel sleeves).

– Tighten inlet and exhaust camshaft 2nd and 4th bearing caps
alternately and diagonally to 10 Nm (take note of dowel
sleeves).
– Install both bearing caps at inlet and exhaust camshaft chain

sprockets. Check camshafts are positioned correctly and tight‐
en bearing cap to 10 Nm (remember dowel sleeves).
• The two marks on the camshafts must align with the two ar‐
rows on the bearing caps -arrows-.
– Remove retainer for chain tensioner - 3366- .
– Coat hatched area of double bearing cap lightly with sealant -

D 454 300 A2- , install and tighten to 10 Nm (observe dowel
sleeves).
– Install remaining bearing caps and tighten to 10 Nm (remem‐
ber dowel sleeves).
– Install camshaft toothed belt pulley.

• Installation position: The narrow web of the camshaft pulley
faces outwards -arrows- and the TDC marking is visible.

– Check position of camshafts to one another.

• The two marks on the camshafts must align with the two ar‐
rows on the bearing caps -arrows-.
quence.
Installing toothed belt and adjusting valve timing. ⇒ page 38
Note
After installing camshafts wait for approx. 30 minutes before start‐

ing engine. Hydraulic compensation elements must settle (other‐
wise valves will strike pistons).
Sealing transition points between double bearing cap and cylinder

head
– Carefully apply a thin coat of sealant - D 454 300 A2- to both
edges of sealing surfaces between double bearing cap and
cylinder head -arrows- using a small screwdriver.
Sealing transition points between camshaft adjuster and cylinder

head
– Carefully apply a thin coat of sealant - D 454 300 A2- to half-
moon area and both edges of sealing surfaces between cam‐
shaft adjuster and cylinder head -arrows- using a small
screwdriver.
2.7 Checking valve guides


♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: 0.8 mm
2.8 Renewing valve stem seals


equipment required
1331-
1332-
♦ Spark plug socket and ex‐
tension - 3122 B-
♦ Valve stem seal puller -
3364-
♦ Pressure hose - VW 653/3-
♦ Hold down tool for valve
springs - 3362- and press
piece - 3362/1-
♦ Valve stem seal fitting tool -
3365-
(With cylinder head installed)
2.8.1 Removing
– Remove camshafts ⇒ page 58 .
– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that the tappets are
not interchanged.
– Remove spark plugs using spark plug socket and extension -
3122 B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Screw pressure hose - VW 653/3- into spark plug thread.

– Secure valve spring tool - 3362- to cylinder head with the tool
securing bolts.
– Set tool for compressing valve springs to one of the following
positions, outer inlet valves: lower position, centre inlet valve:
upper position, exhaust valve: lower position
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals using valve stem seal puller - 3364- .
2.8.2 Installing
– Place plastic sleeve supplied on respective valve stem. This
will prevent damage to new valve stem seal.
– Place new valve stem seal in valve stem seal fitting tool -
3365- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
quence.

17 – Lubrication
1 Parts of lubrication system
Note
♦ If large quantities of swarf or metal particles (caused, for ex‐

ample, by partial seizure of the crankshaft or conrod bearings)
are found in the engine oil when performing repairs, clean the
oil passages thoroughly and renew the oil cooler in order to
prevent subsequent damage.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 67 .
Engine oil ⇒ page 66 .

Assembly overview - parts of lubrication system ⇒ page 67
Removing and installing sump ⇒ page 71 .
Checking oil pressure ⇒ page 75 .
1.1 Engine oil

Oil capacities ⇒ page 66
Engine oil specification ⇒ page 66
Markings on oil dipstick ⇒ page 67
1.1.1 Oil capacities

Without oil filter 3.0 l 7)
With small oil filter (approx. 76 mm ∅) 3.5 l7)
With large oil filter (approx. 93 mm ∅) 3.9 l7)
7) Up-to-date figures: ⇒ Data sheets for exhaust emissions test
1.1.2 Engine oil specifications

Engine oil conforming to VW standard 500 00, 501 01 or 502 00
can be used. In exceptional cases only: multi-grade/single-grade
oil conforming to ACEA A2 or A3.
Vehicles with long-life service:
Use engine oils conforming to VW standard 503 00.
Note
Engine oils conforming to VW standard 500 00, 501 01 or 502 00

can be used furthermore. The oil must then be changed every 12
months or every 15,000 km and the service interval display must
be programmed accordingly. Procedure: ⇒ Maintenance ; Book‐
let 36
66 Rep. gr.17 - Lubrication

1.1.3 Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: Can be topped up with engine
oil.
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
1.2 Assembly overview - parts of lubrication

system
Vehicles without oil level/oil temperature sender ⇒ page 67
Vehicles with oil level/oil temperature sender ⇒ page 69
1.2.1 Vehicles with no oil level/oil temperature sender
1 - Gasket
2 - Cover cap
3 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Area above hatched
zone up to max. mark:
do not replenish engine
oil!
❑ Oil level in hatched
zone: engine oil can be
replenished
❑ Area min. mark up to
hatched zone: replenish
engine oil
4 - Dipstick guide
❑ Pull out to extract oil.
5 - Gasket
❑ Renew.
6 - Oil supply line, 20 Nm
AEB, ANB, ATW and
APU
❑ To turbocharger.
7 - 30 Nm
8 - Seal
❑ Renew.
9 - 25 Nm
11 - 1.4 bar oil pressure switch - F1- , 25 Nm
❑ Black
1. Parts of lubrication system 67

❑ If seal is leaking, nip open and renew.
12 - O-ring
❑ Renew.
13 - Oil cooler
❑ Coat contact surface to oil filter bracket outside the seal with sealing paste - AMV 188 100 02-
14 - 25 Nm
15 - Oil filter
16 - Cover cap
17 - Drive gear
❑ For oil pump.
18 - Gears
❑ Checking backlash ⇒ page 71 .
19 - Oil pump cover with pressure relief valve
20 - 10 Nm
21 - 25 Nm
22 - Baffle plate
23 - 10 Nm
❑ Remove and install both rear bolts to gearbox using T-bar and socket, 10 mm - 3185-
24 - Oil drain plug, 30 Nm
❑ Renew plug with attached seal.
25 - Seal
❑ Renew.
26 - Oil sump
❑ Aluminium
27 - Gasket
❑ Renew.
❑ Before fitting coat transition points sealing flange/cylinder block with sealant - D 454 300 A2- .
28 - Gasket
❑ Renew.
29 - Oil return line
❑ From turbocharger
30 - 10 Nm
31 - Suction line
❑ Clean strainer if soiled.

32 - 10 Nm
33 - O-ring
❑ Renew.
35 - Oil spray jet
36 - Non-return valve, 5 Nm
1.2.2 Vehicles with oil level/oil temperature sender
1 - Gasket
2 - Cover cap
3 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Area above hatched
zone up to max. mark:
do not replenish engine
oil!
❑ Oil level in hatched
zone: engine oil can be
replenished
❑ Area min. mark up to
hatched zone: replenish
engine oil
4 - Dipstick guide
❑ Pull out to extract oil.
5 - Gasket
❑ Renew.
6 - Oil supply line, 20 Nm
AEB, ANB, ATW and
APU
❑ To turbocharger.
7 - 30 Nm
8 - Seal
❑ Renew.
9 - 25 Nm
11 - 1.4 bar oil pressure switch - F1- , 25 Nm
❑ Black
❑ If seal is leaking, nip open and renew.
12 - O-ring
❑ Renew.

13 - Oil cooler
❑ Coat contact surface to oil filter bracket outside the seal with sealing paste - AMV 188 100 02-
14 - 25 Nm
15 - Oil filter
16 - Cover cap
17 - Drive gear
❑ For oil pump.
18 - Gears
❑ Checking backlash ⇒ page 71 .
19 - Oil pump cover with pressure relief valve
20 - 10 Nm
21 - 25 Nm
22 - Baffle plate
23 - 45 Nm
❑ Sump to gearbox securing bolts
24 - 45 Nm
25 - 10 Nm
26 - Seal
❑ Renew.
27 - Oil level and oil temperature sender - G266-
❑ Checking: ⇒ Vehicle diagnostic tester.
28 - Cover plate
29 - 10 Nm
30 - Oil drain plug, 30 Nm
❑ Renew plug with attached seal.
31 - Seal
❑ Renew.
32 - Oil sump
❑ Install with silicone sealant - D 176 404 A2- ⇒ page 71 .
❑ Aluminium
33 - Gasket
❑ Renew.
❑ From turbocharger

35 - 10 Nm
36 - Suction line
37 - 10 Nm
38 - O-ring
❑ Renew.
40 - Oil spray jet
41 - Non-return valve, 5 Nm
Checking oil pump backlash

New: 0.05 mm
Wear limit: 0.20 mm
Checking oil pump axial clearance

Wear limit: 0.15 mm
1.3 Removing and installing oil sump

♦ Support bracket - 10 - 222 A- with rack - 10 - 222 A /1-

♦ Workshop hoist - V.A.G 1202 A-
♦ Hand drill with plastic brush attachment

♦ Silicone sealant - D 176 404 A2-
♦ 5 mm ∅ drift
♦ Cable ties
1.3.1 Removing
– Drain engine oil.
– Mark direction of rotation of poly V-belt.
Vehicles with air conditioning system:
– Remove air conditioner compressor poly V-belt tensioning
roller complete.
– Remove air conditioner compressor poly V-belt.
– Lock viscous fan coupling pulley with a drift (5 mm ∅) -1-.
– Remove viscous fan coupling securing bolts (using 8 mm allen
key -2-) and remove viscous fan coupling with belt pulley.
– Remove torque steady bracket -arrows-.

– Cut through cable ties -arrows-, open retainer for starter wiring
and take wiring out.
– Remove support between sump and combined vacuum pipe.
– Unbolt left engine mounting at top.
– Mark the fitting position of threaded connections -1- and lo‐

cating sleeves -2- below on the left and right engine mounts.
– Unbolt both engine mountings from below.
– Push lock carrier to rear again and secure at top.
– Attach support bracket - 10 - 222 A- as shown.

– Support engine on front lifting eye with support bracket.
– Lift engine via support bracket spindle, until the air hose to
throttle valve control module contacts bulkhead.
– Remove left engine mounting.
– Support subframe with workshop hoist - V.A.G 1202 A- .
– First remove front bolts -2- and -3- on left and right-hand sides
of subframe Then remove bolts -4-.
Note
To avoid having to perform wheel alignment, the subframe must

only be loosened or lowered at the front end.

– Loosen rear right gearbox mounting rear bolt -2- several turns,
remove right gearbox mounting front bolt -1-.
– Loosen left gearbox mounting nut -arrow- until it is flush with

end of bolt (turned approx. 4 threads).
– Lower subframe slowly with workshop hoist.

– Remove workshop hoist, swivel anti-roll bar down.
– Remove sump, it may be necessary to release sump by tap‐
ping lightly with a rubber head hammer.
Vehicles without a hard gasket:
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump using a rotating brush, e.g.

an electric drill with a plastic brush attachment (wear safety
goggles).
– Clean sealing surfaces. They must be free of oil and grease.
1.3.2 Installing
– Install sump with previous hard gasket.

Vehicles without a hard gasket:
Note
♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
line strainer.
– Apply silicone sealing compound bead as shown to the clean

sealing surface of the sump. (The figure shows the position of
the sealant bead on the cylinder block.)
– Install sump immediately and tighten all sump bolts lightly.
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.

– Tighten oil sump bolts to 10 Nm.
quence.
– Tighten bolts securing sump to gearbox to 45 Nm.
– Tighten M10 bolts of sump/cylinder block to 45 Nm.
1.3.3 Specified torques

Component Nm
Engine mounting to subframe 25
Engine mounting to engine support 25
Torque support bracket to engine 25
Gearbox support to gearbox mounting M10 40
Gearbox mounting to subframe M8 25
Combined vacuum pipe bracket 25
1.4 Checking oil pressure and oil pressure switch


equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Voltage tester - V.A.G 1527
B-
♦ Auxiliary measuring set -
V.A.G 1594 C- or -V.A.G
1594 A-
1.4.1 Test prerequisites

• Engine oil level OK.
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations

1.4.2 Test procedure

– Remove oil pressure switch - F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594 C- . LED must not light up.
– If the LED lights up, renew 1.4 bar oil pressure switch - F1- .
If LED does not light up:
– Start engine and run at idling speed. At 1.2…1.6 bar, the LED
must light up. Otherwise replace oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80°C the oil pressure should be between 2.7 and
4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If specification is not attained:
– Check strainer in suction line for soiling ⇒ Item 36 (page 71)
(36) or ⇒ Item 31 (page 68) (31).
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
If no fault is found:
– Renew oil pump .
If the specification is exceeded:
– Check oil channels.
– If necessary, renew oil pump cover (oil pump) with pressure
relief valve.

19 – Cooling
1 Parts of cooling system
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers - VAS 5024A- are recommended for in‐
stallation of spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Test for leaks in cooling system using cooling system tester -

V.A.G 1274- and adapter for cooling system tester - V.A.G
1274/8- and adapter for cooling system tester - V.A.G 1274/9- .
Assembly overview - parts of cooling system, body side
⇒ page 78 .
Assembly overview - parts of cooling system, engine side
⇒ page 80 .
Assembly overview - coolant pump and compact bracket
⇒ page 82
Tightening sequence, compact bracket to cylinder block
⇒ page 83 .
Assembly overview - coolant pump ⇒ page 84
Coolant hose schematic diagram ⇒ page 84 .
Draining and filling with coolant ⇒ page 87 .
Coolant mixture specifications ⇒ page 87 .
Removing and installing radiator ⇒ page 90 .
Removing and installing viscous fan coupling ⇒ page 92
Removing and installing viscous fan mounting bush
⇒ page 92
Removing and installing coolant pump V-belt ⇒ page 94 .
1.1 Assembly overview - parts of cooling system, body side
78 Rep. gr.19 - Cooling

1 - Radiator
⇒ page 90
❑ After renewing, renew
entire coolant.
❑ With ATF cooler for ve‐
hicles with automatic
gearbox: Dismantling
and assembling gear‐
box; ATF lines and ATF
cooler ⇒ Automatic
gearbox 01N/01V; Rep.
gr. 37 ; Dismantling and
assembling gearbox;
Removing and installing
ATF lines
❑ Cleaning ATF cooler: ⇒
Automatic gearbox 01N/
01V; Rep. gr. 37 ; Dis‐
mantling and assem‐
bling gearbox; Cleaning
ATF lines and ATF cool‐
er
2 - Securing clip
3 - Rubber mounting
4 - Upper coolant hose
❑ Secured to radiator with
retaining clip.
ing.
❑ Coolant hose schematic
diagram ⇒ page 84 .
5 - Rubber washer
6 - Radiator fan - V7-
❑ Electric fan as optional
extra.
7 - Fan ring
❑ Clipped into air ducting and secured with locking bolt ⇒ Item 8 (page 79) .
8 - Locking bolt
9 - 10 Nm
10 - 2-pin connector
11 - Lower coolant hose
❑ Secured to radiator with retaining clip.
❑ Check for secure seating.
❑ Coolant hose schematic diagram ⇒ page 84 .
12 - O-ring
13 - Connector
❑ Black, 3-pin.
❑ For thermal switch for radiator fan.
14 - Radiator fan thermal switch - F18- , 35 Nm
❑ For electric fan.
❑ Switching temperatures: stage 1 on: 92…97 °C off: 84…91 °C, stage 2 on: 99…105 °C off: 91…98 °C
1. Parts of cooling system 79

15 - Seal
❑ Renew.
16 - Drain plug, 10 Nm
1.2 Assembly overview - parts of cooling system, engine side
1 - 20 Nm
part
3 - O-ring
❑ Renew.
4 - Coolant pump
❑ With thermostat
⇒ Item 8 (page 84)
❑ Check for ease of move‐
ment.
coolant pump and com‐
pact bracket
⇒ page 82
bling ⇒ page 84 .
5 - Oil cooler
6 - Retaining clip
ing.
7 - Connector
❑ 4-pin.
❑ Wiring chamber 1 and
wiring chamber 3 for
G62
8 - Coolant temperature send‐
er - G62-
❑ With coolant tempera‐
ture display sender -
G2-
❑ For engine control unit.
❑ Before removing, release pressure in cooling system if necessary.
9 - Plug
10 - To heat exchanger
11 - Connection
12 - 10 Nm
13 - Upper coolant pipe
❑ Secured to intake manifold.
14 - Throttle valve control module
❑ Coolant heated only for engine codes: ADR, APT, ATW and ARG

15 - From heat exchanger

16 - Lower coolant pipe
❑ Secured to oil filter bracket
17 - Cover cap
❑ Check using cooling system tester - V.A.G 1274- and adapter for cooling system tester - V.A.G 1274/9- .
❑ Test pressure: 1.4…1.6 bar.
18 - O-ring
19 - Expansion tank
❑ Test cooling system for leaks using cooling system tester - V.A.G 1274- and adapter for cooling system
tester - V.A.G 1274/8- .
❑ From bottom of radiator.
❑ Secured to radiator with retaining clip.
21 - Compact bracket
❑ For tensioner, viscous fan coupling, alternator and power-assisted steering vane pump
❑ Removing and installing ⇒ page 82 , removing and installing coolant pump and compact bracket
22 - V-belt
❑ Removing and installing coolant pump and compact bracket ⇒ page 82
23 - Fan wheel

1.3 Assembly overview - coolant pump and compact bracket
1 - 20 Nm
part
3 - 25 Nm
4 - Tensioning element for poly
V-belt
poly V-belt ⇒ page 20 .
5 - O-ring
❑ Renew.
6 - Coolant pump
❑ With thermostat
ment.
bling ⇒ page 84 .
❑ Bolted to cylinder block
together with compact
bracket
7 - Compact bracket
❑ For tensioner, viscous
fan coupling, alternator
and power-assisted
steering vane pump
8 - Bush
9 - Support
❑ Between compact
bracket and cylinder
block
10 - 30 Nm
11 - 25 Nm
12 - 30 Nm
❑ Observe tightening sequence ⇒ page 83 .
13 - 45 Nm
❑ For viscous fan coupling.
14 - Support
❑ Between intake manifold and compact bracket
❑ Only engine codes: ADR, APT, AFY and ARG
15 - Support
❑ Only engine codes: AEB, ANB, ATW and APU
16 - V-belt
17 - Bearing bush

18 - Circlip
19 - Lower toothed belt guard: 10 Nm, belt pulley to viscous fan coupling: 30 Nm
20 - Belt pulley
❑ Removing and installing ⇒ page 92 , removing and installing viscous fan coupling.
21 - Viscous fan coupling
1.3.1 Tightening sequence, compact bracket

to cylinder block
Procedure
– Fit compact bracket with coolant pump to cylinder block.
– Tighten compact bracket in sequence as follows to 30 Nm:
1 - Tighten bolt -A-
2 - Tighten bolt -B-
3 - Tighten bolt -C-
4 - Tighten bolt -D-
5 - Tighten bolt -E-
6 - Tighten bolt -F-

1.4 Assembly overview - coolant pump
1 - 20 Nm
part
3 - 10 Nm
4 - Coolant pump
ment.
5 - Gasket
❑ Renew.
6 - O-ring
❑ Renew.
7 - Hammer head bolt
❑ Insert before installing
8 - Thermostat
❑ Checking: heat thermo‐
stat in water.
❑ Opening begins at ap‐
prox. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7
mm.
9 - Connection
10 - Drain plug, 30 Nm
11 - Seal
❑ Renew.
12 - Belt pulley
❑ Mark installation posi‐
tion of each pulley be‐
fore removing
13 - 25 Nm
1.5 Coolant hose schematic diagram

Schematic diagram for engine codes ADR, APT, AFY and ARG
⇒ page 85
Schematic diagram for engine codes AEB, ANB, ATW and APU
⇒ page 86

1.5.1 Schematic diagram for engine codes ADR, APT, AFY and ARG
1 - Heat exchanger for heater

unit
3 - Throttle valve control mod‐
ule
4 - Expansion tank
5 - Oil cooler
6 - Intake manifold
9 - Radiator
11 - Coolant pump and ther‐
mostat
12 - Cylinder head/cylinder
block
13 - Connection

1.5.2 Schematic diagram for engine codes AEB, ANB, ATW and APU
1 - Heat exchanger for heater

unit
3 - Expansion tank
4 - Oil cooler
5 - Intake manifold
8 - Radiator
10 - Coolant pump and ther‐
mostat
11 - Turbocharger
12 - Cylinder head/cylinder
block
13 - Connection

1.6 Draining and filling coolant

equipment required
1331-
VAS 5024A-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Pipe for cooling system
tester - V.A.G 1274/10-
♦ Refractometer - T10007-
♦ Cooling system charge unit
- VAS 6096-
1.6.1 Draining
– Open cap on coolant expansion tank.
– Remove insulation tray ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Removing insulation tray .

– Pull off lower coolant hose retaining clip -arrow- and remove
coolant hose from radiator.
– Remove coolant pump drain plug -arrows-.
Note
Follow disposal regulations for coolant!
1.6.2 Filling
Note
♦ Use only coolant additive G 12 in accordance with

TL VW 774 F. Identification: purple colour.
♦ G 12 purple (in accordance with TL VW 774 F) can be mixed
with the previous coolant additive G 12 red!
♦ G 12 and coolant additives marked “Conforming to
TL VW 774 F” prevent frost and corrosion damage, scaling
and also raise boiling point of coolant. Therefore, the cooling
system must be filled all year round with frost and corrosion
protection additives.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection is required down to about -25°C (in countries
with arctic climates: down to about -35°C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
♦ If for climatic reasons greater frost protection is required, the
amount of G 12 can be increased, but only up to 60% (frost
protection to about -40 °C). Otherwise frost protection and
cooling effectiveness are reduced again.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket is renewed, do not reuse old coolant.
Recommended mixture ratios:

Frost protection Anti-freeze G 128) Water8)

to quantity
-25°C 40 % 3.0 l 4.0 l
-35 °C 50 % 3.5 l 3.5 l
8) The quantity of coolant can vary depending upon vehicle equipment.
– Install lower coolant hose and secure.

– Renew sealing ring and install coolant pump drain plug. Speci‐
fied torque setting: 30 Nm
With cooling system charge unit - VAS 6096-
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
– Fill coolant circuit using cooling system charge unit - VAS
6096- ⇒ Operating instructions for cooling system charge unit
6096 .
– Fit expansion tank cap.
– Set heater controls to maximum heat position.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Then run engine at idling speed until radiator bottom hose be‐
comes hot.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
at the max. mark; when the engine is cold, between the min.
and max. marks.
Without cooling system charge unit - VAS 6096-
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank and extend it with pipe for cooling system test‐
er - V.A.G 1274/10- .

– Loosen coolant hose on heat exchanger and pull back hose

sufficiently so that the bleeder hole -arrow- is no longer sealed
by the connection.
– Fill with coolant until it flows out of the bleeder hole in coolant
hose.
– Push coolant hose onto connection and tighten.
– Fit expansion tank cap.
– Set heater controls to maximum heat position.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Then run engine at idling speed until radiator bottom hose be‐
comes hot.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
at the max. mark; when the engine is cold, between the min.
and max. marks.
1.7 Removing and installing radiator

1.7.1 Removing
– Remove front bumper ⇒ General body repairs; Rep. gr. 63 ;
Front bumper; Removing and installing front bumper .
– Pull coolant hoses off radiator.
– Pull connector off thermal switch.


– Remove ATF lines from radiator ⇒ Automatic gearbox 01N/
01V; Rep. gr. 37 ; Dismantling and assembling gearbox; Re‐
moving and installing ATF lines .
– Unbolt power-assisted steering hydraulic oil cooling pipe -ar‐
rows- and lay free. Do not open hydraulic oil circuit.
– Remove upper radiator securing clips and take radiator out
forwards.
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 91 .
1.7.2 Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Check ATF level ⇒ Automatic gearbox 01N/01V; Rep. gr. 37 ;
Checking ATF level and topping-up .
– Replenish coolant ⇒ page 87 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install front bumper ⇒ General body repairs; Rep. gr. 63 ;
Front bumper; Removing and installing front bumper .
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 36 .
1.7.3 Additional information and assembly

work for vehicles with air conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.
– Remove retaining clamp(s) for refrigerant lines.

– Remove condenser from radiator and pull forward as far as is
possible.
– Secure condenser to body so that the refrigerant lines/hoses
are not under tension.
– Pull radiator out between condenser and lock carrier.

1.8 Removing and installing viscous fan

coupling
♦ 5 mm ∅ drift
1.8.1 Removing
– Remove fan wheel from viscous fan coupling.
– Lock viscous fan coupling pulley with a drift (5 mm ∅) -1-.
– Remove viscous fan coupling securing bolts (using 8 mm allen
key -2-) and remove viscous fan coupling with belt pulley.
– Remove belt pulley from viscous fan coupling.
1.8.2 Installing
note the following:
– Tighten belt pulley on viscous fan coupling to 30 Nm.
– Tighten viscous fan coupling on compact bracket to 45 Nm.
– Tighten fan wheel on viscous fan coupling to 10 Nm.
1.9 Removing and installing viscous fan mounting bush


equipment required
♦ Hexagon nut from assem‐
bly tool - 3301-
♦ Puller tube from assembly
tool - 3350-
♦ Viscous fan fitting tool -
3367-
1.9.1 Removing
– Remove viscous fan coupling (with belt pulley) ⇒ page 92 .
– Remove mounting bush circlip -arrow-.

– Press mounting bush out of compact bracket using socket

head bolt - 3367/3- , the puller tube from assembly tool - 3350-
and the hexagon nut from assembly tool - 3301- .
1.9.2 Installing
– Press mounting bush fully into compact bracket using com‐
pensation piece - 3367/1- , press piece - 3367/2- , socket head
bolt - 3367/3- and hexagon nut from assembly tool - 3301- .
– After installing secure mounting bush with circlip.
– Install viscous fan coupling ⇒ page 92 .
1.10 Removing and installing coolant pump

V-belt
♦ Drift
1.10.1 Removing
– Remove viscous fan coupling (with belt pulley) ⇒ page 92 .
– Mark installation position of 2-part coolant pump belt pulley.

– Lock power-assisted steering vane pump belt pulley with a

punch.
– Unbolt coolant pump 2-part belt pulley and remove V-belt.
1.10.2 Installing
– Position 2-part belt pulley on coolant pump and fit V-belt be‐
tween coolant pump and vane pump.
– Tighten belt pulley uniformly until V-belt has moved fully out
onto its running surface. If necessary, turn vane pump/coolant
pump belt pulley slightly.
– Lock vane pump belt pulley with punch.
– Tighten belt pulley on coolant pump to 25 Nm.
Note
Adjusting V-belt tension is not necessary.
– Install viscous fan coupling ⇒ page 92 .

20 – Fuel supply system

1 Removing and installing parts of fuel
supply system
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
♦ Spring-type clip pliers - V.A.G 1921- are recommended for in‐
stalling spring-type clips.
Observe safety precautions ⇒ page 102 .

Observe rules for cleanliness ⇒ page 102 .
Assembly overview - fuel tank with attachments and fuel filter
⇒ page 96 .
Repairing accelerator mechanism ⇒ page 122 .
Adjusting throttle cable ⇒ page 123 .
Checking electronic power control (EPC) ⇒ page 121 .
Repairing parts of the activated charcoal filter system ⇒ Page
⇒ page 117 .
1.1 Assembly overview - fuel tank with at‐

tachments
All-wheel drive vehicles ⇒ page 96 .
Front-wheel drive vehicles ⇒ page 99 .
1.1.1 Vehicles with four-wheel drive
96 Rep. gr.20 - Fuel supply system

1 - Cover cap
2 - Seal
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
5 - O-ring
6 - Breather valve
❑ To remove valve unclip
sideways out of support.
❑ Remove cap before in‐
stalling
⇒ Item 1 (page 97) .
7 - Connecting hose
8 - Gravity valve
upwards out of support.
❑ Check valve for
through-flow valve verti‐
cal: open, valve tilted 45
°: closed
9 - 25 Nm
10 - Fuel filler neck
11 - Non-return valve
tion.
12 - Connecting hose
13 - Heat shield
❑ For fuel filler neck
14 - 10 Nm
15 - Union nut - 60 Nm
❑ Remove and install using union nut tool - 3218- .
16 - Connector
❑ Black, 4-pin.
❑ For fuel gauge sender - G- and fuel pump - G6- .
17 - Flange
❑ Note installation position on fuel tank ⇒ page 99 .
18 - Seal
❑ Moisten with fuel when installing
19 - Breather line
❑ Black
❑ Secure with spring-type clips.
1. Removing and installing parts of fuel supply system 97

20 - Fuel gauge sender 3 - G237-

21 - Heat shield
❑ For fuel tank.
22 - Securing clip
23 - Securing strap
24 - Fuel gauge sender 2 - G169-
25 - Locking ring 145 Nm
❑ Remove and install using fuel tank sender unit tool - 3087- .
26 - Fuel tank
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
27 - Return line
❑ Blue or with blue marking.
❑ From fuel return pipe on fuel rail
28 - Supply line
❑ Black
29 - Fuel gauge sender - G-
❑ Clipped on reservoir housing in fuel tank.
30 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 110 .
31 - Supply line
❑ Black
❑ To fuel supply pipe on fuel rail
32 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
33 - Breather line
❑ Black
❑ Clipped onto side of fuel tank.
❑ To activated charcoal filter.
34 - Earth connection

Installation position of fuel delivery unit flange

Mark on flange -1- must align with mark on fuel tank -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
Checking breather valve

Lever in rest position: closed.
Lever pushed in direction of arrow: open.
Note
Before installing breather valve remove fuel tank cap.
1.1.2 Front-wheel drive vehicles

1 - Cover cap
2 - Seal
3 - Tank flap unit
❑ With rubber cup.
4 - Securing bolt
5 - Gravity valve
upwards out of support.
❑ Check valve for
through-flow valve verti‐
cal: open, valve tilted 45
°: closed
6 - O-ring
7 - Breather line
❑ Black
❑ Clipped onto side of fuel
tank.
ing.
❑ Secure with spring-type
clips.
❑ To activated charcoal fil‐
ter.
8 - Breather valve
sideways out of support.
❑ Remove cap before in‐
stalling
⇒ Item 1 (page 100) .
10 - Supply line
❑ Black
❑ Between flange ⇒ Item 14 (page 101) and fuel filter ⇒ Item 25 (page 101) .
11 - Return line
❑ Blue or with blue marking.
❑ From fuel return pipe on fuel rail
12 - Connector
❑ Black, 4-pin.
❑ For fuel gauge sender - G- and fuel pump - G6- .

13 - Union nut - 80 Nm
❑ Remove and install using union nut tool - 3217- .
14 - Flange
❑ Note installation position on fuel tank ⇒ page 99 .
15 - Fuel gauge sender - G-
❑ Clipped on reservoir housing in fuel tank.
16 - Supply line
❑ Between flange ⇒ Item 14 (page 101) and fuel delivery unit ⇒ Item 17 (page 101) .
17 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 110 .
❑ Renew complete with flange and supply line only
18 - Seal
❑ Moisten with fuel when installing
19 - 25 Nm
20 - Fuel tank
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
21 - Bracket
❑ For securing straps.
22 - Securing strap
❑ Note different lengths.
❑ Installation position: Fixing point (holes) face in direction of travel.
23 - Retaining ring
❑ Secured to body.
24 - 10 Nm
25 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
26 - Supply line
❑ Black
❑ To fuel supply pipe on fuel rail
27 - Return line
❑ Between flange ⇒ Item 14 (page 101) and reservoir housing in fuel tank.
28 - Breather line
❑ Clipped onto top of fuel tank.

Installation position of fuel delivery unit flange

Mark on flange -1- must align with mark on fuel tank -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
Checking breather valve

Lever in rest position: closed.
Lever pushed in direction of arrow: open.
Note
Before installing breather valve remove fuel tank cap.
1.2 Safety precautions when working on

fuel supply system
WARNING

When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Before beginning work, place an extraction hose close to
sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust gas ex‐
traction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.3 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following “5 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not

use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.4 Removing and installing fuel delivery

unit, front-wheel drive vehicles
♦ Fuel pump tool - 3307-
♦ Union nut tool - 3217-
1.4.1 Removing
– Note safety precautions before beginning work ⇒ page 102 .
theft coding.
– Remove cover in luggage compartment floor.

– Pull 4-pin connector and supply and return lines off flange
-arrows-.
WARNING

– Remove union nut with spanner 3217.

– Pull flange and seal out of opening in fuel tank.
– Pull off fuel lines and connector on underside of flange.
– Unclip fuel gauge sender - G- from reservoir housing and re‐
move.
– Turn fuel delivery unit with fuel pump tool 3307 approx. 15°
anti-clockwise onto stop and remove.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
1.4.2 Installing
– Installation of fuel delivery unit is carried out in reverse order.

Note
♦ Do not bend fuel gauge sender when installing.

♦ Coat flange seal with fuel when fitting.
♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply and return hoses (return hose -
blue-).
♦ Secure fuel hoses with spring-type clips.
♦ Note Installation position of fuel delivery unit flange: Mark on
flange -1- must align with mark -2- on fuel tank.
♦ After installing fuel delivery unit flange, check that the supply,
return and breather pipes are still clipped onto fuel tank.
1.5 Removing and installing fuel delivery

unit, four-wheel drive vehicles
♦ Fuel pump tool - 3307-

♦ Fuel tank sender unit tool - 3087-
1.5.1 Removing
theft coding.
– Pull 4-pin connector and supply and return lines off flange
-arrows-.
WARNING

– Remove locking ring with fuel tank sender unit tool 3087.
– Pull flange and seal out of opening in fuel tank.
– Unclip fuel gauge sender - G- from reservoir housing and re‐
move.

– Turn fuel delivery unit with fuel pump tool 3307 approx. 15°
anti-clockwise onto stop and remove.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
1.5.2 Installing
– Installation of fuel delivery unit is carried out in reverse order.
Note
♦ Do not bend fuel gauge sender when installing.

♦ Coat flange seal with fuel when fitting.
♦ Do not interchange supply and return hoses (return hose -
blue-).
♦ Note Installation position of fuel delivery unit flange: Mark on
flange -1- must align with mark -2- on fuel tank.
♦ After installing fuel delivery unit flange, check that the supply,
return and breather pipes are still clipped onto fuel tank.
1.6 Removing and installing fuel tank

♦ Engine and gearbox jack - V.A.G 1383 A-

All-wheel drive vehicles ⇒ page 108 .

Front-wheel drive vehicles ⇒ page 109 .
1.6.1 Vehicles with four-wheel drive

– Open fuel tank filler flap.
theft coding.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner; Rear wheel housing liner .
– Drain fuel tank and clean fuel filler neck and surrounding area.
– Unscrew securing bolt and remove tank flap unit with rubber
cup.
– Remove filler neck securing bolt.
– Remove shield for filler neck.
– Remove centre and rear silencers of exhaust system
– Remove rear axle ⇒ Running gear; Rep. gr. 42 ; Repairing
rear axle; Removing and installing rear axle .
WARNING

– Pull supply line -1- off inlet to fuel filter.

– Mark return line -2- and breather line -3- and separate at con‐
necting point.
– Remove left and right protective plates on fuel tank and un‐
derbody.
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack - V.A.G 1383 A- .

– Lower with engine and gearbox jack - V.A.G 1383 A- just

enough to allow connector to be pulled off flange -arrow-.
– Lower fuel tank.
Installing
note the following:
♦ Install breather and fuel hoses free of kinks.
♦ Do not interchange supply and return hose (return hose blue
or blue markings, supply hose black).
Note
After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.
1.6.2 Front-wheel drive vehicles

– Open fuel tank filler flap.
theft coding.
– Remove rear right wheel housing liner ⇒ General body re‐
housing liner; Rear wheel housing liner .
– Drain fuel tank and clean fuel filler neck and surrounding area.
– Unscrew securing bolt and remove tank flap unit with rubber
cup.
– Remove filler neck securing bolt.
WARNING


– Mark return line -2- and breather line -3- and separate at con‐
necting point.
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack - V.A.G 1383 A- .

– Lower with engine and gearbox jack - V.A.G 1383 A- just

enough to allow connector to be pulled off flange -arrow-.
– Lower fuel tank.
Installing
note the following:
♦ Install breather and fuel hoses free of kinks.
♦ Do not interchange supply and return hose (return hose blue
or blue markings, supply hose black).
Note
After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.
1.7 Checking fuel pump


equipment required
♦ Pressure gauge - V.A.G
1318-
♦ Adapter set - V.A.G
1318/10-12-
♦ Adapter cable - V.A.G
1348/3-2-
♦ Tester for relay controlled
current circuits - V.A.G
1466A-
♦ Remote control for V.A.G
1348 - V.A.G 1348/3A-
♦ Measuring container
♦ Current flow diagram

♦ Voltage tester - V.A.G

1527B-
V.A.G 1594A- or -V.A.G
1594C-
♦ Multimeter - V.A.G 1715-
1332-
♦ Adapter - V.A.G 1381/1-
♦ For four-wheel drive vehi‐
cles fuel tank sender unit
tool - 3087-
♦ For front-wheel drive vehi‐
cles union nut tool - 3217-

1.7.1 Checking function and voltage supply

• Battery voltage at least 11.5 V
• Fuse No. 28 OK
– Briefly operate starter. Fuel pump must be heard to run.
– Switch off ignition.
If the fuel pump does not start:
– Remove fuse holder cover.
– Pull fuse No. 28 out of fuse holder.

– Connect remote control - V.A.G 1348/3A- with adapter cable
- V.A.G 1348/3-2- to contact 28a to fuel pump and battery
positive (+).
– Operate remote control.
If fuel pump runs:
– Check activation of fuel pump relay ⇒ Fault finding with test
system V.A.G 1466 .
If fuel pump does not run:
– Pull 4-pin connector off fuel tank flange -arrow-.
– Connect voltage tester - V.A.G 1527B- to outer contacts of

connector using auxiliary cables from auxiliary measuring set
- V.A.G 1594C- .
– Operate remote control. LED must light up.
If LED does not light up:
– Locate and eliminate open circuit referring to current flow di‐
agram: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If LED lights up (voltage supply OK):

– Unscrew union nut with union nut tool - 3217- .

– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump defective, renew fuel delivery unit ⇒ page 105 ,
removing and installing fuel delivery unit.
1.7.2 Checking delivery rate

• Voltage supply OK.
• Remote control - V.A.G 1348/3A- connected.
– Remove filler cap from fuel tank filler neck.
– Remove intake manifold cover.
WARNING

– Open the threaded union -arrow- and catch escaping fuel with
a cloth.
– Connect pressure gauge - V.A.G 1318- with adapter - V.A.G

1318/12- to fuel supply line.
– Push adapter - V.A.G 1318/1- onto adapter - V.A.G 1318/11-
of pressure tester and hold it in measuring container.
– Open the pressure tester shut-off tap. The lever then points in
direction of flow -A-.
– Operate remote control - V.A.G 1348/3A- . Then slowly close
shut-off tap until a pressure of 3 bar is displayed on pressure
gauge. From this point on do not move position of shut-off tap.
– Empty measuring container.
– The delivery rate of the fuel pump depends on the battery volt‐
age. Therefore connect the multimeter with auxiliary cables
from auxiliary measuring set - V.A.G 1594C- to the vehicle
battery.
– Operate remote control for 30 seconds while measuring bat‐
tery voltage.

– Compare quantity of fuel delivered with specification.

9) Minimum delivery cm3/30 seconds
10) Voltage at fuel pump with engine not running and pump running (approx. 2
volts less than battery voltage).
Example:
During the test a voltage of 12.2 volts is measured at the battery.
As the voltage at the pump is approx. 2 volts less than the battery
voltage, this will equate to a minimum delivery rate of 550 cm3/30
s.
If minimum delivery rate is not attained:
– Check the fuel pipes for possible restrictions (kinks) or block‐
ages.

– Connect pressure tester - V.A.G 1318- to hose using adapter
- V.A.G 1318/10- .
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained:
– Remove fuel delivery unit ( ⇒ page 105 ) and check fuel strain‐
er for soiling.
Only if still no fault has been detected:
– Fuel pump is defective. Renew fuel delivery unit ⇒ page 105 .
If delivery rate has been attained, but nevertheless you suspect
a fuel supply system fault (e.g. intermittent failure of fuel supply
system):
– Check current draw of fuel pump as follows:
– Reconnect all disconnected fuel lines.
– Connect multimeter - V.A.G 1715- with pick-up clamp to the

green/yellow wire in wiring harness.
– Start engine and run at idling speed.
– Measure current draw of fuel pump. Specification: max. 8
amps.
Note
If the fuel system malfunction is intermittent, you can perform the

check during a road test, but a 2nd person is necessary.
If the current draw is exceeded:

– Fuel pump defective. Renew fuel delivery unit ⇒ page 105 ,
removing and installing fuel delivery unit.
1.7.3 Checking non-return valve for fuel pump

• Remote control - V.A.G 1348/3A- connected.
• Pressure gauge - V.A.G 1318- connected to fuel supply line
from fuel supply pipe.

Note
At the same time, this test checks for leaks in the fuel supply line
connections from the fuel delivery unit to the point at which the
pressure gauge - V.A.G 1318- is connected.
– Close pressure gauge shut-off tap (lever at right angles to

through-flow direction, position -B-).
– Operate remote control at short intervals until a pressure of
approx. 3 bar has built up.
– If pressure builds up too high, relieve excess pressure by
carefully opening shut-off tap.
WARNING
Danger of spray when opening the shut-off tap. Hold container

in front of free connection of the pressure gauge.
– Watch pressure drop on pressure gauge. After 10 minutes,

pressure must not drop below 2.5 bar.
If the pressure drops further:
– Check line connections for leaks.
If no fault in lines is detected:
– Fuel pump defective, renew fuel delivery unit ⇒ page 105 .

2 Activated charcoal filter system
2.1 Function
Depending upon the air pressure and ambient temperature, fuel
vapour will form above the level of fuel in the tank.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
In limited quantities, fuel vapours pass through a gravity valve
(which closes at an angle of 45°) located at the highest point in
the tank and through a pressure retention valve into the activated
charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the car is being driven and the Lambda control is active
(engine warm), the activated charcoal filter solenoid valve 1 -
N80- , also known as regeneration valve, is activated (pulsed) by
the engine control unit depending upon load and engine speed.
The opening period depends on the input signals.
During the purging procedure (regeneration of the activated char‐
coal), the intake manifold vacuum draws in fresh air through the
vent opening on the underside of the activated charcoal filter. The
fuel vapours stored in the activated charcoal and fresh air are fed
to combustion in metered quantities.
The pressure retention valve prevents fuel vapours from being
drawn from the tank when the solenoid valve is open and intake
manifold vacuum is present. It thus ensures that the purging of
the activated charcoal filter has priority.
When not energised (e.g. open circuit), the solenoid valve is
closed. The activated charcoal filter will not be purged.
The vacuum pipe from the throttle valve control module to the
activated charcoal filter has an additional by-pass which is con‐
nected with the crankcase breather valve. The non-return valve
integrated in the crankcase breather valve prevents intake air en‐
tering the crankcase during some partial load ranges. This im‐
proves the overall crankcase breathing. The by-pass ensures an
optimal crankcase breathing.
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Pliers -V.A.G 1921- are recommended when installing spring-
type clips.
Observe safety precautions ⇒ page 102 .

2.2 Assembly overview - activated charcoal filter system
2. Activated charcoal filter system 117

1 - Activated charcoal filter

❑ Location: in front right
wheel housing.
front right wheel hous‐
ing liner ⇒ General body
repairs, exterior; Rep.
gr. 66 ; Removing and
installing wheel housing
liner
2 - 10 Nm
3 - Air filter housing
4 - Retaining ring
❑ For solenoid valve 1
5 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit.
❑ Installation position: ar‐
row indicates direction
of flow.
6 - Connector
❑ Black, 2-pin
❑ For solenoid valve 1
ule
8 - O-ring
9 - Breather line
❑ Black
❑ From gravity valve on fuel tank
10 - Securing bolt
11 - Breather hose
❑ To atmosphere.
12 - To intake hose
❑ Between turbocharger and air filter
❑ Only vehicles with turbocharger
❑ Grey side to activated charcoal filter
❑ Only vehicles with turbocharger
2.3 Checking fuel tank breather


♦ Hand vacuum pump with accessories - V.A.G 1390-
♦ Vacuum tester - V.A.G 1368-
– Remove front right wheel housing liner ⇒ General body re‐

housing liner .
– Pull breather line -2- from activated charcoal filter -1- off sol‐
enoid valve -3-.
– Connect hand vacuum pump - V.A.G 1390- to line -2-.
– Pull breather line from fuel tank -5- off activated charcoal filter
and connect to -connection A- of vacuum tester - V.A.G 1368- .
– Connect vacuum tester - V.A.G 1368- -connection B- to
breather line -4- to activated charcoal filter.
– Set vacuum tester to position -B-.
– Operate hand vacuum pump - V.A.G 1390- several times.
Vacuum must not build up.
If vacuum builds up:
– Check breather hose -6- on activated charcoal filter -1- for
soiling and clean if necessary.
If vacuum does not build up:
– Remove fuel filler cap from filler neck.
2. Activated charcoal filter system 119

– Connect hand vacuum pump - V.A.G 1390- to vacuum tester

- V.A.G 1368- -connection B-.
– Set vacuum tester to -A/B- position.
– Operate -V.A.G 1390- several times. Vacuum must not build
up.
– Check gravity valve ⇒ Item 5 (page 100) or
⇒ Item 8 (page 97) .
– Check line -1- from fuel tank for blockage.
If vacuum does not build up:
– Refit fuel filler cap.
– Operate hand vacuum pump - V.A.G 1390- several times.
Vacuum must not build up.
Note
If the fuel level in the tank is low, the hand vacuum pump must be
operated at least 20-30 times.

– Renew fuel tank cap.

3 Assembly overview - electronic power control (EPC)
1 - Mounting bracket
⇒ Running gear; Rep.
gr. 46 ; Brakes - mech‐
anism; Assembly over‐
view - brake pedal/
mounting bracket
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator pedal position
sender - G79- and accelerator
position pedal sender 2 -
G185-
dash panel cover and
pedal cluster cover.
❑ If renewed adapt control
unit for automatic gear‐
box: ⇒ Vehicle diagnos‐
tic tester; “Guided func‐
tions”
5 - Bracket
❑ For footwell cover
❑ Clipped onto accelera‐
tor pedal.
3. Assembly overview - electronic power control (EPC) 121

4 Accelerator mechanism (throttle ca‐

ble)
Assembly overview - accelerator mechanism ⇒ page 122 .
Removing and installing throttle cable mounting ⇒ page 123
Installation position of accelerator stop on mounting bracket
⇒ page 123 .
Adjusting accelerator cable ⇒ page 123 .
4.1 Assembly overview - accelerator mechanism
1 - Accelerator cable mounting

❑ On bulkhead in plenum
chamber.
⇒ page 123
2 - Accelerator cable mounting
❑ On bulkhead.
❑ Only vehicles with man‐
ual gearbox.
3 - Retaining clip
❑ Only vehicles with man‐
ual gearbox.
ing.
❑ Secured behind bulk‐
head.
4 - Retaining clip
❑ Only on vehicles with
automatic gearbox.
ing.
❑ Secured in front of bulk‐
head.
5 - Kick-down switch - F8-
❑ On bulkhead.
6 - Connector
❑ Black, 2-pin
7 - Accelerator cable
❑ Adjusting ⇒ page 123 .
❑ Do not reuse damaged
accelerator cable, renew. Volkswagen Technical Site: https://vwts.ru
8 - Cable cam
❑ On throttle valve control module.
9 - 10 Nm
10 - Support bracket
❑ For accelerator cable.
11 - Retainer
❑ Adjusting accelerator cable ⇒ page 123 .

12 - Accelerator
13 - Mounting bracket
❑ Removing and installing ⇒ Running gear; Rep. gr. 46 ; Brakes - mechanism; Assembly overview - brake
pedal/mounting bracket
14 - Accelerator pedal stop
❑ Installation position of accelerator stop on mounting bracket ⇒ page 123 .
4.1.1 Removing and installing accelerator ca‐

ble mounting
Removing:
– Turn accelerator cable mounting approx. 90° anti-clockwise
and remove from bulkhead in plenum chamber.
Installing:
– Push accelerator cable through bulkhead in plenum chamber
-arrow 1-.
– Push accelerator cable mounting into bulkhead and turn ap‐
prox. 90° clockwise -arrow 2-.
4.1.2 Installation position of accelerator stop

on mounting bracket
♦ On vehicles with manual gearbox letters “HS” -1- are visible
when installed.
♦ On vehicles with automatic gearbox letters “AG” -2- are visible
when installed.
4.2 Adjusting accelerator cable

Vehicles with manual gearbox ⇒ page 124
Vehicles with automatic gearbox ⇒ page 124
4. Accelerator mechanism (throttle cable) 123

4.2.1 Vehicles with manual gearbox

– Adjust accelerator cable by moving retainer -arrow- at support
bracket, so that full throttle position is attained at cable cam of
throttle valve control module.
4.2.2 Vehicles with automatic gearbox

♦ Hand-held multimeter - V.A.G 1526B-
♦ Auxiliary measuring set - V.A.G 1594C-
– Adjust accelerator cable by moving retainer -arrow- at support

bracket, so that full throttle position is attained at cable cam of
throttle valve control module.
– Release accelerator pedal
– Pull 2-pin connector off kick-down switch - F8- in front of en‐
gine compartment (on the bulkhead).

– Connect hand multimeter - V.A.G 1526B- to kick-down switch

using auxiliary cables from adapter set - V.A.G 1594C- .
– Check resistance at switch. Specification: ∞ Ω.
– Slowly move accelerator in direction of full throttle.
Shortly after the kick-down pressure point the resistance must
drop to 0 Ω. At this point the accelerator must be just off the stop.
4. Accelerator mechanism (throttle cable) 125

21 – Turbocharging/supercharging
1 Charge air system with turbocharger
(engine codes AEB, ANB, APU, AWT
only)
Note
♦ Charge air system must be free of leaks.

♦ Renew self-locking nuts.
♦ When refitting charge pressure hoses and their connections
they must be free of oil and grease.
♦ Do not use lubricant when fitting hose connections, if neces‐
sary moisten with water only.
♦ Observe fitting marks on hoses and components.
♦ Hose connections must be secured with clips ⇒ Replacement
Parts Department .
♦ Spring-type clip pliers - VAS 5024 A- or hose clip pliers - V.A.G
1921- are recommended for installation of spring-type clips.
Rules for cleanliness ⇒ page 126 .

Safety precautions ⇒ page 126 .
Removing and installing turbocharger with attachments
⇒ page 127
Removing and installing parts of charge air cooling
⇒ page 130 .
Schematic diagram of turbocharging system ⇒ page 130 .
Check charge pressure system ⇒ page 134 .

When working on the turbocharger, pay careful attention to the
following “5 rules” for cleanliness:
connecting.
lint-free cloths.
tool boxes etc.).
essary.
1.2 Safety precautions

Observe following if test and measuring instruments are required
during a road test:
126 Rep. gr.21 - Turbocharging/supercharging

♦ Test and measuring instruments must always be secured to

rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
1.3 Assembly overview - turbocharger with

attachments
Caution
When a mechanical fault is found on the turbocharger, e.g. a

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
perform the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
1. Charge air system with turbocharger (engine codes AEB, ANB, APU, AWT only) 127
1 - Exhaust manifold
2 - Gasket
tion.
❑ Renew.
3 - Seal
❑ Renew.
4 - Union, 30 Nm
5 - From oil filter bracket
6 - Oil supply line
❑ Tighten to 25 Nm.
7 - Coolant return line
8 - To upper coolant pipe
9 - Union, 35 Nm
10 - Washer
11 - 30 Nm
❑ Renew.
❑ Coat threads with high-
temperature paste - G
052 112 A3-
12 - Banjo bolt, 35 Nm
13 - To cylinder block.
14 - Hose
❑ To charge pressure
control solenoid valve -
N75-
❑ Engine code AEB:
❑ Engine codes ANB, APU, AWT: ⇒ Item 22 (page 133)
16 - Coolant supply line
17 - 10 Nm
18 - Hose
❑ To charge pressure control solenoid valve - N75-
❑ Engine code AEB: ⇒ Item 13 (page 131)
❑ Engine codes ANB, APU, AWT: ⇒ Item 22 (page 133)
20 - Bracket
❑ Between turbocharger and cylinder block.

21 - 25 Nm
22 - From air filter.
23 - To charge air cooler
24 - 10 Nm
25 - Plug, 15 Nm
❑ To sump.
27 - 10 Nm
28 - Turbocharger
❑ Checking charge pressure control ⇒ page 134 .
❑ The charge pressure control valve and vacuum unit for charge pressure control valve are integral parts
of turbocharger and cannot be replaced individually.
❑ Before connecting oil supply line, fill turbocharger with engine oil via union.
❑ After installing turbocharger, run engine for about 1 minute at idle and do not rev up immediately. This
ensures that the turbocharger is fully primed with oil.
29 - 30 Nm
❑ Renew.
❑ Coat threads with high-temperature paste - G 052 112 A3-
30 - Catalytic converter
31 - 35 Nm
❑ Renew.
❑ Coat threads and bolt head seating surface with high-temperature paste - G 052 112 A3- .
1.4 Assembly overview - charge air cooling
1 - Intake hose
2 - From air filter.
3 - From activated charcoal fil‐
ter
4 - From crankcase breather
5 - To turbocharger.
6 - Pressure regulating valve
❑ For crankcase ventila‐
tion.
7 - Connecting hose
❑ Observe assembly
markings
8 - To throttle valve control
module.
9 - Connecting hose
❑ Charge air cooler/throt‐
tle valve control module.
❑ Observe assembly
markings
10 - 10 Nm
11 - Charge air pressure send‐
er - G31-
❑ Renew O-ring if dam‐
aged.
❑ Not engine code AEB
12 - Charge air cooler
13 - Air duct
❑ Cross tube/charge air cooler
❑ Observe assembly markings
15 - From turbocharger
16 - Cross tube
❑ Turbocharger/cross tube
❑ Observe assembly markings
18 - Vacuum line
19 - Overrun shut-off valve
20 - Elbow
1.5 Schematic diagram of turbocharging

system
Engine code AEB ⇒ page 131

Engine codes ANB, APU, AWT ⇒ page 132
1.5.1 Engine code AEB

2 - Breather line
❑ From gravity valve on
fuel tank
❑ For activated charcoal
filter system.
4 - Turbocharger
❑ The charge pressure
control valve and vac‐
uum unit for charge
pressure control valve
are integral parts of tur‐
bocharger and cannot
be replaced individually.
5 - Fuel pressure regulator
6 - Intake manifold
filter system.
ule
11 - Vacuum unit
❑ For charge pressure
control valve
❑ Integral part of turbo‐
charger and cannot be
replaced.
13 - Charge pressure control solenoid valve - N75-
❑ The valve will be activated from the engine control unit (pulsed).
❑ No current valve closed, charge pressure limited.
❑ For crankcase ventilation.
15 - Activated charcoal filter solenoid valve 1 - N80-
1.5.2 Engine codes ANB, APU, AWT

2 - Breather line
❑ From gravity valve on
fuel tank
filter system.
4 - Turbocharger
❑ The charge pressure
control valve and vac‐
uum unit for charge
pressure control valve
are integral parts of tur‐
bocharger and cannot
be replaced individually.
5 - Combination valve
❑ For secondary air sys‐
tem.
❑ Only engines to D4
standard
7 - To brake servo.
8 - Suction-jet pump
9 - Vacuum reservoir
❑ Secured in front left
wheel housing
13 - Secondary air inlet valve - N112-
❑ Only engines to D4 standard
❑ For activated charcoal filter system.
15 - Turbocharger air recirculation valve - N249-
16 - Charge air pressure sender - G31-
18 - Throttle valve control module
19 - Intake manifold
20 - Vacuum unit
❑ For charge pressure control valve
❑ Integral part of turbocharger and cannot be replaced.


❑ The valve will be activated from the engine control unit (pulsed).
❑ No current valve closed, charge pressure limited.
23 - Secondary air pump motor - V101-
❑ For crankcase ventilation.
2 Checking charge pressure system

Checking charge pressure regulation, vehicles without EPC sys‐
tem ⇒ page 134
Checking charge pressure regulation, vehicles with EPC system
⇒ Vehicle diagnostic tester
Checking vacuum unit for charge pressure control valve
⇒ page 135
Checking overrun shut-off valve ⇒ page 136 .
Checking charge air system for leaks ⇒ page 137
2.1 Checking charge pressure control, ve‐

hicles without EPC system
Vehicles with EPC system ⇒ Vehicle diagnostic tester
♦ Turbocharger tester - V.A.G 1397 A-
• No leaks on intake and exhaust systems

• Engine oil temperature at least 80 °C
• Charge pressure control solenoid valve - N75- checked.
Checking ⇒ page 156
The charge pressure is measured under full load, whilst driving
or on a rolling road. Test duration per measurement max. 10 sec‐
onds.

– Pull connecting hose between intake manifold and overrun

shut-off valve off intake manifold and using T-piece connect to
turbocharger tester - V.A.G 1397 A- .
– Select measuring range l.
Note
♦ To operate turbocharger tester see operating instructions.

♦ The hoses must be connected so that there is no possibility of
leaks.
♦ If charge pressure is measured while the vehicle is in motion,
a second person is required to operate the turbocharger tester
for reasons of safety.
♦ Ensure that the pressure hose is not trapped between the
bonnet and the body.
– Measure charge pressure at full throttle: On rolling road: In 3rd

gear (manual) or 2nd gear (automatic) at 3000…4000 rpm.
During road test: In 2nd gear (manual) or 1st gear (automatic)
accelerate at full throttle and simultaneously brake vehicle and
hold revs at 3000…4000 rpm.
– Press turbocharger tester memory key “M” and read test fig‐
ure. Specification: (absolute pressure) 1.350 … 1.650 bar.
If the charge pressure is exceeded:
– Check charge pressure control solenoid valve - N75- . (Hose
from turbocharger via valve to pressure unit not blocked when
connector is pulled off).
– Check that vacuum unit for charge pressure control valve is
securely mounted on turbocharger.
– Check shaft bearing of charge pressure valve in turbocharger
for ease of movement. If corroded (seized), renew turbocharg‐
er.
2.2 Checking vacuum unit for charge pres‐

sure control valve
• Engine oil temperature at least 80 °C
– Pull connector -2- off charge pressure control solenoid valve
- N75- -1-.
2. Checking charge pressure system 135

– Start engine and bring up to maximum engine speed by ac‐

celerating spontaneously. The charge pressure control valve
operating rod -2- must move.
If the operating rod does not move:
– Check charge pressure control valve lever -1- for ease of
movement. If corroded (seized), renew turbocharger.
If the operating rod does not move, even though the lever is free
to move:
– Check charge pressure control solenoid valve - N75- . (Hose
from turbocharger via valve to pressure unit not blocked when
connector is pulled off).
If solenoid valve is OK.:
– Renew turbocharger ⇒ page 127 .
– Reading and erasing fault memory: ⇒ Vehicle diagnostic test‐
er; “Guided functions” .
2.3 Checking overrun shut-off valve

• Complaint of lack of performance or load change jolts
Note
The overrun shut-off valve is located in front of the turbocharger.

It opens as a result of vacuum pressure in the overrun phase and
at idling speed.
– Connect hand vacuum pump with accessories - V.A.G 1390-

to overrun shut-off valve vacuum connection.
– Operate hand vacuum pump overrun shut-off valve must open
-arrow-.
– Operate hand vacuum pump vent valve. Overrun shut-off
valve must close -arrow-.
If overrun shut-off valve does not open or close, renew valve.
Note
The overrun shut-off valve connections are secured with screw-

type clips.

2.4 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/1-
– Remove intake hose ⇒ Item 1 (page 130) from air filter.
– Insert adapter - 1687/1- into intake hose and seal pressure
regulating valve connection with adapter - V.A.G 1687/4- .
Tighten hose clips.
Prepare charge air system tester - V.A.G 1687- as follows:
– Turn pressure regulating valve -2- anti-clockwise onto stop.

– Close valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect charge air system tester - V.A.G 1687- as shown.
2. Checking charge pressure system 137

– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by listening, touching,
with commercially available leak detector spray or using ultra‐
sonic tester - V.A.G 1842- .
Note
♦ A small amount of air escapes via the turbocharger into sump.

Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
♦ If leaks occur, when doing any repair work observe notes for
charge air system ⇒ page 126 .
♦ Before removing the adapter, depressurise the test circuit by
pulling coupling off adapter - 1687/1- .

24 – Mixture preparation - injection

1 Repairing injection system
Overview - fitting locations, engine codes ADR, APT, ARG, AFY
⇒ page 139 .
Overview - fitting locations, engine codes AEB, ANB, APU, ATW
⇒ page 141 .
Dismantling and assembling air filter, engine codes ADR, APT,
ARG, AFY ⇒ page 147 .
Dismantling and assembling air filter, engine codes AEB, ATW,
ANB, APU ⇒ page 148 .
Dismantling and assembling fuel rail with injectors ⇒ page 149 .
Removing and installing parts of twin path intake manifold
⇒ page 149 .
Rules for cleanliness ⇒ page 154 .
Technical data ⇒ page 154 .
1.1 General notes on injection

Repairing ignition system ⇒ page 174
♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, read fault memory. Also
the vacuum hoses and connections must be checked (unme‐
tered air).
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of clamp or screw-type clips is not
permissible.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control unit
could be damaged.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
The fault memory must be interrogated and if necessary the
control unit adapted ⇒ page 162 .
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all checks and re‐
pairs, read the fault memory and clear if necessary
⇒ page 163 .
1.2 Overview of fitting locations

Engine codes ADR, APT, ARG, AFY ⇒ page 139 .
Engine codes AEB, ANB, APU, ATW ⇒ page 141
1.2.1 Engine codes ADR, APT, ARG, AFY
1. Repairing injection system 139


er - G62-
G2-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
2 - Camshaft adjustment valve
1 - N205- or camshaft adjust‐
ment valve 2 - N208-
3 - Throttle valve module -
J338-
4 - 4-pin connector
❑ Black, for Lambda
probe - G39- .
5 - 3-pin connector
❑ For engine speed send‐
er - G28- , grey.
6 - 3-pin connector
❑ Green: knock sensor 1 -
G61-
7 - 3-pin connector
❑ Blue, for knock sensor 2
- G66-
8 - Motronic control unit - J220-
❑ Location: in protective
housing on left in ple‐
num chamber
9 - Engine speed sender -
G28-
❑ Inductive sender.
10 - Knock sensor 2 - G66- ⇒ Item 10 (page 175)
11 - Variable intake manifold changeover valve - N156-
12 - Intake air temperature sender - G42-
14 - Hall sender - G40- or hall sender - G163- ⇒ Item 13 (page 175)
15 - Injector, cylinder 1 - N30- to injector, cylinder 4 - N33-
17 - Ignition coil - N- and ignition coil 2 - N128-
❑ With output stage - N122-
18 - Lambda probe - G39- , 50 Nm
❑ Location: in front exhaust pipe.
❑ Grease threads only with G5 ; G5 must not get into slots in probe body.
❑ On right engine support.
140 Rep. gr.24 - Mixture preparation - injection

20 - Air mass meter - G70-

❑ On air filter
❑ Activated charcoal filter system: ⇒ page 117
1.2.2 Engine codes AEB, ANB, APU, ATW
1 - Air filter
bling ⇒ page 147 .
2 - Lambda probe - G39- , 50
Nm
❑ Location: in front ex‐
haust pipe.
❑ Grease threads only
with G5 ; G5 must not
get into slots in probe
body.
3 - Lambda probe after catalyt‐
ic converter - G130- , 50 Nm
standard or OBD
❑ Grease threads only
with G5 ; G5 must not
get into slots in probe
body.
er - G62-
G2-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
5 - Turbocharger air recircula‐
tion valve - N249-
❑ Not on engine code AEB
6 - Secondary air inlet valve -
N112-
standard
7 - Throttle valve module - J338-
❑ If renewed, adapt engine control unit, ⇒ Vehicle diagnostic tester; “Guided functions” .
8 - Clutch pedal switch - F36- , brake light switch - F- , brake pedal switch - F47- , accelerator position sender
- G79- and accelerator position sender 2 - G185-
❑ In driver footwell
9 - 4-pin connector
❑ Black, for Lambda probe - G39- .
❑ Only engines to D4 standard or OBD

❑ For Lambda probe after catalytic converter - G130-
❑ For engine speed sender - G28- , grey.
❑ Green: knock sensor 1 - G61-
❑ Blue, for knock sensor 2 - G66-
14 - Secondary air pump relay - J299-
❑ Location: in protective housing on left in plenum chamber
16 - Intake air temperature sender - G42-
18 - Charge air pressure sender - G31-
22 - Hall sender - G40- or hall sender - G163- ⇒ Item 18 (page 177)
23 - Injector, cylinder 1 - N30- to injector, cylinder 4 - N33-
24 - Ignition coils
Engine codes AEB, ANB, APU:
❑ Ignition coil 1 - N-
❑ Ignition coil 2 - N128-
Engine code ATW:
❑ Ignition coil 1 with output stage - N70-
❑ On right engine support.
28 - Output stage - N122-
❑ Engine codes AEB, ANB, APU only
❑ Coat underside uniformly with heat sink paste - G 052 170 A2-
❑ On air filter

❑ Activated charcoal filter system: ⇒ page 117
1.3 Assembly overview - parts of injection

system
1 - Air filter
❑ Assembly overview:
⇒ page 147
2 - 20 Nm
4 - Air intake elbow
5 - 10 Nm
6 - To vacuum booster
❑ Only disconnect or con‐
nect connector with igni‐
tion switched off.
❑ Release to pull off.
tion switched off.
9 - Securing strap
10 - Motronic control unit -
J220-
num chamber
11 - Connector
❑ Black, 2-pin
❑ For intake air tempera‐
ture sender - G42-
12 - Intake air temperature
sender - G42-
❑ Grey
❑ For engine speed sender
15 - O-ring
16 - Lambda probe - G39-
❑ Location: in front exhaust pipe.

❑ Black
❑ For Lambda probe and Lambda probe heating
18 - Connector
❑ Black, 2-pin
❑ For variable intake manifold changeover valve - N156-
❑ Removing and installing throttle valve control module: vehicles ► 04.98:
❑ Removing and installing parts of twin path intake manifold: vehicles ► 04.98 ⇒ page 149
❑ Removing and installing parts of twin path intake manifold: vehicles 05.98 ► (plastic intake manifold)
⇒ page 151
20 - 10 Nm
21 - Fuel rail with injectors
❑ Assembly overview: ⇒ page 149
22 - Seal
❑ With locating tab.
23 - Connector
❑ Black, 2-pin
❑ For Injector cylinder 1 - N30- … No. 4 cyl. injector - N33-
24 - Supply line
❑ From fuel filter.
25 - Return line
❑ To fuel delivery unit in fuel tank.
26 - O-ring
27 - Coolant temperature sender - G62-
❑ Blue
❑ With coolant temperature display sender - G2-
28 - Connector
❑ Blue, 4-pin
❑ For coolant temperature sender - G62-
29 - Retaining clip
30 - To crankcase breather valve

1.3.2 Engine codes AEB, ATW, ANB, APU
1 - Air filter
❑ Assembly overview:
⇒ page 148
2 - 20 Nm
3 - Connector
❑ Black, 4-pin.
❑ For air mass meter -
G70-
❑ Location: in air filter
housing
num chamber
6 - Securing strap
tion switched off.
tion switched off.
9 - Intake air temperature
sender - G42-
10 - Connector
❑ Black, 2-pin
❑ For intake air tempera‐
ture sender - G42-
11 - 10 Nm
❑ Black
❑ For Lambda probe and Lambda probe heating
13 - Lambda probe - G39-
❑ Location: Catalytic converter
❑ Grey
❑ For engine speed sender

16 - O-ring
18 - Gasket
❑ Renew.
19 - Throttle valve module - J338-
❑ If renewed, adapt engine control unit, ⇒ Vehicle diagnostic tester; “Guided functions” .
20 - 10 Nm
21 - 20 Nm
22 - Support
23 - Support bracket
24 - 10 Nm
25 - 10 Nm
26 - Gasket
❑ Renew.
27 - Connector
❑ Black, 2-pin
❑ For Injector cylinder 1 - N30- … No. 4 cyl. injector - N33-
28 - Intake hose
29 - Fuel rail with injectors
❑ Assembly overview: ⇒ page 149
30 - Supply line
❑ Black
❑ From fuel filter.
31 - Return line
❑ Blue
❑ To fuel delivery unit in fuel tank.
32 - Retaining clip
33 - O-ring
34 - Coolant temperature sender - G62-
❑ Blue
❑ With coolant temperature display sender - G2-
35 - Connector
❑ Blue, 4-pin
❑ For coolant temperature sender - G62-

1.4 Assembly overview - air filter

Engine codes AEB, ATW, ANB, APU ⇒ page 148
1 - Air ducting
❑ To lock carrier.
2 - Filter element
3 - Air filter upper part
4 - Air duct
5 - Seal
❑ Checking ⇒ page 156
7 - 10 Nm
8 - Heat shield
9 - Rubber grommet
10 - Spacer sleeve
11 - Packing
12 - Air filter lower part

1.4.2 Engine codes AEB, ATW, ANB, APU
1 - Air ducting
❑ To lock carrier.
2 - Filter element
3 - Seal
❑ Checking ⇒ page 156
5 - Air duct
6 - 6 Nm
7 - Air filter upper part
8 - 6 Nm
❑ Coat underside uniform‐
ly with heat sink paste -
G 052 170 A2-
❑ Not engine code ATW
10 - Heat sink
11 - Rubber seal
12 - Line
filter system.
13 - 10 Nm
14 - Heat shield
15 - Rubber grommet
16 - Spacer sleeve
17 - Packing
18 - Air filter lower part

1.5 Assembly overview - fuel rail with injectors
1 - Retaining clip
❑ Ensure correct seating
on injector and fuel dis‐
tributor (fuel rail).
2 - Strainer
4 - O-ring
5 - No.1 cyl. injector - N30- …
No. 4 cyl. injector - N33-
6 - Fuel distributor (fuel rail)
7 - Return line connection
8 - Supply line connection
❑ Counterhold when loos‐
ening and tightening
1.6 Assembly overview - intake manifold

change-over
Only engines without turbocharger
Engine code ADR ► 04.98 ⇒ page 149
Engine code ADR with plastic intake manifold and engine codes
APT, ARG, AFY ⇒ page 151
1.6.1 Engine code ADR ► 04.98

Engine code ADR with plastic intake manifold and engine codes
APT, ARG, AFY ⇒ page 151

1 - Intake manifold
2 - Variable intake manifold
changeover valve - N156-
❑ Checking intake mani‐
fold change-over
⇒ page 156
3 - 6 Nm
4 - Vacuum hose
5 - Change-over barrel
6 - Spring
7 - Seal
8 - Vacuum actuator
9 - 10 Nm
10 - Cover
❑ Installation position:
white side to intake
manifold
12 - Rubber grommet
13 - Vacuum hose

1.6.2 Engine code ADR with plastic intake manifold and engine codes APT, ARG,
AFY
1 - Intake manifold
2 - Seal
3 - Circlip
4 - Seal mounting
5 - Change-over barrel
Installing:
❑ Clip completely assem‐
bled change-over barrel
onto vacuum actuator
(only possible in one po‐
sition). Then slide ac‐
tuator into intake mani‐
fold in the exact position
that it will be secured.
When doing this the
change-over barrel
must not be turned (dan‐
ger of damage to seal‐
ing cage).
6 - Sealing cage
❑ Is clipped onto change-
over barrel
❑ Only renew complete
with change-over barrel
7 - Spring
8 - Variable intake manifold
changeover valve - N156-
❑ Checking intake mani‐
fold change-over
⇒ page 156
❑ Is clipped to vacuum ac‐
tuator
9 - Cover
10 - 10 Nm
11 - Vacuum actuator
❑ Installation position: white side to intake manifold
13 - Rubber grommet
14 - Vacuum hose
1.7 Assembly overview - throttle valve con‐

trol module
Engine codes ADR, APT, ARG, AFY only

1 - Intake manifold
2 - 10 Nm
3 - Support bracket
❑ Not on engines with
EPC
4 - Gasket
❑ Renew.
With plastic intake manifold -
sealing ring:
5 - Throttle valve module -
J338-
❑ If renewed, adapt en‐
gine control unit, ⇒ Ve‐
hicle diagnostic tester;
“Guided functions” .
❑ If renewed adapt control
unit for automatic
gearbox.⇒ Vehicle diag‐
nostic tester
6 - From activated charcoal fil‐
ter system solenoid valve 1 -
N80-
7 - 10 Nm
8 - From expansion tank
9 - To top of radiator
10 - Support
❑ Between intake mani‐
fold and engine block.
11 - 10 Nm
12 - Support
13 - Bonded rubber mounting
14 - To vacuum booster

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, carry out the following
work:
Engine codes ADR, APT, ARG, AFY: ⇒ page 153 .
Engine codes AEB, ANB, APU: ⇒ page 153 .
Engine code ATW: ⇒ page 154 .

1.8.1 Engine codes ADR, APT, ARG, AFY:

– Pull 3-pin connector -1- off output stage for ignition coils -2-.
– Remove fuse 32
Note
Removing fuse 32 interrupts the voltage supply to the injectors.

during a road test:
1.8.2 Engine codes AEB, ANB, APU:


– Remove fuse 32
Note

during a road test:
1.8.3 Engine code ATW

– Remove fuses 29 and 32
Note
♦ Removing fuse 29 interrupts the voltage supply to the ignition

coils.
♦ Removing fuse 32 interrupts the voltage supply to the injec‐
tors.

during a road test:

When working on the fuel supply and injection system, pay careful
attention to the following “5 rules” for cleanliness:
connecting.
lint-free cloths.
tool boxes etc.).
essary.
1.10 Technical data

Engine codes ADR, AEB, AFY ANB, APU, ATW APT, ARG
Idling check

Engine codes ADR, AEB, AFY ANB, APU, ATW APT, ARG
Idling speed 11)
rpm 760...960 750...850 800...920
Engine control unit 12)
System Motronic M 3.8.2 Motronic ME 7.5 Motronic ME 7.1
Part number ⇒ ETKA (Electronic Parts Catalogue)
Governed speed rpm from approx. 6500 from approx. 6800 from approx. 6800
11) Not adjustable, up-to-date figures: ⇒ Data sheets for exhaust emissions test
12) Renewing engine control unit ⇒ page 162 .

2 Checking components
Check components with vehicle diagnosis, test and information
system - VAS 5051A- or vehicle diagnosis and service information
system - VAS 5052- ⇒ page 156 .
Checking intake manifold change-over ⇒ page 156
Checking injectors for leaks and quantity injected ⇒ page 156
Checking fuel pressure regulator and holding pressure
⇒ page 159 .
2.1 Checking components with vehicle di‐

agnosis, test and information system -
VAS 5051A- or vehicle diagnosis and
service information system - VAS 5052-
Select “guided fault finding” in vehicle diagnosis, test and infor‐
mation system - VAS 5051A- or vehicle diagnosis and service
information system - VAS 5052- .
When all control units have been read:
– Press “GoTo” button.
– Select “Function/component selection”.
– “Select power train.”
– Select “Engine code”.
– Select “01-Systems capable of self-diagnosis”.
– Select “Engine management”.
– Select “Electrical components”.
– Select component
2.2 Checking intake manifold change-over

Engine codes ADR, AFY, APT, ARG only
Perform this test only if torque is insufficient, that is when elasticity
or pulling power is inadequate.
• The variable intake manifold changeover valve N156 is tested
with the vehicle diagnosis, testing and information system -
VAS 5051 A- in “guided fault finding”. ⇒ page 156
If the variable intake manifold changeover valve - N156- is OK,
perform the following tests:
– Increase engine speed abruptly (burst of throttle). When doing
this the intake manifold change-over vacuum unit must oper‐
ate. (Location: on front left of intake manifold).
If the changeover does not function as described:
– Check mechanical change-over components for ease of
movement. To do this, operate rods by hand.
– Check that vacuum lines are connected correctly.
– Check vacuum hoses for porosity.
– Check vacuum system for leaks including vacuum reservoir in
intake pipe.
2.3 Checking injectors for leaks and quantity injected


equipment required
♦ Remote control for V.A.G
1348 - V.A.G 1348/3 A-
♦ Adapter cable - V.A.G
1348/3 - 2-
♦ Injection rate tester - V.A.G
1602-
V.A.G 1594 C-
2.3.1 Checking for leaks
WARNING
Fuel system is under pressure! Before opening the system

place a cloth around the connection. Then release pressure by
carefully loosening the connection.
• The fuel pressure must be OK. Checking ⇒ page 159 .
2. Checking components 157

– Pull connectors off injectors.

– Then remove fuel rail complete.
– Pull off vacuum hose off fuel pressure regulator.
– Lift fuel rail with injectors off intake manifold and support it.
– Start final control diagnosis. ⇒ Vehicle diagnostic tester
– Press button on display for “Vehicle self-diagnosis”.
– Press “01 - Engine electronics” button on display.
The control unit identification and coding are indicated on display.
– Press “03 - Final control diagnosis” button on display.
– The fuel pump must now run.
Note
♦ This step serves only to have the fuel pump running when the
engine is stopped.
♦ The final control diagnosis activates the injectors. The con‐
nector for the injectors must be disconnected before activating
the final control diagnosis.
– Check injectors for leaks (visual check). No more than 1 to 2

drops per minute must escape from each valve when fuel
pump is running.
If the fuel loss is greater:
– Switch off ignition and renew leaking injector. ⇒ page 149
Note
Always renew seals.
2.3.2 Checking quantity injected

• The fuel pressure must be OK. Checking ⇒ page 159 .
• Injectors installed in fuel distributor (fuel rail) and fuel line con‐
nected.
– Insert injector to be checked into measuring glass from injec‐
tion rate tester - V.A.G 1602- .

– Connect a contact of injector to be tested to engine earth using

auxiliary cables from auxiliary measuring set - V.A.G 1594 C- .
– Connect second injector contact to remote control - V.A.G
1348/3 A- using adapter cable - V.A.G 1348/3 - 2- .
– Connect crocodile clip to battery (+).
– Start final control diagnosis. ⇒ Vehicle diagnostic tester
The control unit identification and coding are indicated on display.
– Press “03 - Final control diagnosis” button on display.
– The fuel pump must now run.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
– Operate remote control - V.A.G 1348/3 A- for 30 seconds.

– Repeat check on other injectors. Use new measuring beakers.
– After all injectors have been activated, place measuring beak‐
ers on a level surface and compare the quantity injected.
Specification:
Engine code ADR, AFY, AEB ATW, ANB,
ARG, APT APU
ml per valve 85...105 110...130 133..157
When checking the quantity injected, check the spray pattern as
well. The spray patterns must be the same for all injectors.
If the measured values of one or more injectors are above or be‐
low the prescribed specifications:
– Renew defective injector. ⇒ page 149
Note
If injectors are renewed, erase learnt values and adapt engine

control unit again. ⇒ Vehicle diagnostic tester
Install injectors in reverse order. When doing this, note the fol‐
lowing:
♦ Renew O-rings on all injectors and lightly moisten with clean
engine oil.
♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
♦ Fit fuel rail with secured injectors onto intake manifold and
press in evenly.
2.4 Checking fuel pressure regulator and

holding pressure
The fuel pressure regulator regulates the fuel pressure depending
on intake manifold pressure.


♦ Pressure gauge - V.A.G 1318-
♦ Adapter set - V.A.G 1318/6+7-
WARNING
Fuel system is under pressure! Before opening the system

place a cloth around the connection. Then release pressure by
carefully loosening the connection.
– Open the union -arrow- and catch escaping fuel with a cloth.
– Connect pressure tester - V.A.G 1318- using adapter set -

V.A.G 1318/6+7- to supply line -1- and fuel rail.
– Open the pressure tester shut-off tap. The handle points in
direction of flow.
– Measure fuel pressure. Specification: approx. 3.5 bar.

– Pull vacuum hose off fuel pressure regulator -arrow-. The fuel
pressure must increase to approx. 4.0 bar.
If the specification is not attained:
– Check quantity supplied by fuel pump ⇒ page 114 .
If specification is attained:
– Now check for leaks and holding pressure. Do this by observ‐
ing pressure drop on gauge. After 10 minutes, there must be
a residual pressure of at least 2.0 bar.
If the holding pressure drops below 2 bar:
– Switch ignition off after the pressure has built up. At the same
time, close pressure tester - V.A.G 1318- shut-off tap (handle
at right angles to direction of flow -arrow-).
– Watch pressure drop on pressure gauge.
If the pressure does not drop:
– Check fuel pump non-return valve ⇒ page 115 .
If the pressure drops again:
– Open pressure gauge - V.A.G 1318- shut-off tap (handle in

direction of flow).
– Switch ignition off after the pressure has built up. At the same
time, clamp off return hose.
If the pressure does not drop:
– Renew fuel pressure regulator.
If the pressure drops again:
– Check line connections, O-rings on fuel rail and injectors for
leaks.
– Check pressure tester for leaks.
Note
Before removing pressure tester, place a cloth around the con‐

nections to be loosened.

3 Engine control unit

Renewing engine control unit ⇒ page 162 .
Adapting functions and components ⇒ page 162 .
Reading and clearing engine control unit fault memory
⇒ page 163 .
3.1 Renewing engine control unit

– Before removing engine control unit, read the control unit iden‐
tification and with it, the coding of the current control unit.
⇒ page 163
– Remove cover from protective housing for control units.
– Carefully lever off the retaining bar with a screwdriver

-arrow-.
– Release connector from control unit and pull off.
– Remove old control unit and insert new one.
– Insert new control unit and press to the left.
– Adapt new engine control unit. ⇒ Vehicle diagnostic tester;
“Guided functions, renewing control unit”
3.2 Adapting functions and components

♦ Vehicle diagnosis, testing and information system - VAS 5051
A-
Select “Guided fault finding” in the Vehicle diagnosis, testing and

information system - VAS 5051 A- .
When all control units have been read:

– Press “GoTo” button.

– Select “Function/component selection”.
– “Select power train.”
– Select “Engine code”.
– Select “01-Systems capable of self-diagnosis”.
– Select “Engine management”.
– Select “Functions”.
– Select function or component.
3.3 Reading and erasing engine control unit

fault memory
♦ Vehicle diagnosis, testing and information system - VAS 5051
A-
– Connect Vehicle diagnosis, testing and information system -

VAS 5051 A- as follows:
– Remove the diagnostic socket cover on right next to the hand‐
brake lever.
– Push diagnostic cable connector onto diagnostic connector.
Only if engine does not start:
– Switch on ignition.
Selecting operating mode:
Selecting vehicle system:
3. Engine control unit 163

The engine control unit identification and coding -2- are indicated
on the display.
Note
A print-out can be made if required. Press the “Print” button.
Select diagnostic function:

– Press button “02 - Read fault memory” on display.
– If no fault is stored in engine control unit “0 fault detected” is
displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press ← button.
– Press button “05 - Clear fault memory” on display.
– Press function “06-End output”.
Engine codes ANB, ATW, AEB 13)
– Generate readiness code. ⇒ Vehicle diagnostic tester; “Gui‐
ded function”
13) AEB only if USA version

26 – Exhaust system
1 Parts of exhaust system
Note
♦ After working on the exhaust system, ensure that the system

is not under tension and that there is sufficient clearance to
the bodywork. If necessary, loosen double and single clamps
and align silencer and exhaust pipe so that sufficient clearance
is maintained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
Assembly overview - front-wheel drive vehicles ⇒ page 165

Assembly overview - four-wheel drive vehicles ⇒ page 169
1.1 Assembly overview - front-wheel drive

vehicles
Vehicles without turbocharger ⇒ page 165
Vehicles with turbocharger ⇒ page 167
Mounting components ⇒ page 168
1.1.1 Front-wheel drive vehicles, without turbocharger
1. Parts of exhaust system 165

1 - 25 Nm
❑ Removing ⇒ page 127 .
3 - Lambda probe - G39- 50
Nm
❑ Grease only the threads
with high-temperature
paste - G 052 112 A3- ;
high-temperature paste
- G 052 112 A3- must
not get into the slots of
probe body.
❑ Remove and install with
Lambda probe open
ring spanner set -
3337- .
4 - Gasket
❑ Renew.
5 - Front exhaust pipe
6 - 30 Nm
7 - 25 Nm
9 - Mounting
❑ With retaining ring.
10 - Mounting
11 - 25 Nm
12 - Rear silencer
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and rear silencer are supplied separately, with a double clamp for connecting.
❑ Removing and installing:
❑ Cut through connecting pipe with body saw e.g. body saw - V.A.G 1523A- at right angles on the separating
point ⇒ Item 17 (page 166) .
13 - Dimension -a- = approx. 7…9 mm
❑ Exhaust system must be cold
❑ Arrow indicates front of vehicle.
14 - Middle silencer
15 - Double clamp
16 - Washer
17 - Separating point
❑ 140…150 mm in front of centre silencer
166 Rep. gr.26 - Exhaust system

1.1.2 Front-wheel drive vehicles, with turbocharger
1 - 25 Nm
❑ With turbocharger
⇒ page 127
3 - Gasket
❑ Renew.
Nm
paste - G 052 112 A3- ;
- G 052 112 A3- must
probe body.
Lambda probe open
ring spanner set -
3337- .
6 - Lambda probe after catalyt‐
ic converter - G130-
standard or USA ver‐
sion
paste - G 052 112 A3- ;
- G 052 112 A3- must
probe body.
Lambda probe open
ring spanner set -
3337- .
7 - 25 Nm
❑ Renew.
8 - Marking
❑ 3 times on circumference.
❑ Double clamp ⇒ Item 21 (page 168) slide onto pipe up to mark.
9 - Mounting
10 - Mounting
11 - 25 Nm
12 - Rear silencer
❑ Centre and rear silencers are installed as a single component during production. In cases of repair, the
centre and rear silencer are supplied separately, with a double clamp for connecting.
– Cut through connecting pipe with body saw e.g. body saw - V.A.G 1523A- at right angles on the separating
point ⇒ Item 18 (page 168) .

13 - Dimension -a- = approx. 7…9 mm

❑ Exhaust system must be cold
❑ Arrow indicates front of vehicle.
❑ To prepare exhaust system slide double clamp ⇒ Item 21 (page 168) onto exhaust pipe up to mark
⇒ Item 8 (page 167) , and tighten lightly. Slide middle and rear silencers forwards until dimension -a- is
attained. Tighten double clamp.
14 - Bolt head must face to fuel tank
15 - Angle -α- = 30 ± 5°
16 - The ends of the bolts must not be below lower edge of double clamp
❑ Double clamp as seen in direction of travel
17 - Angle -β- = 10 + 5°
❑ Approx. 160…180 mm in front of rear silencer, marked by a rib in pipe.
19 - Double clamp
❑ Tighten evenly to 40 Nm
21 - Double clamp
❑ Tighten evenly to 40 Nm
22 - Decoupling element
❑ Max. deviation 10°
23 - Mounting
❑ Individual parts ⇒ page 168 .
25 - 30 Nm
❑ Renew.
26 - Washer
1.1.3 Individual parts of mounting

1- Buffer
2- Spacer tube
3- Washer
4- Right plate
5- Washer
6- Hexagon bolt
7- Spacer sleeve
8- Left plate
9- Spring
10 - Hexagon bolt
11 - Self-locking nut, 25 Nm

1.2 Assembly overview - four-wheel drive vehicles
1 - Gasket
❑ Renew.
2 - Mounting
4 - 25 Nm
6 - 30 Nm
Nm
paste - G 052 112 A3- ;
- G 052 112 A3- must
probe body.
Lambda probe open
ring spanner set -
3337- .
8 - Washer
❑ With turbocharger
⇒ page 127
10 - 40 Nm
11 - Double clamp
12 - Coach bolt
13 - Mounting
15 - Double clamp
16 - Rear right silencer
17 - Mounting
18 - Bracket
19 - Rear left silencer
❑ Centre and rear silencers are installed as a single component during production. In cases of repair, the
centre and rear silencer are supplied separately, with a double clamp for connecting.
– Cut through connecting pipe with body saw e.g. body saw - V.A.G 1523A- at right angles on the separating
point ⇒ page 170
23 - Lambda probe after catalytic converter - G130-

❑ Grease only the threads with high-temperature paste - G 052 112 A3- ; high-temperature paste - G 052
112 A3- must not get into the slots of probe body.
❑ Remove and install with Lambda probe open ring spanner set - 3337- .
1.2.1 Separating middle and rear silencers

♦ Body saw e.g. body saw - V.A.G 1523A-
– Separate connecting pipe between centre silencer and rear

silencer at the point marked with a groove: Dimension -a- ap‐
prox. 244 mm.

2 Secondary air system

Function ⇒ page 171 .
Assembly overview - secondary air system ⇒ page 171
Checking combination valve ⇒ page 172
Check secondary air inlet valve ⇒ page 173
2.1 Function
The secondary air system blows air in behind the exhaust valves
for max. 100 seconds after a cold start (+5 °C … +33 °C coolant
temperature). This produces an oxygen rich exhaust gas, causing
afterburning and reducing the heat-up phase of the catalytic con‐
verter. The Motronic control unit -J220- activates the system via
the secondary air pump relay -J299- to secondary air inlet valve
( -N112- , switch-over valve) and combination valve. In addition,
after each subsequent engine start (up to max. 96 °C engine tem‐
perature), the secondary air system will switch in for 10 seconds
during idling and will be checked by the self-diagnosis. For this
the Lambda regulation must be active.
2.2 Assembly overview - secondary air system
1 - Combination valve
2 - Bracket
❑ Secured on cylinder
head.
3 - Gasket
❑ Renew.
4 - Rubber bush
5 - Bracket
❑ Secured to intake mani‐
fold.
6 - Secondary air inlet valve -
N112-
8 - From vacuum reservoir
9 - To brake servo.
10 - 6 Nm
11 - Breather connection
12 - Connector
❑ 2-pin.
13 - To turbocharger air recir‐
culation valve - N249-
14 - To pressure unit on turbo‐
charger
15 - 10 Nm
16 - O-ring
2. Secondary air system 171

17 - Pressure hose
❑ Press together at front to release.
19 - To air filter.
20 - Intake hose
❑ For secondary air pump.
21 - Connector
❑ 2-pin.
❑ For secondary air pump motor.
22 - Bracket
❑ For secondary air pump motor.
23 - Insulation ring
24 - Protective ring
25 - 10 Nm
26 - Connecting pipe
27 - Elbow
❑ Secure with screw or spring-type clips
28 - Pressure pipe
29 - 6 Nm
30 - 10 Nm
31 - Gasket
❑ Renew.
2.3 Checking combination valve

Test prerequisites
• No fault stored in fault memory ⇒ Vehicle diagnostic tester.
• Final control diagnosis has been performed ⇒ Vehicle diag‐
nostic tester.
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked or kinked.

Test sequence:
– Pull vacuum hose off combination valve -arrow- and connect
hand vacuum pump with accessories - V.A.G 1390- .
Note
Do not use compressed air during the following check!
– Remove pressure hose -arrow- from secondary air pump mo‐

tor and blow in with slight pressure. Combination valve must
be closed.
– Operate hand vacuum pump. Valve must open.
If combination valve does not open:
– Renew combination valve.
2.4 Checking secondary air inlet valve

• Coolant temperature 5 ... 33 °C
• Secondary air pump motor OK.
– Pull vacuum hose -arrow- off combination valve.
– Start engine and run at idling speed. When the secondary air
pump motor runs, vacuum must be perceptible at vacuum
hose.
If no vacuum is perceptible:
– Switch off engine.
– Check activation of valve: ⇒ page 156 .
2. Secondary air system 173

28 – Ignition system
1 Repairing ignition system
General notes on ignition system ⇒ page 174 .
Assembly overview - ignition system ⇒ page 174 .
Test data, spark plugs ⇒ page 180
1.1 General notes on ignition system

♦ Only the components which specifically relate to the ignition
system are dealt with here. For other components of the in‐
jection and ignition system ⇒ page 139 .
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control unit
could be damaged.
♦ The engine control unit has a self-diagnosis capability.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore after completing all checks and re‐
pairs the fault memory must be read and if necessary cleared.
⇒ Vehicle diagnostic tester; “Guided Functions”
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
The fault memory must then be interrogated and if necessary
the control unit adapted ⇒ Vehicle diagnostic tester; “Guided
functions” .
1.2 Assembly overview - ignition system

Engine codes AEB, ANB, APU ⇒ page 176 .
Engine code ATW ⇒ page 178 .
174 Rep. gr.28 - Ignition system

1 - Ignition coil 1 - N- and igni‐

tion coil 2 - N128-
❑ With output stage -
N122-
2 - Locking device
❑ For connector.
3 - 6 Nm
4 - Spark plug connector with
ignition cable
❑ For No. 1 cylinder
❑ 4..0.6 kΩ
5 - Spark plug connector with
ignition cable
❑ For No. 2 cylinder
❑ 4..0.6 kΩ
6 - Spark plug, 30 Nm
spark plug socket and
extension - 3122 B- .
❑ Type and electrode gap
⇒ page 180 .
7 - 3-pin connector
❑ Gold-plated contacts.
G61-
- G66-
8 - 20 Nm
the knock sensor.
❑ Gold-plated contacts on sensor and connector.
11 - Connector
❑ Black, 3-pin.
❑ For Hall sender - G40- .
12 - 10 Nm
13 - Hall sender - G40- or hall sender - G163-
14 - 25 Nm
15 - Washer
❑ Conical.
16 - Screen
17 - Seal
1. Repairing ignition system 175

18 - Spark plug connector

❑ 4..0.6 kΩ
❑ For cylinders 3 and 4
19 - Mounting stud
20 - Earth wire
❑ Loosen or tighten only with ignition switched off.
21 - Connector
❑ Black, 5-pin
22 - 6 Nm
1.2.2 Engine codes AEB, ANB, APU
1 - Connector
❑ Black, 5-pin
❑ Coat underside uniform‐
ly with heat sink paste -
G 052 170 A2-
3 - 6 Nm
4 - Connector
❑ Black, 4-pin.
5 - 10 Nm
❑ Loosen or tighten only
with ignition switched
off.
6 - Earth wire
❑ Loosen or tighten only
with ignition switched
off.
7 - Connector
❑ Black, 3-pin.
8 - Locking device
❑ For connector.
9 - Ignition coils
❑ Ignition coil 1 - N-
❑ Spark plug connector
can be pulled off
10 - Seal
❑ Remove and install with spark plug socket and extension - 3122 B- .
❑ Type and electrode gap ⇒ page 180

❑ Green: knock sensor 1 - G61-
❑ Blue, for knock sensor 2 - G66-
13 - 20 Nm
❑ The specified torque influences the function of the knock sensor.
16 - Connector
❑ Black, 3-pin.
17 - 10 Nm
18 - Hall sender - G40- or hall sender - G163-
19 - 25 Nm
20 - Washer
❑ Conical.
21 - Screen
22 - Heat sink

1 - Connector
❑ Black, 4-pin.
2 - Ignition coils
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stage - N292-
❑ Tighten securing bolts
to 10 Nm.
3 - Seal
spark plug socket and
extension - 3122 B- .
❑ Type and electrode gap
⇒ page 180
5 - 3-pin connector
G61-
- G66-
6 - 20 Nm
the knock sensor.
9 - Connector
❑ Black, 3-pin.
10 - 10 Nm
11 - Hall sender - G40-
12 - 25 Nm
13 - Washer
❑ Conical.
14 - Screen
❑ For hall sender 2 - G163-
15 - Earth wire

16 - 10 Nm

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, carry out the following
work:
Engine codes ADR, APT, ARG, AFY: ⇒ page 179 .
Engine codes AEB, ANB, APU: ⇒ page 180 .
Engine code ATW: ⇒ page 180 .
1.3.1 Engine codes ADR, APT, ARG, AFY:

– Remove fuse 32
Note

during a road test:

1.3.2 Engine codes AEB, ANB, APU:

– Remove fuse 32
Note

during a road test:

– Remove fuses 29 and 32
Note
♦ Removing fuse 29 interrupts the voltage supply to the ignition

coils.
♦ Removing fuse 32 interrupts the voltage supply to the injec‐
tors.

during a road test:
1.4 Test data, spark plugs

Engine codes ADR, AFY AEB ATW
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Spark plugs14)
VW/Audi 101 000 051 AA 101 000 051 AA 101 000 063 AA

Engine codes ADR, AFY AEB ATW

Manufacturer's designa‐ F 7 LTCR F 7 LTCR PFR 6 Q
tion
VW/Audi 101 000 033 AA — —
Manufacturer's designa‐ BKUR 6 ET-10 — —
tion
VW/Audi 101 000 041 AC — —
Manufacturer's designa‐ 14 FGH -7 DTURX — —
tion
Electrode gap 0.9…1.1 mm 0.9…1.1 mm max. 0.8 mm
Specified torque 30 Nm 30 Nm 30 Nm
Engine codes ARG, APT ANB, APU

Firing order 1-3-4-2 1-3-4-2
Spark plugs14)
VW/Audi 101 000 033 AA 101 000 063 AA
Manufacturer's des‐ BKUR 6 ET-10 PFR 6 Q
ignation
VW/Audi 101 000 041 AC —
Manufacturer's des‐ 14 FGH -7 —
ignation DTURX
Electrode gap 0.9…1.1 mm max. 0.8 mm
Specified torque 30 Nm 30 Nm
14) Up-to -date figures and spark plug change intervals ⇒ Exhaust emissions
test binder

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

1.8 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

1.1 Engine number

1.2 Engine data

Knock control yes yes yes yes

Engine codes ADR AEB AFY ATW

Engine codes ANB APT APU ARG

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

Special tools and workshop

1. Removing and installing engine 3

♦ Drip tray - V.A.G 1306-

Special tools and workshop equipment required

4 Rep. gr.10 - Removing and installing engine

1.1 Notes on removing

1. Removing and installing engine 5

– Unbolt power-assisted steering hydraulic oil cooling pipe -ar‐

6 Rep. gr.10 - Removing and installing engine

– Disconnect throttle cable at throttle valve control module cable

Fuel supply lines are under pressure! Before loosening hose

– Pull all coolant hoses off engine.

– Separate torque converter from drive plate (3 securing nuts).

After removing the engine, secure the torque converter against

– To be able to remove lower engine/gearbox securing bolts, lift

1. Removing and installing engine 7

– Fit support bracket - 10 - 222 A- with hooks - 10 - 222 A /2- as

– Attach lifting tackle - 2024 A- as follows and lift slightly with

Use locking pins -arrows- to secure hooks and locating pins.

♦ The positions marked 1…4 on the bar must be towards the

– Lift engine out forwards.

Guide engine carefully when removing to prevent damage to the

Before carrying out repair work, secure engine on assembly stand

1.2 Notes on installing

8 Rep. gr.10 - Removing and installing engine

– Install air conditioner compressor ⇒ Heating, air conditioning;

1.2.1 Additional information and assembly

The air conditioner refrigerant circuit must not be opened.

To prevent damage to condenser or to refrigerant lines/hoses,

To facilitate removing and installing engine without opening re‐

1. Removing and installing engine 9

– Remove air conditioner compressor ⇒ Heating, air condition‐

1.3 Specified torques

1.3.1 Assembly overview - front engine mounting

Volkswagen Technical Site: https://vwts.ru

10 Rep. gr.10 - Removing and installing engine

1. Removing and installing engine 11

♦ If large quantities of swarf or metal particles (caused, for ex‐

12 Rep. gr.13 - Crankshaft group

1. Dismantling and assembling engine 13

1.1 Part I - Assembly overview